12
Electric Heater Kits Installation in Standard and Variable Speed Indoor Air Handlers H6HK Series Installation Instructions IMPORTANT: The instructions included with this heater kit are for installations in air handlers only. These instructions are primarily intended to assist qualified individuals experienced in the proper installation of heating and/or air condi- tioning appliances. Some local codes require licensed installation/service personnel for this type of equipment. All installations must be in accordance with these instructions and with all applicable national and local codes and standards. Before beginning the installation, read these in- structions thoroughly and follow all warnings and cautions in the instructions and on the unit. Improper installation, service, adjustment, or maintenance can cause explosion, fire, electri- cal shock, or other conditions which may result in personal injury or property damage. Unless otherwise noted in these instructions, only fac- tory authorized kits or accessories may be used when modifying this product. INTRODUCTION The H6HK Series of electric heater kits are approved for field installation in B5 air handlers and variable speed air handlers. All sizes are available with factory-provided circuit-breakers for short circuit protection and to provide a disconnecting means. Also available are 5, 8, and 10 kw electric heater kits without circuit-breakers. Refer to the National Electric Code (ANSI/NFPA 70) and applicable local codes for over-current protection and disconnect requirements. Note: The 20, 25, and 30 kw electric heater kits are Not Approved for installation in A-cabinet air handlers. Reference Table 2 for all Heater Kit applications. Note: These instructions are written assuming the air handler is in the upflow position (with the outlet facing up). For horizontal and downflow applications, it is recommended that the electric heater kit be installed prior to installation of the air handler.

708514-B H6HK Electric Heat kit

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Page 1: 708514-B H6HK Electric Heat kit

Electric Heater KitsInstallation in Standard and Variable Speed Indoor Air Handlers

H6HK Series

Installation Instructions

IMPORTANT:The instructions included with this heater kit are for installations in air handlers only.

These instructions are primarily intended to assist qualifi ed individuals experienced in the proper installation of heating and/or air condi-tioning appliances. Some local codes require licensed installation/service personnel for this type of equipment. All installations must be in accordance with these instructions and with all applicable national and local codes and standards.

Before beginning the installation, read these in-structions thoroughly and follow all warnings and cautions in the instructions and on the unit.

Improper installation, service, adjustment, or maintenance can cause explosion, fi re, electri-cal shock, or other conditions which may result in personal injury or property damage. Unless

otherwise noted in these instructions, only fac-tory authorized kits or accessories may be used when modifying this product.

INTRODUCTIONThe H6HK Series of electric heater kits are approved for fi eld installation in B5 air handlers and variable speed air handlers. All sizes are available with factory-provided circuit-breakers for short circuit protection and to provide a disconnecting means. Also available are 5, 8, and 10 kw electric heater kits without circuit-breakers. Refer to the National Electric Code (ANSI/NFPA 70) and applicable local codes for over-current protection and disconnect requirements.

Note: The 20, 25, and 30 kw electric heater kits are Not Approved for installation in A-cabinet air handlers. Reference Table 2 for all Heater Kit applications.

Note: These instructions are written assuming the air handler is in the upfl ow position (with the outlet facing up). For horizontal and downfl ow applications, it is recommended that the electric heater kit be installed prior to installation of the air handler.

Page 2: 708514-B H6HK Electric Heat kit

2

WARNING:To avoid the risk of electric shock, personal injury, or death, disconnect all electrical power to the unit before performing any maintenance or service. The unit may have more than one electrical power supply.

AIR HANDLER ELECTRICAL SUPPLYAll wiring must be in compliance with the National Electric Code and applicable local codes.

If the air handler was previously installed without electric heat the existing supply wiring may not be suffi cient to carry the increased load. If installing electric heat in the B5 air handler the supply wiring can be aluminum or copper since the circuit breakers and terminal blocks supplied are approved for either wire type. Be sure to follow all of the rating information on the circuit breaker or terminal block and ensure that the supply wiring is sized according to the current NEC codes and any other state or local codes. See the rating label or Table 1 for minimum circuit ampacities and maximum overcurrent protection.

All electric heater kits of 10 kw or less are supplied from the factory confi gured for use with a single supply circuit. Electric heater kits greater than 10 kw are supplied from the factory confi gured for use with two supply circuits. See the ratings label or Table 1 for individual circuit ampacities and over-current protection ratings. If a single supply is desired, accessory kit #913874 is required to convert to single circuit connection.

INSTALLATIONRemove the upper access door from the air handler. Remove the circuit breaker bracket and cover package from the heater kit.

Remove the top-most element Close-off Plate from the back of the air handler control box. For two-tiered electric heater kits remove both Close-off Plates. For three-tiered electric heater kits remove all three Close-off Plates.

Installation into Air Handler, All Heater Kits Insert the element assembly into the opening in the air handler control box being careful not to damage the element wire or the ceramic element supports. Heating element alignment rod(s) will slide into alignment holes in the back of the air handler element box. Secure the element assembly to the back of the air handler control box with the screws removed when removing the element close-off plate(s).

For 25 kw and 30 kw Heater Kits, attach the Auxiliary circuit board bracket to the lower right side of the installed Heater Kit Assembly with two screws that were removed from the element close-off plate(s). Snap on the Auxiliary circuit board as shown below.

Figure 1. Sample Installation.

Shown without access door.

Note: on some units a shipping bracket must be removed before installing the circuit breaker bracket.

Install the circuit-breaker bracket (See Figure 1). Connect the 2-Pin Power plug from the element assembly into the unit's 2-Pin power plug. Connect the 7-Pin Harness from the element assembly to the unit's circuit board. For 25 kw and 30 kw Heater Kits, also attach the 4-Pin and 3-Pin Harnesses to the Auxiliary circuit board.

Page 3: 708514-B H6HK Electric Heat kit

3

Table 1. Electrical Ratings

A wiring diagram and a ratings label are supplied with the electric heater kit. Attach the wiring diagram to the Blower Housing.

When installing the electric heater kit into a stan-dard air handler, attach the rating label (included with the electric heater kit) on the air handler unit data label (located on the lower access door) over the electrical data section.

When installing the electric heater kit into a vari-able speed air handler the rating label supplied with the kit will not be used. Check the appropri-ate block on the air handler additional ratings label located on the lower access door.

WARNING:To avoid risk of electric shock, personal injury, or death, disconnect electrical power to the unit before performing any maintenance or service. The unit may have more than one electric power supply.

Standard Air Handler (A & B size) Variable Speed & Std Air Handler (C size)

Circuit Circuit Circuit Single Circuit Circuit Circuit Single Circuit Circuit Circuit Single Circuit Circuit Circuit Single

A B C Circuit A B C Circuit A B C Circuit A B C Circuit

005H-XX 240 4.8 - - - 30 - - - 30 - - - 34 - - - 40

008H-XX 240 7.5 - - - 45 - - - 50 - - - 48 - - - 50

010H-XX 240 9.6 - - - 55 - - - 60 - - - 59 - - - 60

015H-XX 240 14.4 55 25 - 80 60 30 - 90 59 25 - 83 60 30 - 90

020H-XX 240 19.2 55 50 - 105 60 60 - 125 59 50 - 109 60 60 - 125

025H-XX 240 24.0 - - - - - - - - 59 50 25 134 60 60 30 150

030H-XX 240 28.8 - - - - - - - - 59 50 50 159 60 60 60 175

005H-XX 208 3.6 - - - 27 - - - 30 - - - 30 - - - 40

008H-XX 208 5.6 - - - 39 - - - 40 - - - 42 - - - 50

010H-XX 208 7.2 - - - 48 - - - 50 - - - 52 - - - 60

015H-XX 208 10.8 48 21 - 70 50 25 - 80 52 22 - 73 60 25 - 80

020H-XX 208 14.4 48 43 - 92 50 50 - 100 52 43 - 95 60 50 - 100

025H-XX 208 18.0 - - - - - - - - 52 43 22 117 60 50 25 125

030H-XX 208 21.6 - - - - - - - - 52 43 43 138 60 50 50 150

009Q-XX 240 9.0 - - - 32 - - - 40 - - - 36 - - - 40

015Q-XX 240 14.4 - - - 48 - - - 50 - - - 52 - - - 60

009Q-XX 208 6.8 - - - 29 - - - 30 - - - 32 - - - 40

015Q-XX 208 10.8 - - - 43 - - - 50 - - - 46 - - - 50

Max. Over-Min. Circuit Ampacity

Max. Over-Current Protection

Min. Circuit Ampacity

Model Number H6HK- Voltage KW

Current Protection

Electric Heater Kits without Circuit Breakers —Attach the supplied power terminal block to the circuit-breaker bracket with the supplied screws as shown in Figure 2.

Using the 1/4" terminals, connect the red supply wire(s) from the element assembly to one pole of the terminal block and connect the black wires to the other pole.

Figure 2. Circuit Breaker Brackets. Shown with Line Cover Removed and Terminal Block Installed.

Page 4: 708514-B H6HK Electric Heat kit

4

is required by code in order to protect installers from the line/supply wiring. The line cover should be installed as shown in Figure 4.

5, 8, and 10 kw electric heater kits supplied with a circuit breaker.

Snap the circuit breaker on to the circuit breaker bracket as shown in Figure 5. The orientation of the circuit breaker must be as shown. (Side with 1/4" terminals to the right).

Remove the lower circuit breaker knockout from the air handler upper access door.

15, 20, 25, and 30 kw electric heater kits sup-plied with circuit breakers.

Snap the circuit breakers on to the circuit breaker bracket as shown in Figure 5. The orientation of the circuit breakers must be as shown in Figure 1. (Side with 1/4" terminals to the right).

The heavy red and black supply leads are bundled by circuit with wire ties at the factory. The bundle coming from the top element tier is circuit “A” (note: the element assembly is right-side-up when the limits are on the right side). The bundle coming from the second element tier is circuit “B”. The bundle coming from the bottom element tier is circuit "C".

Remove all necessary circuit breaker knockouts in the air handler upper access door.

3-Phase 9 and 15 kw electric heater kits sup-plied with a circuit breaker.

Figure 5. Installation of Circuit Breakers

Electric Heater Kits with Circuit Breakers —NOTE : Circuit breakers supplied with the H6HK electric heater kits are for short-circuit protection of the internal wiring and to serve as a unit disconnect. Circuit breakers supplied with the H6HK electric heater kits do not provide over-current protection of the supply wiring. Over-current protection of the supply wiring must be provided at the distribution panel and sized as shown in Table 1 or on the unit data label and per the NEC and applicable local codes. In some cases the over-current protection specifi ed in Table 1 or on the unit data label is less than the 60 amp rating of the circuit breakers used in the H6HK electric heater kits. This is because the function of the over-current protection required at the distribution panel (field supplied) and the function of the circuit breakers in the H6HK electric heater kit is different.

Heater Kits with circuit breakers are supplied with a line cover shown in Figure 3. The line cover

Figure 3. Line Cover

Figure 4. Line Cover Installed

Page 5: 708514-B H6HK Electric Heat kit

5

Snap the 3-pole circuit breaker on to the circuit breaker bracket as shown in Figure 5. The ori-entation of the circuit breaker must be as shown. (Side with 1/4" terminals to the right).

Remove all circuit breaker knockouts in the air handler upper access door.

STAGINGAll Single-phase heater kits are internally staged using the B5 Air Handler Circuit Board logic. Reference B5 Air Handler Installation Instruc-tions for "slow" or "fast" staging options. All Three-phase heater kits are not equipped for internal staging.

POWER WIRINGAll wiring must comply with the current revision of the National Electric Code and must be sized for the minimum ampacities as listed on the unit data label or in Table 1.

If a single circuit adaptor kit is used it may need to be re-confi gured for some applications. Remove the single circuit adaptor kit cover and verify that the lugs are confi gured correctly for the application. If the lugs are not confi gured for the application, reference the instructions included with the ki t and modify the confi guration. Install the single circuit adaptor kit (if used) in the line side (“on” end) of the circuit breakers. Tighten the lugs securely (45 in-lbs recommended).

Connect the supply wiring to the circuit breaker(s), single circuit adaptor kit, or terminal block. Tighten the lugs securely.

When using multiple supply circuits verify that the supply sized for circuit “A” is connected to the circuit breaker that is connected to the top element assembly.

Install metal circuit breaker line cover on the left side of the circuit breaker to cover the sup-ply wires.

Note; on 3-phase heater kit installations after the air handler door has been attached to the unit, install the circuit breaker close-off to the opening in the door just above the circuit breaker.

MOTOR SPEED SELECTIONStandard Air Handlers — The blower speed is preset at the factory for operation at the same speed for heating and cooling, by using the blower motor jumpering terminal on the blower motor and connecting it to the desired speed with both the red and black wires connected to the jumpering terminal. For optimum system performance and comfort, it may be necessary to change the factory set speed. To change the blower speed, disconnect all electrical power to the unit and remove the upper door. Remove the black and red wires from the blower motor jumpering terminal. Discard the blower motor jumpering terminal.

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. On standard 3 speed motors terminal 4 = Hi speed, terminal 5 = Med speed and terminal 6 = Low speed. Standard C cabinet units are equipped with 5 selectable blower speeds. Termi-nal 1=Low speed, terminal 2=Medium Low speed, terminal 3=Medium speed, terminal 4=Medium Hi speed and terminal 5=Hi speed.

IMPORTANT: After making any changes to the blower speed setting be sure to bundle and insulate any unused blower motor leads so that they will not come in contact with the air handler cabinet or non-insulated live parts.

High speed operation may be required when using a 20, 25, and 30 kw electric heater kit in a downfl ow application. (See Clearance section.)

Replace the upper door and secure it to the unit. Restore power to the unit.

Variable Speed Air Handlers — The minimum electric heat airfl ow is selected by setting switches on the air handler circuit board. Selecting the minimum electric heat airfl ow sets the minimum air fl ow that will be produced whenever electric heater kits are energized. When the electric heater kits are energized along with a heat pump the airfl ow may be higher depending on the basic cooling/heat-pump airfl ow setting. Reference the variable speed air handler installation instructions for further details.

Page 6: 708514-B H6HK Electric Heat kit

6

Table 2. Blower Heating Speed

MODEL IDENTIFICATION

Product TypeH - Heater

Generation6 - Sixth Series

Product Identifi erHK - Heater Kit

H6 H K - 020 H - 2 1

Staging

Circuit Breakers

Electrical CodeH : 240 - 1 - 60 Q : 208/240 - 3 - 60

Primary Capacity005 - 5kw 009 - 9kw 015 - 15kw 025 - 25kw008 - 8kw 010 - 10kw 020 - 20kw 030 - 30kw

(1) Only on *30 (2.5 Ton) model air handlers

Model H6HK

Applicable Cabinet SizeMinimum Required Blower

Heating SpeedA B C Up-Flow Horizontal Down-Flow

005H X X X LOW LOW LOW008H X X X LOW LOW LOW010H X X X LOW LOW LOW015H X X X LOW LOW MED020H X X LOW LOW HIGH025H X X MED MED HIGH030H X MED MED N/A009Q X X LOW LOW LOW015Q X X LOW LOW MED

(1)*

CLEARANCEStandard Air Handlers — All electric heater kits less than 20 kw are approved for use in air handler installations with zero-clearance to combustibles at any blower speed. For horizontal and upfl ow confi guration, air handlers equipped with 20, 25, and 30 kw electric heater kits are approved for installation with zero clearance to combustibles at any blower speed. When using a 20, 25 kw electric heat kit in a downfl ow installation, the blower MUST be set for high speed for both heating and cooling.

Variable Speed Air Handlers — All installations of H6HK electric heater kits in variable speed air handlers are approved for zero-clearance to combustibles when the minimum electric heat airfl ow is set as directed in these instructions.

Page 7: 708514-B H6HK Electric Heat kit

7

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Page 8: 708514-B H6HK Electric Heat kit

8

Figure 5. Typical System Wiring DiagramH6HK, 8/10 kw 1-stage with circuit breaker

GREY

GR

EY

BL

UE

OR

AN

GE

1 2 3 4 5 6 7

POWER

LIMIT

RED

RE

D

RE

D

BL

AC

K

BL

AC

K

RE

D

BL

AC

K

RELAY

RELAY

TERMINALBLOCK(for selectmodels only)

CIRCUITBREAKER

Legend

Field Wiring

Factory Wiring:Low Voltage

High Voltage

NOTES

1) If any of the original wire supplied with this unit must be replaced, it must be replaced with wiring material of the same gauge size and temperature rating.2) The installation of this heater kit may require a change in the blower speed tap connection. See Installation Instructions for details.3) Use copper conductors with a minimum temperature rating of 60°C for supply connections.

ELEMENT

BLACK

BLACKELEMENT

RED

710561A

Figure 4. Typical System Wiring DiagramH6HK, 5 kw 1-stage with circuit breaker

TERMINALBLOCK(for selectmodels only)

CIRCUITBREAKER(Circuit breakermodels only)

Legend

Field WiringFactory Wiring:

Low VoltageHigh Voltage

RELAY

GR

EY

OR

AN

GE

BL

AC

K

RE

D

RE

D

LIMIT

POWER

BLACK1 2 3 4 5 6 7

NOTES

1) If any of the original wire supplied with this unit must be replaced, it must be replaced with wiring material of the same gauge size and temperature rating.2) The installation of this heater kit may require a change in the blower speed tap connection. See Installation Instructions for details.3) Use copper conductors with a minimum temperature rating of 60°C for supply connections.

BLACK REDELEMENT

710560A

Page 9: 708514-B H6HK Electric Heat kit

9

Figure 7. Typical System Wiring Diagram20 kw 1-stage with circuit breakers

POWER

Legend

Field WiringFactory Wiring:

Low VoltageHigh Voltage

NOTES

1) If any of the original wire supplied with this unit must be replaced, it must be replaced with wiring material of the same gauge size and temperature rating.2) The installation of this heater kit may require a change in the blower speed tap connection. See Installation Instructions for details.3) Use copper conductors with a minimum temperature rating of 60°C for supply connections.

CIRCUIT BREAKERS

SUPPLY VOLTAGE GROUND

GREY

ORAN

GE

BLUE

YELL

OW

RELAY

RELAY

RELAY

ELEMENT LIMIT

BLAC

KBL

ACK

BLAC

K

RED

RED

BLACK

BLACK

BLACK

ELEMENT

ELEMENT

RED

RED

RED

RED

RELAY

BROW

N

ELEMENTBLACK

LIMIT

RED

RED

1 2 3 4 5 6 7

RED

BLAC

K

Figure 6. Typical System Wiring Diagram15 kw 1-stage with circuit breakers

CIRCUIT BREAKERS

SUPPLY VOLTAGE GROUND

1 2 3 4 5 6 7

POWER

GREY OR

ANGE BL

UEYE

LLOW

RELAY

RELAY

RELAY

ELEMENT LIMIT

LIMIT

RED

BLAC

KBL

ACK

Legend

Field WiringFactory Wiring:

Low VoltageHigh Voltage

BLAC

K

RED

RED

RED

BLACK

RED

BLACK

BLACK

BLACK

ELEMENT

ELEMENT

NOTES

1) If any of the original wire supplied with this unit must be replaced, it must be replaced with wiring material of the same gauge size and tempera-ture rating.

2) The installation of this heater kit may require a change in the blower speed tap connection. See Installation Instructions for details.

3) Use copper conductors with a minimum temperature rating of 60°C for supply connections.

RED

RED

710563A

710564A

Page 10: 708514-B H6HK Electric Heat kit

10

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710565A

Page 11: 708514-B H6HK Electric Heat kit

11

Fig

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inst

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r ki

t m

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th

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ith

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um

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f 60

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Y

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RED

RED

RED

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VIOLET

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K

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AC

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ENT

ELEM

ENT

ELEM

ENT

BL

AC

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AC

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AC

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AC

K

BL

AC

K

710566A

Page 12: 708514-B H6HK Electric Heat kit

Specifi cations and illustrations subject to change without notice and without incurring obligations.

Printed in U.S.A. (09/06)

708514B (Replaces 708514A)

INSTALLER: PLEASE LEAVE THESE INSTALLATION INSTRUCTIONS WITH THE HOMEOWNER

¢708514%¤708514B

CIR

CU

IT

BR

EA

KE

RS

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Inst

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s.2)

Dis

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7105670

Fig

ure

10.

Typ

ical

Sys

tem

Wir

ing

Dia

gra

m9k

w a

nd

15k

w 3

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ase

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hea

ter

kit