Heat Controller Geothermal Air Handler Quick Start Guide IOM

2014-07-19

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INSTALLATION, OPERATION
& MAINTENANCE MANUAL

Residential Air Handler
WDG Air Handler Series

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

Installation, Operation & Maintenance

WDG AIR HANDLER SERIES

Heat Controller, LLC

Table of Contents
Model Nomenclature ............................................................................................3
Pre-Installation......................................................................................................4
Safety ...................................................................................................................5
Physical Data........................................................................................................6
Unit Dimensional Data ..........................................................................................7
Installation .......................................................................................................8-13
Electrical - Thermostat Wiring ............................................................................14
ECM Blower Control ...........................................................................................15
Blower Performance Data ..................................................................................16
Electrical - Power Wiring ....................................................................................17
Electrical Table ...................................................................................................17
Wiring Diagram ...................................................................................................18
Electric Heat Installation .....................................................................................19
Electric Heat Wiring .......................................................................................20-21
Electric Heat Staging Options.............................................................................21
Unit & System Checkout.....................................................................................22
Maintenance .......................................................................................................22

WDG AIR HANDLER SERIES

Installation, Operation & Maintenance

Heat Controller, LLC

Model Nomenclature
1

4 5 6

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 ; 22.5 X 55
UNIT SIZE 036, 048, 060, ONLY ; 25.5 X 59

V = TXV w/ECM DRIVE

CONTROLS
S = STANDARD

Installation, Operation & Maintenance

WDG AIR HANDLER SERIES

Heat Controller, LLC

General Information
Inspection
Upon receipt of the equipment, carefully check the shipment against
the bill of lading. Make sure all units have been received. Inspect
the packaging of each unit, and inspect each unit for damage.
Insure that the carrier makes proper notation of any shortages or
damage on all copies of the freight bill and completes a common
carrier inspection report. Concealed damage not discovered during
unloading must be reported to the carrier within 15 days of receipt
of shipment. If not filed within 15 days, the freight company can
deny the claim without recourse. Note: It is the responsibility of
the purchaser to file all necessary claims with the carrier. Notify
your equipment supplier of all damage within fifteen (15) days of
shipment.

WARNING!
WARNING! These instructions are intended as an aid to
qualified licensed service personnel for proper installation,
adjustment and operation of this unit. Read these instructions
thoroughly before attempting installation or operation. Failure
to follow these instructions may result in improper installation,
adjustment, service or maintenance possibly resulting in
property damage, personal injury or death.

CAUTION!
CAUTION! DO NOT store or install units in corrosive
environments or in locations subject to temperature or
humidity extremes. Corrosive conditions and high temperature
or humidity can significantly reduce performance, reliability,
and service life.

Storage
Equipment should be stored in its original packaging in a clean,
dry area. Store units in an upright position at all times. Stack
units a maximum of 3 units high.

CAUTION!

Unit Protection
Cover units on the job site with either the original packaging or an
equivalent protective covering. Cap the open ends of pipes stored
on the job site. In areas where painting, plastering, and/or spraying
has not been completed, all due precautions must be taken to avoid
physical damage to the units and contamination by foreign material.
Physical damage and contamination may prevent proper start-up
and may result in costly equipment clean-up.

CAUTION! CUT HAZARD - Failure to follow this caution may
result in personal injury. Sheet metal parts may have sharp
edges or burrs. Use care and wear appropriate protective
clothing, safety glasses and gloves when handling parts and
servicing.

Examine all pipes, fittings, and valves before installing any of the
system components. Remove any dirt or debris found in or on
these components.
Pre-Installation
Installation, Operation, and Maintenance instructions are
provided with each unit. Horizontal equipment is designed for
installation above false ceiling or in a ceiling plenum. Other
unit configurations are typically installed in a mechanical room.
The installation site chosen should include adequate service
clearance around the unit. Before unit start-up, read all manuals
and become familiar with the unit and its operation. Thoroughly
check the system before operation.
Prepare units for installation as follows:
1. Compare the electrical data on the unit nameplate with
ordering and shipping information to verify that the correct
unit has been shipped.
2. Keep the cabinet covered with the original packaging until
installation is complete and all plastering, painting, etc. is
finished.
3. Verify refrigerant tubing is free of kinks or dents and that it
does not touch other unit components.
4. Inspect all electrical connections. Connections must be clean
and tight at the terminals.

Installation, Operation & Maintenance

WDG AIR HANDLER SERIES

Heat Controller, LLC

Safety
The installation of water source heat pump units and all
associated components, parts and accessories which make
up the installation shall be in accordance with the regulations
of ALL authorities having jurisdiction and MUST conform to
all applicable codes. It is the responsibility of the installing
contractor to determine and comply with ALL applicable codes
and regulations.

WARNING!
WARNING! All refrigerant discharged from this unit must be
recovered WITHOUT EXCEPTION. Technicians must follow
industry accepted guidelines and all local, state, and federal
statutes for the recovery and disposal of refrigerants. To avoid
leakage of compressor oil, refrigerant lines of the compressor
must be sealed after it is removed.

Replacement Parts
Any replacement part must be the same as or an approved
alternate to the original part supplied. The manufacturer will not
be responsible for replacement parts not designed to physically
fit or operate within the design parameters the original parts were
selected for. When ordering replacement parts, it is necessary to
order by part number and include the complete model number
and serial number from the coil rating plate. (See parts list for unit
component part numbers. Parts are available through the local
distributor.)

CAUTION!
CAUTION! To avoid equipment damage, DO NOT use these
units as a source of heating or cooling during the construction
process. The mechanical components and filters will quickly
become clogged with construction dirt and debris, which may
cause system damage.

Safety
Warnings, cautions and notices appear throughout this manual.
Read these items carefully before attempting any installation,
service, or troubleshooting of the equipment.
DANGER: Indicates an immediate hazardous situation, which if
not avoided will result in death or serious injury. DANGER labels
on unit access panels must be observed.
WARNING: Indicates a potentially hazardous situation, which if not
avoided could result in death or serious injury.
CAUTION: Indicates a potentially hazardous situation or an
unsafe practice, which if not avoided could result in minor or
moderate injury or product or property damage.
NOTICE: Notification of installation, operation or maintenance
information, which is important, but which is not hazard-related.

WARNING!
WARNING! The EarthPure® Application and Service Manual
should be read and understood before attempting to service
refrigerant circuits with HFC-410A.

WARNING!
WARNING! To avoid the release of refrigerant into the
atmosphere, the refrigerant circuit of this unit must be serviced
only by technicians who meet local, state, and federal
proficiency requirements.

CAUTION!
CAUTION! It is recommended that an auxiliary secondary
drain pan be installed under units containing evaporator coils
that are located in any area of a structure where damage to
the building or building contents may occur as a result of an
overflow of the coil drain pan or a stoppage in the primary
condensate drain piping.

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]

Suction I.D.

3/4 [1.9]

7/8 [2.22]

Fan Motor Type/Speeds

ECM Variable

Fan Motor (hp)

1/2

Blower Wheel Size (Dia x W)
in. [mm]

9 x 7 [229 x 178]

Air Coil Dimensions (H x W)
in. [mm]

3 - 2 Row 14 x 17 [356 x 432]

Filter Standard - 1” [25mm]
Throwaway

16 x 20 [406 x 508]

1
12 x 10 [305 x 254]
3 - 3 Row 24x17
[610 x 432]

3 - 2 Row 24 x 17 [610 x 432]
20 x 24
[508 x 610]

20 x 20 [508 x 508]

20 x 20
[508 x 508]

20 x 24 [508 x 610]

Weight - Operating lbs. [kg]

80 [36]

163 [74]

173 [78]

181 [82]

180 [82]

188 [85]

198 [90]

Weight - Packaged lbs. [kg]

96 [44]

179 [81]

198 [90]

206 [93]

218 [99]

226 [103]

236 [107]

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]

B = Secondary Drain - Vertical
and Downflow Configuration

4.5 [11.4]
3.7 [9.4]

C = Secondary Drain - Horizontal
Configuration

0.0
3.6
[9.1]

H
D

0.0 1.6
[4.0]

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. Opening
A

0.625
[1.6]

Overall Cabinet

Cabinet
Size

A
Width

B
Height

C
Depth

0.625
[1.6]

R.A. Opening
C

0.75
[1.9]

B - Cabinet

in.

18.5

44.0

22.0

14.0

2.3

4.1

C - Cabinet

in.

22.0

55.0

22.0

18.0

2.1

D - Cabinet

in.

25.5

59.0

22.0

18.0

3.8

2.1

0.875
[2.2]

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. If a return duct is connected to the air handler, it must be the
same dimensions as the return opening.
8. After ductwork connections are made, seal airtight and per local
codes.

Air Handlers are designed for upflow, horizontal, and downflow
applications. The coils have a dry nitrogen holding charge and
are equipped with brazing stub refrigerant connections for easy
installation. Both models come equipped with a factory installed
TXV.
The installer should read the installation manual supplied with
the compressor section for refrigerant line set sizing, connection procedure, and other important information pertaining to the
system installation.
The installer should:
1. Where precise forming of refrigerant lines is required, a copper
tubing bender is recommended for small diameter tubing. One
should avoid sharp bends and contact of the refrigerant lines
with metal surfaces.
2. Refrigerant lines should be protected where they pass through
the raw edges of holes.
3. Air Handler must be level for proper condensate drainage.
4. Seal the openings into the cabinet to reduce risk of condensate blow off from the coil.

Horizontal Right Installation
For maximum efficiency and customer ease of filter
maintenance, it is recommended that a properly sized remote
filter grille be installed for horizontal applications. Airflow should
not exceed the face velocity of the filter being used. The factory
installed filter should then be removed from the unit.
1. To convert the unit to horizontal right, front access, slide the coil
out on the coil channel supports and rotate the complete coil 180
degrees.
2. The coil is then inserted back into the cabinet on the opposite
side coil channel supports. The unit is now horizontal right with
front access.
Position the ECM wire harness connection at the 4 to 8 o’clock
position to prevent condensation from entering motor controller.
3. If the unit is suspended, it must be supported from the bottom
near both ends as well as the middle to prevent sagging. The
service access must remain unobstructed. If the unit is supported
along the length of the front and back with rails, the air handler
only needs to be suspended at both ends. See Figure 1.
If the unit is not suspended it must be supported as mentioned
above and isolated carefully to prevent sound transmission.
Vibration isolators (purchased locally) must be placed under the
unit.
4. It is always recommended that an auxiliary drain pan be installed
under a horizontal air handler (See Condensate Piping) to prevent
possible damage to ceilings.
5. Isolate the auxiliary drain pan from the unit or from the structure.
6. Connect the auxiliary drain line to a separate drain line (no trap is
needed in this line) and terminate according to national and local
codes.
7. If a return duct is connected to the air handler, it must be the
same dimensions as the return opening shown in the outline
drawing on Figure 2.
8. Openings where field wiring enters the cabinet must be
completely sealed.
9. After ductwork connections are made, seal airtight and per local
codes.

Air Handler Installation

WARNING!
WARNING! Electric furnaces may be connected to more than
one supply circuit.

Charging the System
Air Handlers are designed to match HTS split units. For correct
charging, please refer to the Compressor Section IOM.
Upflow Installation
1. Position unit on plenum box or other suitable foundation. Provide
a minimum height for proper unrestricted airflow based on CFM
requirement for each unit size.
2. If a return air duct is connected to the air handler, it must be the
same dimensions as shown in the outline drawing in Figure 2.
3. Plenum box and unit should be isolated from the foundation
using a suitable isolating material.
4. Openings where field wiring enters the cabinet must be
completely sealed. Location of power entry is shown on the
outline drawing.
5. After ductwork connections are made, seal airtight and per local
codes.
Downflow Installation
1. Position unit on plenum box or other suitable foundation. Provide
a minimum height for proper unrestricted airflow based on CFM
requirement for each unit size.
2. If a return air duct is connected to the air handler, it must be the
same dimensions as shown in the outline drawing in Figure 2.
3. Plenum box and unit should be isolated from the foundation
using a suitable isolating material.
4. Openings where field wiring enters the cabinet must be
completely sealed. Location of power entry is shown on the
outline drawing.

Horizontal Left Installation
1. For maximum efficiency and customer ease of filter
maintenance, it is recommended that a properly sized remote
filter grille be installed for horizontal applications. Airflow should
not exceed the face velocity of the filter being used. The factory
installed filter should then be removed from the unit.
2. Unit is shipped from the factory in the upflow or horizontal
left configuration. Unit conversion is not required. Conversion
is required: Rotate motor to ensure connection at the 4 to 8
o’clock position.
8

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. If the unit is not suspended it must be supported as mentioned
above and isolated carefully to prevent sound transmission.
Vibration isolators (purchased locally) must be placed under the
unit.
5. It is always recommended that an auxiliary drain pan be
installed under a horizontal air handler (See Condensate Drain
Piping) to prevent possible damage to ceilings.
6. Isolate the auxiliary drain pan from the unit or from the structure.
7. Connect the auxiliary drain line to a separate drain line (no trap
is needed in this line) and terminate according to national and
local codes.
8. If a return duct is connected to the air handler, it must be the
same dimensions as the return opening shown in the outline
drawing on Figure 2.
9. Openings where field wiring enters the cabinet must be
completely sealed. Location of power entry is shown on the
outline drawing.
10. After ductwork connections are made, seal airtight and per local
codes.

EarthPure®

Auxiliary
Drain Pan
Rail

Tranquility 27
EarthPure®

Duct Connections
The supply and return air ducts should be connected to the unit
with flame retardant duct connectors.

NOTE: No sheetmetal screws may be used to attach
return ductwork on the side.
NOTE: Any duct board return connection can be made
to the sides of the unit using tape or mastic.
Tranquility 27
EarthPure®

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72 ytiliuqnarT

Figure 2: Flange Attachment

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.

5HWXUQ

'LVFKDUJH

5HWXUQ
'LVFKDUJH

LEFT
DISCHARGE

5HWXUQ

TOP
DISCHARGE

'LV
'LVFKDUJH

BOTTOM
DISCHARGE

RIGHT
DISCHARGE

1” to 2” Filter Rack Conversion
The unit is shipped with1” filter rack from the factory. The conversion
process is assumed that the unit is in upflow configuration.
1. Place unit on a flat surface. Remove 2 knurled thumb knobs that
secure the filter rack door at the bottom of the unit.
2. Remove 3 screws that secure the lower filter tracks on each side
of the unit.
3. Lift and rotate the filter tracks upside down and reinstall filter
tracks and screws back.
4. Replace the filter rack door and the 2 knurled thumb knobs.

'LVFKDUJH

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.

Installed and
Insulated)

Equalizer
Line

TXV (‘IN’ toward
compressor section)

Suction Line

CAUTION!

TXV has internal
check valve

CAUTION! Installation of a factory supplied liquid line bidirectional filter drier is required. Never install a suction line
filter in the liquid line.

Liquid Line

Line Set Installation
Figure 4 illustrates a typical installations of an air handler l matched
to an indoor compressor section. Table 1 shows typical line-set
diameters at various lengths. Lineset lengths should be kept to a
minimum and should always be installed with care to avoid kinking.
Line sets over 60 feet [18 meters] long are not recommended due to
potential oil transport problems and excessive pressure drop. If the
line set is kinked or distorted, and it cannot be formed back into its
original shape, the damaged portion of the line should be replaced.
A restricted line set will effect the performance of the system.

Sensing Bulb
IMPORTANT: DO NOT perform any brazing with the TXV
bulb attached to any line. After brazing operations have been
completed, clamp the TXV bulb securely on the suction line at
the 10 or 2 o’clock position with the strap provided in the parts
bag. Insulate the TXV sensing bulb and suction line with the
provided pressure sensitive insulation (size 4” x 7”).
IMPORTANT: TXV sensing bulb should be located on a horizontal
section of suction line, just outside of coil box.
IMPORTANT: Always protect TXV from heat when brazing.
IMPORTANT: TXV sensing bulb is shipped unattached. Installer
must attach bulb to suction line after brazing and cooling line for
proper unit operation.

All brazing should be performed using nitrogen circulating at
2-3 psi [13.8-20.7 kPa] to prevent oxidation inside the tubing.
All linesets should be insulated with a minimum of 1/2” [13mm]
thick closed cell insulation. All insulation tubing should be
sealed using a UV resistant paint or covering to prevent
deterioration from sunlight.

NOTICE! The air coil should be thoroughly washed with a filming
agent, (dishwasher detergent like Cascade) to help condensate
drainage. Apply a 20 to 1 solution of detergent and water. Spray
both sides of coil, repeat and rinse thoroughly with water. Care
should be taken not to overflow drain pan. Wash after connecting
condensate line.

When passing refrigerant lines through a wall, seal opening
See compressor section IOM for refrigerant charge
information.
with silicon-based caulk. Avoid direct contact with water
pipes, duct work, floor joists, wall studs, floors or other
structural components that could transmit compressor
vibration. Do not suspend refrigerant tubing from joists
with rigid straps. Do not attach line set to the wall. When
necessary, use hanger straps with isolation sleeves to
minimize transmission of line set vibration to the structure.

Figure 4: Typical Split/Air Handler Installation

Power
Disconnects
Air
Handler

Installing the Indoor Coil and Lineset
Figure 3 shows the installation of the lineset and TXV to a typical
indoor coil. Braze the copper line set to the coil. Nitrogen should be
circulated through the system at 2-3 psi [13.8-20.7 kPa] to prevent
oxidation inside the refrigerant tubing. Use a low silver phos-copper
braze alloy on all brazed connections.

Insulated
Linesets

Low
Low Voltage
Voltage
PVC Condensate
with vented trap

Compressor Section

Air pad or Extruded
polystryene

Return
Plenum

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. Use a good quality bubble solution to detect leaks on all
connections made in the field. Check the service valve ports and stem
for leaks. If a leak is found, repair it and repeat the above steps. For
safety reasons do not pressurize system above 150 psig [1034 kPa].
System is now ready for evacuation and charging.

Figure 5: Condensate Drain Trap

'2 127 23(5$7( 81,7 :,7+287
&21'(16$7( '5$,1 75$3

81,7

Condensate Drain Tubing
Consult local codes or ordinances for specific requirements.
IMPORTANT: When making drain fitting connections to the drain
pan, use a thin layer of Teflon paste, silicone or Teflon tape and
install hand tight.
IMPORTANT: When making drain fitting connections to drain
pan, do not overtighten. Overtightening fittings can split pipe
connections on the drain pan.
• Install drain lines so they do not block service access to front
of the unit. Minimum clearance of 24 inches is required for
filter, coil or blower removal and service access.
• Make sure unit is level or pitched slightly toward primary drain
connection so that water will drain completely from the pan
(See Figure 5).
• Do not reduce drain line size less than connection size
provided on condensate drain pan.
• All drain lines must be pitched downward away from the unit a
minimum of 1/8” per foot of line to ensure proper drainage.
• Do not connect condensate drain line to a closed or open
sewer pipe. Run condensate to an open drain or outdoors.
• The drain line should be insulated where necessary to prevent
sweating and damage due to condensate forming on the
outside surface of the line.
• Make provisions for disconnecting and cleaning of the primary
drain line should it become necessary. Install a 3 in. trap in the
primary drain line as close to the unit as possible. Make sure
that the top of the trap is below connection to the drain pan to
allow complete drainage of pan (See Figure 5).
• Auxiliary drain line should be run to a place where it will be
noticeable if it becomes operational. Occupant should be
warned that a problem exists if water should begin running
from the auxiliary drain line.
• Plug the unused drain connection with the plugs provided in
the parts bag, using a thin layer of Teflon paste, silicone or
Teflon tape to form a water tight seal.
• Test condensate drain pan and drain line after installation is
complete. Pour water into drain pan, enough to fill drain trap
and line. Check to make sure drain pan is draining completely,
no leaks are found in drain line fittings, and water is draining
from the termination of the primary drain line.

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It is always recommended that an auxiliary drain pan be installed
under a horizontally installed air handler.
Connect the auxiliary drain line to a separate drain line (no trap is
needed in this line) and terminate according to local codes.

NOTE: DO NOT use a torch or flame near the plastic
drain pan coupling.
NOTE: DO NOT tighten the drain pipe excessively.
Support the condensate piping and traps outside the
unit to prevent strain on the drain connection.

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. A
high pressure switch must be installed on the heat pump side
of any field provided shut-off valves and connected to the
heat pump controls in series with the built-in refrigerant circuit
high pressure switch to disable compressor operation if water
pressure exceeds pressure switch setting. The field installed
high pressure switch shall have a cut-out pressure of 300 psig
and a cut-in pressure of 250 psig. This pressure switch can
be ordered from the manufacturer with a 1/4” internal flare
connection as part number 39B0005N02.

Units with ECM Fan

Connection to ECM Control
ATP32U03 Thermostat
Compressor

Compressor Stage 2
Reversing Valve

Fan
24Vac Hot

24Vac Common
Fault LED

L
W1

AL1
W

Electric Heat

CAUTION!
CAUTION! Refrigerant pressure activated water regulating
valves should never be used with the manufacturer’s equipment.

ECM

Field Wiring
Factory Wiring

See equipment wiring diagram for more details.

Thermostat Installation
The thermostat should be located on an interior wall in a
larger room, away from supply duct drafts. DO NOT locate the
thermostat in areas subject to sunlight, drafts or on external
walls. The wire access hole behind the thermostat may in certain
cases need to be sealed to prevent erroneous temperature
measurement. Position the thermostat back plate against the
wall so that it appears level and so the thermostat wires protrude
through the middle of the back plate. Mark the position of the
back plate mounting holes and drill holes with a 3/16” (5mm) bit.
Install supplied anchors and secure plate to the wall. Thermostat
wire must be 18 AWG wire. Wire the appropriate thermostat as
shown in Figures 6 and 7 to the low voltage terminal strip on
the ECM control board. Practically any heat pump thermostat
will work with these units, provided it has the correct number of
heating and cooling stages.

Figure 7: Three Heat / Two Cool, Auto / Manual
Changeover Programmable (7 Day) - NonProgrammable, With Humidity Control
Units with ECM Fan

Connection to ECM Control
ATP32U04 Thermostat
Compressor
Compressor Stage 2

Dehumidification

Reversing Valve
Fan

24Vac Hot
24Vac Common
Fault LED

Electric Heat

G
C
L
W1

ECM
Y1
Y2
DH
O
G
R
C
AL1
W

Notes:
1) ECM dehumidification mode slows down fan speed in the
cooling mode when dehumidification output from thermostat is
active. Normal heating and cooling fan speeds are not
affected.
2) ECM board DIP switch SW9 must be in dehumid. mode.

Field Wiring
Factory Wiring

See equipment wiring diagram for more details.

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. To take full advantage of the ECM motor
features, a multi-stage thermostat should be used (2-stage
heat/2-stage cool or 3-stage heat/2-stage cool).

cooling to increase the moisture removal of the heat pump.
Consult submittal data or specifications catalog for the specific
unit series and model to correlate speed tap to airflow in CFM.
The dehumidification mode can be enabled in two ways.
1.

HFC-410A packaged units built after May 2009 have ECM
controller version III (P/N 17B0034N02). This controller includes
logic and a relay to control.
Note: Power must be off to the unit for at least three seconds
before the ECM motor will recognize a speed change.
The motor will recognize a change in the CFM Adjust or
dehumidification mode settings while the unit is powered.

There are four different airflow settings from lowest airflow rate
(speed tap 1) to the highest airflow rate (speed tap 4). The charts
below indicate settings for both versions of the ECM interface
board, followed by detailed information for each setting.
Cooling Settings: The cooling setting determines the cooling
(normal) CFM. Cooling (normal) setting is used when the unit is
not in dehumidification mode. Tap 1 is the lowest CFM setting,
while tap 4 is the highest CFM setting. To avoid air coil freeze-up,
tap 1 may not be used if the dehumidification mode is selected.
Consult submittal data or specifications catalog for the specific unit
series and model to correlate speed tap setting to airflow in CFM.
Heating Settings: The heating setting determines the heating
CFM. Tap 1 is the lowest CFM setting, while tap 4 is the highest
CFM setting. Consult submittal data or specifications catalog for
the specific unit series and model to correlate speed tap setting to
airflow in CFM.
Auxiliary/Emergency Heat Settings: The auxiliary/emergency
heat setting determines the CFM when the unit is in auxiliary
heat or emergency heat mode. This setting is used for residential
units with internal electric heat. When auxiliary electric heat is
energized (i.e. compressor and electric heat), the greater of the
auxiliary/emergency or heating setting will be used. A “G” (fan)
signal must be present from the thermostat for electric heat to
operate. Consult the submittal data or specifications catalog for
the specific unit series and model to correlate speed tap setting to
airflow in CFM.
CFM Adjust Settings: The CFM adjust setting allows four
selections. The NORM setting is the factory default position. The
+ or – settings adjust the airflow by +/- 5%. The +/- settings are
used to “fine tune” airflow adjustments. The TEST setting runs the
ECM motor at 400 CFM/nominal ton at a constant CFM. Example:
WDG024 = 800 CFM.
Dehumidification Mode Settings: The dehumidification mode
setting provides field selection of humidity control. When
operating in the normal mode, the cooling airflow settings
are determined by the cooling tap setting above. When
dehumidification is enabled there is a reduction in airflow in
14

Constant Dehumidification Mode: When the dehumidification
mode is selected (via DIP switch or jumper setting), the ECM
motor will operate with a multiplier applied to the cooling
CFM settings (approx. 20-25% lower airflow). Any time the
unit is running in the cooling mode, it will operate at the lower
airflow to improve latent capacity. The “DEHUM” LED will
be illuminated at all times. Heating airflow is not affected.
NOTE: Do not select dehumidification mode if cooling setting
is tap 1.
Automatic (Humidistat-controlled) Dehumidification Mode:
When the dehumidification mode is selected (via DIP switch
or jumper setting) AND a humidistat is connected to terminal
DH (version II) or HUM (version I), the cooling airflow will
only be reduced when the humidistat senses that additional
dehumidification is required. The DH (or HUM) terminal is
reverse logic. Therefore, a humidistat (not dehumidistat)
is required. The “DEHUM” LED will be illuminated only
when the humidistat is calling for dehumidification mode.
Heating airflow is not affected. NOTE: Do not select
dehumidification mode if cooling setting is tap 1.

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 Adjust settings: TT, TS Units
Version I
Version II and III
69243707 (17B0019N01 & 17B0034N01)
DIP Switch
Tap
CFM Adj
Setting
Jumper
SW7
SW8
TEST
1
ON
ON
2
ON
OFF
+
3
OFF
ON
NORM
4
OFF
OFF

Dehum Mode settings: TT, TS Units
Version I
Version II and III
69243707 (17B0019N01 & 17B0034N01)
DIP Switch
Tap
Dehumid
SW9
Setting
Jumper
ON
NORM
pins 1,2
Dehumid
pins 2,3
OFF

Table 8a: ECM Version II Interface Layout
Y2

Thermostat
Input LEDs

A L

Table 8b: ECM Version I Interface Layout
A L

1/4" Spade
Connections
to CXM or
DXM Board

Aux/Emerg Heat settings: TT, TS Units
Version I
Version II and III
69243707 (17B0019N01 & 17B0034N01)
DIP Switch
Tap
AUX CFM
Setting
Jumper
SW5
SW6
1
1
ON
ON
2
2
ON
OFF
3
3
OFF
ON
4
4
OFF
OFF

1/4" Spade
Connections
to CXM or
DXM Board

W1 EM C

TB1
Y

Y1 Y2

CFM Counter
1 flash per 100CFM

LED's
CFM
J01

CFM
Adjust

Aux
CFM

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Dehumidification
LED

4
3
2
1

4
3
2

Norm 1

1 2

2 3
Dehumid

Fan Speed Selection Jumpers

Figure 8c: ECM Version III Interface Layout
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ECM Motor
Low Voltage
Connector

Norm
(+)
(–)
Test

4
3
2
1

7 8 9 10

S1
SW1
SW2
SW3
SW4
SW5
SW6
SW7
SW8
SW9
OFF ON

AL1

DEHUM

Fan Speed Selection DIP Switch

+:*/('

Thermostat
Input LEDs

TB01

1 2 3 4 5

Thermostat
Connections

ECM Motor
Low Voltage
Connector

Dehumidification
LED

CFM Counter
1 flash per 100 CFM

Y2 Y1 G O W1 EM NC C R Hum

Thermostat
Connections

CFM

Y2 Y1 G O W C R DH AL1 A

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

810

950

475

630

740

475

920

0.50

1/2

725

850

425

560

660

425

825

0.50

1/2

620

730

370

490

570

370

0.50

1/2

520

610

300

0.50

1/2

1120

1400

700

870

1090

0.50

1/2

1000

1250

630

780

0.50

1/2

860

1080

540

670

0.50

1/2

730

900

450

0.75

1460

1730

870

1140

1350

0.75

1300

1550

780

1020

0.75

1120

1330

670

870

0.75

940

1120

560

0.75

1670

2050

1020

0.75

1500

1825

920

1160

1430

920

1650

2050

920

2040

0.75

1280

1580

790

1000

1230

790

1430

1750

790

1750

0.75

1080

1320

660

1200

1470

660

1470

1300

Fan

AUX
CFM

Aux/
Emerg
Mode

1060

475

1060

950

425

950

710

820

370

820

600

690

300

690

700

1120

1400

700

1400

980

630

1000

1250

630

1350

840

540

860

1080

540

1350

730

900

450

1350

870

1560

1850

870

1850

1210

780

1400

1650

780

1660

1040

670

1200

1430

670

1430

1010

1200

560

1350

1860

2280

1020

2280

1600

1020

Factory shipped on Tap Setting 2
During Auxiliary operation (residential units only) the CFM will run at the higher if the heating (delay jumper) or AUX settings
Airflow is controlled within +/- 5% up to Max ESP shown with wet coil and standard 1” fiberglass filter
Do not select Dehumidification mode if HP CFM is on setting 1
All units AHRI/ISO/ASHRAE 13256-1 rated HP (Cooling) Delay (Heating) CFM Setting 3

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. Follow
instructions on unit wiring diagram located on blower housing
and in the Service Facts document included with the unit.
2. The selection of wire and fuse sizes should be made according
to the Minimum Branch Circuit Ampacity and the Maximum
Overcurrent Device listed on the unit nameplate.
3. Field wiring diagrams for electric heaters and unit accessories
are shipped with the accessory.
4. Wiring must conform to National and Local codes.
5. Ground unit per local codes with good safety procedures.

Figure 9: Install Two Pin Jumper Plug

NOTE: If air handler is used with or without a heater,
the electrical entry hole as well as any other cabinet
penetrations must be sealed air-tight.
Wiring Instructions for 115 volt Conversion from 230 volt
1. Disconnect all power to the unit.
2. Disconnect Transformer primary orange wire from power
block T2 and insulate open end of wire. Connect the white
lead from transformer primary wire to power block terminal T2.
Note: (L2 will be used as Netural)
3. Remove plug in ECM power wiring harness (Fig. 8) and Install
2 pin jumper plug provided in control box (Fig. 9).

Note: For 115V power only. Damage will occur to motor with
230V power supply if 115V jumper is used.

NOTE: When supplementary heaters are installed,
inspect to insure that all packaging material has been
removed.

Table 3: Electric Table
Model

Volt Code
208/230

Rated Voltage
Dual Rated
(115) 208/230

Voltage Min/
Max Dual
Rated
(115) 208/230

Fan
Motor
FLA

Fan
Motor
HP

Max
Fan
ESP

Min Circ
Amp
(115)
208/230

Total
Unit
FLA

Max Fuse/
HACR
(115)
208/230

024

(115) 208/230

(114/132)
197/254

(7.7) 4.3

1/2

1.0

(7.8) 4.9

(7.7) 4.3

(15) 15

036

(115) 208/230

(114/132)
197/254

(7.7) 4.3

1/2

0.9

(7.8) 4.9

(7.7) 4.3

(15) 15

048

(115) 208/230

(114/132)
197/254

(12.8) 7

1.0

(14.4) 8.6

(12.8) 7

(25) 15

060

(115) 208/230

(114/132)
197/254

(12.8) 7

0.7

(14.4) 8.6

(12.8) 7

(25) 15

Rated Voltage of 208/230/60/1, field convertible to 115V.

Installation, Operation & Maintenance

WDG AIR HANDLER SERIES

WDG024-060 Wiring Diagram 115-208-230/60/1 ECM

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. The discharge plenum
must be constructed from non combustible material. The HG
electric heat contains a four stage relay control board which
activates the elements directly via an internally wired low voltage
harness. Low voltage signals (W1 and W2) are staged from the
DXM2 control.
Vertical Upflow or Downflow and Horizontal Installation
1. Disconnect power to the unit
2. Remove blower access panels.
3. Clip wire-tie holding electric heat low voltage 3-wire harness
to discharge panel stiffener.
4. Remove blower mounting screws and then drop down
blower assembly as shown in Figure 11. Removal of blower
wires should not be necessary.
5. Install electric heat in discharge flange where blower
assembly has been removed using provided screws as
shown In Figure 12.
5.5 For downflow or horizontal right discharge units, the air
handler support bracket must be removed to re-install the
blower housing assembly. After re-installing the blower
housing, re-install the air handler support bracket.
6. Re-install blower assembly, Figure 12, into electric heat
assembly using blower mounting screws. Check blower
wiring for proper wiring connections.
7. Route the low voltage harness through the provided ‘pie’
bushing and plug into electric heat control board connector
P2 as shown in Figure 18.
8. Install power conduit through unit corner post knockout and
attach conduit directly to the electric heat control box.
9. Optional: HG**C kits only. Blower power may be supplied
from T3 & T4 CB5 breaker. Refer to WDG wiring diagram
96B0005N58.

Figure 12: HG electric heat mounting and
blower re-installation

Locate electric heat assembly
on pins in discharge panel
and insert screws

Relocate blower in electric
heat assembly in same
manner

Figure 10: Typical air handler installation
Auxiliary electric heat
power supply knockout
opposite air coil

Electric Heat
Assembly

Disconnect (optional
refer to local code)

Air Coil
Route condiut thru cabinet and
connect to electric heat control
box. Seal to eliminate air leaks on
cabinet exterior.
Low voltage control
harness is prewired
on all distributor class units.

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.
If a single circuit supply is desired, install the optional single
circuit accessory kit (P/N 16B0002N02), as shown in Figure
15, that can be obtained from your distributor.
2. Ensure unit airflow setting is above minimum airflow rating for
the electric heat model from Table 2.
3. Check staging jumpers for the application. Typically only
5 kW (factory setting on all models except 10kW on 20kW
models) is needed for first stage electric (W1) to minimize
electric demand. This staging can be adjusted by moving the
staging jumpers as shown in Figure 17. Whatever is jumped
to P1 pin 1 will be energized on 1st stage of electric heat,
and P1-2 will be energized as stage 2 electric heat. See
Table 5 for staging options.
4. Mark the appropriate box of the electric heat model installed
on the additional serial plate on the exterior of the unit.
5. Turn on the power to the unit and the auxiliary
electric heat.

Figure 15: Power Wiring, Dual Circuits, 15 and 20kw

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Figure 16: Staging Jumpers
Staging Example on a 15kW unit W1 (first stage) has
5kW (‘ER1’ 5kW & ‘ER4’ 0kW) and W2 (second stage)
will have 10kW (‘ER2 & 3’ 5kW each)

Auxiliary Electric Heat Start-up
Put thermostat in emergency heat mode (or jumper thermostat
input R to W and R to G) and set point to high setting. Unit will
require 15-20 seconds before engaging emergency heat mode
stage 1 (W1) and then another 15-20 seconds to engage stage 2
(W2) when in ‘Test mode’. Verify proper electric heat operation.

blank
W1
W2 24V

Tan
Ora

AG Electric Heat
HG

Relay Board

P1
4 3 2 1

Low Voltage Connector
(from Unit Control Board)
ER4
Com

Factory Staging
(see Table 2)

ER3
Com

ER2
Com

Side View as seen in Control Box

ER1
Com
NO

Tan
Ora
P1

P2
4 3 2 1

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

7.2

32700 24600

1300

HGL15C

14.4

10.8

49100 36900

1350

HGL20C

19.2

14.4

65500 49200

1350

Black area denotes compatibility
Note: Horizontal units rated for zero clearance unit and 1” clearance for
the first three feet of duct, Vertical units rated for zero clearance for both
unit and duct.

Table 5: HG Electric Heat Staging Options
Staging in kW
Jumper 1-3, 2-4†
Stage 1
Stage 2

Auxiliary Electric
Heat Model

Staging
Options

Factory
Settings
Stage 1

HGM4C

HGM5C

HGM8C

4 or 8

HGM10C

5 or 10

HGL10C

5 or 10

HGL15C

5, 10 or 15

HGL20C

5, 10, 15 or 20

Jumper 1-4, 2-3†
Stage 1
Stage 2

Jumper 1-2-3
Stage 1
Stage 2

† Factory jumper setting

Table 6: HG Electric Heat Electrical Data
Unit Model

Maximum Breaker
Size

Head Kit
Model

Supply

Heater
Amps
240

Heater
Amps
208

Blower
FLA

240 V

208 V

240 V

208 V

HGM4C

SINGLE

15.8

4.3

HGM 5C

SINGLE

17.3

4.3

HGM 8C

SINGLE

31.7

27.5

4.3

Minimum Circuit Amps

024

036

HGM 10C

SINGLE

34.7

4.3

HGL10C

SINGLE

34.7

4.3

HGL15C

DUAL L1/L2

34.7

L3/L4

17.3

4.3

HGL10C

SINGLE

34.7

7.0

HGL15C

DUAL L1/L2

34.7

0.0

L3/L4

17.3

7.0

DUAL L1/L2

34.7

0.0

L3/L4

34.7

7.0

048 and 060
HGL20C

All heaters rated single phase 208-240V 60Hz
All models 15kW or larger feature internal circuit breakers

All Fuses UL Class K general purpose

Installation, Operation & Maintenance

WDG AIR HANDLER SERIES

Heat Controller, LLC

Unit & System Checkout
❑

WARNING!

❑
❑

WARNING! Electrical shock hazard - Lock unit disconnect
switch in open position before servicing unit. Failure
to follow this warning could result in property damage,
personal injury, or death.

❑
❑

After installation has been completed, it is recommended that the
Air Handler be checked against the following checklist:
CHECKOUT PROCEDURE
❑
Power: Make sure power is “OFF” at power disconnect
switch.
❑
Field Wiring: Check all field wiring for tight connections.
See that grounding of unit is in accord with code
❑
Unit Suspension: Make sure unit suspension (if used)
is secure and that there are no tools or loose debris in,
around or on top of the unit.
❑
Ducts: Check all duct outlets; they must be open and
unrestricted.

❑

Drain Lines: Check drain lines and be sure all joints are
tight.
Drain Pan: Make sure secondary drain pan is installed.
Power Supply: Check power supply for correct
requirements per unit nameplate.
Filters: Check filters for proper size. Inform owner of
proper procedure for removal and reinstallation.
Operation: Energize the system and carefully observe
its operation; make any necessary adjustment.
Procedure: Instruct owner, engineer (if possible) on
proper operating procedure and leave Use and Care
Manual with owner.

MAINTENANCE

WARNING!

Indoor Coil - Drain Pipe - Drain Line
Inspect the indoor coil once each year for cleanliness and clean
as necessary. In some cases, it may be necessary to remove the
filter and check the return side of the coil with
a mirror and flashlight.

WARNING! These instructions are intended as
an aid to qualified licensed service personnel for
proper installation, adjustment and operation of
this unit. Read these instructions thoroughly before
attempting installation or operation. Failure to follow
these instructions may result in improper installation,
adjustment, service or maintenance possibly resulting in
property damage, personal injury or death.

IMPORTANT: Do not use caustic household drain cleaners
or bleach in the condensate pan or near the indoor coil. Drain
cleaners will quickly damage the indoor coil.

For continuing high performance and to minimize possible
equipment failure, it is essential that annual maintenance be
performed on this equipment. Consult your local dealer as to the
availability of a maintenance contract.
Air Filter
Check the system filter every ninety days or as often as found to
be necessary and if obstructed, clean or replace at once.
IMPORTANT: Do not operate the system without a filter in place.

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.

*97B0101N03*
97B0101N03
6/17/13

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Heat Controller Geothermal Air Handler Quick Start Guide IOM

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