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.
Installation, Operation & Maintenance WDG AIR HANDLER SERIES Heat Controller, LLC Table of Contents Model Nomenclature ............................................................................................3 Pre-Installation......................................................................................................4 Safety ...................................................................................................................5 Physical Data.......................................
WDG AIR HANDLER SERIES Installation, Operation & Maintenance Heat Controller, LLC Model Nomenclature 1 2 4 5 6 3 8 7 9 10 11 12 W D G 024 V S B - 1 A MODEL TYPE REVISION W = WATER SOURCE AIR HANDLER A = CURRENT REVISION VOLTAGE CONFIGURATION 1 = 208-230/1 ( FIELD CONVERTIBLE TO 115V ) D = DIRECT EXPANSION REFRIGERANT G = R410A CABINET SIZE WIDTH X HEIGHT (INCHES) NOMINAL CAPACITY 024 036 048 060 A B C TXV TYPE UNIT SIZE 024 ONLY ; 18.5 X 44 UNIT SIZE 024, 036, 048 ONLY ; 22.
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.
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.
WDG AIR HANDLER SERIES Installation, Operation & Maintenance Heat Controller, LLC Model Physical Data Table 1: Physical Data Model 026-A 024-B 026-B 024-C 038-B 036-C 038-C 036-D 049-B 048-C 049-C 048-D 064-C 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.
WDG AIR HANDLER SERIES Installation, Operation & Maintenance Heat Controller, LLC Unit Dimensional Data Detail A J A = Primary Drain - Vertical, Horizontal and Downflow Configuration 8.5 [21.6] 6.7 [17.0] 5.6 [14.2] E B = Secondary Drain - Vertical and Downflow Configuration C 4.5 [11.4] 3.7 [9.4] B A C = Secondary Drain - Horizontal Configuration 0.0 3.6 [9.1] H D G 0.0 1.6 [4.0] F 5.8 [14.7] 5.9 [15.0] Detail A Scale 5/32 [0.4] 5.5 [14.0] 8.5 [21.6] 3.6 [9.4] See Detail A R.A.
Installation, Operation & Maintenance WDG AIR HANDLER SERIES Heat Controller, LLC Installation 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 downflow 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.
Installation, Operation & Maintenance WDG AIR HANDLER SERIES Heat Controller, LLC Installation Figure 1: Mounting Installation Options Tranquility 27 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.
WDG AIR HANDLER SERIES Installation, Operation & Maintenance Heat Controller, LLC Installation Applications Air Handlers can be applied in upflow, downflow, horizontal right and horizontal left applications without modifications. 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.
Installation, Operation & Maintenance WDG AIR HANDLER SERIES Heat Controller, LLC Installation Figure 3: Air Coil Connection CAUTION! Bulb (Must be 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.
Installation, Operation & Maintenance WDG AIR HANDLER SERIES Heat Controller, LLC Installation Evacuation and Charging the Unit LEAK TESTING - The refrigeration line set must be pressurized 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.
Installation, Operation & Maintenance WDG AIR HANDLER SERIES Heat Controller, LLC Electrical - Thermostat Wiring Figure 6: Three Heat / Two Cool, Manual / Auto Changeover Programmable CAUTION! CAUTION! Many units are installed with a factory or field supplied manual or electric shut-off valve. DAMAGE WILL OCCUR if shut-off valve is closed during unit operation.
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 field 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.
WDG AIR HANDLER SERIES Installation, Operation & Maintenance Heat Controller, LLC ECM Blower Control Table b: ECM Board Tap Settings Cooling settings: TT, TS Units Version I Version II and III 69243707 (17B0019N01 & 17B0034N01) DIP Switch Tap HP CFM Setting Jumper SW1 SW2 1 1 ON ON 2 2 ON OFF 3 3 OFF ON 4 4 OFF OFF Heating settings: TT, TS Units Version I Version II and III 69243707 (17B0019N01 & 17B0034N01) DIP Switch Tap DELAY Setting Jumper SW3 SW4 1 1 ON ON 2 2 ON OFF 3 3 OFF ON 4 4 OFF OFF CFM Adj
WDG AIR HANDLER SERIES Installation, Operation & Maintenance Heat Controller, LLC Blower Performance Data WDG Blower Airflow in CFM with wet coil and clean air filter Model WDG TAH 024 026 WDG TAH 036 038 TAH WDG 048 049 TAH WDG 060 064 Cooling Mode Dehumid Mode Heating Mode Max ESP (in. wg) Fan Motor (hp) Tap Setting Stg 1 Stg 2 Fan Stg 1 Stg 2 Fan Stg 1 Stg 2 0.50 1/2 4 810 950 475 630 740 475 920 0.50 1/2 3 725 850 425 560 660 425 825 0.
WDG AIR HANDLER SERIES Installation, Operation & Maintenance Heat Controller, LLC Electrical - Power Wiring Figure 8: Remove Harness Plug 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.
Installation, Operation & Maintenance WDG AIR HANDLER SERIES WDG024-060 Wiring Diagram 115-208-230/60/1 ECM 18 Heat Controller, LLC
Installation, Operation & Maintenance WDG AIR HANDLER SERIES Heat Controller, LLC Electric Heat Installation Figure 11: Blower removal Overview The HG Series Auxiliary Electric Heat mounts internally in upflow (Figures 10-12) or downflow units and horizontal units. Horizontal units are rated for zero clearance at the unit and 1" clearance for first three feet of duct, vertical units rated for zero clearance for both unit and duct. Downflow units can not be located directly over a discharge register.
Installation, Operation & Maintenance WDG AIR HANDLER SERIES Heat Controller, LLC Electric Heat Wiring Figure 13: Power Wiring, 4, 5, 8, and 10kw Figure 14: Power Wiring, Single Circuit, 15, 20kw 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.
WDG AIR HANDLER SERIES Installation, Operation & Maintenance Heat Controller, LLC Electrical Heat Staging Options Figure 17: Low Voltage Harness Connection Table 4: HG Electric Heat Ratings Auxiliary Electric Heat Model WDG Models 024 048060 036 kW Rating Btuh Rating Minimum CFM Required 240V 208V 240V 208V 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.
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.
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 Design, material, performance data and components subject to change without notice.
