Air Handler
Contents
1. HEATER P1 Figure 14 Single Stage Control Board T LA CM IM O AZA 9 H HEATER 1 Figure 15 Two Stage Control Board 24 DEHUM Y1 TWIN TEST PORT ooooool Wi EXPANSION PORT 000000 FAN SPEED NOT USED Sov s C C O 00000000 7 N 7 HEAT COOL STATUS BLOWER MOTOR STATUS LIGHTS PA O O L2 OUT L2 IN a z LU m 4 N al 4 FAN SPEED DEHUM L TEST PORT y 1 LL 6 HEAT COOL Ooooooo SENSOR JE EXPANSION PORT 0000 GNDL SS SS BLOWER MOTOR Figure 17 Variable Speed Motor Control Board 6001 V9 0 L LZ ___ 96811041 MO Buu AJoyoe4 YOLOANNOO AL BuuIM pl l i 40 M0IIV 01 03349 6 EET 9NTd H31V3H abneb aues ou TWNIWHAL o1amia Jo am d ddo2 5 501 HLIM Kuo asn padejda s qadd nos Qquvoa dl Buum euu lul AY Jl r pesn A ddns 94 UUM uonisod HS NHOASNVHL de ay u jew dej no wow Orr ld Nid Kjeuuud abe ion jenp e 9 CLI 6LII JSWJOJSUEI DUDIMOS 210J8q 129VV025 0 T suononaisu uonejjeisu ou 995 Q3TIVLSNI LON LIY 831V3H N3HM UMOUS se aq 104 Aew DNISNOH DM1d 3AOW3H OL SAYIM LNO uon uuo2 dej p ds 1010 1 MO Q 9U SILON J9 pUEH ITV NVdO2. e IMPORTANT The steps in the Orifice Removal amp Installation section must be performed before the linesets are connected 1 Remove grommets from line set holes A CAUTION It is recommended that a wet rag be wrapped around the suction line in front of the close off plate or the sensing bulb if TXV is installed before applying heat Failure to keep components cool during brazing may result in structural damage premature equipment failure or possible personal injury 2 Unbraze and remove the cap on the suction line 3 Route and cut both lineset tubes to proper length in accordance with the outdoor unit specifications Verify the ends are round clean and free of any burrs 4 Position grommeton line set with sufficient distance away from brazing area Brazing processes can permanently damage grommets 5 Connect the suction and liquid lineset tubes A CAUTION It is recommended that a wet rag be wrapped around the suction line in front of the close off plate or the sensing bulb if TXV is installed before applying heat Failure to keep components cool during brazing may result in structural damage premature equipment failure or possible personal injury HORIZONTAL 3 4 Adapter w 3 4 dia hose barb 3 4 minimum dia PVC or flexible tubing SN NOTES 1 The drain lines must maintain a downward slope to ensure proper condensate drainage 2 Each condensate drain mu
3. 16 1 0 8LC5 00IIMC 16 FIGURES amp TABLES 17 Figure 12 HMG F1E HMG X1E 8 HCG V1E Physical Dimensions 17 Figure 13 Air Handler Components 18 Airflow 19 Table 5 HMG F1E Air Handlers 19 Table 6 HMG X1E Air Handlers 20 Table 7 HMG X1E Air Handlers Heat Only 21 Table 8 HCG V1E Air Handlers Cool Only 21 Table 9 HCG V1E Airflow Settings 22 Electrical Diagrams amp Data 23 Figure 14 Single Stage Control Board 23 Figure 15 Two Stage Control Board 23 Figure 16 Fixed Speed Control Board 24 Figure 17 Variable Speed Control Board 24 Figure 18 HMG F1E Wiring Diagram 25 Figure 19 HMG X1E Wiring Diagram 26 Figure 20 HCG V1E Wiring Diagram 27 Table 10 HMG F1E MCA amp MOP Data 28 Table 11 HMG X1E amp HCG V1E MCA 8 MOP Data 29 Table 12 Control Board Operation 30 INSTALLATION PERFORMANCE CHECKLIST 32 IMPORTANT SAFETY INFORMATION INSTALLER Please read all instructions before servicing this equipment Pay attention to all safety warnings and any
4. 2 External static pressure ESP is shown in inches w c 3 See unit nameplate or installation instructions for maximum recommended external static pressure Table 5 Airflow Data for HMG F1E Series Air Handlers 19 Switch Settings Cooling or Heating Airflow CFM 0 OFF 1 ON Dry Coil ESP 1 5 2 6 3 7 4 8 0 3 0 4 0 5 0 6 HMG24X1E amp HMG30X1E 2lo 2jol2j ol2j o 2jo 2 o 2jo 2 lo lolola l olola a lololal lolo 2 2 2 2 o o o o 2 2 2 2 o o o o ajalalalalal alalolololololololo Switch Settings Cooling or Heating Airflow CFM 0 OFF 1 ON Dry Coil ESP 1 5 2 6 3 7 4 8 0 3 0 4 0 5 0 6 HMG36X1E amp HMG42X1E 2lo 2jol2j ol2j o 2jo o 2jo 2 o l lololxli lololxl lolol l lolo 1 lo lololololololo alala lalololololala la lalolololo Switch Settings Cooling or Heating Airflow CFM 0 OFF 1 ON Dry Coil ESP 1 5 2 6 3 7 4 8 0 3 0 4 0 5 0 6 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 HMG48X1E amp HMG60X1E lalololalalolola l a lololalalolo alalalalo lo lolola lalalalolololo alalalalalala n lolololololololo NOTE When matched with two stage outdoor units the airflow on low Y1 or W1 input will be 70 of the values shown in this table Table 6 Airflow Da
5. Normal Operation Motor Fault Fixed Speed Furnaces Twin Fault no motor fault Communications Fault Control Fault No Power Normal Operation Motor Fault Communications Fault Variable Speed Furnaces Table 4 Motor Control Board Fault Conditions 2 MI 1 7 8 m 3 5 8 5 5 8 4 I DETAIL gt 113 K O FIGURES amp TABLES 11 4 11 8 K O 2 typ D 13 4 K O typ 1 5 8 1 17 8 1 1 8 718 K O A 24K amp 30K 43 5 16 14 3 16 12 3 4 36K HMG F1E Only 43 5 16 19 11 16 18 1 4 36K amp 42K 49 5 16 19 11 16 18 1 4 48K amp 60K 55 15 16 22 7116 Figure 12 HMG F1E HMG X1E amp HCG V1E Series Physical Dimensions 17 Circuit Breaker 60A 31 Heating Element Assembly gt f Transformer Motor Control 5 s Board gt Upper Door Blower Control M Assembly Wheel Board j Capacitor Motor Mount Kit se S Coil Motor Assembly Filter n Er Blovver Housing Horizontal Door Drain Pan Vertical Drain Pan Filter Tracks Lovver Door Assembly Figure 13 HMG F1E HMG X1E amp HCG V1E Series Air Handler Components Dry Coil ESP HMG24F1E HMG30F1E HMG36F1E
6. on the motor control board of the air handler In this option the DHUM output of the humidistat must be set to be normally open and closed when there is a call for humidification See Figure 11 3 If a humidistat is not available it is an acceptable option to connect the R amp DHUM terminals on the motor control board together with a field supplied wire This option causes the blower to run at a reduced CFM for 10 minutes after a call for cooling NOTE If outdoor unit is a heat pump connect the O terminal to DHUM MOTOR CONTROL BOARD HUMIDISTAT Figure 11 DHUM Wiring Configuration 15 UNIT MAINTENANCE Proper maintenance is most important to achieve the best performance from a air handler Some of the components and their locations are shown in Figure 13 page 18 If any component of the air handler must be replaced use only factory authorized replacement parts specified in the Replacement Parts List provided online A WARNING ELECTRICAL SHOCK FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury or property damage Improper servicing could result in dangerous operation serious injury death or property damage Before servicing disconnect all electrical power to air handler When servicing controls label all wires prior to disconnecting Reconnect wires correctly Verify proper operation after servicing These maintenance instructions are primari
7. HMG42F1E HMG48F1E HMG60F1E NOTES Corrected ESP Medium Corrected ESP Corrected ESP Corrected ESP Medium Corrected ESP Corrected ESP Corrected ESP Medium Corrected ESP Corrected ESP Corrected ESP Medium Corrected ESP Corrected ESP Corrected ESP Medium Corrected ESP Corrected ESP AIRFLOW DATA 0 19 607 975 793 871 EG EUM NEN ET NM m ow 0 00 L o Use HMG X1E airflow data See Table 5 page 20 0 40 0 50 0 60 0 70 0 80 0 30 0 42 0 53 0 65 0 76 5 515 63 345 7 4 63 4 406 34 682 625 564 8 20 860 30 9 0 23 0 36 0 48 0 60 0 72 9 797 7 659 0 14 0 27 0 40 0 53 0 67 53 04 647 5 508 0 27 0 38 0 50 0 62 0 74 874 7 1130 1070 1005 935 860 7 7 81 1046 997 940 99 717 0 17 0 29 0 42 0 55 0 68 0 10 0 23 0 36 0 49 0 63 821 764 01 55 0 27 0 39 0 51 0 62 0 74 91 05 0 15 0 28 0 41 0 54 0 68 31 1188 1133 1067 9 903 8 1333 1270 1196 1113 1018 913 0 09 0 23 0 36 0 50 0 64 1233 1187 1134 1072 1003 1373 1320 1260 1193 1118 0 27 0 38 0 49 0 61 0 72 0 24 0 36 0 47 0 58 0 70 1558 1506 1447 1380 1305 1223 0 21 0 33 0 44 0 56 0 68 1565 0 31 1830 2003 0 26 1524 0 42 1758 1906 0 37 1468 0 52 1675 1805 0 49 1399 0 63 1580 1698 0 60 1316 0 74 1474 1586 0 71 0 28 0 39 0 50 0 61 0 72 1 Airflow is shown in cfm 5
8. arrival should be carefully inspected for damage prior to installing the equipment at the job site Claims for damage apparent or concealed should be filed immediately with the carrier Y it is recommended that the cooling load of the area to be conditioned should be calculated and a system of the proper capacity selected Y Check the electrical supply and verify the power supply is adequate for unit operation The system must be wired and provided with circuit protection in accordance with local building codes If there is any question concerning the power supply contact the local power company N Verify the duct system is appropriate for the air handler being installed Please note that when replacing an existing system with lower air flow the duct system may require modification Locating the Air Handler Survey the job site to determine the best location for mounting the unit Consideration should be given to availability of electric power service access and noise The dimensions of the room or alcove must be able to accommodate the overall size of the unit and the installation clearances listed in Table 1 Physical dimensions for this air handler are also shown in Figure 12 page 17 The air handler should be set into position before routing the refrigerant tubing e Minimum Clearances This appliance must be installed in accordance with clearances listed in Table 1 The air handler must be installed with ample clearance
9. equipped with an option of continuous low speed fan operation When G is energized without Y Y2 the air handler will operate using the cooling speed With G amp Y Y2 or Y Y2 energized the air handler will operate in the selected cooling speed including 40 sec blower off delay Turning the Blower Off Set thermostat s fan mode to AUTO the blower will shut down immediately System Cooling 1 Set the thermostat s system mode to COOL and fan mode to AUTO Lower the thermostat s temperature mode below room temperature and observe that the blower energizes Check the air being discharged at the register is cooler than room temperature Verify unit refrigerant pressures are in order Blower should be turning in direction indicated by arrow NOTE DO NOT alter unit wiring Listen for any unusual noises Locate the source and correct as needed 2 Allow the unit to run for several minutes and then set the thermostat s temperature above room temperature Verify the blower cycles off with the thermostat System Heating 1 Setthe thermostat s system mode to HEAT and the fan mode to AUTO Increase the thermostat s temperature above room temperature and observe that the blower energizes Checkthe air being discharged atthe register is warmer than room temperature 2 Allow the unit to run for several minutes and then set the thermostat s temperature below room temperature Verify the blower cycles off with the thermostat Selectin
10. for easy access to the air filter blower assembly heater assembly controls and vent connections Applicable building codes may require additional clearance to equipment Refer to applicable building codes for details Static pressure drop through louvered openings and through return air plenums should be considered in the overall duct design in the determination of the total external static pressure Operation of Air Handler During Construction A CAUTION Failure to follow these instructions will void the factory warranty and may significantly reduce the life or the performance of the air handler and or result in other unsafe conditions It is the responsibility of the installing contractor to insure these provisions are met Operating an air handler in a construction environment can cause the appliance a variety of problems Proper use of commercial portable space heating equipment during construction is recommended This air handler may be used during construction if it is not in violation of any applicable codes and the following criteria are met The installation must meet all applicable codes and be permanently installed according to the instructions supplied with the air handler including electrical supply and duct work Theairhandler mustbe controlled by a properly installed thermostat that complies with the current provisions of the NEC ANSI NFPA 70 and all applicable codes having jurisdiction Thermostat connecti
11. other special notes highlighted in the manual Safety markings are used frequently throughout this manual to designate a degree or level of seriousness and should not be ignored WARNING indicates a potentially hazardous situation that if not avoided could result in personal injury or death CAUTION indicates a potentially hazardous situation that if not avoided may resultin minor or moderate injury or property damage A WARNING ELECTRICAL SHOCK FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury or property damage Improper servicing could result in dangerous operation serious injury death or property damage Before servicing disconnect all electrical power to air handler When servicing controls label all wires prior to disconnecting Reconnect wires correctly Verify proper operation after servicing N WARNING NITROGEN HEALTH 1 FLAMMABILITY o REACTIVITY 0 Minimal Hazard 1 Slight Hazard HMG F1E HMG X1E amp HCG V1E air handlers leave the factory with a nitrogen holding charge Use caution when preparing coils for field connections If repairs make it necessary for evacuation and charging it should only be attempted by qualified trained personnel thoroughly familiar with this equipment Some local codes require licensed installation service personnel to service this type of equipment Under no circumstances should the equipment owner at
12. property damage Design the duct work according to methods described by the Air Conditioning Contractors of America ACCA Thisunitis designed only for use with a return and supply duct The return air duct must have the same free area as the opening provided on the air handler The ducts should be appropriately sized to the capacity of the air handler to ensure its proper airflow rating Use transition fittings if the supply and or return air openings of the unit do not match the duct openings Thesetransitions should be dimensioned in accordance with standard practice as specified in the ASHRAE recommendations for duct transitions Flexible connectors may be used between the unit and the ductwork to prevent transmission of vibration from the unit to the structure If electric heater kits are installed heat resistant material must be used for the flexible connector at the supply air end of the unit It is good practice to seal all connections and joints with industrial grade sealing tape or liquid sealant Requirements for sealing ducts vary from region to region Consult with local codes for requirements specific to your area Unconditioned Spaces All duct work passing through unconditioned space must be properly insulated to minimize duct losses and prevent condensation Use insulation with an outer vapor barrier Refer to local codes for insulation material requirements Air Filters HMG F1E HMG X1E amp HCG V1E series
13. that the DHUM output should be high energized when dehumidification is needed See also Dehumidification Options section IMPORTANT If coil icing is observed the basic cooling heat pump airflow selected may be too low Verify the setting selected is within the range shown in Table 8 and that the the system is properly charged Please refer to the instructions supplied with the outdoor unit If icing continues to occur raise the selected airflow one or two steps NOTE Variable speed air handlers with SEER ratings higherthan 15 are matched with a 2 stage cooling outdoor unit They are programmed to operate at 75 of the selected airflow while the system is in the lo cool mode and 100 of the selected airflow while in hi cool mode Dehumidification Options HMG X1E or HCG V1E Models Only Both motor control boards Figures 16 amp 17 page 24 have a DHUM connection that allows the system to increase the amount of humidity that is removed from the circulating air This is accomplished by reducing the CFM and allowing the cooling coil to become colder This will only occur when there is a call for cooling There are many ways that this can be electrically wired 1 If the room thermostat incorporates a humidity sensor and DHUM output connectthe DHUM on the thermostat to the DHUM terminal on the motor control board 2 If using a separate humidistat connect the DHUM amp R terminals on the humidistat to the DHUM amp R terminals
14. the unitis properly grounded Make sure all doors are installed before restoring power to the unit N Verify the thermostat is wired correctly Make sure all low voltage wires are securely connected N Verify the power supply branch circuit overcurrent protection is sized properly N Verify filter is properly and securely installed IMPORTANT Before starting the unit install the initial charge on units that are factory shipped with a nitrogen holding charge 1 Read all installation instructions first 2 Purge the nitrogen holding charge 3 Evacuate the unit to 350 500 microns 4 Allow the unit to remain under vacuum for at least 30 minutes 5 Weigh in the proper amount of new or reclaimed refrigerant Refer to the air conditioner or heat pump installation manual for the proper type and quantity of refrigerant 13 Refrigerant Charging The system refrigerant charge can be checked and adjusted through the service ports provided at the front panel of the outdoor unit Use only gauge lines which have a Schrader depression device presentto actuate the valve Air Circulation Running the Blower Continuously Set the thermostat s system mode to OFF and the thermostat s fan mode to ON The blower motor should run continuously Check for air delivery at the register s Ensure that there are no obstructions at the registers or in the ducts Selecting continuous low speed fan operation Standard Blower The air handler is
15. 1 W2 WEOY2GR C 99990 together if not using W2 9 29 9 9 py 9 N on thermostat i NOTE Jumper between io m Air W2 amp E is required when VI Dy Y1 Handler no OD T Stat is used wa S w2 d mM m wi Gd AX v z wi OY 7 W2 0 wit w2 Ro od Ko In 1 q m n b 2 AY 7 AY vive Q Rya OUT G H G e G e RA Ar R q n R ge Re cv Ke c Le Air Air Heat Pum P Handler Heat Pump Handler Heat p mp Typical Heat Pump with Standard Air Handler Typical Heat Pump with 2 Stage Air Handler Typical 2 Stage Heat Pump with 2 Stage Air Handler Figure 10 Typical Thermostat Connections 12 NOTE Variable speed air handlers cannot be twinned Heater Kits When electric heat packages with circuit breakers are field installed the circuit breaker may be used as a disconnecting means in most applications Reference the NEC and local codes for disconnect requirements If a heater kit is installed The HMG F1E series air handler is shipped from the factory without an electric heater kit installed If Electric heat is desired the H6HK heater kit may be purchased separately and field installed Determine the correct size heater kit for your unit by referring to the list below or the units rating label 24K amp 30K BTUH 15Kw max 36K amp 42K BTUH 20Kw max 48K amp 60K BTUH 30Kw max 1 Connect t
16. AIR HANDLER INSTALLATION INSTRUCTIONS HMG F1E HMG X1E amp HCG V1E Series IMPORTANT Please read all information in this manual thoroughly and become familiar with the capabilities and use of your appliance before attempting to operate or maintain this unit These instructions are primarily intended to assist qualified individuals experienced in the proper installation of this appliance Some local codes require licensed installation service personnel for this type of equipment Improper installation service adjustment or maintenance may cause explosion fire electrical shock or other hazardous conditions which may result in personal injury or property damage Unless otherwise noted in these instructions only factory authorized kits or accessories may be used with this product Keep this manual where you have easy access to it in the future If a problem occurs check the instructions and follow recommendations given If these suggestions don t eliminate your problem call your servicing contractor DO NOT DESTROY PLEASE READ CAREFULLY AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE TABLE OF CONTENTS IMPORTANT SAFETY INFORMATION 3 REQUIREMENTS amp CODES 3 GENERAL INFORMATIQN 4 Before You Install this Uhnit 4 Locating the Air Handler 4 M
17. Compartment Dirt and lint can create excessive loads on the motor resulting in higher than normal operating temperatures and shortened service life It is recommended that the blower compartment be cleaned of dirt or lint that may have accumulated in the compartment or on the blower and motor as part of the annual inspection Blower Fan Wheel Inspect the blower wheel blades for accumulations of dirt and clean if necessary Inspect mounting nut for tightness when done Blower Motor amp Assembly Inspect the blower assembly and motor mounting brackets for tightness and corrosion Correct deficiencies if necessary The blower motor contains sealed bearings and under normal operating conditions no maintenance is necessary for the life of the equipment TROUBLESHOOTING If the air handler fails to operate check the following s the electric turned on s the thermostat operating properly Are the blower compartment door s in place Is the air handler disconnect closed Has the circuit breaker tripped or the control board fuse burned open Are any manual reset switches open Is the filter dirty or plugged Is the LED on both control boards constantly ON If not refer to Tables 3 or 4 to determine fault condition e eee e e RED LED AN2 DIAGNOSTIC Control Fault No Power Blower Fault Normal Operation Table 3 Air handler Control Board Fault Conditions DIAGNOSTIC Control Fault No Power
18. I0 Z suononajsu uonej e1su v aas UMOUS se aq 1ou Aew uon uuo dei 09995 J010UJ Jamojq Su l SALON SS3NtdvH GATIVISNI LON LIY H31V3H N3HM DNISNOH 5 1 3AOW3H OL S3HIM LND HEATER PLUG 1O OIN 2uai21J3 UBIH peeds ojqeuen YUM H DUEH IIV INVH VIQ ONIHIM Handler Ir ies A iagram for HCG V1E Seri ing D Ir w igure 20 F 27 240 VAC 50 amp 60 HZ SINGLE PHASE 208 VAC 50 amp 60 HZ SINGLE PHASE HEAT KIT MCA MOP MCA MOP AIR HANDLER MODEL MODEL NUMBER H6HK CIRCUIT A CIRCUIT B CIRCUIT C SINGLE CIRCUIT CIRCUIT A CIRCUIT B CIRCUIT C SINGLE CIRCUIT CIRCUIT A CIRCUIT B CIRCUIT C SINGLE CIRCUIT CIRCUIT A CIRCUIT B CIRCUIT C SINGLE CIRCUIT None 005H XX HMG24F1E 008H XX 010H XX 009Q XX None 005H XX 008H XX HMG30F1E 010H XX 015H XX 009Q XX 015Q XX None 005H XX 008H XX 010H XX 015H XX 020H XX 009Q XX 015Q XX None 005H XX 008H XX 010H XX 015H XX 020H XX 009Q XX 015Q XX None 005H XX 008H XX 010H XX 015H XX 020H XX 024H XX 029H XX 009Q XX 015Q XX None 005H XX 008H XX 010H XX 015H XX 020H XX 024H XX 029H XX 009Q XX 015Q XX o HMG36F1E HMG42F1E HMG48F1E HMG60F1E Table 10 HMG F1E Series Minimum Circuit Ampacity amp Max
19. TIFIED 4 ENERGY STAR www ahridirectory org Intertek Listed HEAT CONTROLLER INC Specifications amp illustrations subject to change without notice or incurring obligations Jackson MI Printed in U S A 09 12 7095570 Replaces 7095090
20. VIG ONIHIM 25 Figure 18 Wiring Diagram for HMG F1E Series Air Handler 0L90 0920112 SSINHVH 9NTd Nid 9 NOISNVdX3 ONISNOH MI 6 0014 Nid 6 abneb aues ay Jo BI M 19ddo 5 801 Kuo esn pe e dai si Bull eu491UI Y JI r pesn abe oa A ddns y YUM uonisod de au V216VV de Kjeuund abejjon enp e euJ J uulOJSue1 DUDIAOS 210 30 JaMOd e 129VV025 0 Z suononuaisu uone eisu eui aas UMOUS S aq ou euJ uon uuo 2 de p ds 1010UJ J9MOJ Q l SALON 14 Nid 9 1 EXPANSION HEATER PLUG 8691 0 UBIH abejjon mo Bun M AJoyoe4 mmmm UNM PI HINHOASNVHL WOO 802 ove c GATIVLSNI LON LIY H31V3H N3HM DNISNOH DM1d 3AOW3H OLS38IM LAD 101CI I UBIH peeds pexi4 ui 19 0V LI IIV NVHOVIG ONTHIM Figure 19 Wiring Diagram for HMG X1E Series Air Handler 26 0130 0220112 2 20 L HOSN3S Cola Co wWnHada ana Naado MOTI3A H NVHO q 1 2 3 4 5 6 74 Nid 9 ONISNOH Nid 6 HINHOASNVHL WOO 802 ove 5 e 9014 Nld 9 2018 3 MOTI3A 3SNVHO qaq NMOHE EXPANSION SM1d Nid 6 abeyon yH oDe30A 01 Gunim I0126 I DUL PI pu b q ebneb awes y JO s Jaddod 5 801 Aquo sn padejday si Bum euja1ut au JI T pesn 9601 0 Ajddns ay uii uonisod dei y U2 eW de Kieuud 960 0 enp eaAeu ew JeuuoJsueJ BUDIAMOS 910190 JAMO e 129VV025
21. age 2 Heat on after 5 seconds delay Stage 3 Heat on after 10 seconds delay Stage 4 Heat on after 15 seconds delay Stage 1Heat on instantly Cool blower on after 3 second delay Stage 2 Heat on after 5 seconds delay Stage 3 Heat on after 10 seconds delay Stage 4 Heat on after 15 seconds delay Stage 5 Heat on after 20 seconds delay Stage 1Heat on instantly Cool blower on after 3 second delay Stage 2 Heat on after 5 seconds delay Stage 3 Heat on after 10 seconds delay Stage 4 Heat on after 15 seconds delay Stage 5 Heat on after 20 seconds delay Stage 6 Heat on after 25 seconds delay Heat stages off instantly Heat blower turns off after 40 second delay o Q O W1 W2 amp Y Y2 AUX HEAT G Fan blower on after 3 second delay FAN Fan blower off instantly Y Y2 Cool blower on after 3 second delay HEAT PUMP amp COOL Cool blower off after 40 second delay Y1 Cool blower on after 3 second delay HEAT PUMP amp COOL Cool blower off after 40 second delay Y1 amp Y Y2 Cool blower on after 3 second delay HEAT PUMP amp COOL Cool blower off after 40 second delay Table 12 Control Board Operation Continued 31 INSTALLATION PERFORMANCE CHECK LIST INSTALLER NAME ELECTRICAL SYSTEM Electrical connections tight CITY Line voltage polarity correct INSTALLATION ADDRESS Supply Voltage Has
22. ain line Horizontal Right Installations 1 Remove the coilaccess door Unscrew the line set tube close off plate from the front left cabinet rail 2 Slide the coil and drain pan assembly out of the unit 3 Remove the sheet metal hairpin covers if supplied from the back of the coil and discard 4 Place the horizontal drain pan on the opposite side of the coil On units with 2 sets of knockouts remove the other set of knockouts in the coil spacing plates and insert support rod 5 Slide the coil and the horizontal drain pan assembly back into the unit Re attach the tube close off plate NOTE For 24K amp 30K BTUH applications it may be preferrable to remove the blower assembly prior to installing the coil amp drainpan In this case follow instructions 1 4 as listed above but also remove the blower access door and blower assembly The blower assembly is secured with two screws on either side near the front With these removed the blower assembly can slide out of the front of the unit Install the coil and drain pan as described in step 5 and then replace the blower assembly Take care to ensure that the flanges on the sides of the blower assembly are captured by the pockets in the blower deck It may be necessary to lift the blower assembly during insertion to allow the lower blower leg to clear the side of the drain pan The blower will stop against the back of the blower deck Replace the two screws and the blower access door
23. air handlers are not supplied with an air filter when shipped from the factory The installer must provide a high velocity filter that is appropriately sized to the return air duct opening or filter rack located in the bottom of the unit Accessing the filter does not require tools and can be removed from the front of the unit by removing the filter door See Unit Maintenance page 16 for filter sizes and installation information A WARNING Never operate the air handler without a filter or with doors removed Dust and lint can build up on internal components resulting in loss of efficiency equipment damage and possible fire Acoustical Duct Work Certain installations may require the use of acoustical lining inside the supply duct work Acoustical insulation must be in accordance with the current revision of the Sheet Metal and Air Conditioning Contractors National Association SMACNA application standard for duct liners Ductlining must be UL classified batts or blankets with a fire hazard classification of FHC 25 50 or less Fiber duct work may be used in place of internal duct liners if the fiber duct work is in accordance with the current revision of the SMACNA construction standard on fibrous glass ducts Fibrous duct work and internal acoustical lining must be NFPA Class 1 air ducts when tested per UL Standard 181 for Class 1 ducts Damping ducts flexible vibration isolators or pleated media style filters on the return air
24. and procede with steps 6 9 6 Remove the plug from one of the threaded holes in the horizontal drain pan Completely remove the webbing located in the threaded holes of the drain pan IMPORTANT If the webbing is not removed the condensate will not drain properly and ceiling damage may occur NOTE It is recommended that the suction line be insulated up to the coil inside of the cabinet 7 Insert the plug from horizontal drain pan into the open and unused drain hole in the drain pan at the bottom of the unit to block bypass air 8 Remove the corresponding drain line knockout from the coil access door to allow access to the horizontal drain 9 Replace the door and attach the drain line Circuit Breaker Cover Installation The air handler circuit breaker cover is designed to protect the breakers of an installed heater kit from debris and condensation The cover attaches to the breaker recess of the air handler upper access door using a double sided adhesive gasket See Figure 5 The heater kit circuit breaker toggles are still accessible and can be switched with the cover in place There are 2 different circuit breaker cover sizes 2 breaker cover for 2 2 5 3 3 5 amp 4 ton air handlers 3 breaker cover for 5 ton air handlers After the heater kit is properly installed remove the appropriate knockouts in the upper air handler access door and follow these instructions to install the breaker cover 1 Clean any oil di
25. ased on the amount of installed heat For both HMG X1E amp HCG V1E models the cooling speed is selected via switches 5 6 7 amp 8 To determine the appropriate switch settings for your installation see Tables 6 7 8 or 9 pages 20 22 Selecting Basic Cooling Heat Pump Airflow The basic cooling heat pump airflow is controlled by setting switches 5 8 on the motor control board mounted on the blower All airflows for other modes of operation except electric heat are determined by this basic setting FAN ONLY would deliver 50 of the selected cooling airflow Table 8 page 21 lists the basic airflow values versus the airflow selector switch settings and ranges of basic airflow settings recommended for each nominal system capacity When operating in the heat pump mode a higher basic airflow setting will increase the energy efficiency and capacity but will also decrease the supply air temperature For maximum capacity and energy efficiency select an airflow at or near the top of the range for that nominal capacity See Table 8 page 21 Formaximum dehumidification selectanairflow nearthe middle or bottom of the range for that nominal capacity Additional information on humidity control can be found in the Humidistat and Delay Setting sections For thermostats with a dehumidifier output use a field supplied wire to connect the thermostat s dehumidifier output to the terminal marked DHUM The thermostat should be set so
26. des and actions Twinning HMG F1E series air handler s are not supplied with a built in twinning capability To connect two air handlers toa common single stage AC condensing unit or heat pump a twinning kit is available for field installation Please follow the instructions supplied with the kit Thermostat Thermostat Thermostat WYGR NOTE Jumper W1 8 W2 WYGR VI W2 WIE Y2 G R together if not using W2 992 9 999 Air th tat e Conditioner mn Yi Yi Avi Air w2 Handler wi D Air wi g Air o dq Conditioner o wi Conditioner D m 1 vz Ry 22 Aya YA A G 6 q A R a R OX A R RA c c Ae Air Air Handler Handler Typical Air Conditioner vvith Typical Air Conditioner vvith Typical 2 Stage Air Conditioner Standard Air Handler 2 Stage Air Handler with 2 Stage Air Handler Thermostat Thermostat Thermostat W20YGRCE NOTE Jumper W1 amp W2 W2OYG RC WE Y
27. device be used to shut down the unit in the event water is detected in the auxiliary drain pan If suspending the air handler from the ceiling assemble a support frame Figure 4 using slotted iron channel and full threaded rod Fasten the frame together with nuts washers and lockwashers Secure the support frame to the rafters with lag bolts The air handler can also be gt RETURN AIR 3 RETURN l E AIR Se Figure 3 Horizontal Configurations Washer and Lockwasher Threaded Rod E Nuts x2 Figure 4 Unit Horizontally Suspended suspended using steel straps around each end of the unit The straps should be attached to the air handler with sheet metal screws and to the rafters with bolts Horizontal Left Installations 1 Remove the coil access door 2 Remove the plug from one of the threaded holes in the horizontal drain pan Completely remove the webbing located in the threaded holes of the horizontal drain pan IMPORTANT If the webbing is not removed the condensate will not drain properly and ceiling damage may occur 3 Insert the plug from horizontal drain pan into the open and unused drain hole in the drain pan at the bottom of the unit to block bypass air 4 Remove the corresponding drain line knockout from the coil access door to allow access to the horizontal drain 5 Replace the door and attach the dr
28. e of the new orifice NOTE The size is stamped on its side Do not use pin gauges to measure the orifice diameter 8 Insert the new orifice into the distributor body rounded end down See Figure 8 A CAUTION To prevent damage to the unit or internal components it is recommended that two wrenches be used when loosening or tightening nuts Do not over tighten Figure 6 Loosening of Nut amp Distributor Body 9 Realign the assembly nut on the distributor body and hand tighten both components Mark a line on both bodies and then tighten an additional 1 4 turn using two wrenches The movement of the two lines will show how much the nut is tightened If a torque wrench is used tighten to 10 12 ft Ibs or 14 16 Nm Figure 8 Restrictor Insertion into Distributor Body Connecting the Linesets IMPORTANT NOTES FOR HORIZONTAL OR DOWNFLOW INSTALLATIONS WITH TXV VALVE The sensing bulb must be located flush against the suction line for optimum heat transfer Avoidattachingthe sensing bulbtothe lowest part of the suction line where condensate may accumulate Do not locate the sensing bulb on vertical sections of the lineset For horizontal lines the bulb should not be located at 12 or 6 o clock position of the suction line The best location is at 4 or 8 o clock For additional information on proper sensing bulb locations please refer to the valve manufacturer s instructions e e e
29. eat stages off instantly Blower off after 15 second delay Stage 1 Heat on instantly Cool blower on after 3 second delay Stage 1 Heat on instantly Cool blower on after 3 second delay Stage 1 Heat on instantly Cool blower on after 3 second delay Stage 2 Heat on after 5 seconds delay Stage 1 Heat on instantly Cool blower on after 3 second delay Stage 2 Heat on after 5 seconds delay W1 amp Y Y2 Stage 3 Heat on after 10 seconds delay AUX HEAT Stage 1 Heat on instantly Cool blower on after 3 second delay Stage 2 Heat on after 5 seconds delay Stage 3 Heat on after 10 seconds delay Stage 1 Heat on instantly Cool blower on after 3 second delay Stage 2 Heat on after 5 seconds delay Stage 3 Heat on after 10 seconds delay Stage 4 Heat on after 15 seconds delay Heat stages off instantly Heat blower turns off after 40 second delay Table 12 Control Board Operation Continued 30 CONTROL SIGNAL amp MODE OPERATION TOTAL KW BOARD ACTION age 1 Heat on instantly ool blower on after 3 second delay age 1 Heat on instantly ool blower on after 3 second delay age 2 Heat on after 5 seconds delay tage 1 Heat on instantly ool blower on after 3 second delay age 2 Heat on after 5 seconds delay Stage 3 Heat on after 30 seconds delay Stage 1 Heat on instantly Cool blower on after 3 second delay St
30. fort Because there are so many different ways to set up the air handler it is important to read and follow these directions carefully HMG X1E amp HCG V1E series air handlers use high efficiency circulating air motors that come in two variations and both are controlled differently The fixed speed motor control board Figure 16 page 24 controls the torque and the variable speed motor control board Figure 17 controls the airflow at a constant CFM Both boards use the same control board Before operation the air handler must be configured to match the unit with the system system options and climatic conditions When configured the air handler responds directly to the thermostat inputs as well as the optional humidistat see page 13 During normal operation the motor will gradually change speeds during start up shut down when thermostat inputs change and when the duct static pressure changes vents closed or opened filter clogging etc The air handler is configured by setting the selector switches and removing jumper connectors Selecting Basic Heating Airflow Fixed amp variable speed motor control boards Figures 16 amp 17 contain a set of dip switches for setting the blower speed For HMG X1E models pins 1 4 set the speed for heating For HCG V1E models the A B switch must be set for the appropriate air handler size either setting can be used for 48K or 60K BTUH applications The airflow is set automatically b
31. g Minimum Electric Heat Airflow The minimum electric heat airflow setting controls the minimum air flow that will be produced whenever electric heater kits are used When the electric heater kit is energized along with a heat pump the airflow may be higher depending on the basic cooling heat pump airflow setting The minimum electric heat airflow is selected by the red blower wire on 3 speed models or setting switches 1 2 3 amp 4 on HMG X1E models HCG V1E models 14 automatically set the heating speed based on the amount of installed heat The remaining 3 HEAT switches have no function Switch settings are listed in Table 6 page 20 or Table 9 page 22 NOTE For HMG X1E Models the minimum electric heat airflow setting may be set higher but must never be set lower than the setting shown in Table 7 page 21 Blower Configurations Determining Nominal System Capacity To select the appropriate airflows for the air handler the nominal system capacity must be known The nominal system capacity is always the nominal capacity of the outdoor unit However in some situations the nominal system capacity may not be the same as the nominal capacity of the air handler Always refer to the nominal capacity of the outdoor unit to determine the nominal System capacity NOTE The CFM values listed in Table 9 page 22 are not dependent on duct static pressure The VSHE motor automatically compensates for changes in duct static pressure wit
32. g the line sets e Orifice Removal amp Installation The orifice installed in the air handler has been sized for use with the most popularly matched outdoor units The orifice size as shipped from the factory is listed on the air handler rating plate Perform steps 1 9 to confirm that the orifice size meets the requirements outlined in the outdoor unit installation manual 1 Remove the cap from the end of the liquid line 2 Verify pressurization by depressing the Schrader valve on the end of the liquid line Listen for any escaping gas If there is no pressure test the coil for leakage If leakage is found clearly mark the location of the leak and return the coil to the distributor for processing f no leaks are found the coil may be installed 3 Depress the valve to relieve all pressure from the coil 4 Remove and discard the valve core A CAUTION To prevent damage to the unit or internal components it is recommended that two wrenches be used when loosening or tightening nuts Do not over tighten 5 Using two wrenches loosen the nut and distributor body as shown in Figure 6 Turn the assembly nut counter clock wise until the orifice body halves are seperated 6 Insert a light gauge wire hook between the distributor body and the restrictor orifice while being careful not to scratch either part Carefully remove the restrictor orifice from the distributor body See Figure 7 7 Check the actual siz
33. he 2 wire plug of the air handler to the mating 2 wire plug of the heater kit 2 Connect the line voltage leads to the circuit breaker or terminal block provided 3 Connect the heater kit plug with the mating receptacle on the air handler control board If a heater kit is not installed 1 Remove the 2 wire plug of the air handler by cutting the wires and discarding the plug 2 Strip the ends of the 2 air handler wires and connect to the line voltage leads with the 2 wire nuts provided Electronic Air Cleaner EAC The unit has an output to power an electronic air cleaner when the blower is running This output is rated to 1 0 amp at 208 240V Humidifier The unit has an output to power a humidifier when the blower is running This output is rated to 1 0 amp at 208 240V Optional Humidistat HMG X1E amp HCG V1E Models Only The optional humidistat may be installed in the return air duct to provide excellent humidity control when needed andmaximum system capacity and energy efficiency when humidity levels are normal The humidistat senses when humidity in the return air stream is above a preset level field adjustable and sends a signal to the motor to reduce the airflow so that more moisture may be removed until the humidity level drops The air handler is pre programmed for humidistat operation Install the humidistat in the return air duct as directed in the installation instructions included with the kit Wire the
34. hin the limits of the motor 3 Speed Units The blower speed is preset at the factory for operation at the same speed for heating and cooling by using the jumping terminal on the blower motor and connecting it to the desired speed with both the red and black wires connected to the jumping terminal NOTE The control board is programmed with a 40 second off delay in the cooling mode for optimum system performance and efficiency A CAUTION To avoid personal injury or property damage make sure the motor leads do not come into contact with any uninsulated metal components of the unit For optimum system performance and comfort it may be necessary to change the factory set speed See Table 5 page 19 for airflow data To change the blower speed 1 Disconnect all electrical power to the unit and remove the upper door 2 Remove the black and red wires from the blower motor jumping terminal Discard the blower motor jumping terminal 3 Connect the heating speed wire red and the cooling speed wire black to the desired blower speed marked on the terminal block of the blower motor Terminal 4 Hi speed Terminal 5 Med speed Terminal 6 Low speed 4 Replace the upper door and secure it to the unit 5 Restore power to the unit High Efficiency Units Variable amp Fixed Speed IMPORTANT This air handler has been designed to give the installer maximum flexibility to optimize system performance efficiency and com
35. hrough a conduit or raceway splices can be made inside the unit however all wiring must be NEC Class 1 and separated from incoming power leads e 11 A CAUTION Isolation must be maintained from the external Class 2 output of any transformer in a cooling circuit Use a thermostat with isolating contacts to prevent inter connection of Class 2 outputs The thermostat should be mounted about 5 feet above the floor on an inside wall DO NOT install the thermostat on an outside wall or any other location where its operation may be adversely affected by radiant heat from fireplaces sunlight or lighting fixtures and convective heat from warm air registers or electrical appliances Refer to the thermostat manufacturer s instruction sheet for detailed mounting and installation information Install the grommet which is packed with the unit in the hole for low voltage wires Properly connect the low voltage wiring between the thermostat outdoor unit and control board NOTE When the low voltage wires are positioned in this grommet the grommet will prevent chafing and or shorting of the low voltage leads Control Board The control board in the air handler controls the timing sequence of the elements The board is equipped with a 3 second blower on delay and a 15 second blower off delay in heating and a 40 second blower off delay in cooling See Figures 14 or 15 page 23 and Table 12 pages 29 31 for control board mo
36. humidistat through the low voltage wire entrance in the air handler to the control board terminal marked DEHUM Wire the humidistat to open on rise in humidity See Figures 16 amp 17 page 24 STARTUP amp ADJUSTMENTS A WARNING NITROGEN HEALTH FLAMMABILITY o REACTIVITY 0 Minimal Hazard 1 Slight Hazard The evaporator coil is shipped from the factory with a nitrogen charge Use caution when preparing coils for field connections If repairs make it necessary for evacuation and charging it should only be attempted by qualified trained personnel thoroughly familiar with this equipment Some local codes require licensed installation service personnel to service this type of equipment Under no circumstances should the equipment owner attempt to install and or servicethis equipment Failureto comply with this warning could result in equipment damage personal injury or death Before You Start the Unit Prior to start up complete the following inspections y Verify the unitis level and properly located with adequate clearances for servicing the unit See Table 1 page 4 Y Check condensate drain line s for proper drainage Verify the surrounding area and top of the unit is free from obstructions and debris Y Check all duct connections Make sure the duct work is adequately sealed to prevent air leakage Y Check all coil connections for leaks N Verify that the line voltage power leads are securely connected and
37. imum Overcurrent Protection 28 HMG X1E amp HCG V1E 240 VAC 50 amp 60 HZ SINGLE PHASE 208 VAC 50 amp 60 HZ SINGLE PHASE MCA MOP MCA MOP HEAT KIT AIR HANDLER MODEL MODELS NUMBER H6HK CIRCUIT CIRCUIT SINGLE CIRCUIT CIRCUIT A CIRCUIT CIRCUIT C SINGLE CIRCUIT CIRCUIT CIRCUIT CIRCUIT C SINGLE CIRCUIT CIRCUIT A CIRCUIT CIRCUIT SINGLE CIRCUIT None HMG24X1E 005H XX HMG30X1E 008H XX amp 010H XX HCG24V1E 015H XX HCG30V1E 009Q XX 015Q XX None HMG36X1E 005H XX 008H XX b E Ta 015H XX HCG36V1E oouxx HCG42V1E 009Q XX 015Q XX None 005H XX HMG48X1E 008H XX HMG60X1E 010FIEXX amp 015H XX 020H XX HCG48V1E iza xx HCG60V1E ozoHXX 009Q XX 015Q XX Table 11 HMG X1E 8 HCG V1E Minimum Circuit Ampacity amp Maximum Overcurrent Protection CONTROL SIGNAL amp MODE OPERATION TOTAL KVV BOARD ACTION age 1 Heat on instantly eat blower on after 3 second delay age 1 Heat on instantly eat blower on after 3 second delay age 1 Heat on instantly eat blower on after 3 second delay age 2 Heat on after 5 second delay age 1 Heat on instantly eat blower on after 3 second delay age 2 Heat on after 5 second delay age 3 Heat on after 10 second delay tage 1 Heat on instantly eat blower on after 3 second delay age 2 Heat on after 5 second delay age 3 Hea
38. inimum Clearances 4 Operation of Air Handler During Construction 4 Installation in a 5 Plenums amp Air DUCTS 5 Unconditioned 2 5 Air FIllerS maaa eee dee u tase 5 Acoustical Duct Work 5 AIR HANDLER INSTALLATION 6 Packaging 6 Mounting 6 Upflow Installations 6 Downflow Installations 6 Horizontal Installations 7 Horizontal Left Installations 7 Horizontal Right Installations 7 Circuit Breaker Cover Installation 8 Refrigerant Line Connections 8 Orifice removal amp Installation 9 Connecting the Linsets 9 Condensate Drainage sees 10 ELECTRICAL CONNECTIONS 11 Pre Electrical Checklist 11 Line Voltage 11 C IM 11 Thermostat Connec
39. inlet of the air handler may be used to reduce the transmission of 5 equipment noise eminating from the air handler These treatments can produce a quieter installation particularly in the heated space However they can increase the pressure drop in the duct system Care must be taken to maintain the proper maximum pressure rise across the air handler temperature rise and flow rate This may mean increasing the duct size and or reducing the blower speed These treatments must be constructed and installed in accordance with NFPA and SMACNA construction standards Consult with local codes for special requirements For best sound performance be sure to install all the needed gaskets and grommets around penetrations into the air handler such as for electrical wiring AIR HANDLER INSTALLATION The HMG F1E HMG X1E amp HCG V1E Series Air Handleris shipped ready for vertical upflow installation and is approved for attic basement alcove closet or crawlspace installation with zero clearance to combustibles See Table 1 page 4 for required installation clearances This appliance is approved only for indoor use The unit must be leveled at installation and attached to a properly installed duct system The surface that the air handler is mounted on must provide sound physical support of the unit The air handler must be installed so that all electrical components are protected from water If a louvered door is installed across the f
40. ire must be copper wire consisting of the same gauge and temperature rating Provide power supply for the unit in accordance with the unit wiring diagram and the unit rating plate Use UL listed conduitand conduit connectors for connecting the supply wires to the unit and for proper grounding Field supplied bushings for the power supply cables must be added to support and protect the power supply cables All 208 230 Volt units are shipped from the factory wired for 240 volt operation For 208V operation remove the lead from the transformer terminal marked 240V and connect it to the terminal marked 208V e e Grounding N WARNING The unit cabinet must have an uninterrupted or unbroken electrical ground to minimize personal injury if an electrical fault should occur Do not use gas piping as an electrical ground This unit must be electrically grounded in accordance with local codes or in the absence of local codes with the National Electrical Code ANSI NFPA 70 or the CSA C22 1 Electrical Code Use the grounding lug provided in the control box for grounding the unit Thermostat Connections Thermostat connections shall be in accordance with the instructions supplied with the thermostat The thermostat used with this equipment must operate in conjunction with any installed accessories Typical AC and air handler hookups are shown in Figure 10 page 12 Where local codes require that the thermostat wiring must be routed t
41. late the drain if itis located in an unconditioned space and test the condensate line for leaks Consult local codes for additional restrictions or precautions During system checkout inspect the drain line and connections to verify proper condensate drainage e e ELECTRICAL CONNECTIONS A WARNING ELECTRICAL SHOCK FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury or property damage Improper servicing could result in dangerous operation serious injury death or property damage Beforeservicing disconnectall electrical power to the air handler When servicing controls label all wires prior to disconnecting Reconnect wires correctly Verify proper operation after servicing Electrical connections must be in compliance with all applicable local codes and ordinances and with the current revision of the National Electric Code ANSI NFPA 70 For Canadian installations the electrical connections and grounding shall comply with the current Canadian Electrical Code CSA C22 1 and or local codes Pre Electrical Checklist Verify the voltage frequency and phase of the supply source match the specifications on the unit rating plate Verify that the service provided by the utility is sufficient to handle the additional load imposed by this equipment See the unit wiring label or Tables 9 10 pages 28 29 for proper high and low voltage wiring N Ve
42. ly intended to assist qualified technicians experienced in the proper maintenance and operation of this appliance Always reinstall the doors on the air handler after servicing orcleaning changing the filters Do not operate the air handler without all doors and covers in place Verify that the thermostat is properly installed and is not being affected by drafts or heat from lamps or other appliances To achieve the best performance and minimize equipment failure it is recommended that a yearly maintenance checkup be performed At a minimum this check should include the following items Air Filter s HMG F1E HMG X1E amp HCG V1E series air handlers are not supplied with a single air filter when shipped from the factory It is recommended that the filter be cleaned or replaced monthly Newly built or recently renovated homes may require more frequent changing until the construction dust has minimized Filter sizes shown in Table 2 are available at most local retailers A WARNING Never operate the air handler without a filter in place Dust and lint in the return air can build up on internal components resulting in loss of efficiency equipment damage and possible fire e Filters designed to remove smaller particles such as pollen may require additional maintenance FURNACE SIZE BTUH FILTER SIZE 24K amp 30K 12x20x1 18x20x1 20x20x1 36K amp 42K 48K amp 60K Table 2 Filter Sizes Blower
43. ons must be made in accordance with instructions supplied with the air handler and thermostat See pages 11 12 The installation must include a properly installed filter in the return air system with no by pass air The filter must be inspected frequently and replaced when necessary Return air must be supplied unrestricted and located such that dust and gases from construction activity are not introduced into the circulating air system Before occupying the structure The filter must be replaced or cleaned the duct work must be inspected and cleaned of any construction debris and the air e INSTALLATION CLEARANCES 0 Inches 15886 Notes RIGHT SIDE TNOTES Alcove nstallations Allovv 24 in minimum clearance from front of unit to nearest wall or partition for servicing Recommended clearance is 36 in Table 1 Minimum Unit Clearances handler must be cleaned and or repaired if found to be dirty damaged or malfunctioning in any way by a qualified HVAC technician The air handler shall be inspected and approved by applicable local authority even if this requires redundant inspections The serial number for the air handler used during construction must be submitted in writing fax and email also acceptable This information will be used to track the long term affects of air handler usage during construction Proof of this submittal shall be available for the final inspection of the air handler p
44. ont side of the unit as shown in Figure 9 The drain pan must be drained with field supplied tubing or pvc pipe and adequately trapped Both drain tubes must have a minimum diameter of 3 4 and be trapped separately e IMPORTANT Failure to install a trap may result in condensation overflowing the drain pan resulting in substantial water damage to surrounding area Route both lines to a suitable drain avoiding sharp bends and pinching of the lines The drain should maintain a minimum horizontal slope in the direction of discharge of not less than 1 vertical for every 10 ft of horizontal run If the air handler is located in or above a living space where damage may result from condensate overflow an auxiliary drain pan shall be installed under the unit A separate drain line should extend from the pan to a conspicuous point and serve as an alarm indicating that the primary drain is restricted As an alternative to a separate drain line an approved water level indicator or float switch device may be used to shut down the unit in the event water is detected in the auxiliary pan e Install a single 5 inch trap in the condensate drain line as close to the coil as possible Make sure that the top of the trap is below the bottom of the drain pan to prevent the condensate from overflowing the drain pan NOTE There must be only one trap in the drain line Using more than one trap May prevent drainage Prime the trap with water Insu
45. rify factory wiring is in accordance with the unit wiring diagram Figures 18 20 pages 25 27 Make sure the connections didn t loosen during shipping or installation Line Voltage Anelectrical disconnectmustbe located within sight of and readily accessible to the unit This switch shall be capable of electrically de energizing the outdoor unit See unit data label for proper incoming field wiring Any other wiring methods must be acceptable to authority having jurisdiction e It is recommended that the line voltage to the unit be supplied from a dedicated branch circuit containing the correct fuse or circuit breaker for the unit Overcurrent protection must be provided at the branch circuit distribution panel and sized as shown on the unit rating label and according to applicable local codes See the unit rating plate and Tables 10 amp 11 pages 28 amp 29 for maximum circuit ampacity and maximum overcurrent protection limits The installer should become familiar with the wiring diagram schematic before making any electrical connections to the unit See the unit wiring label or Figures 18 20 pages 25 27 Use only copper wire for the line voltage power supply to this unit Use proper code agency listed conduit and a conduit connector for connecting the supply wires to the unit Aluminum supply wire may be used if a heater kit is installed If replacing any of the original wires supplied with the unit the replacement w
46. rior to occupancy Installation in a Garage A WARNING Donotplace combustible materials on or against the cabinet Do not place flammable materials gasoline paint thinners etc or any other flammable vapors and liquids in the vicinity of the air handler The HMG F1E HMG X1E amp HCG V1E series air handler may be installed in a residential garage with the provision that the unit must be located or protected to prevent physical damage by vehicles Plenums amp Air Ducts Plenums and air ducts should be installed in accordance with the standards of the National Fire Protection Association Standard for Installation of Air Conditioning Systems NFPA 90A Standard for Installation of Residence Type Warm Air Heating and Air Conditioning Systems NFPA 90B and all applicable local codes NFPA publications are available by writing to National Fire Protection Association Batterymarch Park Quincy ME 02269 or visit www NFPA org online A WARNING All return ducts must be secured to the air handler using appropriate methods All return ducts must be adequately sealed When return air is provided through the bottom of the unit the joint between the air handler and the return air plenum must be air tight Return air and circulating air ducts must not be connected to any other heat producing device such as a fireplace insert stove etc This may result in fire explosion carbon monoxide poisoning personal injury or
47. ront of this unit the appliance must be mounted flush or behind front edge of finished wall Always reinstall the doors on the air handler after servicing orcleaning changing the filters Do not operate the air handler without all doors and covers in place e Packaging Removal Remove the shipping crate and User s Manual from the equipment When removing the crate use extra care so tubing connectios are not damaged Do not pull on the coils upper tubes Mounting Applications Vertical only air handlers are factory ready for upflow applications These units may be applied in downflow applications when applied with the appropriate field kit Factory ready horizontal air handlers may be applied in upflow or horizontal left and right discharge applications These units may also be applied in downflow discharge when applied with the appropriate field kit as specified in the units Technical Specifications Through the floor installations require a 1 4 thick noncombustible resilient gasket to be used whenever the supply or return air ducts pass through the floor The gasket should be positioned between the duct unit and floor Horizontal Drain Pan Return Air Figure 1 Upflow Installation Upflow Installations All air handlers are factory shipped ready for upflow installation The horizontal drain pan may be removed from the air handler when installing the unit in an upflow configuration All ret
48. rt or insulation fibers from the recess area of the air handler access door This step is important for ensuring the gasket adheres properly to the sheet metal door 2 Remove release paper from one side of the gasket and attach to back side of the breaker cover NOTE For proper alignment Itis recommended to leave the center section of the gasket in place when attaching the gasket to the breaker cover Remove the center section after the gasket is applied to the breaker cover Figure 5 Circuit Breaker Cover 3 Remove the release paper from the other side of the gasket and attach to the circuit breaker recess area 4 Press firmly along all four sides of the cover to ensure gasket and cover are securely attached to the access door Refrigerant Line Connections N WARNING NITROGEN 1 HEALTH FLAMMABILITY o 0 Minimal Hazard 1 Slight Hazard REACTIVITY The coilin the air handler is factory shipped with a nitrogen charge Avoid direct face exposure or contact with valve when gas is escaping Alvvays ensure adequate ventilation is present during the depressurization process Address any uncertainties before proceeding Failure to comply with this warning could result in equipment damage personal injury or death The installer should make every effort to ensure the field installed refrigerant containing components of the system have been installed in accordance vvith these instructions and sound in
49. st be trapped separately using a J Trap or field supplied loop Figure 9 Condensate Drainage Example 6 Braze the individual connections with dry nitrogen flowing through the joints NOTE This will prevent internal oxidation and scaling from occurring 7 Wrap the refrigerant lines with pressure sensitive neoprene or other suitable material especially where the lines enter the opening in the sheet metal 8 Evacuatethe system of moisture and non condensables to prevent low efficiency operation or damage to the unit The suggested range of evacuation is 350 500 microns 9 Charge the system with refrigerant Refer to the outdoor unit installation manual for additional charging instructions 10 Check the system for leaks including the lineset and the brazed joints 11 Replace all grommets and properly dispose of all removed parts Condensate Drainage A CAUTION The air handler must be level to ensure proper condensate drainage An unlevel installation may result in structural damage premature equipment failure or possible personal injury Methods for disposing of condensate vary according to local codes Refer to local codes or authority having jurisidiction for restrictions and proper condensate disposal requirements The drain pan that is supplied with this air handler contains a primary and secondary drain fitting The condensate is drained from the unit through two 3 4 female pipe fittings located on the fr
50. stallation practices for reliable system operation and longevity The air handler coil does notcontain a refrigerant charge Refer to the installation instructions supplied vvith the outdoor unit for refrigerant charge information Always refer to the installation instructions supplied with the outdoor unit for piping requirements The suction and liquid lines must be sized in accordance with the condensing unit specifications See Figure 12 page 17 for liquid and suction line locations When connecting refrigerant linesets together it is recommended that dry nitrogen be flowing through the joints during brazing This will prevent internal oxidation and scaling from occurring Refrigerant tubing should be routed in a manner that minimizes the length of tubing and the number of bends in the tubing It should be supported in a manner that prevents it from vibrating or abrading during system operation Tubing should be kept clean of foreign debris during installation If precise forming of refrigerant lines is required a copper tubing bender is recommended Avoid sharp bends and contact of the refrigerant lines with metal surfaces Refrigerant lines should be wrapped with pressure sensitive neoprene or other suitable material where they pass against sharp sheet metal edges HMG F1E HMG X1E amp HCG V1E Series airhandlers are charged through service valves on the end of the liquid tube for each circuit These must be removed before brazin
51. t on after 10 second delay age 1Heat on instantly eat blower on after 3 second delay age 2 Heat on after 5 second delay age 3 Heat on after 10 second delay Stage 4 Heat on after 15 second delay Heat stages off instantly Blower off after 15 second delay oio rioiooirioo oirioloir ioir o LI Table 12 Control Board Operation 29 CONTROL SIGNAL amp MODE OPERATION TOTAL KW BOARD ACTION Stage 1 Heat on instantly Heat blower on after 3 second delay Stage 1 Heat on instantly Heat blower on after 3 second delay Stage 2 Heat on after 5 seconds delay s H s tage 1 Heat on instantly eat blower on after 3 second delay age 2 Heat on after 5 seconds delay Stage 3 Heat on after 10 seconds delay Stage 1 Heat on instantly Heat blower on after 3 second delay Stage 2 Heat on after 5 seconds delay Stage 3 Heat on after 10 seconds delay Stage 4 Heat on after 15 seconds delay Stage 1 Heat on instantly Heat blower on after 3 second delay Stage 2 Heat on after 5 seconds delay Stage 3 Heat on after 10 seconds delay Stage 4 Heat on after 15 seconds delay Stage 5 Heat on after 20 seconds delay Stage 1Heat on instantly Heat blower on after 3 second delay Stage 2 Heat on after 5 seconds delay Stage 3 Heat on after 10 seconds delay Stage 4 Heat on after 15 seconds delay Stage 5 Heat on after 20 seconds delay Stage 6 Heat on after 25 seconds delay H
52. ta for HMG X1E Air Handlers 20 Nominal Electic Heat KW 5 8 10 15 20 25 30 FURNACE MODELS HMG24X1E 8 HMG30X1E 800 900 1000 1300 N A N A N A HMG36X1E amp HMG42X1E 900 1000 1100 1300 1500 N A N A NOTE See Table 6 for appropriate switch settings for these airflows Table 7 Minimum Heating Airflow Settings in CFM for HMG X1E Air Handlers HCG24V1E amp HCG30V1E SWITCH SETTINGS NOMINAL 1 ON 0 OFF CL ON 0 OFE CAPACITY 5 7 8 A O DJ DJ OJ O O OJ O OJ OJ O alalalalo lo lo lolalalaljalololololo alalolola l a lolola a ololalalolo lola lol a o l a o l a o l o la lolalo HCG36V1E amp HCG42V1E HCG48V1E amp HCG60V1E SWITCH SETTINGS SWITCH SETTINGS NOMINAL NOMICAL 1 ON 0 OFF 1 ON 0 OFF HON 0 OFF CAPACITY ZON OS Cro CAPACITY Table 8 Recommended Cooling Airflow Settings for HCG V1E Air Handlers Cooling Airflow Heating Airflow A B Switch Setting 2557 ng Airflow A B Switch Setting Heater Kit Airflow 0 OFF 1 ON CFM 0 OFF 1 ON lnstalled KW HCG24V1E amp HCG30V1E olololololololo olololololololololololololololo alalalalalalal ololo joljolololola a 2 o o 2 2 o o 2 2 oj o 2 2 olo col lol lol lcol lol lol lol lcflo Cooling Airflo
53. taller must comply with safety codes and wear appropriate safety equipment safety glasses work gloves fire extinguisher etc when performing brazing operations Installthis unitonly in a location and position as specified on pages 4 amp 5 This unit is designed only for Indoor installations and should be located with consideration of minimizing the length of the supply and return ducts See Tables 5 9 pages 19 22 and the rating plate for proper circulating airflow data Follow all precautions in the literature on tags and on labels provided with the equipment Read and thoroughly understand the instructions provided with the equipment prior to performing the installation and operational checkout of the equipment This air handler may be used for temporary heating of buildings or structures under construction See the guidelines listed on page 4 Air handler installations in a residential garage must be installed as specified on page 5 GENERAL INFORMATION This appliance has been tested for capacity and efficiency in accordance with AHRI Standards and will provide many years of safe and dependable comfort providing it is properly installed and maintained Abuse improper use and or improper maintenance can shorten the life of the appliance and create unsafe hazards Please read all instructions before installing the unit Before You Install this Unit Y This equipment is securely packaged at the time of shipment and upon
54. tempt to install and or service this equipment Failure to comply with this warning could result in equipment damage personal injury or death A WARNING PROPOSITION 65 WARNING This product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm REQUIREMENTS amp CODES A WARNING This unit must be installed in accordance with instructions outlined in this manual during the installation service and operation of this unit Unqualified individuals should not attempt to interpret these instructions or install this equipment Failure to follow safety recommendations could result in possible damage to the equipment serious personal injury or death The installer must comply with all local codes and regulations which govern the installation of this type of equipment Local codes and regulations take precedence over any recommendations contained in these instructions Consult local building codes for special installation requirements This equipment contains nitrogen gas Installation or servicing should only be performed by qualified trained personnel thoroughly familiar with this type equipment All electrical wiring must be completed in accordance with local state and national codes and regulations and with the National Electric Code ANSI NFPA 70 or in Canada the Canadian Electric Code Part 1 CSA C 22 1 Installation of equipment may require brazing operations Ins
55. the thermostat been calibrated YES Is the thermostat level YES UNIT SERIAL ATTENTION INSTALLERS Minimum clearances per page 4 YES Itis your responsibility to know this product better than your customer Is the 7 properly installed and YES This includes being able to install the product according to strict leveled safety guidelines and instructing the customer on how to operate Does condensate drain properly YES NO and maintain the equipment for the life of the product Safety should in both drain tubes always be the deciding factor when installing this product and using is common sense plays an important role well Pay attention to all Has the owner s information been f YES NO safety warnings and any other special notes highlighted in the manual reviewed with the home owner H Improper installation of the air handler or failure to follow safety Has the literature package been warnings could result in serious injury death or property damage left near the appliance Theseinstructions are primarily intendedto assist qualified individuals experienced in the proper installation of this appliance Some local codes require licensed installation service personnel for this type of equipment Please read all instructions carefully before starting the installation Return these instructions to the customer s package for future reference U DESIGNED ASSEMBLED ARS Zw aed CER
56. tions 11 Control Boards L n cete qu res bedene 12 TWINNING Mae m 12 Heat r Kits 13 Electronic Air Cleaner 13 be 13 Optional Humidistat 13 STARTUP amp ADJUSTMENTS 13 Before You Start the Unit 13 Refrigerant Charging 14 Air Circulation ite eere ees 14 Running the Blower Continuously 14 Selecting Continuous Low Spd Fan Operation 14 Turning the Blower Olf 14 System Cooling 14 System Heating 14 Selecting minimum Electric Heat Airflow 14 Blower Configurations 14 Determining Nominal System Capacity 14 3 Speed Units 14 High Efficiency Units Var amp Fixed Speed 15 Selecting Basic Heating Airflow 15 Selecting Basic Cooling Heat Pump Airflow 15 Dehumidification Options 15 UNIT M IMICM MCC
57. urn air must enter from the bottom of the unit A typical upflow unit is shown in Figure 1 Downflow Installations The downflow accessory kit See Technical Specifications is required for downflow applications Instructions for installing the downflow accessory kit are included with the kit Itis recommended that the accessory be installed prior to installing the unit All return air in downflow applications must enter through the top of the unit A typical installation of the unit in a downflow application is shown in Figure 2 Cabinet A Adaptor Kit Figure 2 Downflow Installation Horizontal Installations These air handlers can be installed horizontally inan attic basement crawl space or alcove It can also be suspended from a ceiling in a basement or utility room in either a right to left airflow or left to right airflow as shown in Figure 3 Air handlers may or may not be shipped from the factory with all the parts required for horizontal left applications and horizontal right applications If your unit does not have parts for a horizontal application a kit may be available NOTE In all horizontal applications in which the unit is installed above a finished ceiling and or living space a secondary drain pan mustbe installed underthe entire unit to avoid damage to the ceiling in the event of condensate overflow Additionally itis recommended that an approved water level indicator or float switch
58. vv Heating Airflovv A B Switch Setting COOL Switch Setting Airflow A B Switch Setting Heater Kit Airflow 0 OFF 1 CFM 0 OFF 1 ON lnstalled KW CFM HCG36V1E amp HCG42V1E 2 2 2 2 2 2 2 2i ojojojoljojoj ojojfo lolol l lololl lolol l lolo Cooling Airflovv Heating Airflovv A B Switch Setting gt 2777 ng Airflow A B Switch Setting Heater Kit Airflow either 0 or 1 CFM either 0 or 1 Installed KW CFM HCG48V1E amp HCG60V1E NOTES Airflow values listed are for 240V operation For 208V operation multiply the CFM value by 95 for HCG24V1E HCG30V1E HCG36V1E amp HCG42V1E units For HCG48V1E amp HCG60V1E units mulitply the CMF value by 90 When matched with two stage outdoor units the airflow on low Y1 or W1 input only will be 70 of the values shown in this table Table 9 Airflow Data for HCG V1E Air Handlers 2 i i iojojojoljojoj oj ojfo i i i lololololxixixixiolololo i iliolxizZ SOiolxiZ oOlolxizZiolo S O O O O C 22 ELECTRICAL DIAGRAMS amp DATA BLWDTC BLWDTC R
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