Heat Controller WDG024VSB-1A, WDG036VSB-1A, WDG048VSB-1A, WDG060VSB-1A Installation, Operation & Maintenance Manual

INSTALLATION, OPERATION

& MAINTENANCE MANUAL

Residential Air Handler

Air Handler Series

Heat Controller, Inc. • 1900 Wellworth Ave. • Jackson, MI 49203 • [phone] • www.heatcontroller.com

Installation, Operation & Maintenance AIR HANDLER SERIES Heat Controller, Inc.

Table of Contents

Model Nomenclature ............................................................................................3

Pre-Installation......................................................................................................4

Safety ...................................................................................................................5

Physical Data........................................................................................................6

Unit Dimensional Data ..........................................................................................7

Installation .......................................................................................................8-13

Electrical - Thermostat Wiring ............................................................................14

ECM Blower Control ...........................................................................................15

Blower Performance Data ..................................................................................16

Electrical - Power Wiring ....................................................................................17

Electrical Table ...................................................................................................17

Wiring Diagram ...................................................................................................18

Electric Heat Installation .....................................................................................19

Electric Heat Wiring .......................................................................................20-21

Electric Heat Staging Options.............................................................................21

Unit & System Checkout.....................................................................................22

Maintenance .......................................................................................................22

2

Installation, Operation & Maintenance AIR HANDLER SERIES Heat Controller, Inc.

Model Nomenclature

123

W D 0 2 4G V S B - 1

MODEL TYPE

W = WA TER SOURCE AIR HANDLER

CONFIGURA TION

D = DIRECT EXPANSION

REFRIGERANT

G = R410A

NOMINAL CAP ACITY

024
036
048
060

4 5 6

7

TXV TYPE

V = TXV w/ECM DRIVE

891011

VOLTAGE

1 = 208-230/1 ( FIELD CONVERTIBLE TO 1 15V )

CABINET SIZE

WIDTH X HEIGHT (INCHES)
UNIT SIZE 024 ONLY ; 18.5 X 44

A
B

UNIT SIZE 024, 036, 048 ONLY ; 22.5 X 55

C

UNIT SIZE 036, 048, 060, ONLY ; 25.5 X 59

CONTROLS

S = STANDARD

12

A

REVISION

A = CURRENT REVISION

3

Installation, Operation & Maintenance AIR HANDLER SERIES Heat Controller, Inc.

General Information

Inspection

Upon receipt of the equipment, carefully check the shipment against
the bill of lading. Make sure all units have been received. Inspect
the packaging of each unit, and inspect each unit for damage.
Insure that the carrier makes proper notation of any shortages or
damage on all copies of the freight bill and completes a common
carrier inspection report. Concealed damage not discovered during
unloading must be reported to the carrier within 15 days of receipt
of shipment. If not fi led within 15 days, the freight company can
deny the claim without recourse. Note: It is the responsibility of
the purchaser to fi le all necessary claims with the carrier. Notify
your equipment supplier of all damage within fi fteen (15) days of
shipment.

Storage

Equipment should be stored in its original packaging in a clean,
dry area. Store units in an upright position at all times. Stack
units a maximum of 3 units high.

Unit Protection

Cover units on the job site with either the original packaging or an
equivalent protective covering. Cap the open ends of pipes stored
on the job site. In areas where painting, plastering, and/or spraying
has not been completed, all due precautions must be taken to avoid
physical damage to the units and contamination by foreign material.
Physical damage and contamination may prevent proper start-up
and may result in costly equipment clean-up.

 WARNING! 

WARNING! These instructions are intended as an aid to
qualifi ed licensed service personnel for proper installation,
adjustment and operation of this unit. Read these instructions
thoroughly before attempting installation or operation. Failure
to follow these instructions may result in improper installation,
adjustment, service or maintenance possibly resulting in
property damage, personal injury or death.

 CAUTION! 

CAUTION! DO NOT store or install units in corrosive
environments or in locations subject to temperature or
humidity extremes. Corrosive conditions and high temperature
or humidity can signifi cantly reduce performance, reliability,
and service life.

 CAUTION! 

CAUTION! CUT HAZARD - Failure to follow this caution may
result in personal injury. Sheet metal parts may have sharp
edges or burrs. Use care and wear appropriate protective
clothing, safety glasses and gloves when handling parts and
servicing.

Examine all pipes, fi ttings, and valves before installing any of the
system components. Remove any dirt or debris found in or on
these components.

Pre-Installation

Installation, Operation, and Maintenance instructions are
provided with each unit. Horizontal equipment is designed for
installation above false ceiling or in a ceiling plenum. Other
unit confi gurations are typically installed in a mechanical room.
The installation site chosen should include adequate service
clearance around the unit. Before unit start-up, read all manuals
and become familiar with the unit and its operation. Thoroughly
check the system before operation.

Prepare units for installation as follows:

1. Compare the electrical data on the unit nameplate with
ordering and shipping information to verify that the correct
unit has been shipped.

2. Keep the cabinet covered with the original packaging until
installation is complete and all plastering, painting, etc. is
fi nished.

3. Verify refrigerant tubing is free of kinks or dents and that it
does not touch other unit components.

4. Inspect all electrical connections. Connections must be clean
and tight at the terminals.

4

Installation, Operation & Maintenance AIR HANDLER SERIES Heat Controller, Inc.

Safety

The installation of water source heat pump units and all
associated components, parts and accessories which make
up the installation shall be in accordance with the regulations
of ALL authorities having jurisdiction and MUST conform to
all applicable codes. It is the responsibility of the installing
contractor to determine and comply with ALL applicable codes
and regulations.

Replacement Parts

Any replacement part must be the same as or an approved
alternate to the original part supplied. The manufacturer will not
be responsible for replacement parts not designed to physically
fi t or operate within the design parameters the original parts were
selected for. When ordering replacement parts, it is necessary to
order by part number and include the complete model number
and serial number from the coil rating plate. (See parts list for unit
component part numbers. Parts are available through the local
distributor.)

Safety

Warnings, cautions and notices appear throughout this manual.
Read these items carefully before attempting any installation,
service, or troubleshooting of the equipment.

WARNING! All refrigerant discharged from this unit must be
recovered WITHOUT EXCEPTION. Technicians must follow
industry accepted guidelines and all local, state, and federal
statutes for the recovery and disposal of refrigerants. To avoid
leakage of compressor oil, refrigerant lines of the compressor
must be sealed after it is removed.

CAUTION! To avoid equipment damage, DO NOT use these
units as a source of heating or cooling during the construction
process. The mechanical components and fi lters will quickly
become clogged with construction dirt and debris, which may
cause system damage.

 WARNING! 

 CAUTION! 

DANGER: Indicates an immediate hazardous situation, which if
not avoided will result in death or serious injury. DANGER labels
on unit access panels must be observed.

WARNING: Indicates a poten tiall y hazardous situa tion , which if no t
avoided could result in death or serious injury.

CAUTION: Indicates a potentially hazardous situation or an
unsafe practice, which if not avoided could result in minor or
moderate injury or product or property damage.

NOTICE: Notifi cation of installation, operation or maintenance
information, which is important, but which is not hazard-related.

 WARNING! 

WARNING! The EarthPure® Application and Service Manual
should be read and understood before attempting to service
refrigerant circuits with HFC-410A.

 WARNING! 

WARNING! To avoid the release of refrigerant into the
atmosphere, the refrigerant circuit of this unit must be serviced
only by technicians who meet local, state, and federal
profi ciency requirements.

 CAUTION! 

CAUTION! It is recommended that an auxiliary secondary
drain pan be installed under units containing evaporator coils
that are located in any area of a structure where damage to
the building or building contents may occur as a result of an
overfl ow of the coil drain pan or a stoppage in the primary
condensate drain piping.

5

Installation, Operation & Maintenance AIR HANDLER SERIES Heat Controller, Inc.

Model Physical Data

Table 1: Physical Data

Model 026-A 026-B 038-B 038-C 049-B 049-C 064-C

024-B

024-C 036-C 036-D

048-C

048-D 060-D

Emerson ECM Fan Motor & Blower in. [cm]

Liquid I.D. 3/8 [0.95] 3/8 [0.95] 3/8 [0.95] 3/8 [0.95] 3/8 [0.95] 3/8 [0.95] 3/8 [0.95]
Suction I.D. 3/4 [1.9] 3/4 [1.9] 7/8 [2.22] 7/8 [2.22] 7/8 [2.22] 7/8 [2.22] 7/8 [2.22]
Fan Motor Type/Speeds ECM Variable
Fan Motor (hp) 1/2 1
Blower Wheel Size (Dia x W)

in. [mm]
Air Coil Dimensions (H x W)

in. [mm]
Filter Standard - 1” [25mm]

Throwaway
Weight - Operating lbs. [kg] 80 [36] 163 [74] 173 [78] 181 [82] 180 [82] 188 [85] 198 [90]
Weight - Packaged lbs. [kg] 96 [44] 179 [81] 198 [90] 206 [93] 218 [99] 226 [103] 236 [107]

16 x 20 [406 x 508] 20 x 20 [508 x 508]

9 x 7 [229 x 178] 12 x 10 [305 x 254]

3 - 2 Row 14 x 17 [356 x 432] 3 - 2 Row 24 x 17 [610 x 432]

20 x 24

[508 x 610]

20 x 20

[508 x 508]

3 - 3 Row 24x17

[610 x 432]

20 x 24 [508 x 610]

6

Installation, Operation & Maintenance AIR HANDLER SERIES Heat Controller, Inc.

Unit Dimensional Data

Detail A

J

E

H

G

FD

8.5 [21.6]

6.7 [17.0]

5.6 [14.2]

4.5 [11.4]

3.7 [9.4]

0.0

0.0 1.6
[4.0]

C

B

A

3.6

[9.1]

5.8

[14.7]

5.9

[15.0]

A = Primary Drain - Vertical,

Horizontal and Downflow
Configuration

B = Secondary Drain - Vertical

and Downflow Configuration

C = Secondary Drain - Horizontal

Configuration

Detail A
Scale 5/32
[0.4]

5.5

[14.0]

8.5

[21.6]

3.6

[9.4]

0.625
[1.6]

Cabinet

Size

B - Cabinet in. 18.5 44.0 22.0 14.0 14.0 2.3 2.3 4.1 4.1
C - Cabinet in. 22.0 55.0 22.0 18.0 18.0 2.1 2.1 2.1 2.1
D - Cabinet in. 25.5 59.0 22.0 18.0 18.0 3.8 3.8 2.1 2.1

Overall Cabinet 1 2 3 4 5 6

A

WidthBHeightCDepth

See Detail A

R.A. Opening

A

D E F G H J

0.625
[1.6]

0.75
[1.9]

7

R.A. Opening

C

0.875
[2.2]

Installation, Operation & Maintenance AIR HANDLER SERIES Heat Controller, Inc.

Installation

Air Handlers are designed for upfl ow, horizontal, and downfl ow
applications. The coils have a dry nitrogen holding charge and
are equipped with brazing stub refrigerant connections for easy
installation. Both models come equipped with a factory installed
TXV.

The installer should read the installation manual supplied with
the compressor section for refrigerant line set sizing, connec­tion procedure, and other important information pertaining to the
system installation.

The installer should:

1. Where precise forming of refrigerant lines is required, a copper
tubing bender is recommended for small diameter tubing. One
should avoid sharp bends and contact of the refrigerant lines
with metal surfaces.

2. Refrigerant lines should be protected where they pass through
the raw edges of holes.

3. Air Handler must be level for proper condensate drainage.

4. Seal the openings into the cabinet to reduce risk of conden­sate blow off from the coil.

Air Handler Installation

 WARNING! 

WARNING! Electric furnaces may be connected to more than
one supply circuit.

Charging the System

Air Handlers are designed to match HTS split units. For correct
charging, please refer to the Compressor Section IOM.

Upfl ow Installation

1. Position unit on plenum box or other suitable foundation. Provide

a minimum height for proper unrestricted airfl ow based on CFM
requirement for each unit size.

2. If a return air duct is connected to the air handler, it must be the

same dimensions as shown in the outline drawing in Figure 2.

3. Plenum box and unit should be isolated from the foundation

using a suitable isolating material.

4. Openings where fi eld wiring enters the cabinet must be

completely sealed. Location of power entry is shown on the
outline drawing.

5. After ductwork connections are made, seal airtight and per local

codes.

Downfl ow Installation

1. Position unit on plenum box or other suitable foundation. Provide

a minimum height for proper unrestricted airfl ow based on CFM
requirement for each unit size.

2. If a return air duct is connected to the air handler, it must be the

same dimensions as shown in the outline drawing in Figure 2.

3. Plenum box and unit should be isolated from the foundation

using a suitable isolating material.

4. Openings where fi eld wiring enters the cabinet must be

completely sealed. Location of power entry is shown on the
outline drawing.

5. After ductwork connections are made, seal airtight and per local
codes.

6. The unit is then placed with the blower side down and the coil is
replaced on the coil channel supports with the drain connections
at the bottom. The unit is now in downfl ow position with front
access.

Position the ECM wire harness connection at the 4 to 8 o’clock

position to prevent condensation from entering motor controller.

7. If a return duct is connected to the air handler, it must be the
same dimensions as the return opening.

8. After ductwork connections are made, seal airtight and per local
codes.

Horizontal Right Installation

For maximum effi ciency and customer ease of fi lter

maintenance, it is recommended that a properly sized remote
fi lter grille be installed for horizontal applications. Airfl ow should
not exceed the face velocity of the fi lter being used. The factory

installed fi lter should then be removed from the unit.

1. To convert the unit to horizontal right, front access, slide the coil
out on the coil channel supports and rotate the complete coil 180
degrees.

2. The coil is then inserted back into the cabinet on the opposite
side coil channel supports. The unit is now horizontal right with
front access.

Position the ECM wire harness connection at the 4 to 8 o’clock

position to prevent condensation from entering motor controller.

3. If the unit is suspended, it must be supported from the bottom
near both ends as well as the middle to prevent sagging. The
service access must remain unobstructed. If the unit is supported
along the length of the front and back with rails, the air handler
only needs to be suspended at both ends. See Figure 1.

If the unit is not suspended it must be supported as mentioned

above and isolated carefully to prevent sound transmission.
Vibration isolators (purchased locally) must be placed under the
unit.

4. It is always recommended that an auxiliary drain pan be installed
under a horizontal air handler (See Condensate Piping) to prevent
possible damage to ceilings.

5. Isolate the auxiliary drain pan from the unit or from the structure.

6. Connect the auxiliary drain line to a separate drain line (no trap is
needed in this line) and terminate according to national and local
codes.

7. If a return duct is connected to the air handler, it must be the
same dimensions as the return opening shown in the outline
drawing on Figure 2.

8. Openings where fi eld wiring enters the cabinet must be
completely sealed.

9. After ductwork connections are made, seal airtight and per local
codes.

Horizontal Left Installation

1. For maximum effi ciency and customer ease of fi lter
maintenance, it is recommended that a properly sized remote
fi lter grille be installed for horizontal applications. Airfl ow should
not exceed the face velocity of the fi lter being used. The factory

installed fi lter should then be removed from the unit.

2. Unit is shipped from the factory in the upfl ow or horizontal

left confi guration. Unit conversion is not required. Conversion
is required: Rotate motor to ensure connection at the 4 to 8
o’clock position.

8

Installation, Operation & Maintenance AIR HANDLER SERIES Heat Controller, Inc.

Rail

Auxiliary

Drain Pan

Tranquility

EarthPure

®

27

Installation

3. If the unit is suspended, it must be supported from the bottom
near both ends as well as the middle to prevent sagging.
The service access must remain unobstructed. If the unit is
supported along the length of the front and back, the air handler
only needs to be suspended at both ends. See Figure 1.

4. If the unit is not suspended it must be supported as mentioned
above and isolated carefully to prevent sound transmission.
Vibration isolators (purchased locally) must be placed under the
unit.

5. It is always recommended that an auxiliary drain pan be
installed under a horizontal air handler (See Condensate Drain
Piping) to prevent possible damage to ceilings.

6. Isolate the auxiliary drain pan from the unit or from the structure.

7. Connect the auxiliary drain line to a separate drain line (no trap
is needed in this line) and terminate according to national and
local codes.

8. If a return duct is connected to the air handler, it must be the
same dimensions as the return opening shown in the outline
drawing on Figure 2.

9. Openings where fi eld wiring enters the cabinet must be
completely sealed. Location of power entry is shown on the
outline drawing.

10. After ductwork connections are made, seal airtight and per local
codes.

Duct Connections

The supply and return air ducts should be connected to the unit
with fl ame retardant duct connectors.

Figure 1: Mounting Installation Options

Tranquility

27

EarthPure

®

NOTE: No sheetmetal screws may be used to attach
return ductwork on the side.

NOTE: Any duct board return connection can be made
to the sides of the unit using tape or mastic.

Figure 2: Flange Attachment

Tranquility

27

E
ar
thPure

®

Tranquility

27

EarthPure

®

9

Installation, Operation & Maintenance AIR HANDLER SERIES Heat Controller, Inc.

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5

'LV

Installation

Applications

Air Handlers can be applied in upfl ow, downfl ow, horizontal
right and horizontal left applications without modifi cations. For
horizontal applications, installation of an auxiliary/secondary
drain pan is required.

 CAUTION! 

CAUTION! For horizontal applications, the horizontal drain pan
must be located under the indoor coil. Failure to place the pan
under the coil can result in property damage.

'LVFKDUJH

5HWXUQ

TOP

DISCHARGE

1” to 2” Filter Rack Conversion

The unit is shipped with1” fi lter rack from the factory. The conversion
process is assumed that the unit is in upfl ow confi guration.

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BOTTOM

DISCHARGE

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LEFT

DISCHARGE

RIGHT

DISCHARGE

1. Place unit on a fl at surface. Remove 2 knurled thumb knobs that

secure the fi lter rack door at the bottom of the unit.

2. Remove 3 screws that secure the lower fi lter tracks on each side

of the unit.

3. Lift and rotate the fi lter tracks upside down and reinstall fi lter

tracks and screws back.

4. Replace the fi lter rack door and the 2 knurled thumb knobs.

10

Installation, Operation & Maintenance AIR HANDLER SERIES Heat Controller, Inc.

Installation

 CAUTION! 

CAUTION! HFC-410A systems operate at higher pressures
than R-22 systems. Be certain that service equipment
(gauges, tools, etc.) is rated for HFC-410A. Some R-22 service
equipment may not be acceptable.

 CAUTION! 

CAUTION! Installation of a factory supplied liquid line bi­directional fi lter drier is required. Never install a suction line
fi lter in the liquid line.

Line Set Installation

Figure 4 illustrates a typical installations of an air handler l matched
to an indoor compressor section. Table 1 shows typical line-set
diameters at various lengths. Lineset lengths should be kept to a
minimum and should always be installed with care to avoid kinking.
Line sets over 60 feet [18 meters] long are not recommended due to
potential oil transport problems and excessive pressure drop. If the
line set is kinked or distorted, and it cannot be formed back into its
original shape, the damaged portion of the line should be replaced.
A restricted line set will effect the performance of the system.

All brazing should be performed using nitrogen circulating at
2-3 psi [13.8-20.7 kPa] to prevent oxidation inside the tubing.
All linesets should be insulated with a minimum of 1/2” [13mm]
thick closed cell insulation. All insulation tubing should be
sealed using a UV resistant paint or covering to prevent
deterioration from sunlight.

When passing refrigerant lines through a wall, seal opening

See compressor section IOM for refrigerant charge
information.

Figure 3: Air Coil Connection

Bulb (Must be

Installed and
Insulated)

Equalizer

Line

TXV (‘IN’ toward

compressor section)

Suction Line

TXV has internal

check valve

Liquid Line

Sensing Bulb
IMPORTANT: DO NOT perform any brazing with the TXV

bulb attached to any line. After brazing operations have been
completed, clamp the TXV bulb securely on the suction line at
the 10 or 2 o’clock position with the strap provided in the parts
bag. Insulate the TXV sensing bulb and suction line with the
provided pressure sensitive insulation (size 4” x 7”).
IMPORTANT: TXV sensing bulb should be located on a horizontal
section of suction line, just outside of coil box.

IMPORTANT: Always protect TXV from heat when brazing.
IMPORTANT: TXV sensing bulb is shipped unattached. Installer

must attach bulb to suction line after brazing and cooling line for
proper unit operation.

NOTICE! The air coil should be thoroughly washed with a fi lming
agent, (dishwasher detergent like Cascade) to help condensate
drainage. Apply a 20 to 1 solution of detergent and water. Spray
both sides of coil, repeat and rinse thoroughly with water. Care
should be taken not to overfl ow drain pan. Wash after connecting
condensate line.

with silicon-based caulk. Avoid direct contact with water
pipes, duct work, fl oor joists, wall studs, fl oors or other
structural components that could transmit compressor
vibration. Do not suspend refrigerant tubing from joists
with rigid straps. Do not attach line set to the wall. When
necessary, use hanger straps with isolation sleeves to
minimize transmission of line set vibration to the structure.

Installing the Indoor Coil and Lineset

Figure 3 shows the installation of the lineset and TXV to a typical
indoor coil. Braze the copper line set to the coil. Nitrogen should be
circulated through the system at 2-3 psi [13.8-20.7 kPa] to prevent
oxidation inside the refrigerant tubing. Use a low silver phos-copper
braze alloy on all brazed connections.

Figure 4: Typical Split/Air Handler Installation

Power

Disconnects

Insulated

Linesets

PVC Condensate

with vented trap

Compressor Section

Air pad or Extruded

polystryene

11

Air

Handler

Low

Low Voltage

Voltage

Return

Plenum

Installation, Operation & Maintenance AIR HANDLER SERIES Heat Controller, Inc.

Installation

Evacuation and Charging the Unit
LEAK TESTING -

and checked for leaks before evacuating and charging the unit. To
pressurize the line set, attach refrigerant gauges to the service ports
and add an inert gas (nitrogen or dry carbon dioxide) until pressure
reaches 60-90 psig [413-620 kPa]. Never use oxygen or acetylene to
pressure test. Use a good quality bubble solution to detect leaks on all
connections made in the fi eld. Check the service valve ports and stem
for leaks. If a leak is found, repair it and repeat the above steps. For
safety reasons do not pressurize system above 150 psig [1034 kPa].
System is now ready for evacuation and charging.

Condensate Drain Tubing

Consult local codes or ordinances for specifi c requirements.
IMPORTANT: When making drain fi tting connections to the drain
pan, use a thin layer of Tefl on paste, silicone or Tefl on tape and
install hand tight.
IMPORTANT: When making drain fi tting connections to drain
pan, do not overtighten. Overtightening fi ttings can split pipe
connections on the drain pan.

• Install drain lines so they do not block service access to front

of the unit. Minimum clearance of 24 inches is required for
fi lter, coil or blower removal and service access.

• Make sure unit is level or pitched slightly toward primary drain

connection so that water will drain completely from the pan
(See Figure 5).

• Do not reduce drain line size less than connection size

provided on condensate drain pan.

• All drain lines must be pitched downward away from the unit a

minimum of 1/8” per foot of line to ensure proper drainage.

• Do not connect condensate drain line to a closed or open

sewer pipe. Run condensate to an open drain or outdoors.

• The drain line should be insulated where necessary to prevent

sweating and damage due to condensate forming on the
outside surface of the line.

• Make provisions for disconnecting and cleaning of the primary

drain line should it become necessary. Install a 3 in. trap in the
primary drain line as close to the unit as possible. Make sure
that the top of the trap is below connection to the drain pan to
allow complete drainage of pan (See Figure 5).

• Auxiliary drain line should be run to a place where it will be

noticeable if it becomes operational. Occupant should be
warned that a problem exists if water should begin running
from the auxiliary drain line.

• Plug the unused drain connection with the plugs provided in

the parts bag, using a thin layer of Tefl on paste, silicone or
Tefl on tape to form a water tight seal.

• Test condensate drain pan and drain line after installation is

complete. Pour water into drain pan, enough to fi ll drain trap
and line. Check to make sure drain pan is draining completely,
no leaks are found in drain line fi ttings, and water is draining
from the termination of the primary drain line.

The refrigeration line set must be pressurized

Figure 5: Condensate Drain Trap

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81,7

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'2 127 29(57,*+7(1 '5$,1 ),77,1*

81,7 0867 %( 6/,*+7/< ,1&/,1('

72:$5' '5$,1 &211(&7,21

It is always recommended that an auxiliary drain pan be installed
under a horizontally installed air handler.

Connect the auxiliary drain line to a separate drain line (no trap is
needed in this line) and terminate according to local codes.

NOTE: DO NOT use a torch or fl ame near the plastic
drain pan coupling.

NOTE: DO NOT tighten the drain pipe excessively.
Support the condensate piping and traps outside the
unit to prevent strain on the drain connection.

12

Installation, Operation & Maintenance AIR HANDLER SERIES Heat Controller, Inc.

Installation

AXM Control

The WDG Air handler is equipped with a communicating
AXM board to allow communication with the communicating
compressor section (HTS) and communicating thermostat.

The AXM control allows either 4-wire connection with
Communicating DXM2 board and Communicating Thermostat.
It can also be connected to a non-communicating thermostat
and compressor section using up to 9-wires (plus additional if
functionality requires). Please see Thermostat section for more
details.

AXM Connections

Sensor

Fan Connections

Electric Heat
Connections

LT2

Condensate

Sensor

DIP #2: Dehumidifi cation Mode - Provides selection of normal or
Dehumidifi cation Fan Mode. In Dehumidifi cation Mode, the fan
speed will be adjusted for Cooling. In Normal Mode, the fan speed
will be normal during Cooling.

On = Normal Fan Mode. Off = Dehumidifi cation Mode
Rest of the DIP switches are not used.

ACCESSORY CONNECTION / CONFIGURATION

2 Accessory outputs on AXM board only track blower operation.
Other accessories are connected to the DXM2 board. Please refer

to DXM2 AOM for more details.

Accessory

outputs

that track

blower

operation

4-wire

connection

to DXM2

9-wire connection to non-

communicating thermostat/

compressor section

4-wire connection to

communicating thermostat

Low Air Temperature Sensor Installation

WDG Air Handlers are shipped with LT2 (Low Air Temperature)
sensor installed in the Air Handler (Figure 3) and connected to the
AXM control. No additional action required (do not clip the VIO
wires).

Test Button

The test button puts the AXM into test mode, which bypasses the
soft start ramping profi le and the blower immediately ramps up to
the nominal target speed.

FIELD SELECTABLE INPUTS
DIP SWITCHES

Note: In the following fi eld confi guration options, DIP switches
should only be moved when power is removed from the DXM2
Control to ensure proper operation.

13

Installation, Operation & Maintenance AIR HANDLER SERIES Heat Controller, Inc.

Electrical - Thermostat Wiring

 CAUTION! 

CAUTION! Many units are installed with a factory or fi eld
supplied manual or electric shut-off valve. DAMAGE WILL
OCCUR if shut-off valve is closed during unit operation. A
high pressure switch must be installed on the heat pump side
of any fi eld provided shut-off valves and connected to the
heat pump controls in series with the built-in refrigerant circuit
high pressure switch to disable compressor operation if water
pressure exceeds pressure switch setting. The fi eld installed
high pressure switch shall have a cut-out pressure of 300 psig
and a cut-in pressure of 250 psig. This pressure switch can
be ordered from the manufacturer with a 1/4” internal fl are
connection as part number 39B0005N02.

 CAUTION! 

CAUTION! Refrigerant pressure activated water regulating

valves should never be used with the manufacturer’s equipment.

Thermostat Installation

The thermostat should be located on an interior wall in a
larger room, away from supply duct drafts. DO NOT locate the
thermostat in areas subject to sunlight, drafts or on external
walls. The wire access hole behind the thermostat may in certain
cases need to be sealed to prevent erroneous temperature
measurement. Position the thermostat back plate against the
wall so that it appears level and so the thermostat wires protrude
through the middle of the back plate. Mark the position of the
back plate mounting holes and drill holes with a 3/16” (5mm) bit.
Install supplied anchors and secure plate to the wall. Thermostat
wire must be 18 AWG wire. Wire the appropriate thermostat as
shown in Figures 6 and 7 to the low voltage terminal strip on
the ECM control board. Practically any heat pump thermostat
will work with these units, provided it has the correct number of
heating and cooling stages.

4-Wire Connection ATC communicating thermostat and DXM2
Communicating control in HTS Splits

AXM control in WDG Air Handler allows 4-wire connection with
Communicating DXM2 board and Communicating Thermostat.

Figure 6:

Connection to Non-Communicating
thermostat and AXM communicating control
in WDG Air Handler

Non-Communicating

2 Cool / 3 Heat Thermostat

Fan

Y1
Y2

R
G
C

DH

L

Compressor

Compressor Stage 2

Reversing Valve O

24Vac Hot

24Vac Common

Dehumidification

Dehumidifi cation

(ATP32U04 Only)

Fault LED

Communicating

TAH AXM Control

Y1
Y2

O

R
G
C

DH

AL1

C
A+

B-

24V

DXM2 In

Compressor

Section

C
A+

B-

24V

Thermostat Connections

C 24V Common for Control Circuit
R 24V Supply for Control Circuit
A+ Communications (Positive)
B – Communications (Negative)

Figure 7: 4-Wire

Connection to ATC communicating
thermostat, AXM Communicating control
and HTS Splits

DXM2 in

Compressor

Section

C

A+

B-

24V

Thermostat

C
R

A+

B-

Communicating

WDG with

AXM Control

C
A+

B-

R

C
A+

B-

24V

Thermostat Connections

C 24V Common for Control Circuit
R 24V Supply for Control Circuit
A+ Communications (Positive)
B – Communications (Negative)

14

Installation, Operation & Maintenance AIR HANDLER SERIES Heat Controller, Inc.

ECM Blower Control

The ECM fan is controlled directly by the DXM2/AXM control
board that converts thermostat inputs and CFM settings to signals
used by the ECM motor controller. To take full advantage of the
ECM motor features, a communicating multi-stage thermostat
should be used.

The AXM control maintains a selectable operating airfl ow [CFM]
for each heat pump operating mode. For each operating mode
there are maximum and minimum airfl ow limits. See the ECM
Blower Performance tables for the maximum, minimum, and
default operating airfl ows.

Airfl ow levels are selected using the confi guration menus of a
communicating thermostat or diagnostic tool. The confi guration
menus allow the installer to independently select and adjust the
operating airfl ow for each of the operating modes. Air fl ow can be
selected in 25 CFM increments within the minimum and maximum
limits shown in Table 8. The blower operating modes include:

• First Stage Cooling (Y1 & O)

• Second Stage Cooling (Y1, Y2, & O)

• First Stage Cooling in Dehumidifi cation Mode
(Y1, O, & Dehumid)

• Second Stage Cooling in Dehumidifi cation Mode
(Y1, Y2, O, & Dehumid)

• First Stage Heating (Y1)

• Second Stage Heating (Y1 & Y2)

• Third Stage (Auxiliary) Heating (Y1, Y2, & W)

• Emergency Heating (W with no Y1 or Y2)

• Fan (G with no Y1, Y2, or W)

Special Note for AHRI Testing: To achieve rated airfl ow for AHRI
testing purposes, it is necessary to change the CFM settings to
rated airfl ow.

Figure 8: Airfl ow Confi guration Screen on Communicating
Thermostat

CFM

AIRFLOW SELECTION

HEAT STAGE 1 600

HEAT STAGE 2 750
AUXILIARY HEAT 850
EMERGENCY HEAT 850
COOL STAGE 1 525
COOL STAGE 2 700
COOL DEHUMID 1 425
COOL DEHUMID 2 550
CONTINUOUS FAN 350
HEAT OFF DELAY 60
COOL OFF DELAY 30

PREVIOUS NEXT

The ECM motor includes “soft start” and “ramp down” features.
The soft start feature is a gentle increase of motor rpm at blower
start up. This creates a much quieter blower start cycle.

The ramp down feature allows the blower to slowly decrease rpm
to a full stop at the end of each blower cycle. This creates a much
quieter end to each blower cycle and adds overall unit effi ciency.

The ramp down feature is eliminated during an ESD (Emergency
Shut Down) situation. When the DXM2 ESD input is activated,
the blower and all other control outputs are immediately de­activated.

The duration of the “ramp down” periods are adjustable from
0 seconds to 255 seconds. This adjustment is available in the
Aifl ow Selection screen using the communicating thermostat or
confi guration/diagnostics tool, see Figure 8.

15

Installation, Operation & Maintenance AIR HANDLER SERIES Heat Controller, Inc.

Blower Performance Data

WDG Blower

Airfl ow in CFM with wet coil and clean air fi lter

Max

Model

ESP

(in. wg)

WDG

024

WDG

036

WDG

048

WDG

060

Airfl ow is controlled within 5% up to the Max ESP shown with wet coil

1.0 1/2

0.9 1/2

1.0 1

0.7 1

Fan

Motor

(hp)

Range

Cooling Mode Dehumid Mode

Stg 2 Stg 1 Stg 2 Stg 1 Stg 2 Stg 1

Default 700 525 550 425 750 600 350 850

Maximum 1000 800 800 600 1000 850 1000 1000

Minimum 600 450 550 400 600 450 300 700

Default 1050 800 850 650 1100 850 550 1350

Maximum 1500 1100 1200 900 1500 1100 1500 1500

Minimum 900 675 825 600 900 675 450 1350

Default 1400 1050 1100 850 1500 1150 700 1500

Maximum 2000 1500 1600 1200 2000 1500 2000 2000

Minimum 1200 900 1100 825 1200 900 600 1350

Default 1750 1300 1400 1050 1875 1450 875 1875

Maximum 2300 1900 2000 1500 2300 1900 2300 2300

Minimum 1500 1100 1375 1000 1500 1100 750 1500

Heating

Mode

Fan

Only

Mode

Aux/

Emerg

Mode

16

Installation, Operation & Maintenance AIR HANDLER SERIES Heat Controller, Inc.

Electrical - Power Wiring

 WARNING! 

WARNING! Electrical shock hazard - Lock unit disconnect
switch in open position before servicing unit. Failure to follow
this warning could result in property damage, personal injury,
or death.

1. These Air Handlers are shipped from the factory wired for
230 volts. The units may be wired for 208 or 115 volts. Follow
instructions on unit wiring diagram located on blower housing
and in the Service Facts document included with the unit.

2. The selection of wire and fuse sizes should be made according
to the Minimum Branch Circuit Ampacity and the Maximum
Overcurrent Device listed on the unit nameplate.

3. Field wiring diagrams for electric heaters and unit accessories
are shipped with the accessory.

4. Wiring must conform to National and Local codes.

5. Ground unit per local codes with good safety procedures.

NOTE: If air handler is used with or without a heater,
the electrical entry hole as well as any other cabinet
penetrations must be sealed air-tight.

Wiring Instructions for 115 volt Conversion from 230 volt

1. Disconnect all power to the unit.

2. Disconnect Transformer primary orange wire from power
block T2 and insulate open end of wire. Connect the white
lead from transformer primary wire to power block terminal T2.
Note: (L2 will be used as Netural)

3. Remove plug in ECM power wiring harness (Fig. 8) and Install
2 pin jumper plug provided in control box (Fig. 9).

NOTE: When supplementary heaters are installed,
inspect to insure that all packaging material has been
removed.

Figure 8: Remove Harness Plug

Figure 9: Install Two Pin Jumper Plug

Note: For 115V power only. Damage will occur to motor with
230V power supply if 115V jumper is used.

Table 3: Electric Table

Model

Rated Voltage of 208/230/60/1, fi eld convertible to 115V.

Volt Code

208/230

024 1 (115) 208/230

036 1 (115) 208/230

048 1 (115) 208/230

060 1 (115) 208/230

Rated Voltage

Dual Rated

(115) 208/230

Voltage Min/

Max Dual

Rated

(115) 208/230

(114/132)

197/254

(114/132)

197/254

(114/132)

197/254

(114/132)

197/254

Fan

Motor

FLA

(7.7) 4.3 1/2 1.0 (7.8) 4.9 (7.7) 4.3 (15) 15

(7.7) 4.3 1/2 0.9 (7.8) 4.9 (7.7) 4.3 (15) 15

(12.8) 7 1 1.0 (14.4) 8.6 (12.8) 7 (25) 15

(12.8) 7 1 0.7 (14.4) 8.6 (12.8) 7 (25) 15

Fan

Motor

HP

Max
Fan
ESP

Min Circ

Amp
(115)

208/230

Total

Unit
FLA

Max Fuse/

HACR

(115)

208/230

17

Installation, Operation & Maintenance AIR HANDLER SERIES Heat Controller, Inc.

WDG024-060 Wiring Diagram 115-208-230/60/1 ECM

18

Installation, Operation & Maintenance AIR HANDLER SERIES Heat Controller, Inc.

Electric Heat Installation

Overview

The HG Series Auxiliary Electric Heat mounts internally in
upfl ow (Figures 10-12) or downfl ow units and horizontal units.
Horizontal units are rated for zero clearance at the unit and 1"
clearance for fi rst three feet of duct, vertical units rated for zero
clearance for both unit and duct. Downfl ow units can not be
located directly over a discharge register. The discharge plenum
must be constructed from non combustible material. The HG
electric heat contains a four stage relay control board which
activates the elements directly via an internally wired low voltage
harness. Low voltage signals (W1 and W2) are staged from the
AXM control.

Vertical Upfl ow or Downfl ow and Horizontal Installation

1. Disconnect power to the unit

2. Remove blower access panels.

3. Clip wire-tie holding electric heat low voltage 3-wire harness

to discharge panel stiffener.

4. Remove blower mounting screws and then drop down

blower assembly as shown in Figure 11. Removal of blower
wires should not be necessary.

5. Install electric heat in discharge fl ange where blower

assembly has been removed using provided screws as
shown In Figure 12.

5.5 For downfl ow or horizontal right discharge units, the air

handler support bracket must be removed to re-install the
blower housing assembly. After re-installing the blower
housing, re-install the air handler support bracket.

6. Re-install blower assembly, Figure 12, into electric heat

assembly using blower mounting screws. Check blower
wiring for proper wiring connections.

7. Route the low voltage harness through the provided ‘pie’

bushing and plug into electric heat control board connector
P2 as shown in Figure 18.

8. Install power conduit through unit corner post knockout and

attach conduit directly to the electric heat control box.

9. Optional: HG**C kits only. Blower power may be supplied

from T3 & T4 CB5 breaker. Refer to WDG wiring diagram
96B0005N58.

Figure 11: Blower removal

Figure 12: HG electric heat mounting and
blower re-installation

Locate electric heat assembly

on pins in discharge panel

and insert screws

Relocate blower in electric

heat assembly in same

manner

Figure 10: Typical air handler installation

Auxiliary electric heat

power supply knockout

opposite air coil

Disconnect (optional

Electric Heat

Assembly

Air Coil

refer to local code)

Route condiut thru cabinet and
connect to electric heat control

box. Seal to eliminate air leaks on

Low voltage control
harness is prewired

on all distributor class units.

cabinet exterior.

19

Installation, Operation & Maintenance AIR HANDLER SERIES Heat Controller, Inc.

21

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Com

ER1

NO

Com

ER2

NO

Com

ER3

NO

Com

ER4

123

Tan

Ora

Factory Staging
(see T able 2)

Low Voltage Connector
(from Unit Control Board)

AG Electric Heat

Relay Board

P1P2

24V

W1

W2

4

5kW (‘ER1’ 5kW & ‘ER4’ 0kW) and W2 (second stage)
will have 10kW (‘ER2 & 3’ 5kW each)

1234

Tan

Ora

P2

Side View as seen in Control Box

P1

Staging Example on a 15kW unit W1 (first stage) has

blank

Electric Heat Wiring

Figure 13: Power Wiring, 4, 5, 8, and 10kw

Wiring and Setup (all models)

1. Install power wiring and connect to power block or circuit

breakers. In 12, 15 or 20kW models two power circuits may
be used to reduce wiring and breaker costs as in Figure 16.
If a single circuit supply is desired, install the optional single
circuit accessory kit (P/N 16B0002N02), as shown in Figure
15, that can be obtained from your distributor.
Ensure unit airfl ow setting is above minimum airfl ow rating for

2.

the electric heat model from Table 2.

3. Check staging jumpers for the application. Typically only

5 kW (factory setting on all models except 10kW on 20kW
models) is needed for fi rst stage electric (W1) to minimize
electric demand. This staging can be adjusted by moving the
staging jumpers as shown in Figure 17. Whatever is jumped
to P1 pin 1 will be energized on 1st stage of electric heat,
and P1-2 will be energized as stage 2 electric heat. See
Table 5 for staging options.

4. Mark the appropriate box of the electric heat model installed

on the additional serial plate on the exterior of the unit.

5. Turn on the power to the unit and the auxiliary

electric heat.

Figure 14: Power Wiring, Single Circuit, 15, 20kw

Figure 15: Power Wiring, Dual Circuits, 15 and 20kw

Figure 16: Staging Jumpers

Auxiliary Electric Heat Start-up

Put thermostat in emergency heat mode (manual mode on
communicating t-stat) and set point to high setting. Unit will
require 15-20 seconds before engaging emergency heat mode
stage 1 (W1) and then another 15-20 seconds to engage stage 2
(W2) when in ‘Test mode’. Verify proper electric heat operation.
Exit manual mode for normal operation.

Y1 COMM OUTPUT OFF

Y1 COMM OUTPUT OFF
Y2 COMM OUTPUT OFF
W COMM OUTPUT OFF

W COMM OUTPUT OFF

O COMM OUTPUT OFF
G COMM OUTPUT OFF

H COMM OUTPUT OFF
DH COMM OUTPUT OFF
ECM AIRFLOW 0
PUMP SPEED 0%
TEST MODE OFF

SELECT OPTION

PREVIOUS SELECT

MANUAL OPERATING MODE

HG

20

Installation, Operation & Maintenance AIR HANDLER SERIES Heat Controller, Inc.

Electrical Heat Staging Options

Figure 17: Low Voltage Harness Connection

Table 4: HG Electric Heat Ratings

Auxiliary

Electric

Heat

Model

HGM4C 3.8 2.9 13000 9900 500
HGM5C 4.8 3.6 16300 12300 500
HGM8C 7.6 5.7 25900 19400 650

HGM10C 9.6 7.2 32700 24600 650

HGL10C 9.6 7.2 32700 24600 1300
HGL15C 14.4 10.8 49100 36900 1350
HGL20C 19.2 14.4 65500 49200 1350

WDG Models kW Rating Btuh Rating

024 036

048-

240V 208V 240V 208V

060

Black area denotes compatibility
Note: Horizontal units rated for zero clearance unit and 1” clearance for
the fi rst three feet of duct, Vertical units rated for zero clearance for both
unit and duct.

Table 5: HG Electric Heat Staging Options

Auxiliary Electric

Heat Model

HGM4C 4 4 404040
HGM5C 5 5 505050

HGM8C 4 or 8 4 444480
HGM10C 5 or 10 5 5555100
HGL10C 5 or 10 5 5555100
HGL15C 5, 10 or 15 5 5 10 10 5 15 0
HGL20C 5, 10, 15 or 20 10 10 10 10 10 15 5

Staging
Options

Factory
Settings
Stage 1

Jumper 1-4, 2-3† Jumper 1-3, 2-4† Jumper 1-2-3

Stage 1 Stage 2 Stage 1 Stage 2 Stage 1 Stage 2

† Factory jumper setting

Staging in kW

Minimum

CFM

Required

Table 6: HG Electric Heat Electrical Data

Unit Model

024

036

048 and 060

Head Kit

Model

HGM4C SINGLE 15.8 14 4.3 25 23 25 25
HGM 5C SINGLE 20 17.3 4.3 30 27 30 30
HGM 8C SINGLE 31.7 27.5 4.3 45 40 45 40

HGM 10C SINGLE 40 34.7 4.3 55 49 60 50

HGL10C SINGLE 40 34.7 4.3 59 52 60 60
HGL15C DUAL L1/L2 40 34.7 0 50 43 50 45

HGL10C SINGLE 40 34.7 7.0 59 52 60 60
HGL15C DUAL L1/L2 40 34.7 0.0 50 43 50 45

HGL20C DUAL L1/L2 40 34.7 0.0 50 43 50 45

Supply

L3/L4 20 17.3 4.3 34 30 35 30

L3/L4 20 17.3 7.0 34 30 35 30

L3/L4 40 34.7 7.0 59 52 60 60

Heater

Amps

240

All heaters rated single phase 208-240V 60Hz All Fuses UL Class K general purpose
All models 15kW or larger feature internal circuit breakers

Heater

Amps

208

Blower

FLA

Minimum Circuit Amps

240 V 208 V 240 V 208 V

Maximum Breaker

Size

21

Installation, Operation & Maintenance AIR HANDLER SERIES Heat Controller, Inc.

Unit & System Checkout

 WARNING! 

WARNING! Electrical shock hazard - Lock unit disconnect
switch in open position before servicing unit. Failure
to follow this warning could result in property damage,
personal injury, or death.

After installation has been completed, it is recommended that the
Air Handler be checked against the following checklist:

CHECKOUT PROCEDURE

❑ Power: Make sure power is “OFF” at power disconnect

switch.

❑ Field Wiring: Check all fi eld wiring for tight connections.

See that grounding of unit is in accord with code

❑ Unit Suspension: Make sure unit suspension (if used)

is secure and that there are no tools or loose debris in,
around or on top of the unit.

❑

Ducts: Check all duct outlets; they must be open and
unrestricted.

MAINTENANCE

 WARNING! 

WARNING! These instructions are intended as
an aid to qualifi ed licensed service personnel for
proper installation, adjustment and operation of
this unit. Read these instructions thoroughly before
attempting installation or operation. Failure to follow
these instructions may result in improper installation,
adjustment, service or maintenance possibly resulting in
property damage, personal injury or death.

❑ Drain Lines: Check drain lines and be sure all joints are

tight.

❑
❑ Power Supply: Check power supply for correct

❑ Filters: Check fi lters for proper size. Inform owner of
❑ Operation: Energize the system and carefully observe
❑ Procedure: Instruct owner, engineer (if possible) on

Indoor Coil - Drain Pipe - Drain Line

Inspect the indoor coil once each year for cleanliness and clean
as necessary. In some cases, it may be necessary to remove the
fi lter and check the return side of the coil with
a mirror and fl ashlight.

IMPORTANT: Do not use caustic household drain cleaners
or bleach in the condensate pan or near the indoor coil. Drain
cleaners will quickly damage the indoor coil.

Drain Pan: Make sure secondary drain pan is installed.
requirements per unit nameplate.
proper procedure for removal and reinstallation.
its operation; make any necessary adjustment.
proper operating procedure and leave Use and Care

Manual with owner.

For continuing high performance and to minimize possible
equipment failure, it is essential that annual maintenance be
performed on this equipment. Consult your local dealer as to the
availability of a maintenance contract.

Air Filter

Check the system fi lter every ninety days or as often as found to
be necessary and if obstructed, clean or replace at once.

IMPORTANT: Do not operate the system without a fi lter in place.

22

Revision History

Revision History

Date Page # Description

21 Feb., 13 All Various Updates

3 May, 12 All First Published

02/2013

*97B0101N03*

97B0101N03