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
Safety ...................................................................................................................5
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
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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
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
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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 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.
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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 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.
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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]
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Installation, Operation & Maintenance WDG AIR HANDLER SERIES Heat Controller, LLC
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]
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
A
WidthBHeightCDepth
D E F G H J
R.A. Opening
A
0.625 [1.6]
0.75 [1.9]
7
R.A. Opening
C
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 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 ef ciency and customer ease of fi lter
maintenance, it is recommended that a properly sized remote 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 ef ciency and customer ease of fi lter maintenance, it is recommended that a properly sized remote 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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Installation, Operation & Maintenance WDG AIR HANDLER SERIES Heat Controller, LLC
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 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
®
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Installation, Operation & Maintenance WDG AIR HANDLER SERIES Heat Controller, LLC
5HWXUQ
'L
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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.
5HWXUQ
'LVFKDUJH
'LVFKDUJH
BOTTOM
DISCHARGE
5HWXUQ
LEFT
DISCHARGE
RIGHT
DISCHARGE
1. Place unit on a fl at surface. Remove 2 knurled thumb knobs that
2. Remove 3 screws that secure the lower fi lter tracks on each side
3. Lift and rotate the fi lter tracks upside down and reinstall fi lter
4. Replace the fi lter rack door and the 2 knurled thumb knobs.
secure the fi lter rack door at the bottom of the unit.
of the unit.
tracks and screws back.
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Installation, Operation & Maintenance WDG AIR HANDLER SERIES Heat Controller, LLC
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 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 WDG AIR HANDLER SERIES Heat Controller, LLC
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 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 Te fl 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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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 WDG AIR HANDLER SERIES Heat Controller, LLC
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.
Figure 6: Three Heat / Two Cool, Manual / Auto Changeover Programmable
Units with ECM Fan
Connection to ECM Control
ATP32U03 Thermostat
Compressor
Compressor Stage 2
Reversing Valve
24Vac Hot
24Vac Common
Fault LED
Electric Heat
Field Wiring Factory Wiring
See equipment wiring diagram for more details.
Figure 7: Three Heat / Two Cool, Auto / Manual Changeover Programmable (7 Day) - Non­ Programmable, With Humidity Control
Y1
Y2
O
Fan
G
R
C
L
W1
Units with ECM Fan
Connection to ECM Control
ATP32U04 Thermostat
Compressor
Compressor Stage 2
Dehumidification
Reversing Valve
Fan
24Vac Hot
24Vac Common
Fault LED
Electric Heat
Y1
Y2
DH
O
G
R
C L
W1
ECM
AL1
ECM
Y1
Y2
O
G
R
C
AL1
W
Y1
Y2
DH
O
G
R
C
W
Notes:
1) ECM dehumidification mode slows down fan speed in the cooling mode when dehumidification output from thermostat is active. Normal heating and cooling fan speeds are not affected.
2) ECM board DIP switch SW9 must be in dehumid. mode.
Field Wiring Factory Wiring
See equipment wiring diagram for more details.
13
Installation, Operation & Maintenance WDG AIR HANDLER SERIES Heat Controller, LLC
ECM Blower Control
The ECM fan is controlled by an interface board that converts thermostat inputs and fi eld selectable CFM settings to signals used by the ECM motor controller. Units manufactured before July 2005 have version I (P/N 69243707). Units manufactured after July 2005 have version II (P/N 17B0019N01). Fan speeds are selected with jumpers for version I or via a nine position DIP switch for version II. To take full advantage of the ECM motor features, a multi-stage thermostat should be used (2-stage heat/2-stage cool or 3-stage heat/2-stage cool).
HFC-410A packaged units built after May 2009 have ECM controller version III (P/N 17B0034N02). This controller includes logic and a relay to control.
Note: Power must be off to the unit for at least three seconds before the ECM motor will recognize a speed change. The motor will recognize a change in the CFM Adjust or dehumidifi cation mode settings while the unit is powered.
There are four different airfl ow settings from lowest airfl ow rate (speed tap 1) to the highest airfl ow rate (speed tap 4). The charts below indicate settings for both versions of the ECM interface board, followed by detailed information for each setting.
Cooling Settings: The cooling setting determines the cooling (normal) CFM. Cooling (normal) setting is used when the unit is not in dehumidifi cation mode. Tap 1 is the lowest CFM setting, while tap 4 is the highest CFM setting. To avoid air coil freeze-up, tap 1 may not be used if the dehumidifi cation mode is selected. Consult submittal data or specifi cations catalog for the specifi c unit series and model to correlate speed tap setting to airfl ow in CFM.
cooling to increase the moisture removal of the heat pump. Consult submittal data or specifi cations catalog for the specifi c unit series and model to correlate speed tap to airfl ow in CFM. The dehumidifi cation mode can be enabled in two ways.
1. Constant Dehumidifi cation Mode: When the dehumidifi cation mode is selected (via DIP switch or jumper setting), the ECM motor will operate with a multiplier applied to the cooling CFM settings (approx. 20-25% lower airfl ow). Any time the unit is running in the cooling mode, it will operate at the lower airfl ow to improve latent capacity. The “DEHUM” LED will be illuminated at all times. Heating airfl ow is not affected. NOTE: Do not select dehumidifi cation mode if cooling setting is tap 1.
2. Automatic (Humidistat-controlled) Dehumidifi cation Mode: When the dehumidifi cation mode is selected (via DIP switch or jumper setting) AND a humidistat is connected to terminal DH (version II) or HUM (version I), the cooling airfl ow will only be reduced when the humidistat senses that additional dehumidifi cation is required. The DH (or HUM) terminal is reverse logic. Therefore, a humidistat (not dehumidistat) is required. The “DEHUM” LED will be illuminated only when the humidistat is calling for dehumidifi cation mode. Heating airfl ow is not affected. NOTE: Do not select
dehumidifi cation mode if cooling setting is tap 1.
Heating Settings: The heating setting determines the heating CFM. Tap 1 is the lowest CFM setting, while tap 4 is the highest CFM setting. Consult submittal data or specifi cations catalog for the specifi c unit series and model to correlate speed tap setting to airfl ow in CFM.
Auxiliary/Emergency Heat Settings: The auxiliary/emergency heat setting determines the CFM when the unit is in auxiliary heat or emergency heat mode. This setting is used for residential units with internal electric heat. When auxiliary electric heat is energized (i.e. compressor and electric heat), the greater of the auxiliary/emergency or heating setting will be used. A “G” (fan) signal must be present from the thermostat for electric heat to operate. Consult the submittal data or specifi cations catalog for the specifi c unit series and model to correlate speed tap setting to airfl ow in CFM.
CFM Adjust Settings: The CFM adjust setting allows four selections. The NORM setting is the factory default position. The + or – settings adjust the airfl ow by +/- 5%. The +/- settings are used to “fi ne tune” airfl ow adjustments. The TEST setting runs the ECM motor at 400 CFM/nominal ton at a constant CFM. Example: WDG024 = 800 CFM.
Dehumidifi cation Mode Settings: The dehumidifi cation mode setting provides fi eld selection of humidity control. When operating in the normal mode, the cooling airfl ow settings are determined by the cooling tap setting above. When dehumidifi cation is enabled there is a reduction in airfl ow in
14
Installation, Operation & Maintenance WDG AIR HANDLER SERIES Heat Controller, LLC
ECM Blower Control
Table b: ECM Board Tap Settings
Cooling settings: TT, TS Units Heating settings: TT, TS Units Aux/Emerg Heat settings: TT, TS Units
Version I Version I Version I 69243707 69243707 69243707
Tap HP CFM Tap
Setting Jumper SW1 SW2 Setting Jumper SW3 SW4 Setting Jumper SW5 SW6
1 1 ON ON 1 1 ON ON 1 1 ON ON 2 2 ON OFF 2 2 ON OFF 2 2 ON OFF 3 3 OFF ON 3 3 OFF ON 3 3 OFF ON 4 4 OFF OFF 4 4 OFF OFF 4 4 OFF OFF
CFM Adjust settings: TT, TS Units Dehum Mode settings: TT, TS Units
Version I Version I 69243707 69243707
Tap CFM Adj Tap Dehumid
Setting Jumper SW7 SW8 Setting Jumper
TEST 1 ON ON NORM pins 1,2
-
2 ON OFF Dehumid pins 2,3
+ 3 OFF ON
NORM 4 OFF OFF
Version II and III
(17B0019N01 & 17B0034N01)
DIP Switch DIP Switch
Version II and III
(17B0019N01 & 17B0034N01)
DELAY
Version II and III
(17B0019N01 & 17B0034N01)
Version II and III
(17B0019N01 & 17B0034N01)
DIP Switch DIP Switch
SW9
ON
OFF
Tap AUX CFM
Version II and III
(17B0019N01 & 17B0034N01)
DIP Switch
Table 8a: ECM Version II Interface Layout
1/4" Spade
Connections
to CXM or
DXM Board
Thermostat
Connections
Dehumidification
LED
Y1
Y2
G
R
GGGGR
C
TB1
Y2
Y1
G
O
W
C
R DH
AL1
A
A
AL1
Fan Speed Selection DIP Switch
G
DEHUM
OFF
ON
SW9
SW8
SW7
SW6
SW5
SW4
O
SW3
SW2
W
CFM
SW1
S1
Y
J1
Thermostat Input LEDs
CFM Counter 1 flash per 100 CFM
ECM Motor Low Voltage Connector
Figure 8c: ECM Version III Interface Layout
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Table 8b: ECM Version I Interface Layout
Adjust
Delay
J01
CFM
1/4" Spade Connections to CXM or DXM Board
Thermostat Input LEDs
CFM Counter 1 flash per 100CFM
ECM Motor Low Voltage Connector
Dehumidification LED
AL
AL
A
L
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Y2
LED's
1
Y1
Thermostat Connections
2
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TB01
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2
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1
2
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CFM
3
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4
CFM
Aux
4
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HP
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Hum
Dehumid
2 3
Fan Speed Selection Jumpers
Norm
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15
Installation, Operation & Maintenance WDG AIR HANDLER SERIES Heat Controller, LLC
Blower Performance Data
WDG Blower
Airfl ow in CFM with wet coil and clean air fi lter
Model
ESP
(in. wg)
0.50 1/2 4 810 950 475 630 740 475 920 1060 475 4 1060
Max
WDG
TAH
024
026
WDG
TAH
036
038
TAH
WDG
048
049
TAH
WDG
060
064
Factory shipped on Tap Setting 2 During Auxiliary operation (residential units only) the CFM will run at the higher if the heating (delay jumper) or AUX settings Airfl ow is controlled within +/- 5% up to Max ESP shown with wet coil and standard 1” fi berglass fi lter Do not select Dehumidifi cation mode if HP CFM is on setting 1 All units AHRI/ISO/ASHRAE 13256-1 rated HP (Cooling) Delay (Heating) CFM Setting 3
0.50 1/2 3 725 850 425 560 660 425 825 950 425 3 950
0.50 1/2 2 620 730 370 490 570 370 710 820 370 2 820
0.50 1/2 1 520 610 300 600 690 300 1 690
0.50 1/2 4 1120 1400 700 870 1090 700 1120 1400 700 4 1400
0.50 1/2 3 1000 1250 630 780 980 630 1000 1250 630 3 1350
0.50 1/2 2 860 1080 540 670 840 540 860 1080 540 2 1350
0.50 1/2 1 730 900 450 730 900 450 1 1350
0.75 1 4 1460 1730 870 1140 1350 870 1560 1850 870 4 1850
0.75 1 3 1300 1550 780 1020 1210 780 1400 1650 780 3 1660
0.75 1 2 1120 1330 670 870 1040 670 1200 1430 670 2 1430
0.75 1 1 940 1120 560 1010 1200 560 1 1350
0.75 1 4 1670 2050 1020 1300 1600 1020 1860 2280 1020 4 2280
0.75 1 3 1500 1825 920 1160 1430 920 1650 2050 920 3 2040
0.75 1 2 1280 1580 790 1000 1230 790 1430 1750 790 2 1750
0.75 1 1 1080 1320 660 1200 1470 660 1 1470
Fan
Motor
(hp)
Tap
Setting
Cooling Mode Dehumid Mode Heating Mode
Stg 1 Stg 2 Fan Stg 1 Stg 2 Fan Stg 1 Stg 2 Fan
AUX CFM
Aux/
Emerg
Mode
16
Installation, Operation & Maintenance WDG AIR HANDLER SERIES Heat Controller, LLC
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 WDG AIR HANDLER SERIES Heat Controller, LLC
WDG024-060 Wiring Diagram 115-208-230/60/1 ECM
18
Installation, Operation & Maintenance WDG AIR HANDLER SERIES Heat Controller, LLC
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 DXM2 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
on all distributor class units.
cabinet exterior.
Low voltage control harness is prewired
19
Installation, Operation & Maintenance WDG AIR HANDLER SERIES Heat Controller, LLC
21
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Factory Staging (see Table 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
Ta n
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 (or jumper thermostat input R to W and R to G) 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.
HG
20
Installation, Operation & Maintenance WDG AIR HANDLER SERIES Heat Controller, LLC
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 WDG AIR HANDLER SERIES Heat Controller, LLC
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 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 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
Date Page # Description
17 June, 13 13, 14 Text Updates
16 May, 13 All Miscellaneous Text Edits, New Wire Diagram ECM Board
21 Feb., 13 All Various Updates
3 May, 12 All First Published
6/17/13
Design, material, performance data and components
subject to change without notice.
*97B0101N03*
97B0101N03
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