INSTALLATION INSTRUCTION ELECTRIC HEAT ACCESSORY 20, 30 & 40 kw for 15 Ton Split System Air Conditioners Models: LB180 & LL-15 CONTENTS GENERAL...2 NOTES, CAUTIONS AND WARNINGS........... 2 REFERENCE...2 INSTALLATION...3 ELECTRICALCOMPONENTS... 5 START-UP...5 MAINTENANCE.......5 FIGURES HEATERINSTALLATION...2 FIELDWIRING...6 CONTROL BOX AND HARNESS SUPPORT..... 7 HEATERDIMENSIONS...7 TRANSFORMERWIRING...8 TABLES HEATERCAPACITY...3 TERMINALCONNECTIONS...5 AUTOMATICRESETS...5 HEATERDIMENSIONS...8 2HFHEATERPARTS...9 2HGHEATERPARTS...9 CAUTION: SAVE THIS MANUAL READ ALL SAFETY GUIDES BEFORE YOU START TO INSTALL YOUR FURNACE. 035-18546-000-A-0102
GENERAL This instruction covers the installation and operation of these electric heat accessories. Every electric heat accessory is shipped in two parts, (1) 2HF Model Heater and (1) 2HG Model Heater. The heaters are shipped completely assembled and pre-wired with all of the power and control wiring that will be required to interconnect them with the basic unit. However, the basic LB180/LL-15 unit control transformer is not sized to handle the amp draw of the electric heat accessory controls. Therefore, the 2HF Model Heater contains a 150 VA transformer in addition to fuse holders, fuses and all connection wiring. Refer to Table 1 for accessory model numbers and for capacity ratings based on the voltage of the power supply and the mode of operation. Theseelectricheaterscanbeinstalledoneitherverticalor horizontal units supplied with ductwork. Note: The Electric Heat Accessory is not ETL approved on freestanding units equipped with a Supply Air Plenum Accessory. Split-system units equipped with an electric heat accessory will require only one power supply for both the heater elements and the supply air blower motor. Refer to Figures 1 and 4 for the locations of both the power and the control wire access openings and to the following instructions for routing and connecting the wires. When an indoor unit is equipped with electric heat, provide at least 1 Inch clearance to combustible material around heater cabinet, supply air plenum and supply air ducts up to 3 feet from unit. NOTES, CAUTIONS AND WARNINGS Installer should pay particular attention to the words: NOTE, CAUTION, andwarning. Notesare intended to clarify or make the installation easier. Cautions are given to prevent equipment damage. Warnings are given to alert installer that personal injury and/or equipment damage may result if installation procedure is not followed correctly. REFERENCE Refer to the indoor section instructions for additional information on the installation of the basic unit, for the application limitations of the total system and for the minimum clearance requirements of the indoor unit. FIGURE 1 : HEATER INSTALLATION Unitary Products Group 2
TABLE 1: HEATER CAPACITY HEATER MODEL HEATING CAPACITY 1 HEATER RATING CONTROL BOXSIDE 1ST. STAGE OPPOSITE CONTROL BOX SIDE 2ND. STAGE POWER SUPPLY 1ST. STAGE KW 2ND. STAGE KW 20 kw 2HF04501025 2HG04501025 208-3-60 7.5 7.5 230-3-60 10 10 2HF04501046 2HG04501046 460-3-60 10 10 30 kw 2HF04502025 2HG04501025 208-3-60 15 7.5 230-3-60 20 10 2HF04502046 2HG04501046 460-3-60 20 10 40 kw 2HF04502025 2HG04502025 208-3-60 15 15 230-3-60 20 20 2HF04502046 2HG04502046 460-3-60 20 20 1. Capacity ratings do not include heat generated by the supply air blower. INSTALLATION WARNING If the unit is connected to power sources, make sure that all electrical power to the unit has been disconnected prior to installation Install these electric heat accessories per the following step-by-step procedures and the illustrations shown in Figures 1 and 2. 1. Remove the electrical heat accessories from their shipping containers. 2. Remove the control box access panels from the heater cabinets. 3. Remove both end access panels of the indoor unit blower section. 4. Remove the cover from the indoor unit electrical control box. 5. Remove the two 1 knockouts from the top of the indoor unit. See Figure 1 for their location. These knockouts are located in the top panel on both sides of the unit. 6. Remove the 3/4 knockout from the bottom of the 2HF heater cabinet. 7. Remove the four #10 x ½ screws from the top of the indoor unit. Two each located adjacent to the outside edge of both Air Supply Duct Flanges. See Figure 1 for their location.. 8. Set the 2HF heater cabinet on top of the unit as shown in Figure1. 9. Position the heater so that: The duct flanges around the unit s supply air opening fit into the heater opening. The 3/4 knockout hole in the bottom of the heater control box aligns with the 1 knockout removed per step 5. The two slotted screw holes in the bottom of the heater control box align with the two holes on the top of the indoor unit, where screws were removed per step 7. 10. Secure the heater to the unit at the holes aligned per step 9 using the two #10 x ½ screws previously removed from the top panel per step 7. See Figure 1. 11. Drill three 5/32 holes through the top of the unit using, as a template, the holes in the ¾ mounting flange located on the opposite end of the electric heater. See Figure 1. 12. Secure the heater to the unit at these locations using the three remaining #10 x ½ screws provided with the accessory. 13. Insert snap bushing into the 3/4 knockout hole, removed per step 6, and through the 1 knockout removed from the top of unit per step 5. 14. Route the heater wiring harness through the snap bushing. 15. Repeat steps 7 14 for the mounting of the 2HG heater cabinet. This heater is mounted opposite the control box of the indoor unit. See Figure 1. 3 UnitaryProductsGroup
16. Insert the 3/4 snap bushing, provided with the accessory, in the side panel of the indoor unit electrical control box.seefigure3. 17. Route line voltage wires 724/R, 725/R and 726/R of the 2HF heater wiring harness through the bushing installed per step 16. Connect 724/R to Terminal L1 on Contactor (M1). Contactor (M1) is located in the indoor unit control box. Connect 725/R to Terminal L2 on Contactor (M1). Connect 726/R to Terminal L3 on Contactor (M1). Secure this harness to the support angles with wire ty-raps (provided). 18. Route control voltage wires 801/R, 804/BK, 806/BL and 811/BK of the 2HF heater wiring harness through the bushing installed per step 16. Connect 801/R to Terminal W1 on Terminal Block (TB1). Connect 804/BK to Terminal HC on Terminal Block (TB1). Connect 806/BL to Terminal C on Terminal Block (TB1) Connect 811/BK to Terminal HR on Terminal Block (TB1) Secure this harness to the support angles with wire ty-raps (provided). 19. Route line voltage wires 735/R, 736/R and 737/R of the 2HG heater wiring harness through the snap bushing on the bottom of the 2HF heater control box. Connect 735/R to Terminal L1 on Terminal Block (TB10). Connect 736/R to Terminal L2 on Terminal Block (TB10). Connect 737/R to Terminal L3 on Terminal Block (TB10). Secure this harness to the support angles with wire ty-raps (provided). 20. Route control voltage wires 830/W, 833/BK, 835/BL and 836/BK of the 2HG heater wiring harness through the bushing installed per step 16. Connect 830/W to Terminal W2 on Terminal Block (TB1). Connect 833/BK to Terminal HC on Terminal Block (TB1). Connect 835/BL to Terminal C on Terminal Block (TB1) Connect 836/BK to Terminal HR on Terminal Block (TB1) Secure this harness to the support angles with wire ty-raps (provided). 21. Place new terminal label (provided in kit) over old terminal label in the indoor unit control box. 22. Remove existing 75 VA Transformer (T1) from the indoor unit control box. 23. Install new 150 VA Transformer (T1) (provided) in the indoor unit control box, with screws removed from step 21. Mounting holes are pre-punched in the control panel at the position marked Transformer (T1) as shown on the unit connection diagram. 24. Install Transformer (T1) Fuse Holders and Fuses (FU1/ FU2/FU3) in the indoor unit control box (with screws provided). Mounting holes are pre-punched in the control panel at the position marked Optional Fuses (FU1/FU2/ FU3) as shown on the unit connection diagram. 25. Wire new Transformer (T1) and Fuse Holders (FU1/FU2/ FU3) to Figure 5 as follows: Connect wire 105/BL to the Common Primary Terminal on Transformer (T1). Connect wire 104/BK to the appropriate Primary Terminal on Transformer (T1) for the Supply Voltage of the unit. Connect wire 204/BR to one of the 24 Volt Secondary Terminals of Transformer (T1). Connect wire 206/RD to the other 24 Volt Secondary Terminal of Transformer (T1). Remove end of existing wire 104/BK from Terminal L1 on Contactor (M1) and connect it to Fuse (FU1). Connect wire 750/BK from Terminal L1 on Contactor (M1) to Fuse (FU1). Remove end of existing wire 105/BL from Terminal L2 on Contactor (M1) and connect it to Fuse (FU2). Connect wire 751/BL from Terminal L2 on Contactor (M1) to Fuse (FU2). Remove end of existing wire 206/RD from 3 amp. Circuit Breaker (CB1) and connect it to Fuse (FU3). Remove end of existing wire 205/RD from 3 amp. Circuit Breaker (CB1) and connect it to Fuse (FU3). Remove end of existing wire 205/RD from Terminal 7 on Blower Relay (BR1) and connect it to Terminal HR on Terminal Block (TB1). Remove end of existing wire 204/BR from Contactor (M1) Holding Coil and connect it to Terminal HC on Terminal Block (TB1). Connect wire 850/BR from Contactor (M1) Holding Coil to Terminal HC on Terminal Block (TB1). Unitary Products Group 4
Connect wire 851/RD from Terminal 7 on Blower Relay (BR1) to Terminal HR on Terminal Block (TB1). Note: All field wiring must follow all city, local and / or national codes in effect at time of installation of this heater. 26. Use knockout (provided) on the back of 2HF heater for field supplied main power conduit. See Figure 4. Route power wiring into 2HF heater control box, and connect the power and ground wires to the Terminal Block (TB10) and ground lug as shown on the 2HF heater wiring diagram. 27. Use 7/8 knockout (provided) on top of unit for field supplied control-wiring conduit. See Figure 1 for its location. Connect control wiring as shown in Figure 2. 28. Make sure all electrical connections are tight. 29. Replace all panels and control box covers. The indoor unit electrical control box cover. Both end access panels of the indoor blower section. Both heater control box access panels. TABLE 2: TERMINAL CONNECTIONS 2HF Heater kw Terminal Designation on TB1 2HG Heater Terminal Designation on TB1 C W1 HR HC kw C W2 HR HC 10 806/BL 801/R 811/BK 804/BK 10 835/BL 830/W 836/BK 833/BK 20 806/BL 801/R 811/BK 804/BK 20 835/BL 830/W 836/BK 833/BK ELECTRICAL COMPONENTS These electric heat accessories include staging relays, contactors and two high limit controls (1 LC and 2 LC). On a call for heat the staging relay is energized through the system thermostat. The staging relay contacts close, energizing the heater contactor. The heater contactor contacts close energizing the heater element. The high limit controls are in series with the staging relay contacts to prevent the electric heat accessory from operating at an excessive temperature. They will open and reset automatically at the temperatures listed below. Open the main disconnect switch before servicing the heating accessory. TABLE 3: AUTOMATIC RESETS HIGH LIMIT CONTROL WARNING LOCATION 2HF & 2HG OPENS CLOSES 1LC Entering 130 0 F 80 0 F 2LC Leaving 130 0 F 80 0 F START-UP Make sure that all electrical connections are tight before closing the disconnect switch to the indoor unit. Close the disconnect switch and check the operation of each heating stage. Check the total unit CFM in accordance with the basic unit instruction as referenced on page 2. De-energize the electric heat accessory after it has been operating for several hours, and recheck all of the electrical connections for tightness. MAINTENANCE CAUTION Failure to properly adjust the supply air CFM could cause nuisance tripping of the high limit controls. Although these electric heat accessories do not require any specified maintenance, the factory recommends a semiannual inspection of all components to see if they are functioning properly. Check all unit filters for dirt accumulation. Dirty filters will restrict air flow and could cause nuisance tripping of the high limit controls. Filters must be changed as often as necessary to assure good air flow and filtering action. 5 UnitaryProductsGroup
FIGURE 2 : FIELD WIRING Unitary Products Group 6
FIGURE 3 : CONTROL BOX AND HARNESS SUPPORT FIGURE 4 : HEATER DIMENSIONS 7 UnitaryProductsGroup
TABLE 4: HEATER DIMENSIONS HEATER MODEL 1 NOM. KW HEATER DIMENSIONS (INCHES) A B C D E F G H K L M 2HF04501025, 46 10 2HF04502025, 46 20 2HG04501025, 46 10 27-1/4 25-1/4 13 1 4 1/2 5 1/2 1 1/2 1 1/2 22-1/4 19-1/4 2HG04502025, 46 20 1. The 2HF heaters are installed on the drive side of the Indoor unit. The 2HG heaters are installed on the opposite end. FIGURE 5 : 150 VA TRANSFORMER WIRING Unitary Products Group 8
TABLE 5: 2HF HEATER PARTS ITEM QTY. PART NO. DESCRIPTION 1* 1ea 025-37378-000 1ea 025-37378-002 (T1) Transformer, 150 VA 208/230 Volt. (T1) Transformer, 150 VA 460 Volt. 2 2ea 025-17407-000 Transformer Pri. Fuse Holder 3 2ea 025-23183-000 Transformer Pri. Fuse 4 1ea 025-13991-000 Transformer Sec. Fuse Holder 5 1ea 025-37488-000 Transformer Sec. Fuse 6 4ea 021-15513-000 Screw, PNH #6-32 X.5 7 2ea 021-15515-000 Screw, PNH #8-32 X.5 8 6ea 021-15525-000 Screw, Hex #10 X.5 9 2ea 025-22674-000 Bushing, Snap 10 1ea 035-18566-000 Terminal Label 11 6ea 025-09607-000 Cable Strap 12 1ea 750/BK Wire 13 1ea 751/BL Wire 14 1ea 850/BR Wire 15 1ea 851/R Wire From Terminal L1 on (M1) Contactor to Fuse (FU1) From Terminal L2 on (M1) Contactor to Fuse (FU2) From (M1) Contactor Holding Coil to Terminal (HC) on Terminal Block (TB1) From Terminal (7) on Blower Relay (BR1) to Terminal (HR) on Terminal Block (TB1) *Depends on Primary Voltage of heater ordered. TABLE 6: 2HG HEATER PARTS ITEM QTY. PART NO. DESCRIPTION 1 3ea 021-15525-000 Screw, Hex #10 X.5 2 1ea 025-22674-000 Bushing, Snap 3 6ea 025-09607-000 Cable Strap 9 UnitaryProductsGroup
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Subject to change without notice. Printed in U.S.A. Copyright by Unitary Products Group 1999. All rights reserved. Supersedes: Nothing 035-18546-000-A-0102 Unitary 5005 Interstate Norman Product Drive OK Group North 73069