Electric Heater KitFor use with GB, GP and GT SeriesGeothermal Heat Pumps

Installation Instructions

KWAEH0101N05KWAEH0101N10KWAEH0101F15KWAEH0101F20

NOTE: Read the entire instruction manual before starting theinstallation.

SAFETY CONSIDERATIONSImproper installation, adjustment, alteration, service, maintenance,or use can cause explosion, fire, electrical shock, or otherconditions which may cause death, personal injury, or propertydamage. Consult a qualified installer, service agency, or yourdistributor or branch for information or assistance. The qualifiedinstaller or agency must use factory--authorized kits or accessorieswhen modifying this product. Refer to the individual instructionspackaged with the kits or accessories when installing.Follow all safety codes. Wear safety glasses, protective clothing,and work gloves. Use quenching cloth for brazing operations.Have fire extinguisher available. Read these instructionsthoroughly and follow all warnings or cautions included inliterature and attached to the unit.. Consult local building codesand current editions of the National Electrical Code ( NEC ) NFPA70. In Canada, refer to current editions of the Canadian electricalcode CSA 22.1.

Recognize safety information. This is the safety--alert symbol !! .When you see this symbol on the unit and in instructions ormanuals, be alert to the potential for personal injury.Understand the signal words DANGER, WARNING, andCAUTION. These words are used with the safety--alert symbol.DANGER identifies the most serious hazards which will result insevere personal injury or death. WARNING signifies hazardswhich could result in personal injury or death. CAUTION is usedto identify unsafe practices which may result in minor personalinjury or product and property damage. NOTE is used to highlightsuggestions which will result in enhanced installation, reliability, oroperation.

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury ordeath.

Before beginning any installation or modification, be sure themain electrical disconnect switch is in the OFF position. TAGTHE DISCONNECT SWITCH WITH A SUITABLEWARNING LABELUnit contains two power supplies -- make sure BOTH are offbefore servicing.

! WARNING

UNIT DAMAGE HAZARD

Failure to follow this caution may result in compressordamage.

NEVER turn unit on its top or side to install support feet.

CAUTION!

UNIT DAMAGE HAZARD

Failure to follow this caution may result in unit damage.

This Electric Heater Kit is designed for installation in the heatpump model published in this document. Do not install thisheater kit in a heat pump not specified in this manual.

CAUTION!

CUT HAZARD

Failure to follow this caution may result in personal injury.

Sheet metal parts may have sharp edges or burrs. Use care andwear appropriate protective clothing and gloves whenhandling parts.

CAUTION!

INTRODUCTIONThe Electric Heater Kit is a field installable electric resistanceheater kit designed for the GB, GP and GT series heat pumps.The heater kit requires separate electrical service connection,independent from the heat pump’s power supply. Installation ofthis Heater Kit will convert the heat pump into a two point powerconnection. The Heater Kit is available in several kW capacities.Unit tonnage vs Heater Kit capacity compatibility table is below.The Heater Kit can be installed on vertical (VT), horizontal (HZ)and counter--flow (CF) units.

Aux. Heat Size CompatibilityGHP Model 5 Kw 10 Kw 15 Kw 20 KwGT024 • • --- ---GT036 • • • ---GT048 • • • •GT060 • • • •GT072 • • • •GP024 • • --- ---GP036 • • • ---GP048 • • • •GP060 • • • •GP072 • • • •GB018 • --- --- ---GB024 • • --- ---GB030 • • --- ---GB036 • • • ---GB042 • • • ---GB048 • • • •GB060 • • • •

• = Heater Kit compatible / — = Heater Kit NOT compatible

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AUXILIARY HEATER KIT NOMENCLATURE

1 2 3 4-5 6-7 8-9 10 11-12

K W A EH 01 01 F 15

Kit KW05 Kw

Usage 10 Kw

W = Water Source / Geothermal 15 Kw

20 Kw

SeriesA = Current Circuit Protection

F = Fused (15, 20 Kw)

Type N = Non-fused (5, 10 Kw)

EH = Electric Heat

PackSequential 01 = Single

01 = Current

PRE--INSTALLATION

UNIT DAMAGE HAZARD

Failure to follow this caution may result in unit damage.

DO NOT wire the heater elements into the same circuit as thecompressor.

CAUTION!

IMPORTANT: Electric Heater Kit can only be installed on singlephase units.IMPORTANT: A heater collar is installed in the geothermal heatpumps so there is no need to order a collar separately.

IMPORTANT: A heat pump thermostat with supplemental electricheat feature is required to operate the system when this kit isinstalled.

Unpacking and Inspection1. Unpack the heater kit and inspect contents and condition. Ifany part or the kit appears damaged (i.e.: broken heater ele-ments, damage relays) or missing, do not attempt to installthe kit. Contact your local distributor for further help.

2. Ensure that the heater kit package includes all the listedcomponents. Contact your local distributor for further help.

Components List:

S Pre--wired heater electrical box (including fuses onKWAEH0101F15 and KWAEH0101F20)

S Heater elements

S Heater element(s) protective metal cover

S Wire harness pre--wired at one end .

S Wiring diagram

S Adhesive backed electrical data label

S Clear hardware accessory bag containing:-- Heater element mounting screws(4 for each element bank)

-- Heater element cover mounting screws(2 for each cover)

-- Four electrical box mounting screws-- Push in wire ties-- This installation manual

Required Tools:S Phillips screwdriver

S Small flat head screwdriver

S 5/16” socket and a ratchet or drill

S Wire cutter

S Wire stripper

S Torque Phillips head screwdriver

S Multi meterELECTRIC HEAT KIT

The Electric Heat field installed kit contains two main electricalenclosures: Electric Heat Control Box and Electric Heat Elements,both are located in the blower compartment. (Fig. 1 through Fig. 4)The control box attaches to the corner post and the heat elements tothe blower heater collar in the blower compartment.

Fig. 1 — Electric Heater Element Cover (1) and Electric HeatControl Box (2) Location -- Vertical Configuration

Fig. 2 — Electric Heater Element Cover (1) and Electric HeatControl Box (2) Location -- Counterflow Configuration

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Fig. 3 — Electric Heater Element Cover (1) and Electric HeatControl Box (2) Location -- RH Horiz. End Discharge Config.

Fig. 4 — Electric Heater Element Cover (1) and Electric HeatControl Box (2) Location -- LH Horiz. End Discharge Config.

INSTALLATION -- HARDWARE1. At Thermostat Turn system to “OFF”2. Turn the main power to the heat pump to “OFF” at theunit’s disconnect switch or breaker panel.

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury ordeath.

Before beginning any installation or modification, be sure themain electrical disconnect switch is in the OFF position. TAGTHE DISCONNECT SWITCH WITH A SUITABLEWARNING LABELUnit contains two power supplies -- make sure BOTH are offbefore servicing.

! WARNING

3. Prior to removing the blower panel, disconnect unit displayfrom the back of the panel (see Fig. 5)

Fig. 5 — Disconnect Unit Display

4. Remove the access panel(s) from the unit exposing theblower section and compressor section of the packaged heatpump unit.

5. Remove the heater collar cover plate(s) (see Fig. 6)

Fig. 6 — Heater Collar Cover Plate Removal

6. In preparation for heater element installation, orient theheating elements with thermal overloads (cut--outs) are onthe right side for VT & CF and top for HZ (see Fig. 7)

UNIT DAMAGE HAZARD

Failure to follow this caution may result in unit damage.

Proper thermal overloads (cut--outs) orientation is required forsafe unit operation.

CAUTION!

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Fig. 7 — Thermal Overloads Cut--Outs

7. Insert heating element(s) into collar. Heating element rodsmust be inserted into inner most holes as shown in Fig. 8.This will support and prevent vibration of heater elements.

IMPORTANT: Model sizes 060 and 072 have an additionalextension bracket mounted on each cover plate. Heating elementrods must be aligned to extension brackets accordingly.

Fig. 8 — Heating Element Rods

IMPORTANT: If only one heating element is being installed,install it into the position closest to the blower wheel. Coverremaining opening with one of the cover plates removed in step 5..

8. Secure each insert with four of the supplied sheet metalscrews (see Fig. 9)

Fig. 9 — Secure Insert with Supplied Sheet Metal Screws

INSTALLATION -- WIRINGThe electric heater control box is completely pre--wired from thefactory.There are two Electric Heater control box layouts depending onheater kit model (see Fig. 10 and Fig. 11)HR1 controls heating elements 1 and 3 and HR2 controls heatingelements 2 and 4.

Fig. 10 — 5kW--10kW Control Box(KWAEH0101N05 / KWAEH0101N10)

Fig. 11 — 15kW--20kW Control Box(KWAEH0101F15 / KWAEH0101F20)

1. Route the high voltage Red and Black wires, originatingfrom the Electric Heater control box, through grommets inthe Electric Heater Element cover as show in Fig. 12.

IMPORTANT: Route all red wired together through the samegrommet and black wires through the second grommet.

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1

2

1 = red wire 2 = black wire

Fig. 12 — Routing Red and Black Wires

2. For vertical (VT) and horizontal (HZ) units, install theheater control box between the unit corner posts at thebottom of the of the blower section. For counter flow (CF)units, install the heater control box between the unit cornerposts at the bottom of the of the blower section. (See Fig. 1through Fig. 4)Orient the heater control box with contactor(s) towards bot-tomHoles for control box are pre--punched between the metalparts.

3. Connect red and black high voltage wires, originating fromElectric Heater control box, to the Electric Heater elementsas shown in Fig. 13. Terminate Black wires labeled HLS atthe thermal limits (cutouts) and Red wires labeled HT at theheater element connections (see Fig. 13 and 14).

NOTE: Each wire is labeled for ease of identification. See wiringdiagram on page

Fig. 13 — Heater Element

4. Install the cover for the control box with the providedscrews.

5. Remove and retain cork tape covering the hole in thedivider panel.

6. On the wiring harness supplied with this kit, identify J39plug. (Fig. 14)

J39

J12 J19ATTACH TO ELECTRICAL

HEAT BOX

TO CONTROL SIGNALS

TO BLOWER MOTOR POWER

TRANSFORMER POWER

Fig. 14 — Electric Heater Harness

7. Route J39 plug through the hole in the divider panel andmate the plug to the receiving connector P39 on the side ofthe electric heat control box.

8. Re--apply cork tape to the divider panel hole.9. Route the other end of the harness (3 connector end) alongthe already installed blower harness, and terminate it at theunit electrical box (E--Box). Use tie--wraps every 12--18inches for a neater finish.

Fig. 15 — J19 Blower Plug (two position)

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Fig. 16 — P12 Control Signal Plug (three position)

Fig. 17 — Transformer Power

10. In the heat pump electrical box, disconnect the J19/P19high voltage wires that connect the blower motor to the“line voltage” these wires are located on the left--hand sideof the E--box shown in the Fig. 18.

Fig. 18 — Disconnect J19/P19 High Voltage Wires

11. Mate J19 plug originating from the electric heat control box(red and black wires) with P19 plug originating fromblower harness at E--box (see Fig. 19).

IMPORTANT: When mating plugs, push both connectorstogether until they snap with a click.

Fig. 19 — Mate J19 from Electric Heat Control Box to P19from Blower Harness at E--box

12. Disconnect the red and black line voltage harness from thetransformer primary side and the contactor line side. Re-move the harness from the E--box entirely. (See Fig. 20 and21)

Fig. 20 — Transformer Primary Connected

Fig. 21 — Primary Disconnected

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13. Route the two line voltage wires that derived from the P19plug, these wires should be routed under the contactor alongthe bottom of the electrical box (see Fig. 22).

PERSONAL INJURY AND/OR UNIT DAMAGEHAZARD

Failure to follow this caution may result in personal injuryand/or unit damage.

When routing wiring, avoid sharp edges as these can chafewiring insulation, exposing the conductor which can result inequipment damage and personal injury.

CAUTION!

Fig. 22 — Route Line Voltage Wires from P19 Plug

14. Connect red and black wires from electric heat harness totransformer primary winding per wire labels.

15. There will be one harness (black and white wires) left--con-nected to the compressor contactor. Remove and discardthis loose harness from the contactor (see Fig. 23)

Fig. 23 — Connecting Red & Black Wires from Elect. HeatHarness to Transformer Primary Winding

16. There should now be one plug left labeled P12 on theelectric heat harness. Mate this plug to its counterpart plugalready available on the left--hand side of the E--box labeledJ12. (See Fig. 24)

Fig. 24 — P12 Plug mated to J12 Plug

17. Ensure heater element wires are routed through the plasticbushings available in the kit, and perform a continuity testto ensure all connections are secure.

IMPORTANT: Use bottom holes on the plate to inset the plasticgrommets and prevent the wires from laying on sharp edges (seeFig. 25).

Fig. 25 — Plastic Grommets to Prevent Wire Damage

18. Remove two (2) screws as shown in Fig. 26.

Fig. 26 — Remove Two (2) Screws

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19. Mount heater element cover to blower collar using four (4)screws as shown in Fig. 27.

Fig. 27 — Mount Heater Element Cover to Blower Collar

20. Use push in wire ties to secure cables to cover and blowerbracket (see Fig. 28)

Fig. 28 — Secure Cables to Cover and Blower Bracket

THERMOSTATWIRE CONNECTIONS1. Assure that two low voltage wires are available from thethermostat to make the “W1” and “EM” connections. Ifthese wires are not located, they will need to be pulled androuted from the back of the thermostat to main thermostatconnections on the electrical box or to the motor controlboard.

2. Strip the insulation off of the “W1” and “EM” wires andinsert into the thermostat control wire block or on the motorcontrol board thermostat interface. Connect the other end ofthe wires to the back of the thermostat to the supplementaland emergency heat terminals. Reference the ThermostatManual for proper connection.

Fig. 29 — Connect Thermostat Wires

SITE LINE VOLTAGE CONNECTIONRouting new line voltage wires from circuit breaker panel to heaterelectrical box:

1. Select the proper wire size based upon the heater electricalload that the blower motor and electric heater element(s)will require. Refer to the data tag label that is included inthe heater kit or the electrical data at the end of this manual.Ensure that all national and local electrical codes arefollowed for installation, wire sizing, and breaker sizing.

2. Select the proper breaker size based upon the heaterelectrical load that the heat pump will require. Refer to thedata tag label that is included in the heater kit or theelectrical data at the end of this manual.

3. Route the new line voltage wiring and the ground wire fromthe circuit breaker panel to the heat pump.

4. Use the knockout provided in the heat pump corner post asthe entry for the electrical service wiring. A plastic bushingshould be used to protect the wire insulation from the metaledge of the knockout

5. Connect one of the line voltage wires to “L1” terminalconnection and the other line voltage wire to “L2” terminalconnection. Torque to 22 in--lbs.

6. Use the ground lug provided in the heater control box toconnect the field ground from the power supply.

WIRING DIAGRAM PLACEMENT1. Remove the wiring diagram that is adhered to the back sideof the front panel. Replace with the wiring diagram that wasincluded with the heater kit (using spray adhesive glue isrecommended).

2. Place the adhesive backed heater data label next to theknockout in the post where the new electrical service for thefan motor and heater elements is entering the cabinet.

UNIT START--UP1. Turn the disconnect switch or breaker switch to the “ON”position for the compressor and for the new separate circuitservicing the blower motor and the heating elements.

2. Run the unit in heating mode with the heating elementsengaged for at least 10 minutes to ensure the unit does notshut down due to any temperature limiting device.

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ELECTRIC HEATER ELECTRICAL DATA

Electric HeaterKit Number

RatedkW Stage

Heater Watts Heater AMPS CircuitFuses

MCA MOP

240V 208V 240V 208V 240V 208V 240V 208V

KWAEH0101N05 4.8 1 4,800 3,600 20.0 17.3 F1/F2 33.8 30.4 35 35

KWAEH0101N10 9.6 1 9,600 7,200 40.0 34.6 F1/F2 58.8 52.0 60 60

KWAEH0101F15 14.41 9,600 7,200 40.0 34.6 F1/F2

83.8 73.6 90.0 80.01+2 14,400 10,800 60.0 51.9 F3/F4

KWAEH0101F20 19.21 9,600 7,200 40.0 34.6 F1/F2

108.8 95.3 110 1001+2 19,200 14,400 80.0 69.2 F3/F4

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WIRING DIAGRAMS

Fig. 30 — Electric Heater Wiring Diagram

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WIRING DIAGRAMS

Fig. 31 — 1 Stage (2 Step) Single Phase EOM Motor

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WIRING DIAGRAMS

Fig. 32 — E--Box

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WIRING DIAGRAMS

Fig. 33 — Wiring Harness

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8 733 904 449 (2013/12)

Copyright 2014 CAC / BDP S 7310 W. Morris St. S Indianapolis, IN 46231

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

Catalog No: IIK--KWAEH--01Replaces: New

Edition Date: 05/14