Heatcontroller WDG Air Handler User Manual

INSTALLATION, OPERATION

& MAINTENANCE MANUAL

Residential Air Handler

WDG Air Handler Series

Heat Controller, LLC • 1900 Wellworth Ave. • Jackson, MI 49203 • (517)787-2100 • www.heatcontroller.com

Installation, Operation & Maintenance WDG AIR HANDLER SERIES Heat Controller, LLC

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

Installation, Operation & Maintenance WDG AIR HANDLER SERIES Heat Controller, LLC

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

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

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

CONTROLS

S = STANDARD

REVISION

A = CURRENT REVISION

Installation, Operation & Maintenance WDG AIR HANDLER SERIES Heat Controller, LLC

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.

Installation, Operation & Maintenance WDG AIR HANDLER SERIES Heat Controller, LLC

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.

Installation, Operation & Maintenance WDG AIR HANDLER SERIES Heat Controller, LLC

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]

Installation, Operation & Maintenance WDG AIR HANDLER SERIES Heat Controller, LLC

Unit Dimensional Data

Detail A

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]

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]

See Detail A

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

WidthBHeightCDepth

D E F G H J

R.A. Opening

0.625 [1.6]

0.75 [1.9]

R.A. Opening

0.875 [2.2]

Installation, Operation & Maintenance WDG AIR HANDLER SERIES Heat Controller, LLC

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.

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