Heat Controller Inc Air Conditioner HCG__V1E User Manual
AIR HANDLER  
INSTALLATION INSTRUCTIONS  
HMG**F1E, HMG**X1E & HCG**V1E Series  
IMPORTANT  
Please read all information in this manual thoroughly and become familiar with the capabilities  
and use of your appliance before attempting to operate or maintain this unit.These instructions  
are primarily intended to assist qualified individuals experienced in the proper installation of  
this appliance. Some local codes require licensed installation/service personnel for this type  
of equipment. Improper installation,service,adjustment,or maintenance may cause explosion,  
fire, electrical shock or other hazardous conditions which may result in personal injury or  
property damage.  
Unless otherwise noted in these instructions, only factory authorized kits or accessories may  
be used with this product. Keep this manual where you have easy access to it in the future. If a  
problemoccurs,checktheinstructionsandfollowrecommendationsgiven.Ifthesesuggestions  
don’t eliminate your problem, call your servicing contractor.  
DO NOT DESTROY. PLEASE READ CAREFULLY AND  
KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.  
IMPORTANT SAFETY INFORMATION  
WARNING:  
INSTALLER:Please read all instructions before servicing  
this equipment. Pay attention to all safety warnings and  
any other special notes highlighted in the manual. Safety  
markings are used frequently throughout this manual to  
designate a degree or level of seriousness and should not  
be ignored. WARNING indicates a potentially hazardous  
situation that if not avoided, could result in personal injury  
or death. CAUTION indicates a potentially hazardous  
situationthatifnotavoided,mayresultinminorormoderate  
injury or property damage.  
PROPOSITION 65 WARNING: This product  
contains chemicals known to the state of  
California to cause cancer, birth defects or  
other reproductive harm.  
REqUIREMENTS & CODES  
WARNING:  
This unit must be installed in accordance with  
instructions outlined in this manual during  
the installation, service, and operation of  
this unit. Unqualified individuals should not  
attempt to interpret these instructions or  
install this equipment. Failure to follow safety  
recommendations could result in possible  
damage to the equipment, serious personal  
injury or death.  
WARNING:  
ELECTRICAL SHOCK, FIRE OR EXPLOSION  
HAZARD  
Failure to follow safety warnings exactly could  
result in serious injury or property damage.  
Improper servicing could result in dangerous  
operation, serious injury, death or property  
damage.  
• The installer must comply with all local codes and  
regulations which govern the installation of this type  
of equipment. Local codes and regulations take  
precedence over any recommendations contained in  
these instructions. Consult local building codes for  
special installation requirements.  
• This equipment contains nitrogen gas. Installation or  
servicing should only be performed by qualified trained  
personnel thoroughly familiar with this type equipment.  
• All electrical wiring must be completed in accordance  
with local, state and national codes and regulations  
and with the National Electric Code (ANSI/NFPA 70)  
or in Canada the Canadian Electric Code Part 1 CSA  
C.22.1.  
• Beforeservicing,disconnectallelectricalpower  
to air handler.  
• When servicing controls, label all wires prior  
to disconnecting. Reconnect wires correctly.  
• Verify proper operation after servicing.  
WARNING:  
NITROGEN  
• Installationofequipmentmayrequirebrazingoperations.  
Installer must comply with safety codes and wear  
appropriate safety equipment (safety glasses, work  
gloves, fire extinguisher, etc.) when performing brazing  
operations.  
HEALTH  
1
FLAMMABILITY  
0
0
REACTIVITY  
• Installthisunitonlyinalocationandpositionasspecified  
on pages 4 & 5. This unit is designed only for Indoor  
installations and should be located with consideration  
of minimizing the length of the supply and return ducts.  
See Tables 5 - 9 (pages 19 - 22) and the rating plate for  
proper circulating airflow data.  
• Follow all precautions in the literature, on tags, and  
on labels provided with the equipment. Read and  
thoroughly understand the instructions provided with  
the equipment prior to performing the installation and  
operational checkout of the equipment.  
• This air handler may be used for temporary heating  
of buildings or structures under construction. See the  
guidelines listed on page 4.  
• Air handler installations in a residential garage must be  
installed as specified on page 5.  
0 Minimal Hazard  
1 Slight Hazard  
HMG**F1E,HMG**X1E&HCG**V1Eairhandlers  
leave the factory with a nitrogen holding  
charge. Use caution when preparing coils for  
field connections. If repairs make it necessary  
for evacuation and charging, it should only  
be attempted by qualified, trained personnel  
thoroughly familiar with this equipment. Some  
localcodesrequirelicensedinstallationservice  
personnel to service this type of equipment.  
Undernocircumstancesshouldtheequipment  
owner attempt to install and/or service this  
equipment.Failure to comply with this warning  
could result in equipment damage, personal  
injury, or death.  
3
Operation of Air Handler During Construction  
GENERAL INFORMATION  
Thisappliancehasbeentestedforcapacityandefficiency  
in accordance with AHRI Standards and will provide  
many years of safe and dependable comfort, providing  
it is properly installed and maintained. Abuse, improper  
use, and/or improper maintenance can shorten the life  
of the appliance and create unsafe hazards. Please read  
all instructions before installing the unit.  
CAUTION:  
Failure to follow these instructions will void the  
factory warranty and may significantly reduce  
the life or the performance of the air handler,  
and/or result in other unsafe conditions. It is  
the responsibility of the installing contractor  
to insure these provisions are met.  
beforeYou Install this Unit  
√ This equipment is securely packaged at the time of  
shipmentanduponarrivalshouldbecarefullyinspected  
for damage prior to installing the equipment at the job  
site.Claimsfordamage(apparentorconcealed)should  
be filed immediately with the carrier.  
√ it is recommended that the cooling load of the area to  
be conditioned should be calculated and a system of  
the proper capacity selected.  
√ Check the electrical supply and verify the power supply  
isadequateforunitoperation.Thesystemmustbewired  
and provided with circuit protection in accordance with  
local building codes.If there is any question concerning  
the power supply, contact the local power company.  
√ Verify the duct system is appropriate for the air handler  
being installed. Please note that when replacing an  
existing system with lower air-flow, the duct system  
may require modification.  
Operating an air handler in a construction environment  
can cause the appliance a variety of problems. Proper  
use of commercial portable space heating equipment  
during construction is recommended. This air handler  
may be used during construction if it is not in violation of  
any applicable codes and the following criteria are met:  
• The installation must meet all applicable codes and  
be permanently installed according to the instructions  
supplied with the air handler including electrical supply  
and duct work.  
• Theairhandlermustbecontrolledbyaproperlyinstalled  
thermostat that complies with the current provisions  
of the NEC (ANSI/NFPA 70) and all applicable codes  
having jurisdiction. Thermostat connections must be  
made in accordance with instructions supplied with the  
air handler and thermostat. See pages 11 - 12.  
• The installation must include a properly installed filter in  
the return air system with no by-pass air.The filter must  
be inspected frequently and replaced when necessary.  
• Return air must be supplied unrestricted and located  
such that dust and gases from construction activity are  
not introduced into the circulating air system.  
Locating the Air Handler  
• Survey the job site to determine the best location for  
mounting the unit. Consideration should be given to  
availability of electric power, service access, and noise.  
• The dimensions of the room or alcove must be able  
to accommodate the overall size of the unit and the  
installation clearances listed in Table 1. Physical  
dimensions for this air handler are also shown in Figure  
12 (page 17).  
• Before occupying the structure: The filter must be  
replaced or cleaned, the duct work must be inspected  
and cleaned of any construction debris, and the air  
• Theairhandlershouldbesetintopositionbeforerouting  
the refrigerant tubing.  
INSTALLATION CLEARANCES  
Minimum Clearances  
Left Side......... 0 Inches Right Side ...... 0 Inches  
Back............... 0 Inches  
Front........... †See Notes  
• This appliance must be installed in accordance with  
clearances listed in Table 1. The air handler must be  
installed with ample clearance for easy access to the  
air filter, blower assembly, heater assembly, controls,  
and vent connections. Applicable building codes may  
require additional clearance to equipment. Refer to  
applicable building codes for details.  
• Static pressure drop through louvered openings and  
through return air plenums should be considered in  
the overall duct design in the determination of the total  
external static pressure.  
REAR  
LEFT  
SIDE  
RIGHT  
SIDE  
FRONT  
†NOTES:  
Alcove Installations - Allow 24 in. minimum clearance  
fromfrontofunittonearestwallorpartitionforservicing.  
Recommended clearance is 36 in.  
Table 1. Minimum Unit Clearances  
4
handler must be cleaned and/or repaired if found to  
be dirty, damaged, or malfunctioning in any way by  
a qualified HVAC technician. The air handler shall be  
as the opening provided on the air handler. The ducts  
should be appropriately sized to the capacity of the air  
handler to ensure its proper airflow rating.  
inspected and approved by applicable local authority • Use transition fittings if the supply and/or return air  
even if this requires redundant inspections.  
openings of the unit do not match the duct openings.  
Thesetransitionsshouldbedimensionedinaccordance  
with standard practice as specified in the ASHRAE  
recommendations for duct transitions.  
• The serial number for the air handler used during  
construction must be submitted in writing (fax and  
email also acceptable).This information will be used to  
track the long-term affects of air handler usage during • Flexible connectors may be used between the unit  
construction.Proofofthissubmittalshallbeavailablefor  
the final inspection of the air handler prior to occupancy.  
and the ductwork to prevent transmission of vibration  
from the unit to the structure. If electric heater kits are  
installed, heat resistant material must be used for the  
flexible connector at the supply air end of the unit.  
• It is good practice to seal all connections and joints  
with industrial grade sealing tape or liquid sealant.  
Requirements for sealing ducts vary from region to  
region.Consultwithlocalcodesforrequirementsspecific  
to your area.  
Installation in a Garage  
WARNING:  
Donotplacecombustiblematerialsonoragainst  
the cabinet. Do not place flammable materials,  
(gasoline, paint thinners, etc.) or any other  
flammable vapors and liquids, in the vicinity Unconditioned Spaces  
of the air handler.  
All duct work passing through unconditioned space must  
be properly insulated to minimize duct losses and prevent  
condensation. Use insulation with an outer vapor barrier.  
Refer to local codes for insulation material requirements.  
The HMG**F1E, HMG**X1E & HCG**V1E series air  
handler may be installed in a residential garage with the  
provision that the unit must be located or protected to  
prevent physical damage by vehicles.  
Air Filters  
HMG**F1E, HMG**X1E & HCG**V1E series air handlers  
are not supplied with an air filter when shipped from the  
factory. The installer must provide a high velocity filter  
that is appropriately sized to the return air duct opening  
or filter rack located in the bottom of the unit. Accessing  
the filter does not require tools and can be removed from  
the front of the unit by removing the filter door. See Unit  
Maintenance (page 16) for filter sizes and installation  
information.  
Plenums & Air Ducts  
• Plenums and air ducts should be installed in  
accordance with the standards of the National Fire  
Protection Association Standard for Installation of  
Air Conditioning Systems (NFPA 90A), Standard for  
Installation of Residence Type Warm Air Heating  
and Air Conditioning Systems (NFPA 90B), and all  
applicable local codes.NFPA publications are available  
by writing to: National Fire Protection Association,  
Batterymarch Park, Quincy, ME 02269 or visit  
www.NFPA.org online.  
WARNING:  
Never operate the air handler without a filter  
or with doors removed. Dust and lint can build  
up on internal components, resulting in loss of  
efficiency,equipmentdamage,andpossiblefire.  
WARNING:  
All return ducts must be secured to the air  
handler using appropriate methods. All return  
ducts must be adequately sealed.When return  
air is provided through the bottom of the unit,  
the joint between the air handler and the return  
air plenum must be air tight.  
Acoustical Duct Work  
• Certain installations may require the use of acoustical  
lining inside the supply duct work. Acoustical insulation  
must be in accordance with the current revision of the  
Sheet Metal and Air Conditioning Contractors National  
Association (SMACNA) application standard for duct  
liners.DuctliningmustbeULclassifiedbattsorblankets  
with a fire hazard classification of FHC-25/50 or less.  
• Fiber duct work may be used in place of internal duct  
liners if the fiber duct work is in accordance with the  
current revision of the SMACNA construction standard  
on fibrous glass ducts. Fibrous duct work and internal  
acoustical lining must be NFPA Class 1 air ducts when  
tested per UL Standard 181 for Class 1 ducts.  
Return air and circulating air ducts must not be  
connected to any other heat producing device  
such as a fireplace insert, stove, etc.This may  
result in fire, explosion, carbon monoxide  
poisoning,personalinjury,orpropertydamage.  
• Design the duct work according to methods described  
by the Air Conditioning Contractors of America (ACCA).  
• Thisunitisdesignedonlyforusewithareturnandsupply  
duct.The return air duct must have the same free area  
• Damping ducts, flexible vibration isolators, or pleated  
media-style filters on the return air inlet of the air  
handler may be used to reduce the transmission of  
5
equipment noise eminating from the air handler.These  
treatmentscanproduceaquieterinstallation,particularly  
in the heated space. However, they can increase the  
pressure drop in the duct system. Care must be taken  
to maintain the proper maximum pressure rise across  
the air handler, temperature rise and flow rate. This  
may mean increasing the duct size and/or reducing the  
blower speed. These treatments must be constructed  
and installed in accordance with NFPA and SMACNA  
construction standards. Consult with local codes for  
special requirements. For best sound performance, be  
sure to install all the needed gaskets and grommets  
around penetrations into the air handler, such as for  
electrical wiring.  
Horizontal  
Drain Pan  
AIR HANDLER INSTALLATION  
The HMG**F1E, HMG**X1E & HCG**V1E Series Air  
Handlerisshippedreadyforverticalupflowinstallationand  
isapprovedforattic,basement,alcove/closetorcrawlspace  
installation with zero clearance to combustibles. See  
Table 1 (page 4) for required installation clearances.This  
appliance is approved only for indoor use.  
Return  
Air  
Figure 1. Upflow Installation  
Upflow Installations  
All air handlers are factory shipped, ready for upflow  
installation. The horizontal drain pan may be removed  
from the air handler when installing the unit in an upflow  
configuration. All return air must enter from the bottom of  
the unit. A typical upflow unit is shown in Figure 1.  
• The unit must be leveled at installation and attached to  
a properly installed duct system.  
• The surface that the air handler is mounted on must  
provide sound physical support of the unit.  
• The air handler must be installed so that all electrical  
components are protected from water.  
• If a louvered door is installed across the front of this  
unit, the appliance must be mounted flush or behind  
front edge of finished wall.  
• Always reinstall the doors on the air handler after  
servicingorcleaning/changingthefilters.Donotoperate  
theairhandlerwithoutalldoorsandcoversinplace.  
Downflow Installations  
Thedownflowaccessorykit(SeeTechnicalSpecifications)  
is required for downflow applications. Instructions for  
installingthedownflowaccessorykitareincludedwiththe  
kit.Itisrecommendedthattheaccessorybeinstalledprior  
to installing the unit.All return air in downflow applications  
must enter through the top of the unit.A typical installation  
of the unit in a downflow application is shown in Figure 2.  
Packaging Removal  
Remove the shipping crate and User’s Manual from the  
equipment. When removing the crate, use extra care so  
tubing connectios are not damaged. Do not pull on the  
coils upper tubes.  
Mounting Applications  
Vertical only air handlers are factory ready for upflow  
applications. These units may be applied in downflow  
applications when applied with the appropriate field kit.  
Cabinet  
Tube  
Close-off  
Plate  
Factory ready horizontal air handlers may be applied in  
upflow or horizontal-left and -right discharge applications.  
These units may also be applied in downflow discharge  
when applied with the appropriate field kit as specified in  
the units Technical Specifications.  
Adaptor Kit  
Coil  
Through-the-floor installations require a 1/4” thick  
noncombustible resilient gasket to be used whenever the  
supplyorreturnairductspassthroughthefloor.Thegasket  
should be positioned between the duct, unit, and floor.  
Figure 2. Downflow Installation  
6
Horizontal Installations  
suspended using steel straps around each end of the  
Theseairhandlerscanbeinstalledhorizontallyinanattic, unit.The straps should be attached to the air handler with  
basement,crawlspaceoralcove.Itcanalsobesuspended sheet metal screws and to the rafters with bolts.  
from a ceiling in a basement or utility room in either a right  
Horizontal Left Installations:  
to left airflow or left to right airflow as shown in Figure 3.  
1.Remove the coil access door.  
Air handlers may or may not be shipped from the factory  
2.Remove the plug from one of the threaded holes in the  
with all the parts required for horizontal left applications  
horizontal drain pan. Completely remove the webbing  
andhorizontalrightapplications.Ifyourunitdoesnothave  
located in the threaded holes of the horizontal drain  
parts for a horizontal application, a kit may be available.  
pan. IMPORTANT: If the webbing is not removed, the  
condensate will not drain properly and ceiling damage  
may occur.  
3.Insert the plug (from horizontal drain pan) into the open  
NOTE: In all horizontal applications in which the unit is  
installed above a finished ceiling and/or living space, a  
secondarydrainpanmustbeinstalledundertheentireunit  
and unused drain hole in the drain pan at the bottom  
to avoid damage to the ceiling in the event of condensate  
of the unit to block bypass air.  
overflow.Additionally,itisrecommendedthatanapproved  
4.Remove the corresponding drain line knockout from  
water level indicator or float switch device be used to  
the coil access door to allow access to the horizontal  
shut down the unit in the event water is detected in the  
drain.  
auxiliary drain pan.  
5.Replace the door and attach the drain line.  
If suspending the air handler from the ceiling, assemble  
a support frame (Figure 4) using slotted iron channel and  
Horizontal Right Installations:  
1.Remove the coil access door.Unscrew the line-set tube  
full threaded rod. Fasten the frame together with nuts,  
close-off plate from the front left cabinet rail.  
washers, and lockwashers. Secure the support frame  
2.Slide the coil and drain pan assembly out of the unit.  
to the rafters with lag bolts. The air handler can also be  
3.Remove the sheet metal hairpin covers (if supplied)  
from the back of the coil and discard.  
4.Place the horizontal drain pan on the opposite side of  
the coil. On units with 2 sets of knockouts, remove the  
other set of knockouts in the coil spacing plates and  
insert support rod.  
5.Slide the coil and the horizontal drain pan assembly  
back into the unit. Re-attach the tube close off plate.  
HORIZONTAL RIGHT  
HORIZONTAL LEFT  
RETURN  
AIR  
NOTE: For 24K & 30K BTUH applications, it may  
be preferrable to remove the blower assembly prior  
to installing the coil & drainpan. In this case follow  
instructions 1-4 as listed above but also remove the  
blower access door and blower assembly. The blower  
assembly is secured with two screws on either side  
nearthefront.Withtheseremovedtheblowerassembly  
can slide out of the front of the unit. Install the coil and  
drain pan as described in step 5 and then replace the  
blower assembly. Take care to ensure that the flanges  
on the sides of the blower assembly are captured by  
the pockets in the blower deck. It may be necessary to  
lift the blower assembly during insertion to allow the  
lower blower leg to clear the side of the drain pan.The  
blower will stop against the back of the blower deck.  
Replace the two screws and the blower access door  
and procede with steps 6-9.  
RETURN  
AIR  
Figure 3. Horizontal Configurations  
6.Remove the plug from one of the threaded holes in the  
horizontal drain pan. Completely remove the webbing  
located in the threaded holes of the drain pan.  
Nuts (x2)  
Lag  
Bolt  
Washer  
and  
Lockwasher  
IMPORTANT: If the webbing is not removed, the  
condensate will not drain properly and ceiling  
damage may occur.  
Threaded  
Rod  
Nuts (x2)  
NOTE: It is recommended that the suction line be  
insulated up to the coil inside of the cabinet.  
Figure 4. Unit Horizontally Suspended  
7
7.Insert the plug (from horizontal drain pan) into the open 3.Remove the release paper from the other side of the  
and unused drain hole in the drain pan at the bottom  
of the unit to block bypass air.  
8.Remove the corresponding drain line knockout from  
the coil access door to allow access to the horizontal  
drain.  
gasket and attach to the circuit breaker recess area.  
4.Press firmly along all four sides of the cover to ensure  
gasket and cover are securely attached to the access  
door.  
Refrigerant Line Connections  
9.Replace the door and attach the drain line  
Circuit breaker Cover Installation  
WARNING:  
Theairhandlercircuitbreakercoverisdesignedtoprotect  
the breakers of an installed heater kit from debris and  
condensation.The cover attaches to the breaker recess  
of the air handler upper access door using a double-sided  
adhesive gasket. See Figure 5. The heater kit circuit  
breaker toggles are still accessible and can be switched  
with the cover in place.  
NITROGEN  
HEALTH  
1
FLAMMABILITY  
0
0
REACTIVITY  
0 Minimal Hazard  
1 Slight Hazard  
Thecoilintheairhandlerisfactoryshippedwith  
a nitrogen charge. Avoid direct face exposure  
or contact with valve when gas is escaping.  
Always ensure adequate ventilation is present  
during the depressurization process. Address  
any uncertainties before proceeding. Failure  
to comply with this warning could result in  
equipment damage, personal injury, or death.  
There are 2 different circuit breaker cover sizes:  
• 2-breaker cover for 2, 2.5, 3, 3.5, & 4 ton air handlers.  
• 3-breaker cover for 5 ton air handlers.  
After the heater kit is properly installed, remove the  
appropriateknockoutsintheupperairhandleraccessdoor  
and follow these instructions to install the breaker cover:  
1.Clean any oil, dirt, or insulation fibers from the recess  
areaoftheairhandleraccessdoor.Thisstepisimportant  
for ensuring the gasket adheres properly to the sheet  
metal door.  
2.Remove release paper from one side of the gasket  
and attach to back side of the breaker cover.  
NOTE:Forproperalignment,Itisrecommendedtoleave  
thecentersectionofthegasketinplacewhenattaching  
the gasket to the breaker cover. Remove the center  
section after the gasket is applied to the breaker cover.  
• The installer should make every effort to ensure the  
field installed refrigerant containing components of the  
system have been installed in accordance with these  
instructions and sound installation practices for reliable  
system operation and longevity.  
• Theairhandlercoildoesnotcontainarefrigerantcharge.  
Refer to the installation instructions supplied with the  
outdoor unit for refrigerant charge information.  
• Alwaysrefertotheinstallationinstructionssuppliedwith  
the outdoor unit for piping requirements. The suction  
and liquid lines must be sized in accordance with the  
condensing unit specifications. See Figure 12 (page  
17) for liquid and suction line locations.  
• When connecting refrigerant linesets together, it is  
recommended that dry nitrogen be flowing through the  
joints during brazing.This will prevent internal oxidation  
and scaling from occurring.  
C
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Breakers  
• Refrigerant tubing should be routed in a manner that  
minimizes the length of tubing and the number of bends  
in the tubing. It should be supported in a manner that  
prevents it from vibrating or abrading during system  
operation.Tubing should be kept clean of foreign debris  
during installation.  
• Ifpreciseformingofrefrigerantlinesisrequired,acopper  
tubing bender is recommended.Avoid sharp bends and  
contact of the refrigerant lines with metal surfaces.  
• Refrigerant lines should be wrapped with pressure  
sensitive neoprene or other suitable material where  
they pass against sharp sheet metal edges.  
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Air Handler A  
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• HMG**F1E,HMG**X1E&HCG**V1ESeriesairhandlers  
are charged through service valves on the end of the  
liquid tube for each circuit. These must be removed  
before brazing the line sets.  
Figure 5. Circuit breaker Cover  
8
Orifice Removal & Installation  
9.Realign the assembly nut on the distributor body and  
hand tighten both components. Mark a line on both  
bodies and then tighten an additional 1/4 turn using two  
wrenches.Themovementofthetwolineswillshowhow  
much the nut is tightened. If a torque wrench is used,  
tighten to 10-12 ft. lbs. or 14-16 Nm.  
The orifice installed in the air handler has been sized for  
use with the most popularly matched outdoor units. The  
orifice size as shipped from the factory is listed on the air  
handler rating plate. Perform steps 1 - 9 to confirm that  
the orifice size meets the requirements outlined in the  
outdoor unit installation manual.  
1.Remove the cap from the end of the liquid line.  
2.Verify pressurization by depressing the Schrader valve  
on the end of the liquid line.Listen for any escaping gas.  
If there is no pressure, test the coil for leakage.  
• If leakage is found, clearly mark the location of the leak  
and return the coil to the distributor for processing.  
• If no leaks are found, the coil may be installed.  
3.Depress the valve to relieve all pressure from the coil.  
4.Remove and discard the valve core.  
CAUTION:  
To prevent damage to the unit or internal  
components, it is recommended that two  
wrenchesbeusedwhenlooseningortightening  
nuts. Do not over tighten!  
Figure 7. Removal of Orifice  
5.Usingtwowrenches,loosenthenutanddistributorbody  
as shown in Figure 6. Turn the assembly nut counter-  
clock-wise until the orifice body halves are seperated.  
6.Insert a light-gauge wire hook between the distributor  
body and the restrictor orifice while being careful not  
to scratch either part. Carefully remove the restrictor  
orifice from the distributor body. See Figure 7.  
7.Check the actual size of the new orifice. NOTE: The  
size is stamped on its side. Do not use pin gauges to  
measure the orifice diameter.  
Figure 8. Restrictor Insertion into Distributor body  
8.Insert the new orifice into the distributor body, rounded  
end down. See Figure 8.  
Connecting the Linesets  
IMPORTANT NOTES FOR HORIZONTAL OR  
DOWNFLOW INSTALLATIONS WITH TXV VALVE:  
• The sensing bulb must be located flush against the  
suction line for optimum heat transfer.  
• Avoidattachingthesensingbulbtothelowestpartof  
thesuctionlinewherecondensatemayaccumulate.  
CAUTION:  
To prevent damage to the unit or internal  
components, it is recommended that two  
wrenchesbeusedwhenlooseningortightening  
nuts. Do not over tighten!  
• Do not locate the sensing bulb on vertical sections  
of the lineset.  
• For horizontal lines, the bulb should not be located  
at 12 or 6 o’clock position of the suction line. The  
best location is at 4 or 8 o’clock.  
• For additional information on proper sensing bulb  
locations, please refer to the valve manufacturer’s  
instructions.  
IMPORTANT: The steps in the Orifice Removal &  
Installation section must be performed before the linesets  
are connected.  
Figure 6. Loosening of Nut & Distributor body  
9
1.Remove grommets from line set holes.  
6.Braze the individual connections with dry nitrogen  
flowing through the joints. NOTE: This will prevent  
internal oxidation and scaling from occurring.  
7.Wrap the refrigerant lines with pressure sensitive  
neoprene or other suitable material especially where  
the lines enter the opening in the sheet metal.  
8.Evacuatethesystemofmoistureandnon-condensables  
to prevent low efficiency operation or damage to the  
unit. The suggested range of evacuation is 350 - 500  
microns.  
CAUTION:  
It is recommended that a wet rag be wrapped  
around the suction line in front of the close  
off plate or the sensing bulb (if TXV is  
installed) before applying heat. Failure to keep  
components cool during brazing may result  
in structural damage, premature equipment  
failure, or possible personal injury.  
9.Charge the system with refrigerant. Refer to the  
outdoor unit installation manual for additional charging  
instructions.  
2.Unbraze and remove the cap on the suction line.  
3.Route and cut both lineset tubes to proper length in  
accordance with the outdoor unit specifications. Verify  
the ends are round, clean, and free of any burrs.  
4. Positiongrommetonlinesetwithsufficientdistanceaway  
from brazing area.Brazing processes can permanently  
damage grommets.  
10. Check the system for leaks, including the lineset and  
the brazed joints.  
11. Replace all grommets and properly dispose of all  
removed parts.  
Condensate Drainage  
5.Connect the suction and liquid lineset tubes.  
CAUTION:  
The air handler must be level to ensure proper  
condensate drainage. An unlevel installation  
may result in structural damage, premature  
equipment failure, or possible personal injury.  
CAUTION:  
It is recommended that a wet rag be wrapped  
around the suction line in front of the close  
off plate or the sensing bulb (if TXV is  
installed) before applying heat. Failure to keep  
components cool during brazing may result  
in structural damage, premature equipment  
failure, or possible personal injury.  
• Methods for disposing of condensate vary according  
to local codes. Refer to local codes or authority having  
jurisidiction for restrictions and proper condensate  
disposal requirements.  
• The drain pan that is supplied with this air handler  
contains a primary and secondary drain fitting. The  
condensate is drained from the unit through two 3/4”  
female pipe fittings located on the front side of the unit  
as shown in Figure 9.  
UPFLOW  
• The drain pan must be drained with field supplied tubing  
or pvc pipe and adequately trapped. Both drain tubes  
must have a minimum diameter of 3/4” and be trapped  
separately.  
HORIZONTAL  
3/4” Adapter w/  
3/4” dia. hose barb  
IMPORTANT: Failure to install a trap may result in  
condensation overflowing the drain pan, resulting in  
substantial water damage to surrounding area.  
• Routebothlinestoasuitabledrain,avoidingsharpbends  
and pinching of the lines. The drain should maintain a  
minimum horizontal slope in the direction of discharge  
of not less than 1” vertical for every 10 ft of horizontal  
run.  
DOWNFLOW  
3/4” minimum dia.  
PVC or flexible tubing  
• If the air handler is located in or above a living space  
where damage may result from condensate overflow,  
an auxiliary drain pan shall be installed under the unit.  
A separate drain line should extend from the pan to a  
conspicuous point and serve as an alarm indicating  
that the primary drain is restricted. As an alternative to  
a separate drain line, an approved water level indicator  
or float switch device may be used to shut down the  
unit in the event water is detected in the auxiliary pan.  
NOTES:  
1. The drain lines must maintain a downward slope to ensure proper  
condensate drainage.  
2. Each condensate drain must be trapped separately using a J-Trap or  
field supplied loop.  
Figure 9. Condensate Drainage Example  
10  
• Install a single 5 inch trap in the condensate drain line • It is recommended that the line voltage to the unit be  
as close to the coil as possible. Make sure that the  
top of the trap is below the bottom of the drain pan to  
supplied from a dedicated branch circuit containing the  
correct fuse or circuit breaker for the unit.  
prevent the condensate from overflowing the drain pan. • Overcurrent protection must be provided at the branch  
NOTE: There must be only one trap in the drain line.  
Using more than one trap may prevent drainage.  
• Primethetrapwithwater.Insulatethedrainifitislocated  
inanunconditionedspace, andtestthecondensateline  
for leaks. Consult local codes for additional restrictions  
or precautions.  
circuit distribution panel and sized as shown on the unit  
rating label and according to applicable local codes.  
See the unit rating plate and Tables 10 & 11 (pages  
28 & 29) for maximum circuit ampacity and maximum  
overcurrent protection limits.  
• The installer should become familiar with the wiring  
diagram/schematic before making any electrical  
connections to the unit. See the unit wiring label or  
Figures 18 - 20 (pages 25 - 27).  
• During system checkout, inspect the drain line and  
connections to verify proper condensate drainage.  
• Use only copper wire for the line voltage power supply  
to this unit. Use proper code agency listed conduit and  
a conduit connector for connecting the supply wires to  
the unit. Aluminum supply wire may be used if a heater  
kit is installed.  
• If replacing any of the original wires supplied with the  
unit,thereplacementwiremustbecopperwireconsisting  
of the same gauge and temperature rating.  
• Provide power supply for the unit in accordance with the  
unit wiring diagram, and the unit rating plate. Use UL  
listedconduitandconduitconnectorsforconnectingthe  
supply wires to the unit and for proper grounding. Field  
supplied bushings for the power supply cables must be  
added to support and protect the power supply cables.  
• All 208/230Volt units are shipped from the factory wired  
for 240 volt operation. For 208V operation, remove the  
lead from the transformer terminal marked 240V and  
connect it to the terminal marked 208V.  
ELECTRICAL CONNECTIONS  
WARNING:  
ELECTRICAL SHOCK, FIRE OR EXPLOSION  
HAZARD  
Failure to follow safety warnings exactly could  
result in serious injury or property damage.  
Improper servicing could result in dangerous  
operation, serious injury, death or property  
damage.  
• beforeservicing,disconnectallelectricalpower  
to the air handler.  
• When servicing controls, label all wires prior  
to disconnecting. Reconnect wires correctly.  
• Verify proper operation after servicing.  
Grounding  
• Electrical connections must be in compliance with  
all applicable local codes and ordinances, and with  
the current revision of the National Electric Code  
(ANSI/NFPA 70).  
• For Canadian installations, the electrical connections  
and grounding shall comply with the current Canadian  
Electrical Code (CSA C22.1 and/or local codes).  
WARNING:  
The unit cabinet must have an uninterrupted  
or unbroken electrical ground to minimize  
personalinjuryifanelectricalfaultshouldoccur.  
Do not use gas piping as an electrical ground!  
This unit must be electrically grounded in accordance  
with local codes or, in the absence of local codes, with  
the National Electrical Code (ANSI/NFPA 70) or the CSA  
Pre-Electrical Checklist:  
√ Verify the voltage, frequency, and phase of the supply  
source match the specifications on the unit rating plate.  
√ Verify that the service provided by the utility is sufficient C22.1 Electrical Code. Use the grounding lug provided in  
tohandletheadditionalloadimposedbythisequipment.  
See the unit wiring label orTables 9 - 10 (pages 28 - 29)  
for proper high and low voltage wiring.  
√ Verify factory wiring is in accordance with the unit wiring  
diagram (Figures 18 - 20, pages 25 - 27).Make sure the  
connectionsdidn’tloosenduringshippingorinstallation.  
the control box for grounding the unit.  
Thermostat Connections  
• Thermostat connections shall be in accordance with  
the instructions supplied with the thermostat. The  
thermostat used with this equipment must operate in  
conjunction with any installed accessories. Typical AC  
and air handler hookups are shown in Figure 10 (page  
12).  
• Where local codes require that the thermostat wiring  
must be routed through a conduit or raceway, splices  
can be made inside the unit; however, all wiring must  
be NEC Class 1 and separated from incoming power  
leads.  
Line Voltage  
• Anelectricaldisconnectmustbelocatedwithinsight  
of and readily accessible to the unit.This switch shall  
becapableofelectricallyde-energizingtheoutdoorunit.  
See unit data label for proper incoming field wiring.Any  
other wiring methods must be acceptable to authority  
having jurisdiction.  
11  
low-voltage wiring between the thermostat, outdoor  
unit, and control board. NOTE: When the low voltage  
wires are positioned in this grommet, the grommet will  
preventchafingand/orshortingofthelowvoltageleads.  
CAUTION:  
Isolation must be maintained from the external  
Class 2 output of any transformer in a cooling  
circuit.Useathermostatwithisolatingcontacts  
to prevent inter-connection of Class 2 outputs.  
Control board  
The control board in the air handler controls the timing  
sequence of the elements.The board is equipped with a 3  
second blower on delay and a 15 second blower off delay  
in heating and a 40 second blower off delay in cooling.  
See Figures 14 or 15 (page 23) and Table 12 (pages 29-  
• The thermostat should be mounted about 5 feet above  
theflooronaninsidewall.DONOTinstallthethermostat  
on an outside wall or any other location where its  
operationmaybeadverselyaffectedbyradiantheatfrom 31) for control board modes and actions.  
fireplaces, sunlight, or lighting fixtures, and convective  
Twinning  
heat from warm air registers or electrical appliances.  
HMG**F1E series air handler’s are not supplied with a  
Refertothethermostatmanufacturer’sinstructionsheet  
for detailed mounting and installation information.  
• Install the grommet, which is packed with the unit, in  
the hole for low-voltage wires. Properly connect the  
builtintwinningcapability.Toconnecttwoairhandlerstoa  
commonsinglestageACcondensingunitorheatpump, a  
twinning kit is available for field installation.Please follow  
the instructions supplied with the kit.  
Thermostat  
W Y G R  
Thermostat  
W Y G R  
Thermostat  
Y1 W2 W/E Y2 G R  
NOTE: Jumper W1 & W2  
together if not using W2  
on thermostat  
Air  
Conditioner  
Y1  
Y1  
Y1  
W2  
W2  
Air  
W1  
O
Handler  
W1  
Air  
Conditioner  
O
Air  
W1  
Y
Conditioner  
Y/Y2  
Y/Y2  
Y
Y2  
G
G
Y
G
R
C
R
C
R
C
R
C
Air  
Handler  
Air  
Handler  
C
C
Typical Air Conditioner with  
Standard Air Handler  
Typical Air Conditioner with  
2-Stage Air Handler  
Typical 2-Stage Air Conditioner  
with 2-Stage Air Handler  
Thermostat  
Thermostat  
Thermostat  
O
G R C E  
W2 O Y G R C W/E  
Y1 W2 W/E OY2 G R  
C
W2  
Y
NOTE: Jumper W1 & W2  
together if not using W2  
on thermostat  
NOTE: Jumper between  
W2 & E is required when  
no OD T-Stat is used.  
Y1  
W2  
W1  
Y1  
W2  
W1  
Air  
Handler  
Y1  
W2  
W2  
O
W1  
Y
O
O
W2  
O
Y
O
Y/Y2  
G
Y/Y2  
G
Y
Y2 OUT  
G
R
C
R
R
C
R
C
R
C
R
C
C
Air  
Handler  
Air  
Handler  
Heat Pump  
Heat Pump  
Heat Pump  
Typical Heat Pump with  
2-Stage Air Handler  
Typical 2-Stage Heat Pump with  
2-Stage Air Handler  
Typical Heat Pump with  
Standard Air Handler  
Figure 10.Typical Thermostat Connections  
12  
NOTE: Variable speed air handlers cannot be twinned.  
STARTUP & ADjUSTMENTS  
Heater Kits  
When electric heat packages with circuit breakers are  
field-installed, the circuit breaker may be used as a  
disconnecting means in most applications. Reference  
the NEC and local codes for disconnect requirements.  
WARNING:  
NITROGEN  
HEALTH  
1
0
0
If a heater kit is installed:  
The HMG**F1E series air handler is shipped from the  
factory without an electric heater kit installed. If Electric  
heat is desired, the H6HK heater kit may be purchased  
separately and field installed. Determine the correct size  
heater kit for your unit by referring to the list below or the  
units rating label.  
FLAMMABILITY  
REACTIVITY  
0 Minimal Hazard  
1 Slight Hazard  
The evaporator coil is shipped from the factory  
with a nitrogen charge. Use caution when  
preparing coils for field connections. If repairs  
makeitnecessaryforevacuationandcharging,  
it should only be attempted by qualified,  
trained personnel thoroughly familiar with this  
equipment. Some local codes require licensed  
installation service personnel to service this  
type of equipment. Under no circumstances  
should the equipment owner attempt to install  
and/orservicethisequipment.Failuretocomply  
with this warning could result in equipment  
damage, personal injury, or death.  
24K & 30K BTUH........................................... 15Kw max  
36K & 42K BTUH........................................... 20Kw max  
48K & 60K BTUH........................................... 30Kw max  
1.Connect the 2 wire plug of the air handler to the mating  
2 wire plug of the heater kit.  
2.Connect the line voltage leads to the circuit breaker or  
terminal block provided.  
3.Connect the heater kit plug with the mating receptacle  
on the air handler control board.  
If a heater kit is not installed:  
1.Remove the 2 wire plug of the air handler by cutting the  
wires and discarding the plug.  
2.Strip the ends of the 2 air handler wires and connect  
to the line-voltage leads with the 2 wire nuts provided.  
beforeYou Start the Unit  
Prior to start-up, complete the following inspections:  
√ Verifytheunitislevelandproperlylocatedwithadequate  
clearances for servicing the unit. See Table 1 (page 4).  
√ Check condensate drain line(s) for proper drainage.  
√ Verify the surrounding area and top of the unit is free  
from obstructions and debris.  
√ Check all duct connections. Make sure the duct work  
is adequately sealed to prevent air leakage.  
√ Check all coil connections for leaks.  
√ Verify that the line voltage power leads are securely  
connectedandtheunitisproperlygrounded.Makesure  
all doors are installed before restoring power to the unit  
√ Verify the thermostat is wired correctly. Make sure all  
low voltage wires are securely connected.  
Electronic Air Cleaner (EAC)  
The unit has an output to power an electronic air cleaner  
when the blower is running. This output is rated to 1.0  
amp at 208/240V.  
Humidifier  
The unit has an output to power a humidifier when the  
blower is running. This output is rated to 1.0 amp at  
208/240V.  
Optional Humidistat  
(HMG**X1E & HCG**V1E Models Only)  
The optional humidistat may be installed in the return air  
duct to provide excellent humidity control when needed  
andmaximumsystemcapacityandenergyefficiencywhen  
humidity levels are normal. The humidistat senses when  
humidity in the return air stream is above a preset level  
(fieldadjustable)andsendsasignaltothemotortoreduce  
theairflowsothatmoremoisturemayberemoveduntilthe  
humidity level drops. The air handler is pre-programmed  
for humidistat operation.  
√ Verify the power supply branch circuit overcurrent  
protection is sized properly.  
√ Verify filter is properly and securely installed.  
IMPORTANT: Before starting the unit, install the initial  
charge on units that are factory shipped with a nitrogen  
holding charge:  
1.Read all installation instructions first.  
2.Purge the nitrogen holding charge.  
3.Evacuate the unit to 350 - 500 microns.  
4.Allow the unit to remain under vacuum for at least 30  
minutes.  
5.Weigh in the proper amount of new (or reclaimed)  
refrigerant. Refer to the air conditioner or heat pump  
installation manual for the proper type and quantity of  
refrigerant.  
Install the humidistat in the return air duct as directed in  
the installation instructions included with the kit.Wire the  
humidistat through the low-voltage wire entrance in the  
air handler to the control board terminal marked DEHUM.  
Wirethehumidistattoopenonriseinhumidity.SeeFigures  
16 & 17 (page 24).  
13  
Refrigerant Charging  
automatically set the heating speed based on the amount  
The system refrigerant charge can be checked and of installed heat.The remaining 3 HEAT switches have no  
adjusted through the service ports provided at the front function. Switch settings are listed in Table 6 (page 20)  
paneloftheoutdoorunit.Useonlygaugelineswhichhave or Table 9 (page 22). NOTE: For HMG**X1E Models, the  
aSchraderdepressiondevicepresenttoactuatethevalve. minimum electric heat airflow setting may be set higher,  
but must never be set lower than the setting shown in  
Table 7 (page 21).  
Air Circulation  
Running the Blower Continuously  
Set the thermostat’s system mode to OFF and the  
thermostat’s fan mode to ON. The blower motor should  
run continuously. Check for air delivery at the register(s).  
Ensure that there are no obstructions at the registers or  
in the ducts.  
blower Configurations  
Determining Nominal System Capacity  
To select the appropriate airflows for the air handler, the  
nominal system capacity must be known. The nominal  
system capacity is always the nominal capacity of the  
outdoor unit. However, in some situations the nominal  
system capacity may not be the same as the nominal  
capacity of the air handler. Always refer to the nominal  
capacity of the outdoor unit to determine the nominal  
system capacity.  
Selecting continuous low speed fan operation  
(Standard Blower)  
The air handler is equipped with an option of continuous  
low speed fan operation.When G is energized without Y/  
Y2, the air handler will operate using the cooling speed.  
With G & Y/Y2 or Y/Y2 energized, the air handler will  
operate in the selected cooling speed (including 40 sec  
blower-off delay).  
NOTE: The CFM values listed in Table 9 (page 22) are  
not dependent on duct static pressure. The VSHE motor  
automatically compensates for changes in duct static  
pressure (within the limits of the motor).  
Turning the Blower Off  
Set thermostat’s fan mode to AUTO, the blower will shut  
down immediately.  
3-Speed Units  
The blower speed is preset at the factory for operation  
at the same speed for heating and cooling, by using the  
jumping terminal on the blower motor and connecting it  
to the desired speed with both the red and black wires  
connected to the jumping terminal. NOTE: The control  
board is programmed with a 40 second off delay in the  
cooling mode for optimum system performance and  
efficiency.  
System Cooling  
1. Set the thermostat’s system mode to COOL and fan  
mode to AUTO. Lower the thermostat’s temperature  
mode below room temperature and observe that the  
blower energizes. Check the air being discharged at  
the register is cooler than room temperature. Verify  
unit refrigerant pressures are in order. Blower should  
be turning in direction indicated by arrow.  
CAUTION:  
NOTE: DO NOT alter unit wiring.Listen for any unusual  
noises. Locate the source and correct as needed.  
To avoid personal injury or property damage,  
make sure the motor leads do not come into  
contactwithanyuninsulatedmetalcomponents  
of the unit.  
2. Allow the unit to run for several minutes and then set  
the thermostat’s temperature above room temperature.  
Verify the blower cycles off with the thermostat.  
For optimum system performance and comfort, it may be  
necessary to change the factory set speed. See Table 5  
(page 19) for airflow data. To change the blower speed:  
1.Disconnect all electrical power to the unit and remove  
the upper door.  
2.Remove the black and red wires from the blower motor  
jumping terminal. Discard the blower motor jumping  
terminal.  
System Heating  
1.Set the thermostat’s system mode to HEAT and the fan  
mode to AUTO. Increase the thermostat’s temperature  
above room temperature and observe that the blower  
energizes.Checktheairbeingdischargedattheregister  
is warmer than room temperature.  
2. Allow the unit to run for several minutes and then set  
the thermostat’s temperature below room temperature.  
Verify the blower cycles off with the thermostat.  
3.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.  
Selecting Minimum Electric Heat Airflow  
The minimum electric heat airflow setting controls the  
minimum air flow that will be produced whenever electric  
heater kits are used. When the electric heater kit is  
energized along with a heat pump, the airflow may be  
higher depending on the basic cooling/heat-pump airflow  
setting. The minimum electric heat airflow is selected by  
theredblowerwireon3-speedmodelsorsettingswitches  
1,2,3 & 4 on HMG**X1E models. HCG**V1E models  
• Terminal 4 = Hi speed  
• Terminal 5 = Med speed  
• Terminal 6 = Low speed  
14  
4.Replace the upper door and secure it to the unit.  
5.Restore power to the unit.  
• Formaximumdehumidification,selectanairflownearthe  
middle or bottom of the range for that nominal capacity.  
Additional information on humidity control can be found  
in the Humidistat and Delay Setting sections.  
• For thermostats with a dehumidifier output, use a field  
supplied wire to connect the thermostat’s dehumidifier  
output to the terminal marked DHUM. The thermostat  
should be set so that the DHUM output should be high  
(energized) when dehumidification is needed.See also  
Dehumidification Options section.  
High Efficiency Units (Variable & Fixed Speed)  
IMPORTANT! This air handler has been designed to  
give the installer maximum flexibility to optimize system  
performance, efficiency, and comfort. Because there  
are so many different ways to set up the air handler it is  
important to read and follow these directions carefully.  
HMG**X1E & HCG**V1E series air handlers use high  
efficiencycirculatingairmotorsthatcomeintwovariations  
and both are controlled differently.The fixed speed motor  
control board (Figure 16, page 24) controls the torque  
and the variable speed motor control board (Figure 17)  
controls the airflow at a constant CFM. Both boards use  
the same control board.  
IMPORTANT! If coil icing is observed, the basic cooling/  
heat-pump airflow selected may be too low. Verify the  
setting selected is within the range shown in Table 8 and  
thatthethesystemisproperlycharged.Pleaserefertothe  
instructionssuppliedwiththeoutdoorunit.Ificingcontinues  
to occur, raise the selected airflow one or two steps.  
Before operation, the air handler must be configured to  
matchtheunitwiththesystem,systemoptions,andclimatic  
conditions. When configured, the air handler responds  
directly to the thermostat inputs, as well as the optional  
humidistat (see page 13). During normal operation, the  
motor will gradually change speeds during start-up, shut  
down, whenthermostatinputschange, andwhentheduct  
static pressure changes (vents closed or opened, filter  
clogging, etc.). The air handler is configured by setting  
the selector switches and removing jumper connectors.  
NOTE: Variable speed air handlers with SEER ratings  
higherthan15arematchedwitha2-stagecoolingoutdoor  
unit. They are programmed to operate at 75% of the  
selected airflow while the system is in the lo-cool mode  
and 100% of the selected airflow while in hi-cool mode.  
Dehumidification Options  
(HMG**X1E or HCG**V1E Models Only)  
Both motor control boards (Figures 16 & 17, page 24)  
have a DHUM connection that allows the system to  
increase the amount of humidity that is removed from  
the circulating air. This is accomplished by reducing the  
CFM and allowing the cooling coil to become colder.This  
will only occur when there is a call for cooling. There are  
many ways that this can be electrically wired.  
Selecting Basic Heating Airflow  
Fixed & variable speed motor control boards (Figures 16  
& 17) contain a set of dip switches for setting the blower  
speed.For HMG**X1E models, pins 1-4 set the speed for  
heating. For HCG**V1E models, the A/B switch must be  
set for the appropriate air handler size (either setting can  
be used for 48K or 60K BTUH applications).The airflow is  
set automatically based on the amount of installed heat.  
For both HMG**X1E & HCG**V1E models, the cooling  
speed is selected via switches 5,6,7,& 8. To determine  
the appropriate switch settings for your installation, see  
Tables 6, 7, 8, or 9 (pages 20 - 22).  
1. If the room thermostat incorporates a humidity sensor  
andDHUMoutput,connecttheDHUMonthethermostat  
to the DHUM terminal on the motor control board.  
2. If using a separate humidistat, connect the DHUM & R  
terminals on the humidistat to the DHUM & R terminals  
on the motor control board of the air handler. In this  
option, the DHUM output of the humidistat must be set  
to be normally open and closed when there is a call for  
humidification. See Figure 11.  
Selecting Basic Cooling / Heat Pump Airflow  
3.If a humidistat is not available, it is an acceptable option  
to connect the R & DHUM terminals on the motor  
control board together with a field supplied wire. This  
option causes the blower to run at a reduced CFM for  
10 minutes after a call for cooling. NOTE: If outdoor  
unit is a heat pump, connect the O terminal to DHUM.  
Thebasiccooling/heat-pumpairflowiscontrolledbysetting  
switches 5 - 8 on the motor control board (mounted on the  
blower). All airflows for other modes of operation (except  
electric heat) are determined by this basic setting. FAN  
ONLY would deliver 50% of the selected cooling airflow.  
Table 8 (page 21) lists the basic airflow values versus the  
airflowselectorswitchsettingsandrangesofbasicairflow  
settings recommended for each nominal system capacity.  
MOTOR  
CONTROL BOARD  
HUMIDISTAT  
• When operating in the heat pump mode, a higher  
basic airflow setting will increase the energy efficiency  
and capacity but will also decrease the supply air  
temperature.  
DHUM  
R
DHUM  
R
• For maximum capacity and energy efficiency, select an  
airflow at or near the top of the range for that nominal  
capacity. See Table 8 (page 21).  
Figure 11. DHUM Wiring Configuration  
15  
UNIT MAINTENANCE  
FURNACE SIZE (bTUH)  
FILTER SIZE  
Propermaintenanceismostimportanttoachievethebest  
performance from a air handler.Some of the components  
and their locations are shown in Figure 13 (page 18). If  
any component of the air handler must be replaced, use  
only factory authorized replacement parts specified in the  
Replacement Parts List provided online.  
24K & 30K  
36K & 42K  
48K & 60K  
12 x 20 x 1  
18 x 20 x 1  
20 x 20 x 1  
Table 2. Filter Sizes  
blower Compartment  
Dirt and lint can create excessive loads on the motor  
resulting in higher than normal operating temperatures  
and shortened service life. It is recommended that the  
blower compartment be cleaned of dirt or lint that may  
have accumulated in the compartment or on the blower  
and motor as part of the annual inspection.  
WARNING:  
ELECTRICAL SHOCK, FIRE OR EXPLOSION  
HAZARD  
Failure to follow safety warnings exactly could  
result in serious injury or property damage.  
blower Fan Wheel  
Inspect the blower wheel blades for accumulations of dirt  
and clean if necessary.Inspect mounting nut for tightness  
when done.  
Improper servicing could result in dangerous  
operation, serious injury, death or property  
damage.  
blower Motor & Assembly  
•Beforeservicing,disconnectallelectricalpower  
to air handler.  
• When servicing controls, label all wires prior  
to disconnecting. Reconnect wires correctly.  
• Verify proper operation after servicing.  
Inspect the blower assembly and motor mounting  
brackets for tightness and corrosion.Correct deficiencies  
if necessary.The blower motor contains sealed bearings  
and under normal operating conditions, no maintenance  
is necessary for the life of the equipment.  
• These maintenance instructions are primarily intended  
toassistqualifiedtechniciansexperiencedintheproper  
maintenance and operation of this appliance.  
TROUbLESHOOTING  
If the air handler fails to operate, check the following:  
• Is the electric turned on?  
• Always reinstall the doors on the air handler after  
servicingorcleaning/changingthefilters.Donotoperate  
theairhandlerwithoutalldoorsandcoversinplace.  
• Verify that the thermostat is properly installed and is  
not being affected by drafts or heat from lamps or other  
appliances.  
• To achieve the best performance and minimize  
equipment failure, it is recommended that a yearly  
maintenance checkup be performed. At a minimum,  
this check should include the following items:  
• Is the thermostat operating properly?  
• Are the blower compartment door(s) in place?  
• Is the air handler disconnect closed?  
• Has the circuit breaker tripped or the control board fuse  
burned open?  
• Are any manual reset switches open?  
• Is the filter dirty or plugged?  
• Is the LED on both control boards constantly ON? If  
not, refer to Tables 3 or 4 to determine fault condition.  
Air Filter(s)  
RED LED (AN2)  
DIAGNOSTIC  
HMG**F1E, HMG**X1E & HCG**V1E series air handlers  
are not supplied with a single air filter when shipped from  
the factory. It is recommended that the filter be cleaned  
or replaced monthly. Newly built or recently renovated  
homes may require more frequent changing until the  
construction dust has minimized. Filter sizes shown in  
Table 2 are available at most local retailers.  
OFF  
Flash  
ON  
Control Fault (No Power)  
Blower Fault  
Normal Operation  
Table 3. Air handler Control board Fault Conditions  
GREEN  
LED  
RED  
LED  
DIAGNOSTIC  
Control Fault (No Power)  
Normal Operation  
Off  
On  
Off  
On  
WARNING:  
Fixed  
Speed  
Furnaces  
Motor Fault  
On  
Flash  
On  
Never operate the air handler without a filter in  
place. Dust and lint in the return air can build  
up on internal components, resulting in loss of  
efficiency,equipmentdamage,andpossiblefire.  
Twin Fault (no motor fault)  
Communications Fault  
Control Fault (No Power)  
Normal Operation  
Flash  
Flash  
Off  
Flash  
Off  
Variable  
Speed  
Furnaces  
On  
On  
Filters designed to remove smaller particles such as  
pollen, may require additional maintenance.  
Motor Fault  
On  
Flash  
Flash  
Communications Fault  
Flash  
Table 4. Motor Control board Fault Conditions  
16  
FIGURES & TAbLES  
3/4”  
3/4”  
3/4”  
13”  
11/8” K.O.  
(typ.)  
“A”  
1 7/8" K.O.  
11/4”  
15/8”  
17/8”  
11/4”  
3 1/4”  
2 5/8”  
1 7/8”  
1 1/8”  
7/8" K.O.  
11/8” K.O.  
(typ.)  
1 7/8”  
3 5/8”  
5 5/8”  
13/4” K.O.  
(typ.)  
DETAIL “D”  
“H”  
3 1/4”  
2 1/4”  
SUCTION  
LIQUID  
15 1/4”  
13”  
“W”  
22"  
FURNACE SIZE (bTUH)  
H
W
A
Detail D  
24K & 30K  
36K (HMG**F1E Only)  
36K & 42K  
43-5/16  
43-5/16  
49-5/16  
55-15/16  
14-3/16  
12-3/4  
18-1/4  
18-1/4  
21  
No  
No  
No  
Yes  
19-11/16  
19-11/16  
22-7/16  
48K & 60K  
Figure 12. HMG**F1E, HMG**X1E & HCG**V1E Series Physical Dimensions  
17  
Circuit  
Breaker (60A)  
Heating Element  
Assembly  
Transformer  
Motor Control  
Board  
Blower  
Wheel  
Control  
Board  
Upper Door  
Assembly  
Capacitor  
Motor  
Mount Kit  
Blower  
Housing  
Blower  
Motor  
Coil  
Assembly  
Filter  
Door  
Horizontal  
Drain Pan  
Vertical  
Drain Pan  
Filter  
Tracks  
Lower Door  
Assembly  
Figure 13. HMG**F1E, HMG**X1E & HCG**V1E Series Air Handler Components  
18  
AIRFLOW DATA  
Dry Coil ESP  
0.10  
0.20  
0.30  
0.40  
0.50  
0.60  
0.70  
0.80  
Low  
683  
0.00  
861  
647  
0.07  
823  
607  
0.19  
781  
563  
0.30  
734  
515  
0.42  
682  
463  
0.53  
625  
406  
0.65  
564  
345  
0.76  
498  
Corrected ESP1  
Medium  
HMG24F1E  
HMG30F1E  
HMG36F1E  
HMG42F1E  
Corrected ESP1  
High  
Corrected ESP1  
0.00  
1072  
0.00  
849  
0.00  
1026  
0.00  
825  
0.11  
975  
0.23  
920  
0.36  
860  
0.48  
797  
0.60  
730  
0.72  
659  
0.00  
793  
0.14  
753  
0.27  
704  
0.40  
647  
0.53  
581  
0.67  
508  
Low  
Corrected ESP1  
Medium  
0.00  
1118  
0.00  
1277  
0.00  
953  
0.04  
1087  
0.00  
1233  
0.00  
915  
0.15  
1046  
0.04  
1184  
0.00  
871  
0.27  
997  
0.38  
940  
0.50  
874  
0.62  
799  
0.74  
717  
Corrected ESP1  
0.17  
1130  
0.10  
821  
0.29  
1070  
0.23  
764  
0.42  
1005  
0.36  
701  
0.55  
935  
0.68  
860  
High  
Corrected ESP1  
Low  
0.49  
631  
0.63  
555  
Corrected ESP1  
0.00  
1265  
0.00  
1427  
0.00  
1324  
0.00  
1485  
0.00  
1637  
0.00  
1605  
0
0.04  
1232  
0.00  
1385  
0.00  
1302  
0.06  
1455  
0.00  
1601  
0.00  
1606  
0.11  
1939  
0
0.16  
1188  
0.03  
1333  
0.00  
1271  
0.17  
1418  
0.13  
1558  
0.00  
1592  
0.21  
1890  
0.18  
2095  
0
0.27  
1133  
0.15  
1270  
0.09  
1233  
0.27  
1373  
0.24  
1506  
0.21  
1565  
0.31  
1830  
0.28  
2003  
0.26  
0.39  
1067  
0.28  
1196  
0.23  
1187  
0.38  
1320  
0.36  
1447  
0.33  
1524  
0.42  
1758  
0.39  
1906  
0.37  
0.51  
991  
0.62  
903  
0.74  
805  
Medium  
Corrected ESP1  
High  
Corrected ESP1  
0.41  
1113  
0.36  
1134  
0.49  
1260  
0.47  
1380  
0.44  
1468  
0.52  
1675  
0.50  
1805  
0.49  
0.54  
1018  
0.50  
1072  
0.61  
1193  
0.58  
1305  
0.56  
1399  
0.63  
1580  
0.61  
1698  
0.60  
0.68  
913  
0.64  
1003  
0.72  
1118  
0.70  
1223  
0.68  
1316  
0.74  
1474  
0.72  
1586  
0.71  
Low  
Corrected ESP1  
Medium  
Corrected ESP1  
High  
Corrected ESP1  
Low  
Corrected ESP1  
Medium  
1977  
0
HMG48F1E  
HMG60F1E  
Corrected ESP1  
High  
Corrected ESP1  
2264  
0
2182  
0
Use HMG**X1E airflow data. See Table 5 (page 20).  
NOTES:  
1) Airflow is shown in cfm, +/- 5%.  
2) External static pressure (ESP) is shown in inches w.c.  
3) See unit nameplate or installation instructions for maximum recommended external static pressure.  
Table 5. Airflow Data for HMG**F1E Series Air Handlers  
19  
Cooling or Heating Airflow (CFM)  
Dry Coil ESP  
Switch Settings  
0 = OFF, 1 = ON  
1/5 2/6 3/7 4/8  
0.1  
0.2  
0.3  
0.4  
0.5  
0.6  
0.7  
0.8  
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
585  
710  
550  
670  
520  
650  
460  
610  
420  
560  
405  
530  
475  
625  
440  
580  
845  
790  
765  
715  
680  
655  
890  
865  
840  
785  
760  
710  
680  
655  
955  
925  
900  
850  
825  
790  
770  
720  
HMG24X1E  
&
HMG30X1E  
1030  
1115  
1155  
1200  
1240  
1320  
1355  
1405  
1440  
1465  
1465  
995  
975  
940  
910  
870  
840  
815  
1085  
1130  
1175  
1215  
1290  
1330  
1375  
1415  
1425  
1425  
1060  
1095  
1145  
1195  
1265  
1305  
1345  
1385  
1390  
1390  
1020  
1070  
1110  
1170  
1240  
1280  
1325  
1355  
1355  
1355  
995  
965  
925  
905  
1040  
1085  
1140  
1215  
1255  
1295  
1325  
1320  
1320  
1010  
1060  
1110  
1185  
1220  
1275  
1290  
1290  
1290  
985  
950  
1025  
1080  
1160  
1200  
1250  
1255  
1260  
1260  
1000  
1060  
1130  
1175  
1210  
1215  
1215  
1215  
Cooling or Heating Airflow (CFM)  
Dry Coil ESP  
Switch Settings  
0 = OFF, 1 = ON  
1/5 2/6 3/7 4/8  
0.1  
0.2  
0.3  
0.4  
0.5  
0.6  
0.7  
0.8  
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
600  
660  
550  
610  
430  
540  
390  
460  
425  
580  
830  
750  
695  
640  
520  
600  
860  
825  
765  
690  
630  
525  
620  
485  
585  
935  
895  
835  
790  
710  
655  
HMG36X1E  
&
HMG42X1E  
1045  
1095  
1155  
1230  
1285  
1330  
1395  
1450  
1490  
1530  
1530  
975  
920  
875  
830  
795  
720  
685  
1040  
1105  
1185  
1260  
1290  
1365  
1405  
1450  
1485  
1490  
995  
950  
900  
850  
805  
750  
1060  
1140  
1210  
1245  
1315  
1375  
1410  
1460  
1465  
1010  
1090  
1165  
1205  
1275  
1335  
1385  
1425  
1425  
965  
920  
870  
825  
1045  
1125  
1170  
1235  
1295  
1340  
1380  
1390  
1010  
1080  
1125  
1205  
1260  
1300  
1350  
1350  
965  
920  
1040  
1085  
1160  
1220  
1270  
1310  
1310  
1010  
1045  
1130  
1180  
1230  
1280  
1285  
Cooling or Heating Airflow (CFM)  
Dry Coil ESP  
Switch Settings  
0 = OFF, 1 = ON  
1/5 2/6 3/7 4/8  
0.1  
0.2  
0.3  
0.4  
0.5  
0.6  
0.7  
0.8  
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
710  
830  
580  
690  
395  
675  
530  
665  
505  
560  
930  
875  
710  
530  
705  
1065  
1185  
1275  
1365  
1480  
1560  
1650  
1730  
1785  
1865  
1920  
2010  
2065  
1015  
1115  
1220  
1350  
1430  
1535  
1600  
1685  
1740  
1820  
1890  
1965  
2020  
900  
840  
800  
665  
830  
635  
745  
1010  
1175  
1255  
1370  
1485  
1545  
1660  
1695  
1785  
1850  
1960  
1985  
960  
925  
875  
HMG48X1E  
&
HMG60X1E  
1120  
1200  
1325  
1430  
1500  
1610  
1645  
1750  
1805  
1900  
1955  
1060  
1150  
1265  
1375  
1450  
1570  
1615  
1695  
1765  
1850  
1915  
970  
930  
890  
1105  
1225  
1335  
1405  
1520  
1545  
1655  
1715  
1810  
1880  
1060  
1185  
1285  
1360  
1470  
1510  
1605  
1675  
1775  
1840  
1025  
1140  
1240  
1305  
1420  
1470  
1560  
1640  
1730  
1810  
NOTE: When matched with two-stage outdoor units, the airflow on low (Y1 or W1) input will be 70% of the values shown in this table.  
Table 6. Airflow Data for HMG**X1E Air Handlers  
20  
Nominal Electic Heat KW  
FURNACE MODELS  
5
8
10  
15  
20  
25  
30  
HMG24X1E & HMG30X1E  
HMG36X1E & HMG42X1E  
HMG48X1E & HMG60X1E  
800  
900  
900  
1000 1300  
N/A  
N/A  
N/A  
N/A  
N/A  
1000 1100 1300 1500  
1000 1100 1200 1400 1600 1800 2000  
NOTE: See Table 6 for appropriate switch settings for these airflows.  
Table 7. Minimum Heating Airflow Settings (in CFM)  
for HMG**X1E Air Handlers  
HCG24V1E & HCG30V1E  
SWITCH SETTINGS  
NOMINAL  
(1 = ON, 0 = OFF)  
CFM  
CAPACITY  
5
6
7
8
525  
560  
600  
625  
700  
750  
800  
850  
875  
890  
930  
950  
1000  
1050  
1125  
1200  
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
HCG36V1E & HCG42V1E  
HCG48V1E & HCG60V1E  
SWITCH SETTINGS  
(1 = ON, 0 = OFF)  
SWITCH SETTINGS  
(1 = ON, 0 = OFF)  
NOMINAL  
CAPACITY  
NOMICAL  
CAPACITY  
CFM  
CFM  
5
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
6
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
7
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
8
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
5
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
6
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
7
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
8
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
525  
560  
1100  
1200  
1250  
1300  
1350  
1400  
1450  
1500  
1550  
1600  
1650  
1700  
1750  
1800  
1900  
2000  
600  
650  
700  
750  
800  
850  
875  
950  
1050  
1150  
1250  
1350  
1400  
1600  
Table 8. Recommended Cooling Airflow Settings for HCG**V1E Air Handlers  
21  
Cooling Airflow  
Heating Airflow  
COOL Switch Setting  
Airflow  
(CFM)  
Heater Kit  
Installed (KW)  
Airflow  
(CFM)  
A/b Switch Setting  
0 = OFF, 1 = ON  
A/b Switch Setting  
0 = OFF, 1 = ON  
0 = OFF, 1 = ON  
5
6
7
8
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
525  
560  
600  
625  
700  
750  
800  
850  
875  
890  
930  
950  
1000  
1050  
1125  
1200  
0
0
0
0
0
0
0
0
0
600  
800  
1000  
1000  
1300  
n/a  
5
8
10  
15  
20  
25  
30  
HCG24V1E  
&
HCG30V1E  
n/a  
n/a  
Cooling Airflow  
Heating Airflow  
COOL Switch Setting  
Airflow  
(CFM)  
Heater Kit  
Installed (KW)  
Airflow  
(CFM)  
A/b Switch Setting  
0 = OFF, 1 = ON  
A/b Switch Setting  
0 = OFF, 1 = ON  
0 = OFF, 1 = ON  
5
6
7
8
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
525  
560  
1
1
1
1
1
1
1
1
0
700  
900  
5
600  
8
1100  
1100  
1300  
1500  
n/a  
650  
10  
15  
20  
25  
30  
700  
HCG36V1E  
&
HCG42V1E  
750  
800  
n/a  
850  
875  
950  
1050  
1150  
1250  
1350  
1400  
1600  
Cooling Airflow  
Heating Airflow  
COOL Switch Setting  
A/b Switch Setting  
(* = either 0 or 1)  
Airflow  
(CFM)  
A/b Switch Setting  
(* = either 0 or 1)  
Heater Kit  
Installed (KW)  
Airflow  
(CFM)  
0 = OFF, 1 = ON  
5
6
7
8
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
1100  
1200  
1250  
1300  
1350  
1400  
1450  
1500  
1550  
1600  
1650  
1700  
1750  
1800  
1900  
2000  
*
*
*
*
*
*
*
*
0
800  
5
1000  
1200  
1200  
1400  
1600  
1800  
2000  
8
10  
15  
20  
25  
30  
HCG48V1E  
&
HCG60V1E  
NOTES:  
•
•
Airflow values listed are for 240V operation. For  
208V operation, multiply the CFM value by .95 for  
HCG24V1E, HCG30V1E, HCG36V1E, & HCG42V1E units.  
For HCG48V1E & HCG60V1E units, mulitply the CMF value  
by .90.  
When matched with two-stage outdoor units the airflow on  
low (Y1 or W1) input only will be 70% of the values shown in  
this table.  
Table 9. Airflow Data for HCG**V1E Air Handlers  
22  
ELECTRICAL DIAGRAMS & DATA  
W
C Y G R  
P2  
3A Fuse  
BLWDTC  
BLWDTC_R  
L 2  
L 1  
EAC  
COOL  
HEAT  
LED 1  
HEATER P1  
Figure 14. Single Stage Control board  
1 Y 2 W L 1 W  
O
Y 2 / Y  
R
G
C
P3  
P2  
LED 1  
HEATER P1  
Figure 15.Two - Stage Control board  
23  
TEST PORT  
W1  
EXPANSION  
PORT  
FAN SPEED  
8
1 2 3 5 6 7  
4
COOL  
HEAT  
STATUS  
BLOWER MOTOR  
Figure 16. Fixed Speed Motor Control board  
STATUS LIGHTS  
L2-IN  
L2-OUT  
W
Y/Y2  
Y1  
L1-IN  
L1-OUT  
H
DEHUM  
Y1  
FAN SPEED  
8
2 3 5 6 7  
4
TEST PORT  
R
C
COOL  
HEAT  
SENSOR  
GND  
EXPANSION PORT  
BLOWER MOTOR  
Figure 17. Variable Speed Motor Control board  
24  
C K B L A  
R E D  
RELAY  
R E D  
Y
G R A  
G R E E N  
W H I T E  
O W Y E L L  
Figure 18. Wiring Diagram for HMG**F1E Series Air Handler  
25  
BLUE  
GREEN  
YELLOW  
ORANGE  
RED  
BLUE  
GREEN  
YELLOW  
ORANGE  
RED  
BROWN  
BROWN  
EXPANSION  
L1  
L2  
HUM  
EAL  
HEATER PLUG  
Figure 19. Wiring Diagram for HMG**X1E Series Air Handler  
26  
WHITE  
BLACK  
1
2
3
4
5
6
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
9
9
1
2
3
4
5
6
Y
G R A  
EXPANSION  
W H I T E  
K
A C B L  
L1  
L2  
HUM  
EAL  
HEATER PLUG  
Figure 20. Wiring Diagram for HCG**V1E Series Air Handler  
27  
HMG**F1E SERIES  
240 VAC, 50 & 60 HZ, SINGLE PHASE  
208 VAC, 50 & 60 HZ, SINGLE PHASE  
MCA MOP  
MCA  
MOP  
HEAT KIT  
MODEL  
NUMbER  
H6HK-  
AIR HANDLER  
MODEL  
None  
1.6  
26.6  
41.2  
51.6  
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
1.6  
15  
-
-
-
-
-
-
-
-
-
30  
-
-
-
-
-
-
30  
60  
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
15  
1.6  
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
1.6  
15  
-
-
-
-
-
-
-
-
-
25  
-
-
-
-
-
-
25  
45  
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
15  
25  
40  
45  
30  
15  
25  
40  
50  
70  
30  
45  
15  
25  
40  
50  
70  
90  
30  
45  
15  
25  
40  
50  
70  
90  
30  
45  
15  
30  
40  
50  
80  
100  
005H-XX  
008H-XX  
010H-XX  
009Q-XX  
None  
005H-XX  
008H-XX  
010H-XX  
015H-XX  
009Q-XX  
015Q-XX  
None  
005H-XX  
008H-XX  
010H-XX  
015H-XX  
020H-XX  
009Q-XX  
015Q-XX  
None  
005H-XX  
008H-XX  
010H-XX  
015H-XX  
020H-XX  
009Q-XX  
015Q-XX  
None  
005H-XX  
008H-XX  
010H-XX  
015H-XX  
020H-XX  
024H-XX  
029H-XX  
009Q-XX  
015Q-XX  
None  
005H-XX  
008H-XX  
010H-XX  
015H-XX  
020H-XX  
024H-XX  
029H-XX  
009Q-XX  
015Q-XX  
26.6 30  
41.2 45  
51.6 60  
28.7  
3.1  
28.1 30  
42.7 45  
53.1 60  
65.6 60  
30.2  
46.4  
2.6  
27.6 30  
42.2 45  
52.6 60  
64.7 60  
102.6 60  
29.7  
45.9  
3.1  
28.1 30  
42.7 45  
53.1 60  
65.6 60  
103.1 60  
30.2  
46.4  
5.4  
30 23.3  
45 35.9  
60 45.0  
30  
15  
30 24.8  
45 37.4  
60 46.5  
23.3 25  
35.9 40  
45.0 45  
18.8  
3.1  
24.8 25  
37.4 40  
46.5 50  
68.1 50  
26.6  
40.6  
2.6  
24.3 25  
36.9 40  
46.0 50  
67.6 50  
89.3 50  
26.1  
40.2  
3.1  
24.8 25  
37.4 40  
46.5 50  
68.1 50  
89.8 50  
26.6  
40.7  
5.4  
HMG24F1E  
HMG30F1E  
-
15  
-
-
15  
3.1  
3.1  
28.1  
42.7  
53.1  
53.1 25.0  
-
80 46.5 21.7  
-
-
-
-
-
-
-
-
15  
35  
50  
15  
30 24.3  
45 36.9  
60 46.0  
80 46.0 21.7  
110 46.0 43.3  
30  
50  
15  
30 24.8  
45 37.4  
60 46.5  
80 46.5 21.7  
110 46.5 43.3  
35  
50  
15  
35 27.0  
45 39.7  
60 48.7  
-
-
-
-
-
-
-
-
-
-
15  
-
2.6  
27.6  
42.2  
52.6  
52.6 25.0  
52.6 50.0  
2.6  
HMG36F1E  
-
-
-
-
-
-
-
-
-
-
15  
-
-
-
-
-
-
-
-
-
-
15  
3.1  
28.1  
42.7  
53.1  
53.1 25.0  
53.1 50.0  
3.1  
-
-
HMG42F1E  
30  
60  
-
-
-
-
-
-
30  
60  
60  
60  
-
-
-
-
-
25  
45  
-
-
-
-
-
-
25  
45  
45  
45  
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
15  
-
-
-
-
-
-
-
-
-
-
15  
5.4  
30.4  
45.0  
55.4  
55.4 25.0  
55.4 50.0  
55.4 50.0 25.0 130.4 60  
55.4 50.0 50.0 155.4 60  
-
5.4  
30.4 35  
45.0 45  
55.4 60  
80.4 60  
105.4 60  
27.0 30  
39.7 40  
48.7 50  
70.4 50  
92.0 50  
90 48.7 21.7  
110 48.7 43.3  
HMG48F1E  
60 150 48.7 43.3 21.7 113.7 50  
60 175 48.7 43.3 43.3 135.4 50  
45 125  
45 150  
-
-
-
-
-
-
-
-
-
-
-
-
-
-
32.4  
48.7  
6.3  
31.3 35  
45.8 50  
56.3 60  
81.3 60  
106.3 60  
-
-
15  
-
-
-
-
-
-
-
-
35  
50  
15  
35 28.4  
50 41.1  
60 50.1  
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
28.8  
42.9  
6.8  
28.4 30  
41.1 45  
50.1 60  
71.8 60  
93.4 60  
-
-
15  
-
-
-
-
-
-
-
-
30  
45  
15  
30  
45  
60  
80  
100  
-
6.3  
31.3  
45.8  
56.3  
56.3 25.0  
56.3 50.0  
56.3 50.0 25.0 131.3 60  
56.3 50.0 50.0 156.3 60  
-
-
6.8  
-
-
30  
60  
60  
60  
-
90 50.1 21.7  
110 50.1 43.3  
25  
45  
45  
45  
-
HMG60F1E  
30 150 50.1 43.3 21.7 115.1 60  
60 175 50.1 43.3 43.3 136.8 60  
-
-
25 125  
45 150  
-
-
-
-
-
-
33.3  
49.6  
-
-
35  
50  
-
-
-
-
-
-
30.2  
44.3  
-
-
35  
45  
-
-
Table 10. HMG**F1E Series Minimum Circuit Ampacity & Maximum Overcurrent Protection  
28  
HMG**X1E & HCG**V1E  
240 VAC, 50 & 60 HZ, SINGLE PHASE  
208 VAC, 50 & 60 HZ, SINGLE PHASE  
MCA MOP  
MCA  
MOP  
HEAT KIT  
MODEL  
NUMbER  
H6HK-  
AIR HANDLER  
MODELS  
None  
4.5  
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
4.5  
15  
-
-
-
-
30  
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
15  
4.8  
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
4.8  
15  
-
-
-
-
25  
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
15  
30  
40  
50  
70  
30  
45  
15  
30  
40  
50  
70  
100  
30  
45  
15  
30  
45  
60  
80  
100  
HMG24X1E  
HMG30X1E  
&
HCG24V1E  
HCG30V1E  
005H-XX 29.5  
008H-XX 44.1  
010H-XX 54.5  
29.5 30  
44.1 45  
54.5 60  
68.1 60  
31.6  
47.8  
4.5  
29.5 30  
44.1 45  
54.5 60  
68.1 60  
104.5 60  
31.6  
47.8  
6.3  
30 26.4  
45 39.1  
60 48.1  
26.4 30  
39.1 40  
48.1 50  
69.8 50  
28.2  
42.3  
4.8  
26.4 30  
39.1 40  
48.1 50  
69.8 50  
91.4 50  
28.2  
42.3  
6.8  
015H-XX 54.5 25.0  
80 48.1 21.7  
009Q-XX  
015Q-XX  
None  
005H-XX 29.5  
008H-XX 44.1  
010H-XX 54.5  
015H-XX 54.5 25.0  
020H-XX 54.5 50.0  
009Q-XX  
015Q-XX  
None  
005H-XX 31.3  
008H-XX 45.8  
010H-XX 56.3  
015H-XX 56.3 25.0  
020H-XX 56.3 50.0  
024H-XX 56.3 50.0 25.0 131.3 60  
029H-XX 56.3 50.0 50.0 156.3 60  
009Q-XX  
015Q-XX  
-
-
-
-
-
-
-
-
-
-
15  
35  
50  
15  
30 26.4  
45 39.1  
60 48.1  
80 48.1 21.7  
110 48.1 43.3  
35  
50  
15  
35 28.4  
50 41.1  
60 50.1  
90 50.1 21.7  
110 50.1 43.3  
-
-
-
-
-
-
-
-
-
-
15  
4.5  
4.8  
HMG36X1E  
HMG42X1E  
&
HCG36V1E  
HCG42V1E  
-
-
30  
60  
-
-
-
-
-
-
30  
60  
60  
60  
-
25  
45  
-
-
-
-
-
-
25  
45  
45  
45  
-
-
-
-
-
-
-
-
-
-
-
15  
-
-
-
-
-
-
-
-
-
-
15  
6.3  
6.8  
31.3 35  
45.8 50  
56.3 60  
81.3 60  
106.3 60  
28.4 30  
41.1 45  
50.1 60  
71.8 60  
93.4 60  
HMG48X1E  
HMG60X1E  
&
HCG48V1E  
HCG60V1E  
60 150 50.1 43.3 21.7 115.1 60  
60 175 50.1 43.3 43.3 136.8 60  
-
-
45 125  
45 150  
-
-
-
-
-
-
-
-
33.3  
49.6  
-
-
35  
50  
-
-
-
-
-
-
30.2  
44.3  
-
-
35  
45  
-
-
Table 11. HMG**X1E & HCG**V1E Minimum Circuit Ampacity & Maximum Overcurrent Protection  
CONTROL SIGNAL & MODE OPERATION  
TOTAL KW  
bOARD ACTION  
Stage 1 Heat on instantly  
5 KW  
Heat blower on after 3 second delay  
Stage 1 Heat on instantly  
10 KW  
15 KW  
Heat blower on after 3 second delay  
Stage 1 Heat on instantly  
Heat blower on after 3 second delay  
Stage 2 Heat on after 5 second delay  
Stage 1 Heat on instantly  
Heat blower on after 3 second delay  
Stage 2 Heat on after 5 second delay  
Stage 3 Heat on after 10 second delay  
Stage 1 Heat on instantly  
20 KW  
25 KW  
ON  
W1 only  
EHEAT  
Heat blower on after 3 second delay  
Stage 2 Heat on after 5 second delay  
Stage 3 Heat on after 10 second delay  
Stage 1Heat on instantly  
Heat blower on after 3 second delay  
Stage 2 Heat on after 5 second delay  
Stage 3 Heat on after 10 second delay  
Stage 4 Heat on after 15 second delay  
Heat stages off instantly  
30 KW  
OFF  
Blower off after 15 second delay  
Table 12. Control board Operation  
29  
CONTROL SIGNAL & MODE OPERATION  
TOTAL KW  
bOARD ACTION  
Stage 1 Heat on instantly  
5 KW  
Heat blower on after 3 second delay  
Stage 1 Heat on instantly  
10 KW  
15 KW  
Heat blower on after 3 second delay  
Stage 2 Heat on after 5 seconds delay  
Stage 1 Heat on instantly  
Heat blower on after 3 second delay  
Stage 2 Heat on after 5 seconds delay  
Stage 3 Heat on after 10 seconds delay  
Stage 1 Heat on instantly  
Heat blower on after 3 second delay  
Stage 2 Heat on after 5 seconds delay  
Stage 3 Heat on after 10 seconds delay  
Stage 4 Heat on after 15 seconds delay  
Stage 1 Heat on instantly  
20 KW  
25 KW  
ON  
W1 & W2  
EHEAT  
Heat blower on after 3 second delay  
Stage 2 Heat on after 5 seconds delay  
Stage 3 Heat on after 10 seconds delay  
Stage 4 Heat on after 15 seconds delay  
Stage 5 Heat on after 20 seconds delay  
Stage 1Heat on instantly  
Heat blower on after 3 second delay  
Stage 2 Heat on after 5 seconds delay  
Stage 3 Heat on after 10 seconds delay  
Stage 4 Heat on after 15 seconds delay  
Stage 5 Heat on after 20 seconds delay  
Stage 6 Heat on after 25 seconds delay  
Heat stages off instantly  
30 KW  
OFF  
Blower off after 15 second delay  
Stage 1 Heat on instantly  
5 KW  
Cool blower on after 3 second delay  
Stage 1 Heat on instantly  
10 KW  
Cool blower on after 3 second delay  
Stage 1 Heat on instantly  
15 KW  
20 KW  
Cool blower on after 3 second delay  
Stage 2 Heat on after 5 seconds delay  
Stage 1 Heat on instantly  
Cool blower on after 3 second delay  
Stage 2 Heat on after 5 seconds delay  
Stage 3 Heat on after 10 seconds delay  
Stage 1 Heat on instantly  
ON  
W1 & Y/Y2  
AUX HEAT  
Cool blower on after 3 second delay  
Stage 2 Heat on after 5 seconds delay  
Stage 3 Heat on after 10 seconds delay  
Stage 1 Heat on instantly  
25 KW  
30 KW  
Cool blower on after 3 second delay  
Stage 2 Heat on after 5 seconds delay  
Stage 3 Heat on after 10 seconds delay  
Stage 4 Heat on after 15 seconds delay  
Heat stages off instantly  
OFF  
Heat blower turns off after 40 second delay  
Table 12. Control board Operation - Continued  
30  
CONTROL SIGNAL & MODE OPERATION  
TOTAL KW  
bOARD ACTION  
Stage 1 Heat on instantly  
5 KW  
Cool blower on after 3 second delay  
Stage 1 Heat on instantly  
10 KW  
15 KW  
Cool blower on after 3 second delay  
Stage 2 Heat on after 5 seconds delay  
Stage 1 Heat on instantly  
Cool blower on after 3 second delay  
Stage 2 Heat on after 5 seconds delay  
Stage 3 Heat on after 30 seconds delay  
Stage 1 Heat on instantly  
Cool blower on after 3 second delay  
Stage 2 Heat on after 5 seconds delay  
Stage 3 Heat on after 10 seconds delay  
Stage 4 Heat on after 15 seconds delay  
Stage 1Heat on instantly  
20 KW  
25 KW  
ON  
W1, W2 & Y/Y2  
AUX HEAT  
Cool blower on after 3 second delay  
Stage 2 Heat on after 5 seconds delay  
Stage 3 Heat on after 10 seconds delay  
Stage 4 Heat on after 15 seconds delay  
Stage 5 Heat on after 20 seconds delay  
Stage 1Heat on instantly  
Cool blower on after 3 second delay  
Stage 2 Heat on after 5 seconds delay  
Stage 3 Heat on after 10 seconds delay  
Stage 4 Heat on after 15 seconds delay  
Stage 5 Heat on after 20 seconds delay  
Stage 6 Heat on after 25 seconds delay  
Heat stages off instantly  
30 KW  
OFF  
Heat blower turns off after 40 second delay  
On  
Off  
On  
Off  
On  
Off  
On  
Off  
Fan blower on after 3 second delay  
Fan blower off instantly  
G
FAN  
Cool blower on after 3 second delay  
Cool blower off after 40 second delay  
Cool blower on after 3 second delay  
Cool blower off after 40 second delay  
Cool blower on after 3 second delay  
Cool blower off after 40 second delay  
Y/Y2  
HEAT PUMP & COOL  
Y1  
HEAT PUMP & COOL  
Y1 & Y/Y2  
HEAT PUMP & COOL  
Table 12. Control board Operation - Continued  
31  
INSTALLATION / PERFORMANCE CHECK LIST  
INSTALLER NAME:  
ELECTRICAL SYSTEM:  
Electrical connections tight?  
Line voltage polarity correct?  
YES  
YES  
NO  
NO  
CITY:  
STATE:  
STATE:  
Supply Voltage: ___________________________________(V)  
INSTALLATION ADDRESS:  
Has the thermostat been calibrated?  
Is the thermostat level?  
YES  
YES  
YES  
NO  
NO  
NO  
CITY:  
UNIT MODEL #  
Is the heat anticipator setting correct?  
UNIT SERIAL #  
ATTENTION INSTALLERS:  
Minimum clearances per page 4?  
YES  
NO  
NO  
Itisyourresponsibilitytoknowthisproductbetterthanyourcustomer.  
This includes being able to install the product according to strict  
safety guidelines and instructing the customer on how to operate  
and maintain the equipment for the life of the product. Safety should  
always be the deciding factor when installing this product and using  
common sense plays an important role as well. Pay attention to all  
safetywarningsandanyotherspecialnoteshighlightedinthemanual.  
Improper installation of the air handler or failure to follow safety  
warnings could result in serious injury, death, or property damage.  
Is the unit properly installed and  
leveled?  
YES  
YES  
YES  
YES  
Does condensate drain properly  
in both drain tubes?  
NO  
NO  
NO  
Has the owner’s information been  
reviewed with the home-owner?  
Has the literature package been  
left near the appliance?  
Theseinstructionsareprimarilyintendedtoassistqualifiedindividuals  
experienced in the proper installation of this appliance. Some local  
codes require licensed installation/service personnel for this type of  
equipment. Please read all instructions carefully before starting the  
installation. Return these instructions to the customer’s package for  
future reference.  
Specifications & illustrations subject to change without notice or incurring obligations.  
Jackson, MI | Printed in U.S.A. (11/12)  
709557A (Replaces 7095570)  

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