Heat Controller HCG''V1E, HMG''X1E, HMG''F1E User Manual

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AIR HANDLER

Installation Instructions

HMG**F1E, HMG**X1E & HCG**V1E Series

IMPORTANT

Please read all information in this manual thoroughly and become familiar with the capabilities and use of your appliance before attempting to operate or maintain this unit.These instructions are primarily intended to assist qualified individuals experienced in the proper installation of this appliance. Some local codes require licensed installation/service personnel for this type of equipment. Improper installation, service, adjustment, or maintenance may cause explosion, fire, electrical shock or other hazardous conditions which may result in personal injury or property damage.

Unless otherwise noted in these instructions, only factory authorized kits or accessories may be used with this product. Keep this manual where you have easy access to it in the future. If a problem occurs,check the instructions and follow recommendations given.If these suggestions don’t eliminate your problem, call your servicing contractor.

DO NOT DESTROY. PLEASE READ CAREFULLY AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.

TABLE OF CONTENTS

Important Safety Information........................

3

Requirements & Codes........................................

3

General Information...........................................

4

Before You Install this Unit.........................................

4

Locating the Air Handler............................................

4

Minimum Clearances.................................................

4

Operation of Air Handler During Construction...........

4

Installation in a Garage..............................................

5

Plenums & Air Ducts..................................................

5

Unconditioned Spaces............................................

5

Air Filters................................................................

5

Acoustical Duct Work..............................................

5

Air Handler Installation...................................

6

Packaging Removal...................................................

6

Mounting Applications................................................

6

Upflow Installations....................................................

6

Downflow Installations...............................................

6

Horizontal Installations...............................................

7

Horizontal Left Installations....................................

7

Horizontal Right Installations..................................

7

Circuit Breaker Cover Installation...............................

8

Refrigerant Line Connections....................................

8

Orifice removal & Installation..................................

9

Connecting the Linsets...........................................

9

Condensate Drainage .............................................

10

Electrical Connections..................................

11

Pre-Electrical Checklist............................................

11

Line Voltage.............................................................

11

Grounding................................................................

11

Thermostat Connections..........................................

11

Control Board...........................................................

12

Twinning................................................................

12

Heater Kits...............................................................

13

Electronic Air Cleaner..............................................

13

Humidifier.................................................................

13

Optional Humidistat..................................................

13

Startup & Adjustments....................................

13

Before You Start the Unit..........................................

13

Refrigerant Charging................................................

14

Air Circulation...........................................................

14

Running the Blower Continuously.........................

14

Selecting Continuous Low Spd Fan Operation.....

14

Turning the Blower Off..........................................

14

System Cooling....................................................

14

System Heating....................................................

14

Selecting minimum Electric Heat Airflow..............

14

Blower Configurations..............................................

14

Determining Nominal System Capacity................

14

3-Speed Units.......................................................

14

High Efficiency Units (Var. & Fixed Speed)...........

15

Selecting Basic Heating Airflow............................

15

Selecting Basic Cooling / Heat Pump Airflow.......

15

Dehumidification Options.........................................

15

Unit Maintenance................................................

16

Troubleshooting................................................

16

Figures & Tables..................................................

17

Figure 12. HMG**F1E, HMG**X1E &

 

HCG**V1E Physical Dimensions.........

17

Figure 13. Air Handler Components.....................

18

Airflow Data..............................................................

19

Table 5. HMG**F1E Air Handlers..........................

19

Table 6. HMG**X1E Air Handlers..........................

20

Table 7. HMG**X1E Air Handlers (Heat Only)......

21

Table 8. HCG**V1E Air Handlers (Cool Only).......

21

Table 9. HCG**V1E Airflow Settings.....................

22

Electrical Diagrams & Data......................................

23

Figure 14. Single Stage Control Board.................

23

Figure 15. Two-Stage Control Board.....................

23

Figure 16. Fixed Speed Control Board.................

24

Figure 17. Variable Speed Control Board.............

24

Figure 18. HMG**F1E Wiring Diagram.................

25

Figure 19. HMG**X1E Wiring Diagram.................

26

Figure 20. HCG**V1E Wiring Diagram.................

27

Table 10. HMG**F1E MCA & MOP Data..............

28

Table 11. HMG**X1E & HCG**V1E

 

MCA & MOP Data.................................

29

Table 12. Control Board Operation.......................

30

Installation / Performance Checklist......

32

2

Important SAFETY INFORMATION

INSTALLER: Please read all instructions before servicing this equipment. Pay attention to all safety warnings and any other special notes highlighted in the manual. Safety markings are used frequently throughout this manual to designate a degree or level of seriousness and should not be ignored. WARNING indicates a potentially hazardous situation that if not avoided, could result in personal injury or death. CAUTION indicates a potentially hazardous situation that if not avoided, may result in minor or moderate injury or property damage.

WARNING:

ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD

Failure to follow safety warnings exactly could result in serious injury or property damage.

Improper servicing could result in dangerous operation, serious injury, death or property damage.

Beforeservicing,disconnectallelectricalpower to air handler.

When servicing controls, label all wires prior to disconnecting. Reconnect wires correctly.

Verify proper operation after servicing.

WARNING:

NITROGEN

 

 

 

 

 

 

 

HEALTH

1

 

 

 

 

 

 

 

 

 

 

 

 

 

FLAMMABILITY

0

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

REACTIVITY

0

 

 

 

 

 

 

0 Minimal Hazard 1 Slight Hazard

HMG**F1E,HMG**X1E & HCG**V1E air handlers leave the factory with a nitrogen holding charge. Use caution when preparing coils for field connections. If repairs make it necessary for evacuation and charging, it should only be attempted by qualified, trained personnel thoroughly familiar with this equipment. Some local codes require licensed installation service personnel to service this type of equipment. Under no circumstances should the equipment owner attempt to install and/or service this equipment. Failure to comply with this warning could result in equipment damage, personal injury, or death.

WARNING:

PROPOSITION 65 WARNING: This product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.

Requirements & Codes

WARNING:

This unit must be installed in accordance with instructions outlined in this manual during the installation, service, and operation of this unit. Unqualified individuals should not attempt to interpret these instructions or install this equipment. Failure to follow safety recommendations could result in possible damage to the equipment, serious personal injury or death.

The installer must comply with all local codes and regulations which govern the installation of this type of equipment. Local codes and regulations take precedence over any recommendations contained in these instructions. Consult local building codes for special installation requirements.

This equipment contains nitrogen gas. Installation or servicing should only be performed by qualified trained personnel thoroughly familiar with this type equipment.

All electrical wiring must be completed in accordance with local, state and national codes and regulations and with the National Electric Code (ANSI/NFPA 70) or in Canada the Canadian Electric Code Part 1 CSA C.22.1.

Installationofequipmentmayrequirebrazingoperations.

Installer must comply with safety codes and wear appropriate safety equipment (safety glasses, work gloves, fire extinguisher, etc.) when performing brazing operations.

Installthisunitonlyinalocationandpositionasspecified on pages 4 & 5. This unit is designed only for Indoor installations and should be located with consideration of minimizing the length of the supply and return ducts. See Tables 5 - 9 (pages 19 - 22) and the rating plate for proper circulating airflow data.

Follow all precautions in the literature, on tags, and on labels provided with the equipment. Read and thoroughly understand the instructions provided with the equipment prior to performing the installation and operational checkout of the equipment.

This air handler may be used for temporary heating of buildings or structures under construction. See the guidelines listed on page 4.

Air handler installations in a residential garage must be installed as specified on page 5.

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GENERAL INFORMATION

This appliance has been tested for capacity and efficiency in accordance with AHRI Standards and will provide many years of safe and dependable comfort, providing it is properly installed and maintained. Abuse, improper use, and/or improper maintenance can shorten the life of the appliance and create unsafe hazards. Please read all instructions before installing the unit.

Before You Install this Unit

This equipment is securely packaged at the time of shipment and upon arrival should be carefully inspected for damage prior to installing the equipment at the job site.Claims for damage (apparent or concealed) should be filed immediately with the carrier.

it is recommended that the cooling load of the area to be conditioned should be calculated and a system of the proper capacity selected.

Check the electrical supply and verify the power supply is adequate for unit operation.The system must be wired and provided with circuit protection in accordance with local building codes. If there is any question concerning the power supply, contact the local power company.

Verify the duct system is appropriate for the air handler being installed. Please note that when replacing an existing system with lower air-flow, the duct system may require modification.

Locating the Air Handler

Survey the job site to determine the best location for mounting the unit. Consideration should be given to availability of electric power, service access, and noise.

The dimensions of the room or alcove must be able to accommodate the overall size of the unit and the installation clearances listed in Table 1. Physical dimensions for this air handler are also shown in Figure 12 (page 17).

Theairhandlershouldbesetintopositionbeforerouting the refrigerant tubing.

Minimum Clearances

This appliance must be installed in accordance with clearances listed in Table 1. The air handler must be installed with ample clearance for easy access to the air filter, blower assembly, heater assembly, controls, and vent connections. Applicable building codes may require additional clearance to equipment. Refer to applicable building codes for details.

Static pressure drop through louvered openings and through return air plenums should be considered in the overall duct design in the determination of the total external static pressure.

Operation of Air Handler During Construction

CAUTION:

Failure to follow these instructions will void the factory warranty and may significantly reduce the life or the performance of the air handler, and/or result in other unsafe conditions. It is the responsibility of the installing contractor to insure these provisions are met.

Operating an air handler in a construction environment can cause the appliance a variety of problems. Proper use of commercial portable space heating equipment during construction is recommended. This air handler may be used during construction if it is not in violation of any applicable codes and the following criteria are met:

The installation must meet all applicable codes and be permanently installed according to the instructions supplied with the air handler including electrical supply and duct work.

Theairhandlermustbecontrolledbyaproperlyinstalled thermostat that complies with the current provisions of the NEC (ANSI/NFPA 70) and all applicable codes having jurisdiction. Thermostat connections must be made in accordance with instructions supplied with the air handler and thermostat. See pages 11 - 12.

The installation must include a properly installed filter in the return air system with no by-pass air.The filter must be inspected frequently and replaced when necessary.

Return air must be supplied unrestricted and located such that dust and gases from construction activity are not introduced into the circulating air system.

Before occupying the structure: The filter must be replaced or cleaned, the duct work must be inspected and cleaned of any construction debris, and the air

INSTALLATION CLEARANCES

Left Side

......... 0 Inches

Right Side

....... 0 Inches

Back................

0 Inches

Front...........

See Notes

 

REAR

 

 

LEFT

RIGHT

 

 

SIDE

SIDE

 

FRONT

NOTES:

Alcove Installations - Allow 24 in. minimum clearance from front of unit to nearest wall or partition for servicing. Recommended clearance is 36 in.

Table 1. Minimum Unit Clearances

4

handler must be cleaned and/or repaired if found to be dirty, damaged, or malfunctioning in any way by a qualified HVAC technician. The air handler shall be inspected and approved by applicable local authority even if this requires redundant inspections.

The serial number for the air handler used during construction must be submitted in writing (fax and email also acceptable). This information will be used to track the long-term affects of air handler usage during construction.Proof of this submittal shall be available for the final inspection of the air handler prior to occupancy.

Installation in a Garage

WARNING:

Donotplacecombustiblematerialsonoragainst the cabinet. Do not place flammable materials, (gasoline, paint thinners, etc.) or any other flammable vapors and liquids, in the vicinity of the air handler.

The HMG**F1E, HMG**X1E & HCG**V1E series air handler may be installed in a residential garage with the provision that the unit must be located or protected to prevent physical damage by vehicles.

Plenums & Air Ducts

Plenums and air ducts should be installed in accordance with the standards of the National Fire Protection Association Standard for Installation of Air Conditioning Systems (NFPA 90A), Standard for Installation of Residence Type Warm Air Heating and Air Conditioning Systems (NFPA 90B), and all applicable local codes. NFPA publications are available by writing to: National Fire Protection Association, Batterymarch Park, Quincy, ME 02269 or visit www.NFPA.org online.

WARNING:

All return ducts must be secured to the air handler using appropriate methods. All return ducts must be adequately sealed.When return air is provided through the bottom of the unit, the joint between the air handler and the return air plenum must be air tight.

Return air and circulating air ducts must not be connected to any other heat producing device such as a fireplace insert, stove, etc. This may result in fire, explosion, carbon monoxide poisoning,personal injury,or property damage.

Design the duct work according to methods described by the Air Conditioning Contractors of America (ACCA).

Thisunitisdesignedonlyforusewithareturnandsupply duct. The return air duct must have the same free area

as the opening provided on the air handler. The ducts should be appropriately sized to the capacity of the air handler to ensure its proper airflow rating.

Use transition fittings if the supply and/or return air openings of the unit do not match the duct openings. These transitions should be dimensioned in accordance with standard practice as specified in the ASHRAE recommendations for duct transitions.

Flexible connectors may be used between the unit and the ductwork to prevent transmission of vibration from the unit to the structure. If electric heater kits are installed, heat resistant material must be used for the flexible connector at the supply air end of the unit.

It is good practice to seal all connections and joints with industrial grade sealing tape or liquid sealant. Requirements for sealing ducts vary from region to region.Consult with local codes for requirements specific to your area.

Unconditioned Spaces

All duct work passing through unconditioned space must be properly insulated to minimize duct losses and prevent condensation. Use insulation with an outer vapor barrier. Refer to local codes for insulation material requirements.

Air Filters

HMG**F1E, HMG**X1E & HCG**V1E series air handlers are not supplied with an air filter when shipped from the factory. The installer must provide a high velocity filter that is appropriately sized to the return air duct opening or filter rack located in the bottom of the unit. Accessing the filter does not require tools and can be removed from the front of the unit by removing the filter door. See Unit Maintenance (page 16) for filter sizes and installation information.

WARNING:

Never operate the air handler without a filter or with doors removed. Dust and lint can build up on internal components, resulting in loss of efficiency,equipmentdamage,andpossiblefire.

Acoustical Duct Work

Certain installations may require the use of acoustical lining inside the supply duct work. Acoustical insulation must be in accordance with the current revision of the Sheet Metal and Air Conditioning Contractors National Association (SMACNA) application standard for duct liners.Duct lining must be UL classified batts or blankets with a fire hazard classification of FHC-25/50 or less.

Fiber duct work may be used in place of internal duct liners if the fiber duct work is in accordance with the current revision of the SMACNA construction standard on fibrous glass ducts. Fibrous duct work and internal acoustical lining must be NFPA Class 1 air ducts when tested per UL Standard 181 for Class 1 ducts.

Damping ducts, flexible vibration isolators, or pleated media-style filters on the return air inlet of the air handler may be used to reduce the transmission of

5

equipment noise eminating from the air handler.These treatmentscanproduceaquieterinstallation,particularly in the heated space. However, they can increase the pressure drop in the duct system. Care must be taken to maintain the proper maximum pressure rise across the air handler, temperature rise and flow rate. This may mean increasing the duct size and/or reducing the blower speed. These treatments must be constructed and installed in accordance with NFPA and SMACNA construction standards. Consult with local codes for special requirements. For best sound performance, be sure to install all the needed gaskets and grommets around penetrations into the air handler, such as for electrical wiring.

Air handler INSTALLATION

The HMG**F1E, HMG**X1E & HCG**V1E Series Air Handler is shipped ready for vertical upflow installation and isapprovedforattic,basement,alcove/closetorcrawlspace installation with zero clearance to combustibles. See Table 1 (page 4) for required installation clearances. This appliance is approved only for indoor use.

The unit must be leveled at installation and attached to a properly installed duct system.

The surface that the air handler is mounted on must provide sound physical support of the unit.

The air handler must be installed so that all electrical components are protected from water.

If a louvered door is installed across the front of this unit, the appliance must be mounted flush or behind front edge of finished wall.

Always reinstall the doors on the air handler after servicingorcleaning/changingthefilters.Donotoperate the air handler without all doors and covers in place.

Packaging Removal

Remove the shipping crate and User’s Manual from the equipment. When removing the crate, use extra care so tubing connectios are not damaged. Do not pull on the coils upper tubes.

Mounting Applications

Vertical only air handlers are factory ready for upflow applications. These units may be applied in downflow applications when applied with the appropriate field kit.

Factory ready horizontal air handlers may be applied in upflow or horizontal-left and -right discharge applications. These units may also be applied in downflow discharge when applied with the appropriate field kit as specified in the units Technical Specifications.

Through-the-floor installations require a 1/4” thick noncombustible resilient gasket to be used whenever the supply or return air ducts pass through the floor.The gasket should be positioned between the duct, unit, and floor.

Horizontal

Drain Pan

Retur

Air

Figure 1. Upflow Installation

Upflow Installations

All air handlers are factory shipped, ready for upflow installation. The horizontal drain pan may be removed from the air handler when installing the unit in an upflow configuration. All return air must enter from the bottom of the unit. A typical upflow unit is shown in Figure 1.

Downflow Installations

The downflow accessory kit (SeeTechnical Specifications) is required for downflow applications. Instructions for installing the downflow accessory kit are included with the kit.It is recommended that the accessory be installed prior to installing the unit.All return air in downflow applications must enter through the top of the unit.A typical installation of the unit in a downflow application is shown in Figure 2.

Cabinet

Tube

Close-off

Plate

Adaptor Kit

Coil

Figure 2. Downflow Installation

6

Horizontal Installations

These air handlers can be installed horizontally in an attic, basement, crawl space or alcove.It can also be suspended from a ceiling in a basement or utility room in either a right to left airflow or left to right airflow as shown in Figure 3. Air handlers may or may not be shipped from the factory with all the parts required for horizontal left applications and horizontal right applications.If your unit does not have parts for a horizontal application, a kit may be available.

NOTE: In all horizontal applications in which the unit is installed above a finished ceiling and/or living space, a secondary drain pan must be installed under the entire unit to avoid damage to the ceiling in the event of condensate overflow.Additionally, it is recommended that an approved water level indicator or float switch device be used to shut down the unit in the event water is detected in the auxiliary drain pan.

If suspending the air handler from the ceiling, assemble a support frame (Figure 4) using slotted iron channel and full threaded rod. Fasten the frame together with nuts, washers, and lockwashers. Secure the support frame to the rafters with lag bolts. The air handler can also be

HORIZONTAL RIGHT

RETURN

AIR

HORIZONTAL LEFT

RETURN

AIR

Figure 3. Horizontal Configurations

 

Nuts (x2)

 

Lag

 

Bolt

Threaded

Washer

and

Rod

Lockwasher

 

 

Nuts (x2)

Figure 4. Unit Horizontally Suspended

suspended using steel straps around each end of the unit.The straps should be attached to the air handler with sheet metal screws and to the rafters with bolts.

Horizontal Left Installations:

1.Remove the coil access door.

2.Remove the plug from one of the threaded holes in the horizontal drain pan. Completely remove the webbing located in the threaded holes of the horizontal drain pan. IMPORTANT: If the webbing is not removed, the condensate will not drain properly and ceiling damage may occur.

3.Insert the plug (from horizontal drain pan) into the open and unused drain hole in the drain pan at the bottom of the unit to block bypass air.

4.Remove the corresponding drain line knockout from the coil access door to allow access to the horizontal drain.

5.Replace the door and attach the drain line.

Horizontal Right Installations:

1.Remove the coil access door.Unscrew the line-set tube close-off plate from the front left cabinet rail.

2.Slide the coil and drain pan assembly out of the unit.

3.Remove the sheet metal hairpin covers (if supplied) from the back of the coil and discard.

4.Place the horizontal drain pan on the opposite side of the coil. On units with 2 sets of knockouts, remove the other set of knockouts in the coil spacing plates and insert support rod.

5.Slide the coil and the horizontal drain pan assembly back into the unit. Re-attach the tube close off plate.

NOTE: For 24K & 30K BTUH applications, it may be preferrable to remove the blower assembly prior to installing the coil & drainpan. In this case follow instructions 1-4 as listed above but also remove the blower access door and blower assembly. The blower assembly is secured with two screws on either side near the front.With these removed the blower assembly can slide out of the front of the unit. Install the coil and drain pan as described in step 5 and then replace the blower assembly. Take care to ensure that the flanges on the sides of the blower assembly are captured by the pockets in the blower deck. It may be necessary to lift the blower assembly during insertion to allow the lower blower leg to clear the side of the drain pan. The blower will stop against the back of the blower deck. Replace the two screws and the blower access door and procede with steps 6-9.

6.Remove the plug from one of the threaded holes in the horizontal drain pan. Completely remove the webbing located in the threaded holes of the drain pan.

IMPORTANT: If the webbing is not removed, the condensate will not drain properly and ceiling damage may occur.

NOTE: It is recommended that the suction line be insulated up to the coil inside of the cabinet.

7

7.Insert the plug (from horizontal drain pan) into the open and unused drain hole in the drain pan at the bottom of the unit to block bypass air.

8.Remove the corresponding drain line knockout from the coil access door to allow access to the horizontal drain.

9.Replace the door and attach the drain line

Circuit Breaker Cover Installation

The air handler circuit breaker cover is designed to protect the breakers of an installed heater kit from debris and condensation.The cover attaches to the breaker recess of the air handler upper access door using a double-sided adhesive gasket. See Figure 5. The heater kit circuit breaker toggles are still accessible and can be switched with the cover in place.

There are 2 different circuit breaker cover sizes:

2-breaker cover for 2, 2.5, 3, 3.5, & 4 ton air handlers.

3-breaker cover for 5 ton air handlers.

After the heater kit is properly installed, remove the appropriate knockouts in the upper air handler access door and follow these instructions to install the breaker cover:

1.Clean any oil, dirt, or insulation fibers from the recess area of the air handler access door.This step is important for ensuring the gasket adheres properly to the sheet metal door.

2.Remove release paper from one side of the gasket and attach to back side of the breaker cover. NOTE:For proper alignment, It is recommended to leave the center section of the gasket in place when attaching the gasket to the breaker cover. Remove the center section after the gasket is applied to the breaker cover.

Circuit

 

Breakers

 

Recess

 

Circuit

 

Breaker

 

Cover

 

Air

 

Handler A

 

ccess

 

Door

Figure 5. Circuit Breaker Cover

3.Remove the release paper from the other side of the gasket and attach to the circuit breaker recess area.

4.Press firmly along all four sides of the cover to ensure gasket and cover are securely attached to the access door.

Refrigerant Line Connections

WARNING:

NITROGEN

 

 

 

 

 

 

 

HEALTH

1

 

 

 

 

 

 

 

 

 

 

 

 

 

FLAMMABILITY

0

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

REACTIVITY

0

 

 

 

 

 

 

0 Minimal Hazard 1 Slight Hazard

The coil in the air handler is factory shipped with a nitrogen charge. Avoid direct face exposure or contact with valve when gas is escaping. Always ensure adequate ventilation is present during the depressurization process. Address any uncertainties before proceeding. Failure to comply with this warning could result in equipment damage, personal injury, or death.

The installer should make every effort to ensure the field installed refrigerant containing components of the system have been installed in accordance with these instructions and sound installation practices for reliable system operation and longevity.

Theairhandlercoildoesnotcontainarefrigerantcharge.

Refer to the installation instructions supplied with the outdoor unit for refrigerant charge information.

Alwaysrefertotheinstallationinstructionssuppliedwith the outdoor unit for piping requirements. The suction and liquid lines must be sized in accordance with the condensing unit specifications. See Figure 12 (page 17) for liquid and suction line locations.

When connecting refrigerant linesets together, it is recommended that dry nitrogen be flowing through the joints during brazing.This will prevent internal oxidation and scaling from occurring.

Refrigerant tubing should be routed in a manner that minimizes the length of tubing and the number of bends in the tubing. It should be supported in a manner that prevents it from vibrating or abrading during system operation.Tubing should be kept clean of foreign debris during installation.

Ifpreciseformingofrefrigerantlinesisrequired,acopper tubing bender is recommended.Avoid sharp bends and contact of the refrigerant lines with metal surfaces.

Refrigerant lines should be wrapped with pressure sensitive neoprene or other suitable material where they pass against sharp sheet metal edges.

HMG**F1E,HMG**X1E&HCG**V1ESeriesairhandlers are charged through service valves on the end of the liquid tube for each circuit. These must be removed before brazing the line sets.

8

Orifice Removal & Installation

The orifice installed in the air handler has been sized for use with the most popularly matched outdoor units. The orifice size as shipped from the factory is listed on the air handler rating plate. Perform steps 1 - 9 to confirm that the orifice size meets the requirements outlined in the outdoor unit installation manual.

1.Remove the cap from the end of the liquid line.

2.Verify pressurization by depressing the Schrader valve on the end of the liquid line.Listen for any escaping gas.

If there is no pressure, test the coil for leakage.

If leakage is found, clearly mark the location of the leak and return the coil to the distributor for processing.

If no leaks are found, the coil may be installed.

3.Depress the valve to relieve all pressure from the coil.

4.Remove and discard the valve core.

CAUTION:

To prevent damage to the unit or internal components, it is recommended that two wrenchesbeusedwhenlooseningortightening nuts. Do not over tighten!

5.Using two wrenches, loosen the nut and distributor body as shown in Figure 6. Turn the assembly nut counter- clock-wise until the orifice body halves are seperated.

6.Insert a light-gauge wire hook between the distributor body and the restrictor orifice while being careful not to scratch either part. Carefully remove the restrictor orifice from the distributor body. See Figure 7.

7.Check the actual size of the new orifice. NOTE: The size is stamped on its side. Do not use pin gauges to measure the orifice diameter.

8.Insert the new orifice into the distributor body, rounded end down. See Figure 8.

CAUTION:

To prevent damage to the unit or internal components, it is recommended that two wrenchesbeusedwhenlooseningortightening nuts. Do not over tighten!

9.Realign the assembly nut on the distributor body and hand tighten both components. Mark a line on both bodies and then tighten an additional 1/4 turn using two wrenches.The movement of the two lines will show how much the nut is tightened. If a torque wrench is used, tighten to 10-12 ft. lbs. or 14-16 Nm.

Figure 7. Removal of Orifice

Figure 8. Restrictor Insertion into Distributor Body

Connecting the Linesets

IMPORTANT NOTES FOR HORIZONTAL OR DOWNFLOW INSTALLATIONS WITH TXV VALVE:

The sensing bulb must be located flush against the suction line for optimum heat transfer.

Avoidattachingthesensingbulbtothelowestpartof the suction line where condensate may accumulate.

Do not locate the sensing bulb on vertical sections of the lineset.

For horizontal lines, the bulb should not be located at 12 or 6 o’clock position of the suction line. The best location is at 4 or 8 o’clock.

For additional information on proper sensing bulb locations, please refer to the valve manufacturer’s instructions.

IMPORTANT: The steps in the Orifice Removal & Installation section must be performed before the linesets are connected.

Figure 6. Loosening of Nut & Distributor Body

9

1. Remove grommets from line set holes.

CAUTION:

It is recommended that a wet rag be wrapped around the suction line in front of the close off plate or the sensing bulb (if TXV is installed) before applying heat. Failure to keep components cool during brazing may result in structural damage, premature equipment failure, or possible personal injury.

2.Unbraze and remove the cap on the suction line.

3.Route and cut both lineset tubes to proper length in accordance with the outdoor unit specifications. Verify the ends are round, clean, and free of any burrs.

4.Positiongrommetonlinesetwithsufficientdistanceaway from brazing area.Brazing processes can permanently damage grommets.

5.Connect the suction and liquid lineset tubes.

CAUTION:

It is recommended that a wet rag be wrapped around the suction line in front of the close off plate or the sensing bulb (if TXV is installed) before applying heat. Failure to keep components cool during brazing may result in structural damage, premature equipment failure, or possible personal injury.

UPFLOW

HORIZONTAL

3/4” Adapter w/ 3/4” dia. hose barb

DOWNFLOW

3/4” minimum dia. PVC or flexible tubing

NOTES:

1.The drain lines must maintain a downward slope to ensure proper condensate drainage.

2.Each condensate drain must be trapped separately using a J-Trap or field supplied loop.

Figure 9. Condensate Drainage Example

6.Braze the individual connections with dry nitrogen flowing through the joints. NOTE: This will prevent internal oxidation and scaling from occurring.

7.Wrap the refrigerant lines with pressure sensitive neoprene or other suitable material especially where the lines enter the opening in the sheet metal.

8.Evacuate the system of moisture and non-condensables to prevent low efficiency operation or damage to the unit. The suggested range of evacuation is 350 - 500 microns.

9.Charge the system with refrigerant. Refer to the outdoor unit installation manual for additional charging instructions.

10.Check the system for leaks, including the lineset and the brazed joints.

11.Replace all grommets and properly dispose of all removed parts.

Condensate Drainage

CAUTION:

The air handler must be level to ensure proper condensate drainage. An unlevel installation may result in structural damage, premature equipment failure, or possible personal injury.

Methods for disposing of condensate vary according to local codes. Refer to local codes or authority having jurisidiction for restrictions and proper condensate disposal requirements.

The drain pan that is supplied with this air handler contains a primary and secondary drain fitting. The condensate is drained from the unit through two 3/4” female pipe fittings located on the front side of the unit as shown in Figure 9.

Thedrainpanmustbedrainedwithfieldsuppliedtubing or pvc pipe and adequately trapped. Both drain tubes must have a minimum diameter of 3/4” and be trapped separately.

IMPORTANT: Failure to install a trap may result in condensation overflowing the drain pan, resulting in substantial water damage to surrounding area.

Routebothlinestoasuitabledrain,avoidingsharpbends and pinching of the lines. The drain should maintain a minimum horizontal slope in the direction of discharge of not less than 1” vertical for every 10 ft of horizontal run.

If the air handler is located in or above a living space where damage may result from condensate overflow, an auxiliary drain pan shall be installed under the unit. A separate drain line should extend from the pan to a conspicuous point and serve as an alarm indicating that the primary drain is restricted. As an alternative to a separate drain line, an approved water level indicator or float switch device may be used to shut down the unit in the event water is detected in the auxiliary pan.

10

Install a single 5 inch trap in the condensate drain line as close to the coil as possible. Make sure that the top of the trap is below the bottom of the drain pan to prevent the condensate from overflowing the drain pan. NOTE: There must be only one trap in the drain line. Using more than one trap may prevent drainage.

Primethetrapwithwater.Insulatethedrainifitislocated in an unconditioned space, and test the condensate line for leaks. Consult local codes for additional restrictions or precautions.

During system checkout, inspect the drain line and connections to verify proper condensate drainage.

ELECTRICAL connections

WARNING:

ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD

Failure to follow safety warnings exactly could result in serious injury or property damage.

Improper servicing could result in dangerous operation, serious injury, death or property damage.

Beforeservicing,disconnectallelectricalpower to the air handler.

When servicing controls, label all wires prior to disconnecting. Reconnect wires correctly.

Verify proper operation after servicing.

Electrical connections must be in compliance with all applicable local codes and ordinances, and with the current revision of the National Electric Code (ANSI/NFPA 70).

For Canadian installations, the electrical connections and grounding shall comply with the current Canadian Electrical Code (CSA C22.1 and/or local codes).

Pre-Electrical Checklist:

Verify the voltage, frequency, and phase of the supply source match the specifications on the unit rating plate.

Verify that the service provided by the utility is sufficient to handle the additional load imposed by this equipment. See the unit wiring label or Tables 9 - 10 (pages 28 - 29) for proper high and low voltage wiring.

Verify factory wiring is in accordance with the unit wiring diagram (Figures 18 - 20, pages 25 - 27).Make sure the connections didn’t loosen during shipping or installation.

Line Voltage

Anelectricaldisconnectmustbelocatedwithinsight of and readily accessible to the unit.This switch shall be capable of electrically de-energizing the outdoor unit. See unit data label for proper incoming field wiring. Any other wiring methods must be acceptable to authority having jurisdiction.

It is recommended that the line voltage to the unit be supplied from a dedicated branch circuit containing the correct fuse or circuit breaker for the unit.

Overcurrent protection must be provided at the branch circuit distribution panel and sized as shown on the unit rating label and according to applicable local codes. See the unit rating plate and Tables 10 & 11 (pages 28 & 29) for maximum circuit ampacity and maximum overcurrent protection limits.

The installer should become familiar with the wiring diagram/schematic before making any electrical connections to the unit. See the unit wiring label or Figures 18 - 20 (pages 25 - 27).

Use only copper wire for the line voltage power supply to this unit. Use proper code agency listed conduit and a conduit connector for connecting the supply wires to the unit. Aluminum supply wire may be used if a heater kit is installed.

If replacing any of the original wires supplied with the unit,thereplacementwiremustbecopperwireconsisting of the same gauge and temperature rating.

Provide power supply for the unit in accordance with the unit wiring diagram, and the unit rating plate. Use UL listed conduit and conduit connectors for connecting the supply wires to the unit and for proper grounding. Field supplied bushings for the power supply cables must be added to support and protect the power supply cables.

All 208/230Volt units are shipped from the factory wired for 240 volt operation. For 208V operation, remove the lead from the transformer terminal marked 240V and connect it to the terminal marked 208V.

Grounding

WARNING:

The unit cabinet must have an uninterrupted or unbroken electrical ground to minimize personalinjuryifanelectricalfaultshouldoccur. Do not use gas piping as an electrical ground!

This unit must be electrically grounded in accordance with local codes or, in the absence of local codes, with the National Electrical Code (ANSI/NFPA 70) or the CSA C22.1 Electrical Code. Use the grounding lug provided in the control box for grounding the unit.

Thermostat Connections

Thermostat connections shall be in accordance with the instructions supplied with the thermostat. The thermostat used with this equipment must operate in conjunction with any installed accessories. Typical AC and air handler hookups are shown in Figure 10 (page 12).

Where local codes require that the thermostat wiring must be routed through a conduit or raceway, splices can be made inside the unit; however, all wiring must be NEC Class 1 and separated from incoming power leads.

11

CAUTION:

Isolation must be maintained from the external Class 2 output of any transformer in a cooling circuit.Use a thermostat with isolating contacts to prevent inter-connection of Class 2 outputs.

The thermostat should be mounted about 5 feet above the floor on an inside wall.DO NOT install the thermostat on an outside wall or any other location where its operation may be adversely affected by radiant heat from fireplaces, sunlight, or lighting fixtures, and convective heat from warm air registers or electrical appliances. Refer to the thermostat manufacturer’s instruction sheet for detailed mounting and installation information.

Install the grommet, which is packed with the unit, in the hole for low-voltage wires. Properly connect the

low-voltage wiring between the thermostat, outdoor unit, and control board. NOTE: When the low voltage wires are positioned in this grommet, the grommet will prevent chafing and/or shorting of the low voltage leads.

Control Board

The control board in the air handler controls the timing sequence of the elements.The board is equipped with a 3 second blower on delay and a 15 second blower off delay in heating and a 40 second blower off delay in cooling. See Figures 14 or 15 (page 23) and Table 12 (pages 2931) for control board modes and actions.

Twinning

HMG**F1E series air handler’s are not supplied with a built in twinning capability.To connect two air handlers to a common single stage AC condensing unit or heat pump, a twinning kit is available for field installation.Please follow the instructions supplied with the kit.

 

Thermostat

 

Thermostat

 

Thermostat

 

W Y G R

NOTE: Jumper W1 & W2

W Y G R

 

Y1 W2 W/E Y2 G R

 

 

 

 

 

 

 

together if not using W2

 

 

Air

 

 

on thermostat

 

 

Conditioner

 

 

 

 

 

 

 

Y1

 

Y1

Y1

 

 

 

 

 

Air

 

W2

 

W2

 

Handler

 

W1

Air

W1

 

W1

Air

O

Conditioner

O

 

Conditioner

Y/Y2

Y

Y/Y2

Y2

 

 

Y

 

 

 

Y

G

 

G

 

 

 

 

G

 

R

 

R

R

 

 

C

C

C

R

 

C

 

 

Air

 

Air

C

C

 

 

 

 

Handler

 

Handler

 

Typical Air Conditioner with

Typical Air Conditioner with

Typical 2-Stage Air Conditioner

Standard Air Handler

2-Stage Air Handler

with 2-Stage Air Handler

 

Thermostat

 

 

Thermostat

 

W2 O Y G R C E

NOTE: Jumper W1 & W2

W2 O Y G R C W/E

 

 

together if not using W2

 

 

 

 

on thermostat

 

Air

NOTE: Jumper between

Y1

 

W2 & E is required when

 

Handler

 

 

no OD T-Stat is used.

W2

 

 

 

O

W1

W2

W1

 

 

 

 

W2

O

O

 

 

 

Y

 

Y

Y/Y2

Y

 

 

 

G

 

 

G

 

R

 

R

R

R

 

 

 

C

 

C

C

C

 

 

 

 

 

Heat Pump

Air

Heat Pump

 

 

Handler

 

 

 

 

 

Thermostat

 

Y1 W2 W/E OY2 G R C

Y1

Y1

 

W2

 

W1

W2

O

O

 

Y/Y2

Y2 OUT

 

G

 

R

R

 

C

C

 

Air

Heat Pump

Handler

 

Typical Heat Pump with

Typical Heat Pump with

Typical 2-Stage Heat Pump with

Standard Air Handler

2-Stage Air Handler

2-Stage Air Handler

 

Figure 10. Typical Thermostat Connections

 

12

NOTE: Variable speed air handlers cannot be twinned.

Heater Kits

When electric heat packages with circuit breakers are field-installed, the circuit breaker may be used as a disconnecting means in most applications. Reference the NEC and local codes for disconnect requirements.

If a heater kit is installed:

The HMG**F1E series air handler is shipped from the factory without an electric heater kit installed. If Electric heat is desired, the H6HK heater kit may be purchased separately and field installed. Determine the correct size heater kit for your unit by referring to the list below or the units rating label.

24K & 30K BTUH...........................................

15Kw max

36K & 42K BTUH...........................................

20Kw max

48K & 60K BTUH...........................................

30Kw max

1.Connect the 2 wire plug of the air handler to the mating 2 wire plug of the heater kit.

2.Connect the line voltage leads to the circuit breaker or terminal block provided.

3.Connect the heater kit plug with the mating receptacle on the air handler control board.

If a heater kit is not installed:

1.Remove the 2 wire plug of the air handler by cutting the wires and discarding the plug.

2.Strip the ends of the 2 air handler wires and connect to the line-voltage leads with the 2 wire nuts provided.

Electronic Air Cleaner (EAC)

The unit has an output to power an electronic air cleaner when the blower is running. This output is rated to 1.0 amp at 208/240V.

Humidifier

The unit has an output to power a humidifier when the blower is running. This output is rated to 1.0 amp at 208/240V.

Optional Humidistat

(HMG**X1E & HCG**V1E Models Only)

The optional humidistat may be installed in the return air duct to provide excellent humidity control when needed and maximum system capacity and energy efficiency when humidity levels are normal. The humidistat senses when humidity in the return air stream is above a preset level (field adjustable) and sends a signal to the motor to reduce the airflow so that more moisture may be removed until the humidity level drops. The air handler is pre-programmed for humidistat operation.

Install the humidistat in the return air duct as directed in the installation instructions included with the kit. Wire the humidistat through the low-voltage wire entrance in the air handler to the control board terminal marked DEHUM. Wire the humidistat to open on rise in humidity.See Figures 16 & 17 (page 24).

Startup & Adjustments

WARNING:

NITROGEN

 

 

 

 

 

 

 

HEALTH

1

 

 

 

 

 

 

 

 

 

 

 

 

 

FLAMMABILITY

0

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

REACTIVITY

0

 

 

 

 

 

 

0 Minimal Hazard 1 Slight Hazard

The evaporator coil is shipped from the factory with a nitrogen charge. Use caution when preparing coils for field connections. If repairs make it necessary for evacuation and charging, it should only be attempted by qualified, trained personnel thoroughly familiar with this equipment. Some local codes require licensed installation service personnel to service this type of equipment. Under no circumstances should the equipment owner attempt to install and/orservicethisequipment.Failuretocomply with this warning could result in equipment damage, personal injury, or death.

Before You Start the Unit

Prior to start-up, complete the following inspections:

Verify the unit is level and properly located with adequate clearances for servicing the unit. See Table 1 (page 4).

Check condensate drain line(s) for proper drainage.

Verify the surrounding area and top of the unit is free from obstructions and debris.

Check all duct connections. Make sure the duct work is adequately sealed to prevent air leakage.

Check all coil connections for leaks.

Verify that the line voltage power leads are securely connected and the unit is properly grounded.Make sure all doors are installed before restoring power to the unit

Verify the thermostat is wired correctly. Make sure all low voltage wires are securely connected.

Verify the power supply branch circuit overcurrent protection is sized properly.

Verify filter is properly and securely installed.

IMPORTANT: Before starting the unit, install the initial charge on units that are factory shipped with a nitrogen holding charge:

1.Read all installation instructions first.

2.Purge the nitrogen holding charge.

3.Evacuate the unit to 350 - 500 microns.

4.Allow the unit to remain under vacuum for at least 30 minutes.

5.Weigh in the proper amount of new (or reclaimed) refrigerant. Refer to the air conditioner or heat pump installation manual for the proper type and quantity of refrigerant.

13

Refrigerant Charging

The system refrigerant charge can be checked and adjusted through the service ports provided at the front panel of the outdoor unit.Use only gauge lines which have a Schrader depression device present to actuate the valve.

Air Circulation

Running the Blower Continuously

Set the thermostat’s system mode to OFF and the thermostat’s fan mode to ON. The blower motor should run continuously. Check for air delivery at the register(s). Ensure that there are no obstructions at the registers or in the ducts.

Selecting continuous low speed fan operation

(Standard Blower)

The air handler is equipped with an option of continuous low speed fan operation. When G is energized without Y/ Y2, the air handler will operate using the cooling speed. With G & Y/Y2 or Y/Y2 energized, the air handler will operate in the selected cooling speed (including 40 sec blower-off delay).

Turning the Blower Off

Set thermostat’s fan mode to AUTO, the blower will shut down immediately.

System Cooling

1. Set the thermostat’s system mode to COOL and fan mode to AUTO. Lower the thermostat’s temperature mode below room temperature and observe that the blower energizes. Check the air being discharged at the register is cooler than room temperature. Verify unit refrigerant pressures are in order. Blower should be turning in direction indicated by arrow.

NOTE: DO NOT alter unit wiring. Listen for any unusual noises. Locate the source and correct as needed.

2. Allow the unit to run for several minutes and then set the thermostat’s temperature above room temperature. Verify the blower cycles off with the thermostat.

System Heating

1.Set the thermostat’s system mode to HEAT and the fan mode to AUTO. Increase the thermostat’s temperature above room temperature and observe that the blower energizes.Check the air being discharged at the register is warmer than room temperature.

2.Allow the unit to run for several minutes and then set the thermostat’s temperature below room temperature. Verify the blower cycles off with the thermostat.

Selecting Minimum Electric Heat Airflow

The minimum electric heat airflow setting controls the minimum air flow that will be produced whenever electric heater kits are used. When the electric heater kit is energized along with a heat pump, the airflow may be higher depending on the basic cooling/heat-pump airflow setting. The minimum electric heat airflow is selected by the red blower wire on 3-speed models or setting switches 1,2,3 & 4 on HMG**X1E models. HCG**V1E models

automatically set the heating speed based on the amount of installed heat.The remaining 3 HEAT switches have no function. Switch settings are listed in Table 6 (page 20) or Table 9 (page 22). NOTE: For HMG**X1E Models, the minimum electric heat airflow setting may be set higher, but must never be set lower than the setting shown in Table 7 (page 21).

Blower Configurations

Determining Nominal System Capacity

To select the appropriate airflows for the air handler, the nominal system capacity must be known. The nominal system capacity is always the nominal capacity of the outdoor unit. However, in some situations the nominal system capacity may not be the same as the nominal capacity of the air handler. Always refer to the nominal capacity of the outdoor unit to determine the nominal system capacity.

NOTE: The CFM values listed in Table 9 (page 22) are not dependent on duct static pressure. The VSHE motor automatically compensates for changes in duct static pressure (within the limits of the motor).

3-Speed Units

The blower speed is preset at the factory for operation at the same speed for heating and cooling, by using the jumping terminal on the blower motor and connecting it to the desired speed with both the red and black wires connected to the jumping terminal. NOTE: The control board is programmed with a 40 second off delay in the cooling mode for optimum system performance and efficiency.

CAUTION:

To avoid personal injury or property damage, make sure the motor leads do not come into contactwithanyuninsulatedmetalcomponents of the unit.

For optimum system performance and comfort, it may be necessary to change the factory set speed. See Table 5 (page 19) for airflow data. To change the blower speed:

1.Disconnect all electrical power to the unit and remove the upper door.

2.Remove the black and red wires from the blower motor jumping terminal. Discard the blower motor jumping terminal.

3.Connect the heating speed wire (red) and the cooling speed wire (black) to the desired blower speed marked on the terminal block of the blower motor.

Terminal 4 = Hi speed

Terminal 5 = Med speed

Terminal 6 = Low speed

14

4.Replace the upper door and secure it to the unit.

5.Restore power to the unit.

High Efficiency Units (Variable & Fixed Speed)

IMPORTANT! This air handler has been designed to give the installer maximum flexibility to optimize system performance, efficiency, and comfort. Because there are so many different ways to set up the air handler it is important to read and follow these directions carefully.

HMG**X1E & HCG**V1E series air handlers use high efficiency circulating air motors that come in two variations and both are controlled differently.The fixed speed motor control board (Figure 16, page 24) controls the torque and the variable speed motor control board (Figure 17) controls the airflow at a constant CFM. Both boards use the same control board.

Before operation, the air handler must be configured to matchtheunitwiththesystem,systemoptions,andclimatic conditions. When configured, the air handler responds directly to the thermostat inputs, as well as the optional humidistat (see page 13). During normal operation, the motor will gradually change speeds during start-up, shut down, when thermostat inputs change, and when the duct static pressure changes (vents closed or opened, filter clogging, etc.). The air handler is configured by setting the selector switches and removing jumper connectors.

Selecting Basic Heating Airflow

Fixed & variable speed motor control boards (Figures 16 & 17) contain a set of dip switches for setting the blower speed. For HMG**X1E models, pins 1-4 set the speed for heating. For HCG**V1E models, the A/B switch must be set for the appropriate air handler size (either setting can be used for 48K or 60K BTUH applications).The airflow is set automatically based on the amount of installed heat. For both HMG**X1E & HCG**V1E models, the cooling speed is selected via switches 5,6,7,& 8. To determine the appropriate switch settings for your installation, see Tables 6, 7, 8, or 9 (pages 20 - 22).

Selecting Basic Cooling / Heat Pump Airflow

Thebasiccooling/heat-pumpairflowiscontrolledbysetting switches 5 - 8 on the motor control board (mounted on the blower). All airflows for other modes of operation (except electric heat) are determined by this basic setting. FAN ONLY would deliver 50% of the selected cooling airflow. Table 8 (page 21) lists the basic airflow values versus the airflow selector switch settings and ranges of basic air flow settings recommended for each nominal system capacity.

When operating in the heat pump mode, a higher basic airflow setting will increase the energy efficiency and capacity but will also decrease the supply air temperature.

For maximum capacity and energy efficiency, select an airflow at or near the top of the range for that nominal capacity. See Table 8 (page 21).

Formaximumdehumidification,selectanairflownearthe middle or bottom of the range for that nominal capacity. Additional information on humidity control can be found in the Humidistat and Delay Setting sections.

For thermostats with a dehumidifier output, use a field supplied wire to connect the thermostat’s dehumidifier output to the terminal marked DHUM. The thermostat should be set so that the DHUM output should be high (energized) when dehumidification is needed. See also Dehumidification Options section.

IMPORTANT! If coil icing is observed, the basic cooling/ heat-pump airflow selected may be too low. Verify the setting selected is within the range shown in Table 8 and that the the system is properly charged.Please refer to the instructions supplied with the outdoor unit.If icing continues to occur, raise the selected airflow one or two steps.

NOTE: Variable speed air handlers with SEER ratings higher than 15 are matched with a 2-stage cooling outdoor unit. They are programmed to operate at 75% of the selected airflow while the system is in the lo-cool mode and 100% of the selected airflow while in hi-cool mode.

Dehumidification Options

(HMG**X1E or HCG**V1E Models Only)

Both motor control boards (Figures 16 & 17, page 24) have a DHUM connection that allows the system to increase the amount of humidity that is removed from the circulating air. This is accomplished by reducing the CFM and allowing the cooling coil to become colder.This will only occur when there is a call for cooling. There are many ways that this can be electrically wired.

1.If the room thermostat incorporates a humidity sensor and DHUMoutput, connect the DHUMon the thermostat to the DHUM terminal on the motor control board.

2.If using a separate humidistat, connect the DHUM & R terminals on the humidistat to the DHUM & R terminals on the motor control board of the air handler. In this option, the DHUM output of the humidistat must be set to be normally open and closed when there is a call for humidification. See Figure 11.

3.If a humidistat is not available, it is an acceptable option to connect the R & DHUM terminals on the motor control board together with a field supplied wire. This option causes the blower to run at a reduced CFM for 10 minutes after a call for cooling. NOTE: If outdoor unit is a heat pump, connect the O terminal to DHUM.

 

 

 

 

MOTOR

HUMIDISTAT

CONTROL BOARD

 

 

 

 

DHUM

 

 

DHUM

 

 

R

 

 

R

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Figure 11. DHUM Wiring Configuration

15

UNIT MAINTENANCE

Proper maintenance is most important to achieve the best performance from a air handler. Some of the components and their locations are shown in Figure 13 (page 18). If any component of the air handler must be replaced, use only factory authorized replacement parts specified in the Replacement Parts List provided online.

WARNING:

ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD

Failure to follow safety warnings exactly could result in serious injury or property damage.

Improper servicing could result in dangerous operation, serious injury, death or property damage.

Beforeservicing,disconnectallelectricalpower to air handler.

When servicing controls, label all wires prior to disconnecting. Reconnect wires correctly.

Verify proper operation after servicing.

These maintenance instructions are primarily intended to assist qualified technicians experienced in the proper maintenance and operation of this appliance.

Always reinstall the doors on the air handler after servicingorcleaning/changingthefilters.Donotoperate the air handler without all doors and covers in place.

Verify that the thermostat is properly installed and is not being affected by drafts or heat from lamps or other appliances.

To achieve the best performance and minimize equipment failure, it is recommended that a yearly maintenance checkup be performed. At a minimum, this check should include the following items:

Air Filter(s)

HMG**F1E, HMG**X1E & HCG**V1E series air handlers are not supplied with a single air filter when shipped from the factory. It is recommended that the filter be cleaned or replaced monthly. Newly built or recently renovated homes may require more frequent changing until the construction dust has minimized. Filter sizes shown in Table 2 are available at most local retailers.

WARNING:

Never operate the air handler without a filter in place. Dust and lint in the return air can build up on internal components, resulting in loss of efficiency,equipmentdamage,andpossiblefire.

Filters designed to remove smaller particles such as pollen, may require additional maintenance.

Furnace Size (BTUH)

Filter Size

 

 

24K & 30K

12 x 20 x 1

36K & 42K

18 x 20 x 1

 

 

48K & 60K

20 x 20 x 1

Table 2. Filter Sizes

Blower Compartment

Dirt and lint can create excessive loads on the motor resulting in higher than normal operating temperatures and shortened service life. It is recommended that the blower compartment be cleaned of dirt or lint that may have accumulated in the compartment or on the blower and motor as part of the annual inspection.

Blower Fan Wheel

Inspect the blower wheel blades for accumulations of dirt and clean if necessary. Inspect mounting nut for tightness when done.

Blower Motor & Assembly

Inspect the blower assembly and motor mounting brackets for tightness and corrosion. Correct deficiencies if necessary. The blower motor contains sealed bearings and under normal operating conditions, no maintenance is necessary for the life of the equipment.

TROUBLESHOOTING

If the air handler fails to operate, check the following:

Is the electric turned on?

Is the thermostat operating properly?

Are the blower compartment door(s) in place?

Is the air handler disconnect closed?

Has the circuit breaker tripped or the control board fuse burned open?

Are any manual reset switches open?

Is the filter dirty or plugged?

Is the LED on both control boards constantly ON? If not, refer to Tables 3 or 4 to determine fault condition.

Red LED (AN2)

Diagnostic

 

 

OFF

Control Fault (No Power)

Flash

Blower Fault

ON

Normal Operation

Table 3. Air handler Control Board Fault Conditions

 

Diagnostic

Green

Red

 

LED

LED

 

 

 

Control Fault (No Power)

Off

Off

Fixed

Normal Operation

On

On

Speed

Motor Fault

On

Flash

Furnaces

Twin Fault (no motor fault)

Flash

On

 

Communications Fault

Flash

Flash

Variable

Control Fault (No Power)

Off

Off

Normal Operation

On

On

Speed

Motor Fault

On

Flash

Furnaces

 

 

 

Communications Fault

Flash

Flash

 

Table 4. Motor Control Board Fault Conditions

16

Figures & Tables

3/4”

3/4”

3/4”

 

13”

 

11/8” K.O.

 

(typ.)

 

 

“A”

 

 

1 7/8" K.O.

 

 

11/4”

 

 

 

15/8”

11/4”

 

 

17/8”

 

 

3 1/4”

 

2 5/8”

 

1 1/8”

 

 

1 7/8”

11/8” K.O.

 

7/8" K.O.

3 5/8”

(typ.)

 

1 7/8”

 

 

 

 

 

5 5/8”

13/4” K.O.

 

 

 

 

 

 

(typ.)

 

 

DETAIL “D”

 

 

 

“H”

3 1/4”

SUCTION

2 1/4”

 

 

LIQUID

15 1/4”

 

13”

 

“W”

22"

Furnace Size (BTUH)

H

W

A

Detail D

 

 

 

 

 

24K & 30K

43-5/16

14-3/16

12-3/4

No

 

 

 

 

 

36K (HMG**F1E Only)

43-5/16

19-11/16

18-1/4

No

 

 

 

 

 

36K & 42K

49-5/16

19-11/16

18-1/4

No

 

 

 

 

 

48K & 60K

55-15/16

22-7/16

21

Yes

 

 

 

 

 

Figure 12. HMG**F1E, HMG**X1E & HCG**V1E Series Physical Dimensions

17

Upper Door

Assembly

Lower Door

Assembly

Circuit

 

Breaker (60A)

Heating Element

 

Assembly

 

Transformer

Motor Control

 

Board

 

Blower

Control

Wheel

Board

 

Capacitor

 

Motor

 

Mount Kit

Blower

Housing

Blower

Coil Motor

Assembly

Horizontal

Drain Pan Vertical

Drain Pan

Filter

Tracks

Filter

Door

Figure 13. HMG**F1E, HMG**X1E & HCG**V1E Series Air Handler Components

18

AIRFLOW DATA

Dry Coil ESP

0.10

 

0.20

0.30

0.40

0.50

 

0.60

0.70

0.80

 

 

 

 

 

 

 

 

 

 

 

 

 

Low

683

 

647

607

563

515

 

463

406

345

 

Corrected ESP1

0.00

 

0.07

0.19

0.30

0.42

 

0.53

0.65

0.76

HMG24F1E

Medium

861

 

823

781

734

682

 

625

564

498

Corrected ESP1

0.00

 

0.00

0.11

0.23

0.36

 

0.48

0.60

0.72

 

 

 

 

High

1072

 

1026

975

920

860

 

797

730

659

 

Corrected ESP1

0.00

 

0.00

0.00

0.14

0.27

 

0.40

0.53

0.67

 

Low

849

 

825

793

753

704

 

647

581

508

 

Corrected ESP1

0.00

 

0.04

0.15

0.27

0.38

 

0.50

0.62

0.74

HMG30F1E

Medium

1118

 

1087

1046

997

940

 

874

799

717

Corrected ESP1

0.00

 

0.00

0.04

0.17

0.29

 

0.42

0.55

0.68

 

 

 

 

High

1277

 

1233

1184

1130

1070

 

1005

935

860

 

Corrected ESP1

0.00

 

0.00

0.00

0.10

0.23

 

0.36

0.49

0.63

 

Low

953

 

915

871

821

764

 

701

631

555

 

Corrected ESP1

0.00

 

0.04

0.16

0.27

0.39

 

0.51

0.62

0.74

HMG36F1E

Medium

1265

 

1232

1188

1133

1067

 

991

903

805

Corrected ESP1

0.00

 

0.00

0.03

0.15

0.28

 

0.41

0.54

0.68

 

 

 

 

High

1427

 

1385

1333

1270

1196

 

1113

1018

913

 

Corrected ESP1

0.00

 

0.00

0.00

0.09

0.23

 

0.36

0.50

0.64

 

Low

1324

 

1302

1271

1233

1187

 

1134

1072

1003

 

Corrected ESP1

0.00

 

0.06

0.17

0.27

0.38

 

0.49

0.61

0.72

HMG42F1E

Medium

1485

 

1455

1418

1373

1320

 

1260

1193

1118

Corrected ESP1

0.00

 

0.00

0.13

0.24

0.36

 

0.47

0.58

0.70

 

 

 

 

High

1637

 

1601

1558

1506

1447

 

1380

1305

1223

 

Corrected ESP1

0.00

 

0.00

0.00

0.21

0.33

 

0.44

0.56

0.68

 

Low

1605

 

1606

1592

1565

1524

 

1468

1399

1316

 

Corrected ESP1

0

 

0.11

0.21

0.31

0.42

 

0.52

0.63

0.74

HMG48F1E

Medium

1977

 

1939

1890

1830

1758

 

1675

1580

1474

Corrected ESP1

0

 

0

0.18

0.28

0.39

 

0.50

0.61

0.72

 

 

 

 

High

2264

 

2182

2095

2003

1906

 

1805

1698

1586

 

Corrected ESP1

0

 

0

0

0.26

0.37

 

0.49

0.60

0.71

HMG60F1E

 

 

Use HMG**X1E airflow data. See Table 5 (page 20).

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

NOTES:

1)Airflow is shown in cfm, +/- 5%.

2)External static pressure (ESP) is shown in inches w.c.

3)See unit nameplate or installation instructions for maximum recommended external static pressure.

Table 5. Airflow Data for HMG**F1E Series Air Handlers

19

 

Switch Settings

 

 

Cooling or Heating Airflow (CFM)

 

 

 

0 = OFF, 1 = ON

 

 

 

Dry Coil ESP

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1/5

2/6

3/7

4/8

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

 

0

0

0

0

585

550

520

460

420

405

 

 

 

1

0

0

0

710

670

650

610

560

530

475

440

 

0

1

0

0

845

790

765

715

680

655

625

580

 

1

1

0

0

890

865

840

785

760

710

680

655

HMG24X1E

0

0

1

0

955

925

900

850

825

790

770

720

1

0

1

0

1030

995

975

940

910

870

840

815

&

 

 

 

 

 

 

 

 

 

 

 

 

0

1

1

0

1115

1085

1060

1020

995

965

925

905

HMG30X1E

1

1

1

0

1155

1130

1095

1070

1040

1010

985

950

 

 

0

0

0

1

1200

1175

1145

1110

1085

1060

1025

1000

 

1

0

0

1

1240

1215

1195

1170

1140

1110

1080

1060

 

0

1

0

1

1320

1290

1265

1240

1215

1185

1160

1130

 

1

1

0

1

1355

1330

1305

1280

1255

1220

1200

1175

 

0

0

1

1

1405

1375

1345

1325

1295

1275

1250

1210

 

1

0

1

1

1440

1415

1385

1355

1325

1290

1255

1215

 

0

1

1

1

1465

1425

1390

1355

1320

1290

1260

1215

 

1

1

1

1

1465

1425

1390

1355

1320

1290

1260

1215

 

Switch Settings

 

 

Cooling or Heating Airflow (CFM)

 

 

 

0 = OFF, 1 = ON

 

 

 

Dry Coil ESP

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1/5

2/6

3/7

4/8

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

 

0

0

0

0

600

550

430

390

 

 

 

 

 

1

0

0

0

660

610

540

460

425

 

 

 

 

0

1

0

0

830

750

695

640

580

520

 

 

 

1

1

0

0

860

825

765

690

630

600

525

485

HMG36X1E

0

0

1

0

935

895

835

790

710

655

620

585

1

0

1

0

1045

975

920

875

830

795

720

685

&

 

 

 

 

 

 

 

 

 

 

 

 

0

1

1

0

1095

1040

995

950

900

850

805

750

HMG42X1E

1

1

1

0

1155

1105

1060

1010

965

920

870

825

 

 

0

0

0

1

1230

1185

1140

1090

1045

1010

965

920

 

1

0

0

1

1285

1260

1210

1165

1125

1080

1040

1010

 

0

1

0

1

1330

1290

1245

1205

1170

1125

1085

1045

 

1

1

0

1

1395

1365

1315

1275

1235

1205

1160

1130

 

0

0

1

1

1450

1405

1375

1335

1295

1260

1220

1180

 

1

0

1

1

1490

1450

1410

1385

1340

1300

1270

1230

 

0

1

1

1

1530

1485

1460

1425

1380

1350

1310

1280

 

1

1

1

1

1530

1490

1465

1425

1390

1350

1310

1285

 

Switch Settings

 

 

Cooling or Heating Airflow (CFM)

 

 

 

0 = OFF, 1 = ON

 

 

 

Dry Coil ESP

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1/5

2/6

3/7

4/8

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

 

0

0

0

0

710

580

395

 

 

 

 

 

 

1

0

0

0

830

690

675

530

505

 

 

 

 

0

1

0

0

930

875

710

665

560

530

 

 

 

1

1

0

0

1065

1015

900

840

800

705

665

635

HMG48X1E

0

0

1

0

1185

1115

1010

960

925

875

830

745

1

0

1

0

1275

1220

1175

1120

1060

970

930

890

&

 

 

 

 

 

 

 

 

 

 

 

 

0

1

1

0

1365

1350

1255

1200

1150

1105

1060

1025

HMG60X1E

1

1

1

0

1480

1430

1370

1325

1265

1225

1185

1140

 

 

0

0

0

1

1560

1535

1485

1430

1375

1335

1285

1240

 

1

0

0

1

1650

1600

1545

1500

1450

1405

1360

1305

 

0

1

0

1

1730

1685

1660

1610

1570

1520

1470

1420

 

1

1

0

1

1785

1740

1695

1645

1615

1545

1510

1470

 

0

0

1

1

1865

1820

1785

1750

1695

1655

1605

1560

 

1

0

1

1

1920

1890

1850

1805

1765

1715

1675

1640

 

0

1

1

1

2010

1965

1960

1900

1850

1810

1775

1730

 

1

1

1

1

2065

2020

1985

1955

1915

1880

1840

1810

NOTE: When matched with two-stage outdoor units, the airflow on low (Y1 or W1) input will be 70% of the values shown in this table.

Table 6. Airflow Data for HMG**X1E Air Handlers

20

Furnace Models

 

 

Nominal Electic Heat KW

 

 

 

 

 

 

 

 

 

 

 

 

5

8

 

10

15

20

 

25

30

HMG24X1E & HMG30X1E

800

900

 

1000

1300

N/A

 

N/A

N/A

HMG36X1E & HMG42X1E

900

1000

 

1100

1300

1500

 

N/A

N/A

HMG48X1E & HMG60X1E

1000

1100

 

1200

1400

1600

 

1800

2000

NOTE: See Table 6 for appropriate switch settings for these airflows.

Table 7. Minimum Heating Airflow Settings (in CFM) for HMG**X1E Air Handlers

HCG24V1E & HCG30V1E

 

Switch Settings

 

Nominal

CFM

(1 = ON, 0 = OFF)

 

 

Capacity

 

 

 

 

 

 

 

5

6

7

8

 

 

 

525

0

0

0

0

 

 

 

560

0

0

0

1

TON

 

 

 

 

 

 

 

 

 

600

0

0

1

0

 

 

1.5

 

 

625

0

0

1

1

 

 

 

 

 

700

0

1

0

0

 

TON

 

 

 

 

 

 

 

 

750

0

1

0

1

 

800

0

1

1

0

 

2

 

 

 

 

850

0

1

1

1

 

 

 

875

1

0

0

0

 

 

TON

890

1

0

0

1

 

 

 

 

2.5

930

1

0

1

0

 

 

 

 

 

950

1

0

1

1

 

 

 

1000

1

1

0

0

 

 

 

1050

1

1

0

1

 

 

 

1125

1

1

1

0

 

 

 

1200

1

1

1

1

 

 

 

 

 

 

 

 

 

 

 

3 TON

HCG36V1E & HCG42V1E

 

Switch Settings

 

 

Nominal

 

 

CFM

(1 = ON, 0 = OFF)

 

 

 

 

 

 

Capacity

 

 

 

 

 

 

 

 

 

 

 

 

5

6

7

8

 

 

 

 

 

 

525

0

0

0

0

 

 

 

 

 

 

560

0

0

0

1

TON

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

600

0

0

1

0

 

 

 

 

 

1.5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

650

0

0

1

1

 

 

 

 

 

 

 

 

 

 

 

750

0

1

0

1

 

TON2

 

 

 

 

700

0

1

0

0

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

800

0

1

1

0

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

850

0

1

1

1

 

 

TON

 

 

 

875

1

0

0

0

 

 

 

 

 

 

 

2.5

 

 

 

950

1

0

0

1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1050

1

0

1

0

 

 

 

TON3

 

 

1150

1

0

1

1

 

 

 

TON

 

 

 

 

 

 

 

1250

1

1

0

0

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3.5

 

1350

1

1

0

1

 

 

 

 

TON

 

 

 

 

 

 

 

 

 

1400

1

1

1

0

 

 

 

 

1600

1

1

1

1

 

 

 

 

 

4

 

 

 

 

 

 

HCG48V1E & HCG60V1E

 

Switch Settings

 

Nomical

CFM

(1 = ON, 0 = OFF)

 

 

Capacity

 

 

 

 

 

 

 

5

6

7

8

 

 

 

1100

0

0

0

0

3 TON

 

 

1200

0

0

0

1

 

 

 

 

 

 

 

 

 

 

1250

0

0

1

0

 

TON

 

 

 

 

 

 

 

 

1300

0

0

1

1

 

 

 

3.5

 

1350

0

1

0

0

 

 

 

 

 

1400

0

1

0

1

 

 

TON

 

 

 

 

 

 

 

1450

0

1

1

0

 

 

 

 

 

 

 

 

4

1500

0

1

1

1

 

 

 

 

 

1550

1

0

0

0

 

 

 

1600

1

0

0

1

 

 

 

 

 

 

 

 

 

 

 

1650

1

0

1

0

 

 

 

1700

1

0

1

1

 

 

 

1750

1

1

0

0

 

 

 

 

 

 

 

 

 

 

 

1800

1

1

0

1

 

 

 

 

 

 

 

 

 

 

 

1900

1

1

1

0

 

 

 

2000

1

1

1

1

 

 

 

 

 

 

 

 

 

 

 

Table 8. Recommended Cooling Airflow Settings for HCG**V1E Air Handlers

5 TON

21

 

 

Cooling Airflow

 

 

 

 

 

 

 

 

 

 

A/B Switch Setting

COOL Switch Setting

Airflow

 

 

0 = OFF, 1 = ON

 

 

0 = OFF, 1 = ON

 

 

(CFM)

 

 

 

 

 

 

 

 

 

5

 

6

7

 

8

 

 

0

0

 

0

0

 

0

525

 

0

0

 

0

0

 

1

560

 

0

0

 

0

1

 

0

600

 

0

0

 

0

1

 

1

625

HCG24V1E

0

0

 

1

0

 

0

700

&

0

0

 

1

0

 

1

750

HCG30V1E

0

0

 

1

1

 

0

800

 

0

0

 

1

1

 

1

850

 

0

1

 

0

0

 

0

875

 

0

1

 

0

0

 

1

890

 

0

1

 

0

1

 

0

930

 

0

1

 

0

1

 

1

950

 

0

1

 

1

0

 

0

1000

 

0

1

 

1

0

 

1

1050

 

0

1

 

1

1

 

0

1125

 

0

1

 

1

1

 

1

1200

 

 

 

 

 

 

 

Cooling Airflow

 

 

 

 

 

 

 

A/B Switch Setting

COOL Switch Setting

Airflow

 

 

0 = OFF, 1 = ON

 

 

0 = OFF, 1 = ON

 

 

(CFM)

 

 

 

 

 

 

 

 

 

5

 

6

7

 

8

 

 

1

0

 

0

0

 

0

525

 

1

0

 

0

0

 

1

560

 

1

0

 

0

1

 

0

600

 

1

0

 

0

1

 

1

650

HCG36V1E

1

0

 

1

0

 

0

700

&

1

0

 

1

0

 

1

750

HCG42V1E

1

0

 

1

1

 

0

800

 

1

0

 

1

1

 

1

850

 

1

1

 

0

0

 

0

875

 

1

1

 

0

0

 

1

950

 

1

1

 

0

1

 

0

1050

 

1

1

 

0

1

 

1

1150

 

1

1

 

1

0

 

0

1250

 

1

1

 

1

0

 

1

1350

 

1

1

 

1

1

 

0

1400

 

1

1

 

1

1

 

1

1600

 

 

 

 

 

 

 

Cooling Airflow

 

 

 

A/B Switch Setting

COOL Switch Setting

Airflow

 

 

0 = OFF, 1 = ON

 

 

(* = either 0 or 1)

 

 

(CFM)

 

 

 

 

 

 

 

 

 

5

 

6

7

 

8

 

 

*

0

 

0

0

 

0

1100

 

*

0

 

0

0

 

1

1200

 

*

0

 

0

1

 

0

1250

 

*

0

 

0

1

 

1

1300

HCG48V1E

*

0

 

1

0

 

0

1350

&

*

0

 

1

0

 

1

1400

HCG60V1E

*

0

 

1

1

 

0

1450

 

*

0

 

1

1

 

1

1500

 

*

1

 

0

0

 

0

1550

 

*

1

 

0

0

 

1

1600

 

*

1

 

0

1

 

0

1650

 

*

1

 

0

1

 

1

1700

 

*

1

 

1

0

 

0

1750

 

*

1

 

1

0

 

1

1800

 

*

1

 

1

1

 

0

1900

 

*

1

 

1

1

 

1

2000

Heating Airflow

A/B Switch Setting

Heater Kit

Airflow

0 = OFF, 1 = ON

Installed (KW)

(CFM)

 

 

 

0

0

600

0

5

800

0

8

1000

0

10

1000

0

15

1300

0

20

n/a

0

25

n/a

0

30

n/a

Heating Airflow

A/B Switch Setting

Heater Kit

Airflow

0 = OFF, 1 = ON

Installed (KW)

(CFM)

 

 

 

1

0

700

1

5

900

1

8

1100

1

10

1100

1

15

1300

1

20

1500

1

25

n/a

1

30

n/a

Heating Airflow

A/B Switch Setting

Heater Kit

Airflow

(* = either 0 or 1)

Installed (KW)

(CFM)

 

 

 

*

0

800

*

5

1000

*

8

1200

*

10

1200

*

15

1400

*

20

1600

*

25

1800

*

30

2000

NOTES:

Airflow values listed are for 240V operation. For

208V operation, multiply the CFM value by .95 for HCG24V1E, HCG30V1E, HCG36V1E, & HCG42V1E units. For HCG48V1E & HCG60V1E units, mulitply the CMF value by .90.

When matched with two-stage outdoor units the airflow on low (Y1 or W1) input only will be 70% of the values shown in this table.

Table 9. Airflow Data for HCG**V1E Air Handlers

22

Electrical diagrams & Data

Y

RCGW

BLWDTC

BLWDTC_R

LED 1

HEATER P1

P2

3A Fuse

L 2

L 1

EAC

COOL

HEAT

Figure 14. Single Stage Control Board

L

Y1

2W

1W

O

Y2/Y

G

R

C

 

 

 

 

 

 

 

 

3A Fuse

P3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

P2

 

 

 

 

 

 

 

 

L 2

 

 

 

 

 

 

 

 

HUM

 

 

 

 

 

 

 

 

EAC

 

 

 

 

 

 

 

 

LED 1

 

 

 

 

 

HEATER P1

 

 

Figure 15. Two - Stage Control Board

23

R

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

C

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Y1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

DEHUM

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TWIN

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FAN SPEED

ON

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

 

2

 

3

 

4

 

5

 

6

 

7

8

OFF

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

HEAT

 

COOL

 

 

 

 

TEST PORT

W1

EXPANSION

PORT

RED

GREEN

NOT USED

 

 

STATUS

BLOWER MOTOR

Figure 16. Fixed Speed Motor Control Board

OUTPUTS

R

C

W

 

Y/Y2

RED

 

Y1

 

H

 

TEST PORT

EXPANSION PORT

STATUS LIGHTS

L2-OUT L2-IN

RED

GREEN

L1-IN

L1-OUT

ON

 

FAN SPEED

 

DEHUM

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

OFF

A/B

2

3

4

 

5

6

7

8

Y1

 

INPUTS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

HEAT

 

COOL

 

 

 

 

 

 

 

SENSOR

GND

BLOWER MOTOR

Figure 17. Variable Speed Motor Control Board

24

Handler Air Series HMG**F1E for Diagram Wiring .18 Figure

WIRING DIAGRAM

Air Handler

YELL

WHITE GREEN GRAY

RED

OW

Y - W G C R

BLW DTC

BLACK R

IF BOARD

EQUIPPED

WITH

BLWDTC

TERMINAL

7 6 5 4 3 2 1

HEATER PLUG

Legend

Field Wiring

Factory Wiring:

Low Voltage

High Voltage

4-PIN PLUG (18)

RELAY

RELAY

CUT WIRES TO REMOVE PLUG HOUSING

WHEN HEATER KIT NOT INSTALLED

1

2

RED BLACK

WHITE

 

BLACK

 

 

 

 

240 208

COM

 

 

TRANSFORMER

R

RED

R

C

C

 

24 V

 

L2

 

 

 

L1

 

 

 

L2

 

GRAY

 

L1

 

 

 

EAC

 

 

 

COOL

 

BLACK

 

HEAT

RED

 

 

 

WHITE

 

 

BROWN

 

 

 

BROWN

 

 

 

1=COM

1

 

 

2

 

 

2=CAP.

 

 

3

 

CAP.

3=CAP.

 

 

4=HI

4

 

 

5=MED

5

 

 

6=LOW

6

 

NOTES:

1.The blower motor speed tap connection may not be as shown. See the Installation Instructions.

2.Disconnect all power before servicing.

3.Transformer may have a dual voltage primary tap. Match the tap position with the supply voltage used.

4.If the internal wiring is replaced, use only 105°C copper wire of the same gauge.

MOTOR

LOCATION OF

3-SPEED

“T” CONNECTOR

 

¢711075"¤

711075A

(Replaces 7110750)

 

1009

25

26

Handler Air Series HMG**X1E for Diagram Wiring .19 Figure

WIRING DIAGRAM

Air Handler with Fixed Speed High Efficiency Motor

L

Y1

W2

W1

O

Y/Y2

G

R

C

PLUG HEATER

 

 

EXPANSION

EAL

HUM

L2

L1

CUT WIRES TO REMOVE PLUG HOUSING

WHEN HEATER KIT NOT INSTALLED

1

 

BLACK

 

 

2

 

 

RED

 

 

 

 

 

 

BLACK

WHITE

L1 L2 C R

HARNESS

WHITE BLACK

1

2

3

 

 

 

 

 

 

 

 

 

 

 

ORANGE

 

BROWN

 

 

 

 

 

RED

 

 

 

 

 

 

 

 

 

 

 

 

4 5 6

BLUE

GREEN

YELLOW

6-PIN PLUG

NOTES:

1.The blower motor speed tap connection may not be as shown. See the Installation Instructions.

2.Disconnect all power before servicing.

3.Transformer may have a dual voltage primary tap. Match the tap position with the supply voltage used.

4.If the internal wiring is replaced, use only

105°C copper wire of the same gauge.

240

208

COM

 

 

 

 

 

 

 

 

 

9-PIN PLUG

 

1

2

3

4

5

6

7

8

9

 

 

 

 

TRANSFORMER

 

1

2

3

4

5

6

7

8

9

 

 

 

 

 

 

 

 

 

 

R

24 V

C

 

 

 

 

 

 

 

 

 

9-PIN HOUSING

 

 

 

 

 

 

 

 

 

 

 

 

 

GRAY

 

 

 

 

 

 

 

 

 

 

 

 

RED

 

BLUE GREEN YELLOW ORANGE RED BROWN

 

 

 

 

 

 

 

GREEN

 

 

 

TEST

1

2

3

4

5

6

 

 

 

 

 

 

 

 

 

 

 

 

R

 

 

 

 

 

 

 

 

 

WHITE

 

 

C

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BLACK

 

 

Y

 

 

 

 

 

 

 

 

 

 

 

DEHUM

EXPANSION

 

 

 

6-PIN PLUG

 

Legend

 

 

 

 

 

 

 

 

MOTOR

 

 

 

 

 

 

 

 

 

 

 

 

 

Field Wiring

 

 

 

 

 

MOTOR

 

 

 

 

 

 

 

 

 

Factory Wiring:

 

 

 

 

 

HARNESS

 

 

 

 

 

 

 

 

 

Low Voltage

 

 

 

 

 

TWIN

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

¢711076(¤

7110760

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

High Voltage

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

0510

 

 

 

 

 

 

 

 

 

 

 

 

Handler Air Series HCG**V1E for Diagram Wiring .20 Figure

WIRING DIAGRAM

Air Handler with Variable Speed High Efficiency Motor

PLUG HEATER

 

 

HUM EAL

L2

L1

CUT WIRES TO REMOVE PLUG HOUSING

WHEN HEATER KIT NOT INSTALLED

1

 

BLACK

 

 

 

2

 

 

RED

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

HARNESS

NOTES:

1.The blower motor speed tap connection may not be as shown.

See the Installation Instructions.

2.Disconnect all power before servicing.

3.Transformer may havea dual voltage primary tap. Match the tap

position with the supply voltage used.

4.If the internal wiring is replaced, use only 105°C copper wire of the same gauge.

Legend

Field Wiring

Factory Wiring:

Low Voltage

High Voltage

L

Y1

W2

W1

O

Y/Y2

G

R

C

EXPANSION

L1 L2 C R

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BLACK

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WHITE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WHITE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

K

 

 

ACBL

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

GRAY

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

240

 

 

 

 

208 COM

 

 

 

 

 

 

 

 

 

TRANSFORMER

 

 

 

 

 

 

 

 

R

 

 

 

 

 

 

 

 

C

 

 

 

 

 

 

 

 

 

 

 

 

 

24 V

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

RED

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

9-PIN PLUG

 

1

BROWN

1

2

RED

2

3

ORANGE

3

4

YELLOW

4

5

GREEN

5

6

BLUE

6

 

 

7

 

 

8

 

 

9

6-PIN PLUG

 

9-PIN HOUSING

1

BROWN

3 2

RED

ORANGE

4

YELLOW

6 5

GREEN

BLUE

7

BLACK

8

9

WHITE

6-PIN PLUG

6 5 4 3 2 1

L2 OUT L2 IN

W

Y/Y2

Y1

H

 

 

 

 

 

 

 

 

 

 

 

 

 

DEHUM

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Y1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SENSOR

 

 

 

 

 

 

 

 

 

TEST

 

GND

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

EXPANSION C DXDX+ R

 

MOTOR

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

HARNESS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BLACK

 

 

WHITE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

GREEN

 

 

 

 

MOTOR

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

¢711077.¤ 7110770

0510

27

HMG**F1E Series

 

 

 

240 VAC, 50 & 60 Hz, Single Phase

 

 

208 VAC, 50 & 60 Hz, Single Phase

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Heat KiT

 

MCA

 

 

MOP

 

 

MCA

 

 

MOP

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Air Handler

Model

Circuit A

Circuit B

Circuit C

Single Circuit

Circuit A

Circuit B

Circuit C

 

Single Circuit

Circuit A

Circuit B

Circuit C

Single Circuit

Circuit A

Circuit B

Circuit C

 

Single Circuit

Model

Number

 

 

 

H6HK-

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

None

1.6

-

-

1.6

15

-

-

 

15

1.6

-

-

1.6

15

-

-

 

15

 

005H-XX

26.6

-

-

26.6

30

-

-

 

30

23.3

-

-

23.3

25

-

-

 

25

HMG24F1E

008H-XX

41.2

-

-

41.2

45

-

-

 

45

35.9

-

-

35.9

40

-

-

 

40

 

010H-XX

51.6

-

-

51.6

60

-

-

 

60

45.0

-

-

45.0

45

-

-

 

45

 

009Q-XX

-

-

-

28.7

-

-

-

 

30

-

-

-

18.8

-

-

-

 

30

 

None

3.1

-

-

3.1

15

-

-

 

15

3.1

-

-

3.1

15

-

-

 

15

 

005H-XX

28.1

-

-

28.1

30

-

-

 

30

24.8

-

-

24.8

25

-

-

 

25

 

008H-XX

42.7

-

-

42.7

45

-

-

 

45

37.4

-

-

37.4

40

-

-

 

40

HMG30F1E

010H-XX

53.1

-

-

53.1

60

-

-

 

60

46.5

-

-

46.5

50

-

-

 

50

 

015H-XX

53.1

25.0

-

65.6

60

30

-

 

80

46.5

21.7

-

68.1

50

25

-

 

70

 

009Q-XX

-

-

-

30.2

-

-

-

 

35

-

-

-

26.6

-

-

-

 

30

 

015Q-XX

-

-

-

46.4

-

-

-

 

50

-

-

-

40.6

-

-

-

 

45

 

None

2.6

-

-

2.6

15

-

-

 

15

2.6

-

-

2.6

15

-

-

 

15

 

005H-XX

27.6

-

-

27.6

30

-

-

 

30

24.3

-

-

24.3

25

-

-

 

25

 

008H-XX

42.2

-

-

42.2

45

-

-

 

45

36.9

-

-

36.9

40

-

-

 

40

HMG36F1E

010H-XX

52.6

-

-

52.6

60

-

-

 

60

46.0

-

-

46.0

50

-

-

 

50

015H-XX

52.6

25.0

-

64.7

60

30

-

 

80

46.0

21.7

-

67.6

50

25

-

 

70

 

 

 

 

020H-XX

52.6

50.0

-

102.6

60

60

-

 

110

46.0

43.3

-

89.3

50

45

-

 

90

 

009Q-XX

-

-

-

29.7

-

-

-

 

30

-

-

-

26.1

-

-

-

 

30

 

015Q-XX

-

-

-

45.9

-

-

-

 

50

-

-

-

40.2

-

-

-

 

45

 

None

3.1

-

-

3.1

15

-

-

 

15

3.1

-

-

3.1

15

-

-

 

15

 

005H-XX

28.1

-

-

28.1

30

-

-

 

30

24.8

-

-

24.8

25

-

-

 

25

 

008H-XX

42.7

-

-

42.7

45

-

-

 

45

37.4

-

-

37.4

40

-

-

 

40

HMG42F1E

010H-XX

53.1

-

-

53.1

60

-

-

 

60

46.5

-

-

46.5

50

-

-

 

50

015H-XX

53.1

25.0

-

65.6

60

30

-

 

80

46.5

21.7

-

68.1

50

25

-

 

70

 

 

 

 

020H-XX

53.1

50.0

-

103.1

60

60

-

 

110

46.5

43.3

-

89.8

50

45

-

 

90

 

009Q-XX

-

-

-

30.2

-

-

-

 

35

-

-

-

26.6

-

-

-

 

30

 

015Q-XX

-

-

-

46.4

-

-

-

 

50

-

-

-

40.7

-

-

-

 

45

 

None

5.4

-

-

5.4

15

-

-

 

15

5.4

-

-

5.4

15

-

-

 

15

 

005H-XX

30.4

-

-

30.4

35

-

-

 

35

27.0

-

-

27.0

30

-

-

 

30

 

008H-XX

45.0

-

-

45.0

45

-

-

 

45

39.7

-

-

39.7

40

-

-

 

40

 

010H-XX

55.4

-

-

55.4

60

-

-

 

60

48.7

-

-

48.7

50

-

-

 

50

HMG48F1E

015H-XX

55.4

25.0

-

80.4

60

30

-

 

90

48.7

21.7

-

70.4

50

25

-

 

80

020H-XX

55.4

50.0

-

105.4

60

60

-

 

110

48.7

43.3

-

92.0

50

45

-

 

100

 

 

 

 

024H-XX

55.4

50.0

25.0

130.4

60

60

60

 

150

48.7

43.3

21.7

113.7

50

45

45

 

125

 

029H-XX

55.4

50.0

50.0

155.4

60

60

60

 

175

48.7

43.3

43.3

135.4

50

45

45

 

150

 

009Q-XX

-

-

-

32.4

-

-

-

 

35

-

-

-

28.8

-

-

-

 

30

 

015Q-XX

-

-

-

48.7

-

-

-

 

50

-

-

-

42.9

-

-

-

 

45

 

None

6.3

-

-

6.3

15

-

-

 

15

6.8

-

-

6.8

15

-

-

 

15

 

005H-XX

31.3

-

-

31.3

35

-

-

 

35

28.4

-

-

28.4

30

-

-

 

30

 

008H-XX

45.8

-

-

45.8

50

-

-

 

50

41.1

-

-

41.1

45

-

-

 

45

 

010H-XX

56.3

-

-

56.3

60

-

-

 

60

50.1

-

-

50.1

60

-

-

 

60

HMG60F1E

015H-XX

56.3

25.0

-

81.3

60

30

-

 

90

50.1

21.7

-

71.8

60

25

-

 

80

020H-XX

56.3

50.0

-

106.3

60

60

-

 

110

50.1

43.3

-

93.4

60

45

-

 

100

 

 

 

 

024H-XX

56.3

50.0

25.0

131.3

60

60

30

 

150

50.1

43.3

21.7

115.1

60

45

25

 

125

 

029H-XX

56.3

50.0

50.0

156.3

60

60

60

 

175

50.1

43.3

43.3

136.8

60

45

45

 

150

 

009Q-XX

-

-

-

33.3

-

-

-

 

35

-

-

-

30.2

-

-

-

 

35

 

015Q-XX

-

-

-

49.6

-

-

-

 

50

-

-

-

44.3

-

-

-

 

45

Table 10. HMG**F1E Series Minimum Circuit Ampacity & Maximum Overcurrent Protection

28

HMG**X1E & HCG**V1E

 

 

 

 

 

240 VAC, 50 & 60 Hz, Single Phase

 

 

208 VAC, 50 & 60 Hz, Single Phase

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Heat KiT

 

MCA

 

 

 

MOP

 

 

MCA

 

 

MOP

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Air Handler

Model

 

Circuit A

Circuit B

 

Circuit C

Single Circuit

Circuit A

 

Circuit B

Circuit C

 

Single Circuit

Circuit A

Circuit B

 

Circuit C

Single Circuit

Circuit A

Circuit B

Circuit C

 

Single Circuit

 

Models

Number

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

H6HK-

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

HMG24X1E

None

 

4.5

-

 

-

4.5

15

 

-

-

 

15

4.8

-

 

-

4.8

15

-

-

 

15

 

005H-XX

 

29.5

-

 

-

29.5

30

 

-

-

 

30

26.4

-

 

-

26.4

30

-

-

 

30

 

HMG30X1E

008H-XX

 

44.1

-

 

-

44.1

45

 

-

-

 

45

39.1

-

 

-

39.1

40

-

-

 

40

 

&

010H-XX

 

54.5

-

 

-

54.5

60

 

-

-

 

60

48.1

-

 

-

48.1

50

-

-

 

50

 

HCG24V1E

015H-XX

 

54.5

25.0

 

-

68.1

60

 

30

-

 

80

48.1

21.7

 

-

69.8

50

25

-

 

70

 

HCG30V1E

009Q-XX

 

-

-

 

-

31.6

-

 

-

-

 

35

-

-

 

-

28.2

-

-

-

 

30

 

015Q-XX

 

-

-

 

-

47.8

-

 

-

-

 

50

-

-

 

-

42.3

-

-

-

 

45

 

 

 

 

 

 

 

 

 

 

None

 

4.5

-

 

-

4.5

15

 

-

-

 

15

4.8

-

 

-

4.8

15

-

-

 

15

 

HMG36X1E

005H-XX

 

29.5

-

 

-

29.5

30

 

-

-

 

30

26.4

-

 

-

26.4

30

-

-

 

30

 

008H-XX

44.1

-

 

-

44.1

45

 

-

-

 

45

39.1

-

 

-

39.1

40

-

-

 

40

 

HMG42X1E

 

 

 

 

 

 

010H-XX

 

54.5

-

 

-

54.5

60

 

-

-

 

60

48.1

-

 

-

48.1

50

-

-

 

50

 

&

 

 

 

 

 

 

 

015H-XX

 

54.5

25.0

 

-

68.1

60

 

30

-

 

80

48.1

21.7

 

-

69.8

50

25

-

 

70

 

HCG36V1E

 

 

 

 

 

 

 

020H-XX

 

54.5

50.0

 

-

104.5

60

 

60

-

 

110

48.1

43.3

 

-

91.4

50

45

-

 

100

 

HCG42V1E

 

 

 

 

 

 

 

009Q-XX

 

-

-

 

-

31.6

-

 

-

-

 

35

-

-

 

-

28.2

-

-

-

 

30

 

 

015Q-XX

 

-

-

 

-

47.8

-

 

-

-

 

50

-

-

 

-

42.3

-

-

-

 

45

 

 

None

 

6.3

-

 

-

6.3

15

 

-

-

 

15

6.8

-

 

-

6.8

15

-

-

 

15

 

 

005H-XX

31.3

-

 

-

31.3

35

 

-

-

 

35

28.4

-

 

-

28.4

30

-

-

 

30

 

HMG48X1E

008H-XX

 

45.8

-

 

-

45.8

50

 

-

-

 

50

41.1

-

 

-

41.1

45

-

-

 

45

 

010H-XX

56.3

-

 

-

56.3

60

 

-

-

 

60

50.1

-

 

-

50.1

60

-

-

 

60

 

HMG60X1E

 

 

 

 

 

 

015H-XX

 

56.3

25.0

 

-

81.3

60

 

30

-

 

90

50.1

21.7

 

-

71.8

60

25

-

 

80

 

&

 

 

 

 

 

 

 

020H-XX

 

56.3

50.0

 

-

106.3

60

 

60

-

 

110

50.1

43.3

 

-

93.4

60

45

-

 

100

 

HCG48V1E

 

 

 

 

 

 

 

024H-XX

 

56.3

50.0

 

25.0

131.3

60

 

60

60

 

150

50.1

43.3

 

21.7

115.1

60

45

45

 

125

 

HCG60V1E

 

 

 

 

 

 

 

029H-XX

 

56.3

50.0

 

50.0

156.3

60

 

60

60

 

175

50.1

43.3

 

43.3

136.8

60

45

45

 

150

 

 

009Q-XX

 

-

-

 

-

33.3

-

 

-

-

 

35

-

-

 

-

30.2

-

-

-

 

35

 

 

015Q-XX

 

-

-

 

-

49.6

-

 

-

-

 

50

-

-

 

-

44.3

-

-

-

 

45

 

Table 11. HMG**X1E & HCG**V1E Minimum Circuit Ampacity & Maximum Overcurrent Protection

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Control Signal & MODE

 

Operation

 

 

Total KW

 

 

 

 

 

 

 

Board Action

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5 KW

 

 

Stage 1 Heat on instantly

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Heat blower on after 3 second delay

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

10 KW

 

 

Stage 1 Heat on instantly

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Heat blower on after 3 second delay

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Stage 1 Heat on instantly

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

15 KW

 

 

Heat blower on after 3 second delay

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Stage 2 Heat on after 5 second delay

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Stage 1 Heat on instantly

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

20 KW

 

 

Heat blower on after 3 second delay

 

 

 

 

 

 

 

 

 

 

On

 

 

 

 

 

Stage 2 Heat on after 5 second delay

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

W1 only

 

 

 

 

 

 

 

 

 

 

 

Stage 3 Heat on after 10 second delay

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

EHEAT

 

 

 

 

 

 

 

 

 

 

 

 

Stage 1 Heat on instantly

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

25 KW

 

 

Heat blower on after 3 second delay

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Stage 2 Heat on after 5 second delay

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Stage 3 Heat on after 10 second delay

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Stage 1Heat on instantly

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Heat blower on after 3 second delay

 

 

 

 

 

 

 

 

 

 

 

 

 

 

30 KW

 

 

Stage 2 Heat on after 5 second delay

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Stage 3 Heat on after 10 second delay

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Stage 4 Heat on after 15 second delay

 

 

 

 

 

 

 

 

 

 

Off

 

 

 

 

 

 

 

Heat stages off instantly

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Blower off after 15 second delay

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Table 12. Control Board Operation

29

Control Signal & MODE

Operation

Total KW

Board Action

 

 

 

 

 

 

5 KW

Stage 1 Heat on instantly

 

 

Heat blower on after 3 second delay

 

 

 

 

 

 

Stage 1 Heat on instantly

 

 

10 KW

Heat blower on after 3 second delay

 

 

 

Stage 2 Heat on after 5 seconds delay

 

 

 

Stage 1 Heat on instantly

 

 

15 KW

Heat blower on after 3 second delay

 

 

Stage 2 Heat on after 5 seconds delay

 

 

 

 

 

 

Stage 3 Heat on after 10 seconds delay

 

 

 

Stage 1 Heat on instantly

 

 

 

Heat blower on after 3 second delay

 

 

20 KW

Stage 2 Heat on after 5 seconds delay

 

 

 

Stage 3 Heat on after 10 seconds delay

W1 & W2

On

 

Stage 4 Heat on after 15 seconds delay

 

 

Stage 1 Heat on instantly

EHEAT

 

 

 

 

Heat blower on after 3 second delay

 

 

 

 

 

25 KW

Stage 2 Heat on after 5 seconds delay

 

 

Stage 3 Heat on after 10 seconds delay

 

 

 

 

 

 

Stage 4 Heat on after 15 seconds delay

 

 

 

Stage 5 Heat on after 20 seconds delay

 

 

 

Stage 1Heat on instantly

 

 

 

Heat blower on after 3 second delay

 

 

 

Stage 2 Heat on after 5 seconds delay

 

 

30 KW

Stage 3 Heat on after 10 seconds delay

 

 

 

Stage 4 Heat on after 15 seconds delay

 

 

 

Stage 5 Heat on after 20 seconds delay

 

 

 

Stage 6 Heat on after 25 seconds delay

 

Off

 

Heat stages off instantly

 

 

Blower off after 15 second delay

 

 

 

 

 

5 KW

Stage 1 Heat on instantly

 

 

Cool blower on after 3 second delay

 

 

 

 

 

10 KW

Stage 1 Heat on instantly

 

 

Cool blower on after 3 second delay

 

 

 

 

 

 

Stage 1 Heat on instantly

 

 

15 KW

Cool blower on after 3 second delay

 

 

 

Stage 2 Heat on after 5 seconds delay

 

 

 

Stage 1 Heat on instantly

 

 

20 KW

Cool blower on after 3 second delay

 

On

Stage 2 Heat on after 5 seconds delay

 

 

W1 & Y/Y2

 

Stage 3 Heat on after 10 seconds delay

 

 

AUX HEAT

 

 

Stage 1 Heat on instantly

 

 

25 KW

Cool blower on after 3 second delay

 

 

Stage 2 Heat on after 5 seconds delay

 

 

 

 

 

 

Stage 3 Heat on after 10 seconds delay

 

 

 

Stage 1 Heat on instantly

 

 

 

Cool blower on after 3 second delay

 

 

30 KW

Stage 2 Heat on after 5 seconds delay

 

 

 

Stage 3 Heat on after 10 seconds delay

 

 

 

Stage 4 Heat on after 15 seconds delay

 

Off

 

Heat stages off instantly

 

 

Heat blower turns off after 40 second delay

 

 

 

Table 12. Control Board Operation - Continued

30

Control Signal & MODE

Operation

Total KW

Board Action

 

 

 

 

 

 

5 KW

Stage 1 Heat on instantly

 

 

Cool blower on after 3 second delay

 

 

 

 

 

 

Stage 1 Heat on instantly

 

 

10 KW

Cool blower on after 3 second delay

 

 

 

Stage 2 Heat on after 5 seconds delay

 

 

 

Stage 1 Heat on instantly

 

 

15 KW

Cool blower on after 3 second delay

 

 

Stage 2 Heat on after 5 seconds delay

 

 

 

 

 

 

Stage 3 Heat on after 30 seconds delay

 

 

 

Stage 1 Heat on instantly

 

 

 

Cool blower on after 3 second delay

 

 

20 KW

Stage 2 Heat on after 5 seconds delay

 

 

 

Stage 3 Heat on after 10 seconds delay

W1, W2 & Y/Y2

On

 

Stage 4 Heat on after 15 seconds delay

 

 

Stage 1Heat on instantly

AUX HEAT

 

 

 

 

Cool blower on after 3 second delay

 

 

 

 

 

25 KW

Stage 2 Heat on after 5 seconds delay

 

 

Stage 3 Heat on after 10 seconds delay

 

 

 

 

 

 

Stage 4 Heat on after 15 seconds delay

 

 

 

Stage 5 Heat on after 20 seconds delay

 

 

 

Stage 1Heat on instantly

 

 

 

Cool blower on after 3 second delay

 

 

 

Stage 2 Heat on after 5 seconds delay

 

 

30 KW

Stage 3 Heat on after 10 seconds delay

 

 

 

Stage 4 Heat on after 15 seconds delay

 

 

 

Stage 5 Heat on after 20 seconds delay

 

 

 

Stage 6 Heat on after 25 seconds delay

 

Off

 

Heat stages off instantly

 

 

Heat blower turns off after 40 second delay

 

 

 

G

On

 

Fan blower on after 3 second delay

FAN

Off

 

Fan blower off instantly

Y/Y2

On

 

Cool blower on after 3 second delay

HEAT PUMP & COOL

Off

 

Cool blower off after 40 second delay

Y1

On

 

Cool blower on after 3 second delay

HEAT PUMP & COOL

Off

 

Cool blower off after 40 second delay

Y1 & Y/Y2

On

 

Cool blower on after 3 second delay

HEAT PUMP & COOL

Off

 

Cool blower off after 40 second delay

Table 12. Control Board Operation - Continued

31

INSTALLATION / PERFORMANCE CHECK LIST

INSTALLER NAME:

CITY:

STATE:

 

 

 

 

 

 

 

 

 

 

INSTALLATION ADDRESS:

 

 

 

 

 

 

 

 

 

 

 

CITY:

STATE:

 

 

 

 

 

 

 

 

 

 

UNIT MODEL #

 

 

 

 

 

 

 

 

 

 

 

UNIT SERIAL #

 

 

 

 

 

 

 

 

 

 

 

Minimum clearances per page 4?

YES

 

NO

 

 

 

 

 

 

 

Is the unit properly installed and

YES

 

NO

leveled?

 

 

 

 

 

 

 

 

 

 

 

 

Does condensate drain properly

YES

 

NO

in both drain tubes?

 

 

 

 

 

 

 

 

 

 

 

 

Has the owner’s information been

YES

 

NO

reviewed with the home-owner?

 

 

 

 

 

 

 

 

 

 

 

 

Has the literature package been

YES

 

NO

left near the appliance?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ELECTRICAL SYSTEM:

Electrical connections tight?

YES

NO

 

 

 

Line voltage polarity correct?

YES

NO

 

 

 

Supply Voltage: ___________________________________(V)

Has the thermostat been calibrated?

YES

NO

 

 

 

Is the thermostat level?

YES

NO

 

 

 

Is the heat anticipator setting correct?

YES

NO

 

 

 

ATTENTION INSTALLERS:

It is your responsibility to know this product better than your customer. This includes being able to install the product according to strict safety guidelines and instructing the customer on how to operate and maintain the equipment for the life of the product. Safety should always be the deciding factor when installing this product and using common sense plays an important role as well. Pay attention to all safety warnings and any other special notes highlighted in the manual. Improper installation of the air handler or failure to follow safety warnings could result in serious injury, death, or property damage.

These instructions are primarily intended to assist qualified individuals experienced in the proper installation of this appliance. Some local codes require licensed installation/service personnel for this type of equipment. Please read all instructions carefully before starting the installation. Return these instructions to the customer’s package for future reference.

Specifications & illustrations subject to change without notice or incurring obligations.

 

Jackson, MI | Printed in U.S.A. (11/12)

709557A (Replaces 7095570)