AIR HANDLER Installation Instructions HMG**F1E, HMG**X1E & 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.
TABLE OF CONTENTS Important Safety Information........................3 Requirements & Codes........................................3 General Information...........................................4 Before You Install this Unit..........................................4 Locating the Air Handler.............................................4 Minimum Clearances..................................................4 Operation of Air Handler During Construction............4 Installation in a Garage...................
Important SAFETY INFORMATION INSTALLER: Please read all instructions before servicing this equipment. Pay attention to all safety warnings and any 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.
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.
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.
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.
Horizontal Installations These air handlers can be installed horizontally in an 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.
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.
Orifice Removal & 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. 9. Realign the assembly nut on the distributor body and hand tighten both components.
1. Remove grommets from line set holes. 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.
• 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. Insulate the drain if it is located in an unconditioned space, and test the condensate line for leaks.
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. 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.
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.
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 present to 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).
4. Replace the upper door and secure it to the unit. 5. Restore power to the unit. High Efficiency Units (Variable & Fixed Speed) IMPORTANT! This air handler has been designed to give the installer maximum flexibility to optimize system performance, efficiency, and comfort. Because there are so many different ways to set up the air handler it is important to read and follow these directions carefully.
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. WARNING: ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury or property damage.
Figures & Tables 3/4” 3/4” 3/4” 13” 11/8” K.O. (typ.) “A” 1 7/8" K.O. 11/4” 15/8” 17/8” 2 5/8” 1 7/8” 5 5/8” 3 5/8” 11/4” 3 1/4” 1 1/8” 7/8" K.O. 11/8” K.O. (typ.) 1 7/8” 13/4” K.O. (typ.) DETAIL “D” “H” 3 1/4” 2 1/4” SUCTION LIQUID 15 1/4” 13” “W” 22" Furnace Size (BTUH) H W A Detail D 24K & 30K 43-5/16 14-3/16 12-3/4 No 36K (HMG**F1E Only) 43-5/16 19-11/16 18-1/4 No 36K & 42K 49-5/16 19-11/16 18-1/4 No 48K & 60K 55-15/16 22-7/16 21 Yes Figure 12.
Circuit Breaker (60A) Heating Element Assembly Transformer Motor Control Board Upper Door Assembly Blower Wheel Control Board Capacitor Motor Mount Kit Blower Housing Coil Assembly Horizontal Drain Pan Blower Motor Filter Door Vertical Drain Pan Filter Tracks Lower Door Assembly Figure 13.
AIRFLOW DATA Dry Coil ESP HMG24F1E HMG30F1E HMG36F1E HMG42F1E HMG48F1E HMG60F1E Low Corrected ESP1 Medium Corrected ESP1 High Corrected ESP1 Low Corrected ESP1 Medium Corrected ESP1 High Corrected ESP1 Low Corrected ESP1 Medium Corrected ESP1 High Corrected ESP1 Low Corrected ESP1 Medium Corrected ESP1 High Corrected ESP1 Low Corrected ESP1 Medium Corrected ESP1 High Corrected ESP1 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 683 0.00 861 0.00 1072 0.00 849 0.00 1118 0.00 1277 0.00 953 0.
Cooling or Heating Airflow (CFM) Switch Settings 0 = OFF, 1 = ON 1/5 2/6 3/7 4/8 HMG24X1E & HMG30X1E Dry Coil ESP 0.1 0.2 0.3 0.4 0.5 0.
Nominal Electic Heat KW Furnace Models 5 8 10 15 20 25 30 HMG24X1E & HMG30X1E 800 900 1000 1300 N/A N/A N/A HMG36X1E & HMG42X1E HMG48X1E & HMG60X1E 900 1000 1000 1100 1100 1200 1300 1400 1500 1600 N/A 1800 N/A 2000 NOTE: See Table 6 for appropriate switch settings for these airflows. Table 7.
Cooling Airflow A/B Switch Setting 0 = OFF, 1 = ON HCG24V1E & HCG30V1E 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Heating Airflow COOL Switch Setting 0 = OFF, 1 = ON 5 6 7 8 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 0 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 Airflow (CFM) A/B Switch Setting 0 = OFF, 1 = ON Heater Kit Installed (KW) Airflow (CFM) 525 560 600 625 700 750 800 850 875 890 930 950 1000 1050 1125 1200 0 0 0 0 0 0 0 0 0 5 8 10 15 20 25 30 600 800
Electrical diagrams & Data P2 R C G W 3A Fuse Y BLWDTC BLWDTC_R L2 L1 EAC COOL HEAT LED 1 HEATER P1 Figure 14. Single Stage Control Board R G Y/2Y O W1 W2 Y1 L 3A Fuse C P3 EAC HUM L2 P2 LED 1 HEATER P1 Figure 15.
TEST PORT R W1 NOT USED FAN SPEED GREEN RED OFF ON TWIN DEHUM Y1 C EXPANSION PORT 1 2 3 4 5 6 78 HEAT COOL STATUS BLOWER MOTOR Figure 16. Fixed Speed Motor Control Board STATUS LIGHTS L2-OUT L2-IN GREEN RED Y/Y2 RED OUTPUTS W L1-IN Y1 L1-OUT H 2 3 4 5 6 78 HEAT Y1 COOL SENSOR C GND EXPANSION PORT BLOWER MOTOR Figure 17.
Field Wiring Factory Wiring: Low Voltage High Voltage Legend IF BOARD EQUIPPED WITH BLWDTC TERMINAL BLACK Air Handler R BLW DTC YELLOW W G C HEATER PLUG 7654321 Y R WHITE GREEN GRAY RED WIRING DIAGRAM RELAY 4-PIN PLUG (18) RELAY Figure 18. Wiring Diagram for HMG**F1E Series Air Handler 25 L1 L2 R C L2 L1 HEAT COOL EAC 2 1 RED BLACK CAP. BROWN BROWN RED 3-SPEED MOTOR 1=COM 2=CAP. 3=CAP.
240 24 V C GRAY RED Figure 19. Wiring Diagram for HMG**X1E Series Air Handler TWIN R C Y DEHUM L1 Field Wiring Factory Wiring: Low Voltage High Voltage R L1 L2 C R BLACK MOTOR EXPANSION TEST WHITE HARNESS 1 2 3 4 5 6 HARNESS 6-PIN PLUG 1 2 3 4 5 6 WHITE BLACK MOTOR GREEN 9-PIN HOUSING 9-PIN PLUG 6-PIN PLUG 7110760 0510 NOTES: 1. The blower motor speed tap connection may not be as shown. See the Installation Instructions. 2. Disconnect all power before servicing. 3.
L2 HUM EAL HARNESS BLACK RED Legend Field Wiring Factory Wiring: Low Voltage High Voltage R 24 V WHITE BLACK COM RED C TRANSFORMER 240 208 L1 L2 C R EXPANSION NOTES: 1. The blower motor speed tap connection may not be as shown. See the Installation Instructions. 2. Disconnect all power before servicing. 3. Transformer may havea dual voltage primary tap. Match the tap position with the supply voltage used. 4. If the internal wiring is replaced, use only 105°C copper wire of the same gauge.
HMG**F1E Series 240 VAC, 50 & 60 Hz, Single Phase Circuit C Single Circuit Circuit A Circuit B Circuit C Single Circuit Circuit A Circuit B Circuit C Single Circuit HMG60F1E Circuit B HMG48F1E Circuit A HMG42F1E Single Circuit HMG36F1E MOP Circuit C HMG30F1E None 005H-XX 008H-XX 010H-XX 009Q-XX None 005H-XX 008H-XX 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
HMG**X1E & HCG**V1E 240 VAC, 50 & 60 Hz, Single Phase 15 30 45 60 80 35 50 15 30 45 60 80 110 35 50 15 35 50 60 90 110 150 175 35 50 4.8 26.4 39.1 48.1 48.1 4.8 26.4 39.1 48.1 48.1 48.1 6.8 28.4 41.1 50.1 50.1 50.1 50.1 50.1 - 4.8 26.4 39.1 48.1 21.7 69.8 28.2 42.3 4.8 26.4 39.1 48.1 21.7 69.8 43.3 91.4 28.2 42.3 6.8 28.4 41.1 50.1 21.7 71.8 43.3 93.4 43.3 21.7 115.1 43.3 43.3 136.8 30.2 44.
Control Signal & MODE Operation Total KW 5 KW Board Action Stage 1 Heat on instantly Heat blower on after 3 second delay Stage 1 Heat on instantly 10 KW Heat blower on after 3 second delay Stage 2 Heat on after 5 seconds delay Stage 1 Heat on instantly 15 KW Heat 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 Heat blower on after 3 second delay 20 KW Stage 2 Heat on after 5 seconds delay Stage 3 Heat on after 10
Control Signal & MODE Operation Total KW 5 KW Board Action Stage 1 Heat on instantly Cool blower on after 3 second delay Stage 1 Heat on instantly 10 KW Cool blower on after 3 second delay Stage 2 Heat on after 5 seconds delay Stage 1 Heat on instantly 15 KW Cool blower on after 3 second delay Stage 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 20 KW Stage 2 Heat on after 5 seconds delay Stage 3 Heat on after 10
INSTALLATION / PERFORMANCE CHECK LIST INSTALLER NAME: CITY: ELECTRICAL SYSTEM: STATE: YES NO Line voltage polarity correct? YES NO Supply Voltage: ___________________________________(V) INSTALLATION ADDRESS: CITY: Electrical connections tight? STATE: UNIT MODEL # Has the thermostat been calibrated? YES NO Is the thermostat level? YES NO Is the heat anticipator setting correct? YES NO UNIT SERIAL # Minimum clearances per page 4? YES NO Is the unit properly installed and leveled? YE
