ACCESSORY KIT INSTALLATION INSTRUCTIONS

Transcription

1 ACCESSORY KIT INSTALLATION INSTRUCTIONS UAI-B-1009 Electric Heat Accessory 10, 16, 20, 26, 32, 36 & 52kW For Split-System R-410A Air Handling Units Both Air Conditioners and Heat Pumps 7-1/2, 10, 15 & 20 Tons GENERAL This instruction covers the installation and operation of these electric heat accessories. Every electric heat accessory is shipped completely assembled and pre-wired with all of the power and control wiring that will be required to interconnect this accessory with the basic unit. 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. All wiring connections should be made in accordance with the N.E.C. and C.E.C. These electric heaters can be installed on either vertical or horizontal units, on units with ductwork, or on free standing units equipped with a supply air plenum accessory. NOTE: Electric Heat is not CSA approved with the 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 Figure 1 for the locations of both the power and the control wire access openings and to the following instructions for routing and connecting the wires. All heat pump systems and all air conditioning systems with one of these electric heat accessories will require an electric heat compatible thermostat. NOTE: Heat pump systems with or without electric heat use the same thermostats. Air conditioning systems with one of these electric heat accessories will require a thermostat that can cycle the supply air blower motor with a call for heating as well as a call for cooling. When an indoor unit is equipped with an electric heater, provide at least 1-inch clearance to combustible material around heater cabinet, supply air plenum and supply air ducts up to 3 feet from the unit. REFERENCE Refer to one of the appropriate air handling unit 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 air handling unit. TABLE 1: HEATING CAPACITY Air Handling Unit Tonnage 7.5 and 10 Ton 15 Ton 20 Ton Heater Model Number Nominal Ratings With A/C Heating Capacity 1 Stage 1 Stage 2 Supplemental With Heat Pump Standby and Emergency kw kw kw kw kw 2HJ , HJ , HJ , HJ , HH , HH , HH , HH , HH , HH , HH , Capacity ratings do not include the heat generated by the supply blower motor. Johnson Controls Unitary Products

2 INSTALLATION FOR SPLIT SYSTEM AIR CONDITIONERS AND SPLIT-SYSTEM HEAT PUMPS 7-1/2, 10 & 15 TONS Install these electric heat accessories per the following step-- by--step procedures and the illustrations shown in Figures 1, 3, 4 and Remove the electric heat accessory from its shipping container. 2. Remove the control box access panel from the heater cabinet. 3. Install ¾" strain relief fitting in the center hole of the heater cabinet (See Figure 3). 4. Install foam gasket provided in the kit around the bottom of the heater cabinet (See Figure 4). 5. Remove air handler blower motor compartment access panel, for access to the control box and low voltage terminal block TB2. 6. Remove the knockouts from the top of the air handling unit. Refer to Figure 1 for locations. 7. Set the heater cabinet on top of the unit as shown in Figure Position the heater over the blower opening so that: a. The ¾" strain relief on the bottom of the heater control box fits into the 1 23/32" knockout in the center of the roof panel. b. The holes in the electric heater flanges align with the dimples on the top of the air handling unit. 9. Using the 22" long, 1 1/4" dia. conduit assembly, insert threaded end of 90º ell conduit fitting through 1 23/32" knockout in roof panel and 1 23/32" opening in control box of the heater. Thread nut on fitting loosely to retain fitting in place until heater assembly can be fastened to air handler roof. 10. Secure the heater to the unit at the holes aligned in the previous step using 12 drill screws provided with the accessory. 11. Tighten locknut on 90º ell conduit fitting. 12. Insert the straight 1 ¼" flex conduit fitting into back of air handler control box. Secure fitting in control box by tightening the locknut. 13. Connect wires from conduit attached at heater control box to fuse or breaker per heater wiring diagram. 14. Install terminal block TB1, relay EHR1 and if required relay EHR2 in the air handling unit control box at locations noted in Figure Connect wires from conduit attached at the air handler control box to terminal block TB1 per heater wiring diagram. 16. Connect line voltage wires (from field installed disconnect) to terminals L1, L2 and L3 of terminal block TB1 per heater wiring diagram. 17. Route the control voltage wires of the heater accessory through the ¾" strain relief in bottom of the electric heater to and through the ¾" strain relief on the back of the air handler control box. Connect control wires provided in the kit to air handler and electric heat control boxes as indicated on the electric heater wiring diagram. Secure wires to conduit with tie warps provided in kit. 18. Replace the control box access panels removed from the heater cabinet. 19. Replace blower motor compartment access panel removed from air handling unit. 20. Install properly sized duct work. FOR SPLIT SYSTEM AIR CONDITIONERS AND SPLIT-SYSTEM HEAT PUMPS 20 TONS Install these electric heat accessories per the following step by step procedures and the illustrations shown in Figures 2, 3, 4 and Remove the electric heat accessories from their shipping containers. 2. Remove the control box access panels from the heater cabinets. 3. Install ¾" strain relief fittings in the center holes of both heater cabinets (See Figure 3). 4. Install foam gaskets, provided in the kit (See Figure 4) on bottom of both heater cabinets. 5. Remove air handler blower motor compartment access panel, for access to the control box and low voltage terminal block TB2. 6. Remove blower section front access panels, filter side, to allow for installation of the second electric heater. 7. Remove the (4) knockouts from the top of the air handling unit. Refer to Figure 2 for locations. 2 Johnson Controls Unitary Products

3 8. Remove bottom knockout from the back of the air handler control box. 9. Set the heater cabinets on top of the unit as shown in Figure Position heater #1 (Heater closest to air handler control box) over the blower opening so that: a. The ¾" strain relief on the bottom of the heater control box fits into the 1 23/32" knockout in the center of the air handler roof panel. b. The holes in the electric heater flanges align with the dimples on the top of the air handling unit. 11. Using the 22" long, 1 1/4" dia. conduit assembly, insert threaded end of 90º ell conduit fitting through 1 23/32" knockout in roof panel and 1 23/32" opening in control box of the heater. Thread nut on fitting loosely to retain fitting in place until heater assemblies can be fastened to air handler roof. 12. Secure the heater to the unit at the holes aligned in the previous step using 12 drill screws provided with the accessory. 13. Tighten locknut on 90º ell conduit fitting. 14. Insert the straight 1 ¼" flex conduit fitting into back of air handler control box. Secure fitting in control box by tightening the locknut. 15. Position heater #2 (Heater farthest from the air handler control box) over the blower opening so that: a. The ¾" strain relief on the bottom of the heater control box fits into the 1 23/32" knockout in the center of the air handler roof panel. b. The holes in the electric heater flanges align with the dimples on the top of the air handling unit. 16. Using the 75" long, 1 1/4" dia. conduit assembly, insert threaded end of 90º Ell conduit fitting through 1 23/32" knockout in roof panel and 1 23/32" opening in control box of heater #2. Thread nut onto fitting loosely to retain fitting in place until heater assemblies can be fastened to air handler roof. 17. Secure the heater to the unit at the holes aligned in the previous step using 12 drill screws provided with the accessory. 18. Tighten locknut on 90º ell conduit fitting. 19. Route the 75" long, 11/4" dia. conduit assembly behind blower housing as shown in Figure Insert the straight 1 ¼" flex conduit fitting into back of air handler control box. Secure fitting in control box by tightening the locknut. 21. Secure conduit as shown with tie wraps provided with heater accessory. 22. Install terminal block TB1, relay EHR1 and if required relay EHR2 in the air handling unit control box at locations noted in Figure Connect wires from conduit attached at heater control boxes to fuse or breaker per heater wiring diagram. 24. Connect wires from conduits attached at the air handler control box to terminal block TB1 per heater wiring diagram. 25. Connect line voltage wires (from field installed disconnect) to terminals L1, L2 and L3 of terminal block TB1 per heater wiring diagram. 26. Route the control voltage wires of the heater accessory through the ¾" strain relief in bottom of the electric heater to and through the ¾" strain relief on the side of the air handler control box. Connect control wires provided in the kit to air handler and electric heat control boxes as indicated on the electric heater wiring diagram. Secure wires to conduit with tie warps provided in kit. 27. Replace the control box access panels removed from the heater cabinets. 28. Replace blower motor compartment access panel removed from air handling unit. 29. Replace blower section access panels. 30. Install properly sized duct work. Johnson Controls Unitary Products 3

4 Electric Heater Knockouts Power Knockout Control Knockout Blower and Control Box Panel FIGURE 1 - ACCESSORY INSTALLATION (7-1/5, 10, & 15 TONS) Electric Heater Knockouts Blower and Control Box Access Panel Blower Section Access Panels FIGURE 2 - ACCESSORY INSTALLATION (20 TONS) 4 Johnson Controls Unitary Products

5 Hole for ¾ Control Wiring Strain Relief Hole for 1¼ Conduit fitting FIGURE 3 - HEATER WITH CONTROL COVER REMOVED Hole for 1¼ Conduit Fitting Control Wiring Strain Relief Installed Gasket FIGURE 4 - BOTTOM OF HEATER CABINET Hole for 1¼ Conduit Fitting Location of Line Voltage Terminal Block TB1 Knockout for 1¼ Conduit Fitting FIGURE 5 - AIR HANDLER CONTROL BOX Location of Heat Relay EHR2 Location of Heat Relay EHR1 Location of Control Voltage Terminal Block TB2 Johnson Controls Unitary Products 5

6 FIGURE 6 - CONDUIT BEHIND BLOWER 6 Johnson Controls Unitary Products

7 TABLE 2: ELECTRICAL DATA - ELECTRIC HEAT Motor HP Power Supply Supply Blower Motor Electric Heat Option MCA 1 (Amps) FLA Model KW Stages Amps NC090\NH-07\J07NC\C00B Max Fuse 2 / Breaker 3 Size (Amps) None KW KW KW KW None KW KW KW KW None KW KW KW KW None KW KW KW KW NC090\NH-07\J07NC\C00C, (NC\ND) 120\ (NH\NJ)-10\ J10 (NC\ND) None KW KW KW KW None KW KW KW KW None KW KW KW KW None KW KW KW KW (NC\ND) 120\ (NH\NJ)-10\ J10 (NC\ND) C00D, (NC\ND) 180\ (NH\NJ)-15\ J15 (NC\ND) C00D None KW KW KW KW None KW KW KW KW None KW KW KW KW None KW KW KW KW Johnson Controls Unitary Products 7

8 TABLE 2: ELECTRICAL DATA - ELECTRIC HEAT (CONTINUED) Motor HP Power Supply Supply Blower Electric Heat Option MCA 1 Max Fuse 2 / Motor Breaker (Amps) Size (Amps) FLA Model KW Stages Amps (NC\ND) 180\ (NH\NJ)-15\ J15 (NC\ND) C00E None KW KW KW KW KW None KW KW KW KW KW None KW KW KW KW KW None KW KW KW KW KW (NC\ND) 240\ (NH\NJ)-20\ J20 (NC\ND) C00E None KW KW KW None KW KW KW None KW KW KW None KW KW KW (NC/ND)240C00F None KW KW KW None KW KW KW None KW KW KW None KW KW KW Minimum Circuit Ampacity. 2. Dual Element, Time Delay Type. 3. HACR type per NEC. 8 Johnson Controls Unitary Products

9 TABLE 3: HEATER STATIC RESISTANCE Basic Unit Capacity Heater Accessory 7.5 Ton 10.0 Ton (Nom. Rating) CFM CFM 2,400 2,700 3,000 3,300 3,600 3,200 3,600 4,000 4,400 4,800 10KW KW KW KW Basic Unit Capacity Heater Accessory (Nom. Rating) 15.0 Ton CFM 4,800 5,400 6,000 6,600 7,200 10KW KW KW KW Basic Unit Capacity Heater Accessory (Nom. Rating) 20.0 Ton CFM 6,400 7,200 8,000 8,800 9,600 20KW KW KW TABLE 4: HEATER PHYSICAL DATA Breaker 4 Fuses 5 Heater Capacity Description 10kW 1 16kW 2 26kW 3 36kW Number of Heating Elements Shipping Weight /230 Volts Quantity Size-Amps Volts Quantity Size-Amps kW requires two of these heaters kW requires two of these heaters kW requires two of these heaters. 4. HACR type per NEC. 5. Dual element, time delay type. Johnson Controls Unitary Products 9

10 1 F D M L E G H K 3/4 C 10 1/2 3/4 B A 3/4 FIGURE 7 - HEATER DIMENSIONS TABLE 5: HEATER DIMENSIONS Air Handler Tonnage 7.5, 10 and 20 Ton 15 Ton Heater Model 2HJ ,46 2HJ ,46 2HJ ,46 2HJ ,46 2HH ,46 2HH ,46 2HH ,46 2HH ,46 2HH ,46 2HH ,46 2HH ,46 Dimension (In.) A B C D E F G H K L M Johnson Controls Unitary Products

11 TERMINALS IN ELECTRIC HEAT CONTROL BOX GROUND LUG IN ELECTRIC HEAT CONTROL BOX TERMINALS ON 2-STAGE HEAT, MANUAL CHANGEOVER THERMOSTAT G W1 W2 1 1 Not required on the single stage 10kW heater. TB2 C S1 S2 G1 G EVAPORATOR BLOWER 090, 120, 180 OR 240, MBH WITH ELECTRIC HEAT ACCESSORY FIGURE 8 - FIELD WIRING (SPLIT-SYSTEM AIR CONDITIONER WITH ELECTRIC HEAT ACCESSORY) Johnson Controls Unitary Products 11

12 FIGURE 9 - ELECTRIC HEAT 10KW, 20KW 208/ WIRING DIAGRAM FIGURE 10 - ELECTRIC HEAT 16KW, 26KW 208/ WIRING DIAGRAM 12 Johnson Controls Unitary Products

13 FIGURE 11 - ELECTRIC HEAT 32KW, 52KW 208/ WIRING DIAGRAM FIGURE 12 - ELECTRIC HEAT 36KW 208/ WIRING DIAGRAM Johnson Controls Unitary Products 13

14 FIGURE 13 - ELECTRIC HEAT 10KW, 20KW WIRING DIAGRAM FIGURE 14 - ELECTRIC HEAT 16KW, 26KW WIRING DIAGRAM 14 Johnson Controls Unitary Products

15 FIGURE 15 - ELECTRIC HEAT 32KW, 52KW WIRING DIAGRAM FIGURE 16 - ELECTRIC HEAT 36KW WIRING DIAGRAM Subject to change without notice. Printed in U.S.A. Copyright 2009 by Unitary Products Group. All rights reserved UAI-B-1009 Supersedes: UAI-A-0709 Johnson Controls Unitary Products 5005 York Drive Norman, OK 73069