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1 installation instructions ACCESSORY ELECTRIC HEAT 208/230 AND 460-V UNITS 558E,F Sizes to 27 Tons Cancels: New IIK 558E /1/94 IMPORTANT READ BEFORE INSTALLING 1. Read and become familiar with installation instructions before installing accessory electric heat. 2. Be sure installation conforms to all local and national codes. 3. Open, lock, and tag unit electrical disconnect switch before installing electric heat. SAFETY CONSIDERATIONS Installation and servicing of air-conditioning equipment can be hazardous due to system pressure and electrical components. Only trained and qualified service personnel should install, repair, or service air-conditioning equipment. Untrained personnel can perform basic maintenance functions of cleaning coils and filters and replacing filters. All other operations should be performed by trained service personnel. When working on air-conditioning equipment, observe precautions in the literature, tags and labels attached to the unit, and other safety precautions that may apply. Follow all safety codes. Wear safety glasses and work gloves. Use quenching cloth for unbrazing operations. Have fire extinguisher available for all brazing operations. Recognize safety information. This is the safety-alert symbol. ( ) When you see this symbol on the unit and in instructions or manuals, be alert to the potential for personal injury. Understand the signal words DANGER, WARNING, and CAUTION. These words are used with the safety-alert symbol. Danger identifies the most serious hazards which will result in severe personal injury or death. Warning, on the other hand, could result in personal injury. Caution is used to identify unsafe practices which would result in minor personal injury or product and property damage. WARNING: Before performing service or maintenance operations on unit, turn off main power switch to unit. Electrical shock could cause personal injury. GENERAL See Tables 1 and 2 for accessory usage, and Table 3 for accessory parts list. Item numbers referenced throughout this literature are from Table 3. WARNING: Turn off all power to unit prior to installing accessory electric heater package. All wiring must comply with applicable national and local codes. INSTALLATION I. 558E, LOW- AND MEDIUM-HEAT PACKAGES THROUGH 712 IMPORTANT: During installation, refer to Fig This will make installation easier. 1. Unpack accessory and check that package contains the correct parts as indicated in Table 3. Items 8-18 and are shipped in a plastic bag. 2. Open electric heat access doors and main control box access door. 3. In electric heat section, remove 2 heater box cover plates from heater installation location. See Fig. 2. Save screws. 4. Place heater assembly (item 1) into opening and push all the way in. Engage the back panel of the heater with the capscrews that stick through the back cover of the heater box. It may be necessary to guide the heater from the side. 5. Using 4 screws removed from heater box front cover plate and 2 screws (item 9), secure heater assembly to the flanges on the heater box opening. 6. Reattach side cover of heater box using screws saved from Step Place appropriate connector (item 16 or 17, depending on accessory package) and plug button (item 21) in the holes located in the connector bracket (item 6) as shown in Fig. 1, 3, and 4. Place varnish cloth (item 18) in the opening of the connector. NOTE: Two electrical washers (item 22) are also required, if electrical connector (item 16) is used. 8. Slide the connector bracket over the wires connected to the heater package. 9. Fasten the electric heater cover (item 4) to the heater box as shown, using 5 screws (item 9). See Fig Fasten the connector bracket (item 6) to the electric heater cover (item 4) using 2 screws (item 9). Fasten the mounting bracket (item 43) to the connector bracket (item 6) using 2 screws (item 9). Fasten the wiring shield (item 44) to the mounting bracket (item 43) using 2 screws (item 9). 11. Place connector (item 16) and plug button (item 21) in the correct holes located on the top and on the bottom of the electric heat control box (item 2). Use varnish cloth (item 18) and 2 electrical washers (item 22) in hole with connector. See Fig. 3 and Drill three 5 16-in. diameter holes in the left-hand side of the electric heat section access door frame as shown in Fig. 2. Also, drill three in. diameter holes in the right-hand side of the door frame (Fig. 2). 13. Mount electric heat control box to the right side of the electric heat section access door frame, using 6 rivets (item 12). See Fig. 2. NOTE: If a pop-rivet gun is unavailable, use a in. diameter drill to enlarge the holes in the control box hinge that are used to fasten the control box to the door frame. Use 3 screws (item 9) to fasten the control box to the door frame.

2 ACCESSORY PACKAGE UNIT VOLTAGE (3 Ph, 60 Hz) Table 1 Accessory Data Unit 558E HEATER SELECTION APPLIED TO BASE UNIT 558E TYPICAL MOUNTING FIG. NO. WIRING DIAGRAM FIG. NO Hi 90 kw /230 Lo 18 kw 300, Lo 18 kw /230 Lo 18 kw Med 36 kw /230 Med 36 kw /230 Hi 72 kw ACCESSORY PACKAGE UNIT VOLTAGE (3 Ph, 60 Hz) Table 2 Accessory Data Unit 558F HEATER SELECTION APPLIED TO BASE UNIT 558F TYPICAL MOUNTING FIG. NO. WIRING DIAGRAM FIG. NO Hi 108 kw 300, Hi 90 kw /230 Hi 90 kw Med 36 kw /230 Med 36 kw /230 Lo 18 kw 300, Lo 18 kw /230 Lo 18 kw NOTE: For these high heat applications, the minimum blower speed is 780 rpm. NOTE: Numbers indicate items referenced in Table 3. Numbers in parentheses indicate quantity of parts required. Fig. 1 Electric Heater Box (Vertical Supply/Return) with Electric Heat Installed 2

3 Table 3 Accessory Parts List ITEM NO. DESCRIPTION ACCESSORY PACKAGE NO Heater Assembly 208/230 v v Electric Heat Control Box Assembly Terminal Block 380 amp, 600 v Cover, Electric Heater Bracket, Vertical Supply/Return Heater Control Box Connector Bracket Support Bracket, Horizontal Supply/Return Heater Relay, HR Relay, HR Screw, 1 4 in. AB x 5 8 in. long Screw, 10B-16 x 3 4 in. long Rivet, 3 16 in Locknut, 1 4 in Wire Tie Connector, 1 in Connector, in Varnish Cloth Blockoff, Horizontal Supply/Return Plug Button Electrical Washer for 1 in. Connection Connector Assembly A Wire Harness; three 12 gage 60 in., BLK, YEL, BLU B Wire Harness; three 12 gage 70 in., BLK, YEL, BLU Wire Harness; three 8 gage 120 in., BLK, YEL, BLU Wire Harness; three 8 gage 180 in., BLK, YEL, BLU Wire Harness; three 6 gage 120 in., BLK, YEL, BLU 2 28 Wire Harness; three 6 gage 180 in., BLK, YEL, BLU 2 29 Wire Harness; three 4 gage 120 in., BLK, YEL, BLU 2 30 Wire Harness; three 2 gage 120 in., BLK, YEL, BLU 2 31 Wire Harness, Airflow Switch 1 32 Bracket, Airflow Switch 1 33 Airflow Switch (AFS) 1 34 Screw, No x 1 in Lock Washer, No Nut, No Connector, 1 2 in Conduit Assembly, in Clamp, in Electrical Washer, for in. Connection Mounting Bracket Wiring Shield NOTE: Part numbers 10, 14, 20, 39, and 41 are not included in this kit as they are not needed for these accessory electric heaters. 3

4 14. Run wires connected to heater package through the connector (item 16) in the bottom of the electric heat control box. Connect them to the heater contactors as shown in Fig. 3 and Open the evaporator-fan motor access door and remove the plug button from the hole in the partition separating the indoor section of the unit from the outdoor section. Install connector, varnish cloth, and electrical washers (items 17, 18, and 42) in this hole. See Fig Remove main control box access cover and install heater relay(s) (item 8) as shown in Fig. 3 and 4. Use 2 screws (item 11) to fasten each relay. The wires that connect to the heater relay(s) are already in the main control box. Connect them as shown. 17. Remove control box access door frame with the main control box attached to gain access to the area behind the main control box. 18. There are 2 holes in the bottom of the main control box that accept the electrical connector (item 16). These holes are used for the entry of the electric heat wire harness into the main control box. Remove the plug buttons from the holes. 19. Install connector and varnish cloth (items 16 and 18) in the holes. 20. Connect the wires of the harness or harnesses (item 26) (which will run between the main control box and the electric heat control box) to existing terminal block (ring terminal end of harness) in main control box. Use the nuts from the terminal block to fasten the wires to the studs. 21. Run the other end of the harness through the connector and varnish cloth installed in Step 19 and connector and varnish cloth installed in Step Route the harness through the sheet metal track on the top of the indoor blower. 23. Feed the wire harness in through the connector (installed in Step 11) in the top of the electric heat control box. Connect the pigtails on the harness to the fuse block(s) as shown in Fig. 3 and Run wire harness(es) (item 24B) through the connector installed in the bottom of the electric heat control box, and connect to heater contactor(s) as shown in Fig. 3 and Run the other end of the wire harness(es) (item 24B) through the connector in the connector bracket (item 6) and into the electric heater. Connect wires as shown in Fig. 3 and Plug the quick-connect end of connector assembly (item 23) into the bottom of the main control box as shown. 27. Feed the wires from this connector assembly through the connector (item 17) installed in Step Tighten the connector (item 17) in the indoor/outdoor partition so that the wires are held firmly in place. 29. Route the connector assembly (item 23) wires alongside the harness installed in Steps Bring the assembly wires up through the connector in the bottom of the electric heat control box. Tighten the connector so that the wires are held firmly in place. 31. Fasten the wires to the correct heater contactor terminals as shown in Fig. 3 and Secure the harness installed in Steps to the wires of the connector assembly (item 23) using wire ties (item 15). Do this in the indoor section of the unit. Snap the wire ties in the holes provided. 33. Check that all wiring connections are tight. 34. Fasten the control box bracket (item 5) to the left side of the electric heat section access door frame, using 7 screws (item 9) as shown in Fig Check that the supply power wiring is sufficient to handle the load. The unit informative plate has the necessary data for determining this. The upper section of the informative plate has the MCA (Minimum Circuit Amps) and MOCP (Maximum Overcurrent Protection) values for the cooling portion of the unit. The lower section has the same information for the heating section. 36. Match the accessory package model number on the accessory heater packing crate with one of the accessory model numbers from the lower portion of the informative plate to determine suitability of power wiring for handling the unit electrical load. Once the heater package has been identified, mark the appropriate space on the lower section of the informative plate. 37. Note the MCA and MOCP values for the heater package and connect properly sized power wiring. Reconnect original wires if suitable. Replace main control box and access cover. Close and secure main control box access door as well as any others that are open. 38. Apply power to unit. Set thermostat to call for heat, and check heating effect at supply air ducts. II. 558E, HIGH-HEAT PACKAGES A. Installation, 72 kw Package IMPORTANT: During installation, refer to Fig. 1, 2, and 5. This will make installation easier. 1. Unpack accessory and check that package contains the correct parts as indicated in Table 3. Items 8-18, 21, 23, 40, and 42 are shipped in a plastic bag. 2. Open electric heat access doors and main control box access door. 3. In electric heat section, remove 2 heater box cover plates from heater installation location. See Fig. 2. Save screws. 4. Place heater assembly (item 1) into opening and push all the way in. Engage the back panel of the heater with the capscrews that stick through the back cover of the heater box. It may be necessary to guide the heater from the side. 5. Using 4 screws removed from heater box front cover plate and 2 screws (item 9), secure heater assembly to the flanges on the heater box opening. 6. Reattach side cover of heater box using screws saved from Step Place connector (item 17) in the connector bracket (item 6) as shown in Fig. 5. Place varnish cloth (item 18) in the opening of the connector. 8. Fasten the electric heater cover (item 4) to the heater box as shown, using 5 screws (item 9). See Fig Fasten the connector bracket (item 6) to the electric heater cover (item 4) using 2 screws (item 9). Fasten the mounting bracket (item 43) to the connector bracket (item 6) using 2 screws (item 9). Fasten the wiring shield (item 44) to the mounting bracket (item 43) using 2 screws (item 9). 10. Place 2 connectors (item 17) and 2 varnish cloths (item 18) in the bottom holes of the electric heat control box (item 2) and 2 plug buttons (item 21) in the top holes as shown in Fig The electric heat control box has a 2-in. knockout in the back panel. This is for connection of the conduit assembly (item 38). Remove this knockout. 4

5 HOLES mm DIMENSIONS IN [ ] ARE IN INCHES Symbol Diameter Req d Y V 5.15 [ 13 64] 7.94 [ 5 16] 3 3 NOTES: 1. Dimensions are in millimeters. 2. Numbers indicate items referenced in Table 3. Numbers in ( ) indicate quantity of parts required. Fig.2 Typical Mounting on 558E LEGEND SPA Space 5

6 FB Fuse Block FU Fuse HC Heater Contactor HR Heater Relay LEGEND PL Plug PLR4 Connector Assembly TB Terminal Block NOTE: Numbers indicate items referenced in Table 3. Numbers in ( ) indicate quantity of parts required. Fig. 3 Wiring Diagram, 18 kw Accessory Electric Heat Package, Applied to Models 558E ; 208/230 and 460 V 6

7 LEGEND FB Fuse Block FU Fuse HC Heater Contactor HR Heater Relay PL Plug PLR4 Connector Assembly TB Terminal Block NOTE: Numbers indicate items referenced in Table 3. Numbers in ( ) indicate quantity of parts required. Fig. 4 Wiring Diagram, 36 kw Accessory Electric Heat Package, Applied to Models 558E ; 208/230 and 460 V 7

8 FB Fuse Block FU Fuse HC Heater Contactor HR Heater Relay LEGEND HTB Heater Terminal Block PL Plug TB Terminal Block NOTE: Numbers indicate items referenced in Table 3. Numbers in ( ) indicate quantity of parts required. Fig. 5 Wiring Diagram, 72 kw Accessory Electric Heat Package, Applied to Models 558E ; 208/230 V 8

9 12. Drill three 5 16-in. diameter holes in the left-hand side of the electric heat section access door frame as shown in Fig. 2. Also, drill three in. diameter holes in the right-hand side of the door frame (Fig. 2). 13. Mount electric heat control box to the right side of the electric heat section access door frame, using 6 rivets (item 12). See Fig. 2. NOTE: If a pop-rivet gun is unavailable, use a in. diameter drill to enlarge the 3 holes in the control box hinge that are used to fasten the control box to the door frame. Use 3 screws (item 9) to fasten the control box to the door frame. 14. Install 90-degree connector to the end of the conduit assembly in the knockout hole (from Step 11). Connect the wires to the heater terminal block in the electric heat control box as shown in Fig. 5, using 3 locknuts (item 13). 15. Route the conduit assembly through the holes provided in the indoor blower side plates. 16. Open the evaporator-fan motor access door and remove the plug button from the hole in the partition separating the indoor section of the unit from the outdoor section. Install connector, varnish cloth, and electrical washers (items 17, 18, and 42) in this hole. See Fig. 2. Pull the wires from the conduit assembly through the hole. 17. Install the straight connector on the end of the conduit assembly into the hole. 18. Take all slack out of the conduit assembly by pulling it toward the electric heat control box. The excess conduit should lay in the space between the control box and the side of the blower opposite the evaporator-fan motor. 19. Fasten the conduit assembly to the plate on top of the indoor blower, between the side plates, using 2 clamps (item 40) and 2 screws (item 9). Holes are provided in the plate for this procedure. 20. Remove main control box access cover and install heater relays (item 8) as shown in Fig. 5. Use 2 screws (item 11) to fasten each relay. The wires that connect to the heater relays are already in the main control box. Connect them as shown in Fig Remove the terminal block from the main control box and replace it with the terminal block (item 3) from the accessory package. Fasten it to the back panel of the control box using either the original screws or use 4 screws (item 11). 22. Place the power wires that were fastened to the load side of the terminal block just replaced on the studs of the replacement terminal block. Remove access door frame with the main control box attached to gain access to the area behind the control box. 23. There are 2 holes in the bottom of the main control box that accept the electrical connectors (item 16). These holes are used for the entry of the electric heat wire harness into the main control box. Remove the plug buttons from the holes. 24. Install connector and varnish cloth (items 16 and 18) in the holes. 25. Connect the wires from the conduit assembly (item 38) to the studs of the replacement terminal block in the main control box installed in Step 21. Use locknut (item 13) to tighten ring terminals on the ends of the wires to the studs on the terminal block. 26. Run wire harnesses (item 24B) through the connector installed in the bottom of the electric heat control box, and connect to heater contactors as shown in Fig Run the other end of the wire harnesses (item 24B) through the connector in the connector bracket (item 6) and into the electric heater. Connect wires as shown in Fig Plug the quick-connect end of connector assembly (item 23) into the bottom of the main control box as shown. See Fig Loosen the electrical connector located next to the conduit assembly (item 38) in the indoor/outdoor partition. 30. Feed the wires from this connector assembly (item 23) through the connector. 31. Tighten the connector in the indoor/outdoor partition so that the wires are held firmly in place. 32. Route the wires for the connector assembly (item 23) through the sheet metal track on top of the indoor blower. 33. Bring the wires up through the connector in the bottom of the electric heat control box. Tighten the connector so that the wires are held firmly in place. 34. Fasten the wires to the correct contactor coil terminals as shown. 35. Secure the wires of the connector assembly (item 23) in the indoor section of the unit, using wire ties (item 15). Snap the wire ties in the holes provided. 36. Fasten the control box bracket (item 5) to the left side of the electric heat section access door frame, using 7 screws (item 9). 37. Check that the supply power wiring is sufficient to handle the load. The unit informative plate has the necessary data for determining this. The upper section of the informative plate has the MCA (Minimum Circuit Amps) and MOCP (Maximum Overcurrent Protection) values for the cooling portion of the unit. The lower section has the same information for the heating section. 38. Match the accessory package model number on the accessory heater packing crate with one of the accessory model numbers from the lower portion of the informative plate to determine suitability of power wiring for handling the unit electrical load. Once the heater package has been identified, mark the appropriate space on the lower section of the informative plate. 39. Note the MCA and MOCP values for the heater package and connect properly sized power wiring. Reconnect original wires if suitable. Replace main control box and access cover. Close and secure main control box access door as well as any others that are open. 40. Apply power to unit. Set thermostat to call for heat, and check heating effect at supply air ducts. 9

10 B. Installation, 90 kw Package IMPORTANT: During installation, refer to Fig. 1, 2, and 6. This will make installation easier. 1. Unpack accessory and check that package contains the correct parts as indicated in Table 3. Items 8-18, 21-23, 31-37, and 42 are shipped in a plastic bag. 2. Open electric heat access doors and main control box access door. 3. In electric heat section, remove 2 heater box cover plates from heater installation location. See Fig. 2. Save screws. 4. Place heater assembly (item 1) into opening and push all the way in. Engage the back panel of the heater with the capscrews that stick through the back cover of the heater box. It may be necessary to guide the heater from the side. 5. Using 4 screws removed from heater box front cover plate and 2 screws (item 9), secure heater assembly to the flanges on the heater box opening. 6. Reattach side cover of heater box using screws saved from step 3, or use 7 screws (item 9). 7. Place the connector (item 17) and plug button (item 21) in the holes in the connector bracket (item 6) as shown in Fig. 6. Place varnish cloth (item 18) in the opening of the connector. 8. Fasten the electric heater cover (item 4) to the heater box as shown, using 5 screws (item 9). See Fig Fasten the connector bracket (item 6) to the electric heater cover (item 4) using 2 screws (item 9). Fasten the mounting bracket (item 43) to the connector bracket (item 6) using 2 screws (item 9). Fasten the wiring shield (item 44) to the mounting bracket (item 43) using 2 screws (item 9). 10. Gather items together. 11. Install airflow switch (item 33) in bracket (item 32), using screws, lockwashers and nuts, 2 each (items 34-36). 12. Install connector (item 37) in bracket (item 32). Use varnish cloth (item 18) in the opening of the connector. 13. Connect the 2 wires (item 31) to the switch (item 33). 14. Fasten the assembly from Steps to the blower side plate, on the side of the blower opposite the evaporator- fan motor, using 2 screws (item 9) as shown. Holes are provided. 15. Route the wires (item 31) connected to the switch through the sheet metal track on top of the indoor blower. Let the wires hang loosely on the drive side of the indoor blower. 16. Place the connector (item 16) along with 2 washers (item 22) in the left hole in the top of the electric heat control box (item 2) as shown in Fig. 6. Place the plug button (item 21) in the hole at the right. Use varnish cloth (item 18) in the opening of the connector. 17. Place connector (item 17) in the left hole in the bottom of the electric heat control box (item 2) as shown in Fig. 6. Place plug button (item 21) in the hole at the right. Use varnish cloth (item 18) in the opening of the connector. 18. Drill three 5 16-in. diameter holes in the left-hand side of the electric heat section access door frame as shown in Fig. 2. Also, drill three in. diameter holes in the right-hand side of the door frame (Fig. 2). 19. Mount electric heat control box (item 2) to the right side of the electric heat section access door frame, using 6 rivets (item 12). See Fig. 2. NOTE: If a pop-rivet gun is unavailable, use a in. diameter drill to enlarge the holes in the control box hinge that are used to fasten the control box to the door frame. Use 3 screws (item 9) to fasten the control box to the door frame. 20. Run wires connected to heater package through the connector in the bottom of the electric heat control box. Connect them to the heater contactors. See Fig Open the evaporator-fan motor access door and remove the plug button from the hole in the partition separating the indoor section of the unit from the outdoor section. Install connector, varnish cloth, and electrical washers (items 17, 18, and 42) in this hole. See Fig Remove main control box access cover and install heater relays (item 8) as shown. Use 2 screws (item 11) to fasten each relay. The wires that connect to the heater relays are already in the main control box. Connect them as shown. IMPORTANT: To connect airflow switch in the unit electrical control circuit, perform Step In the main control box, there is a terminal block labelled TB2 with a black jumper wire connected to terminals 7 and 8. Remove this wire to electrically connect the airflow switch. 24. Remove the existing terminal block TB1 (or field power terminal block) from the main control box. Replace it with the terminal block (item 3) from the accessory package. Fasten it to the back panel of the control box using either the original screws or use 4 screws (item 11). 25. Place the power wires that were fastened to the load side of the terminal block just replaced on the studs of the replacement terminal block. Remove access door frame with the main control box attached to gain access to the area behind the control box. 26. There are 2 holes in the bottom of the main control box that accept the electrical connectors (item 16). These holes are used for the entry of the electric heat wire harness into the main control box. Remove the plug buttons from the holes. 27. Install connector and varnish cloth (items 16 and 18) in the hole shown in Fig Connect the wires of the harness (item 28) which run to the main control box to the studs of the replacement terminal block (item 3). Use locknut (item 13), to tighten the ring terminals on the ends of the wires to the studs on the terminal block. 29. Run the other end of the harness through the connector and varnish cloth installed in Step 27 in the bottom of the main control box. 30. Route the harness through the sheet metal track on the top of the indoor blower. 31. Feed the harness through the connector installed in Step 16, in the top of the electric heat control box. Connect the wires to the studs on the terminal block in the electric heat control box, using 3 locknuts (item 13). 32. Run wire harnesses (item 24B) through the connector installed in the bottom of the electric heat control box, and connect to heater contactors as shown in Fig Run the other end of the wire harnesses (item 24B) through the connector in the connector bracket (item 6) and into the electric heater. Connect wires as shown in Fig

11 AFS Airflow Switch FB Fuse Block FU Fuse HC Heater Contactor HR Heater Relay LEGEND HTB Heater Terminal Block PL Plug PLR4 Connector Assembly TB Terminal Block NOTE: Numbers indicate items referenced in Table 3. Numbers in ( ) indicate quantity of parts required. Fig. 6 Wiring Diagram, 90 kw Accessory Electric Heat Package, Applied to Models 558E ; 460 V 11

12 34. Plug the quick-connect end of the connector assembly (item 23) into the bottom of the main control box as shown in Fig Feed the wires from this connector assembly, as well as the wires which go to the airflow switch, through the connector (item 17) installed in Step Tighten the connector (item 17) in the indoor/outdoor partition so that the wires are held firmly in place. 37. Route the connector assembly (item 23) wires alongside the harness (item 28) installed in Steps Bring the wires up through the connector in the bottom of the electric heat control box. Tighten so that the wires are held firmly in place. 39. Fasten the wires to the correct contactor coil terminals as shown. See Fig Secure the connector assembly wires (item 23), the airflow switch wires (item 31), and the wires in the harness (item 28) that run between the control boxes, using wire ties (item 15). Do this in the indoor section of the unit. Snap the wire ties in the holes provided. 41. Check that all wiring connections are tight. 42. Fasten the control box bracket (item 5) to the left side of the electric heat section access door frame, using 3 screws (item 9). 43. Check that the supply power wiring is sufficient to handle the load. The unit informative plate has the necessary data for determining this. The upper section of the informative plate has the MCA (Minimum Circuit Amps) and MOCP (Maximum Overcurrent Protection) values for the cooling portion of the unit. The lower section has the same information for the heating section. 44. Match the accessory package model number on the accessory heater packing crate with one of the accessory model numbers from the lower portion of the informative plate to determine suitability of power wiring for handling the unit electrical load. Once the heater package has been identified, mark the appropriate space on the lower section of the informative plate. 45. Note the MCA and MOCP values for the heater package and connect properly sized power wiring. Reconnect original wires if suitable. Replace main control box and access cover. Close and secure main control box access door as well as any others that are open. 46. Apply power to unit. Set thermostat to call for heat, and check heating effect at supply air ducts. III. UNITS 558F, ALL PACKAGES IMPORTANT: During installation, refer to Fig This will make installation easier. 1. Unpack accessory and check that package contains the correct parts as indicated in Table 3. Items 8-18, 21-23, and 42 are shipped in a plastic bag. 2. Open electric heat access door and main control box access door. 3. In electric heat section, remove heater box cover plate from heater installation location. Save screws. 4. Remove the air baffle and bring it out through the access door so it is out of the way of the heater installation. 5. Push one of the screws saved from Step 3 through one of the holes in either end of the blockoff (item 19). Insert the same screw in one of the engagement holes in the heater top support. Tighten 3 or 4 turns; do not tighten all the way down. 6. Bring the heater assembly (item 1) through the access door opening and position it under the opening in the top support. 7. Push the heater assembly up through the opening. So long as the fastener (Step 5) has not been tightened down, the blockoff plate (item 19) will pivot up far enough to allow the heater to be pushed through the opening. 8. Once the heater assembly is through the opening, lower it down so it rests on the top support and blockoff (item 19). Tighten down the screw installed in the blockoff and insert 2 of the screws saved from Step 3 into the remaining holes of the blockoff. 9. Insert the last 2 screws saved from Step 3 into one of the heater flanges. Insert 4 screws (item 9) into the remaining holes of the heater flanges. 10. Fasten the support bracket (item 7) to the bottom of the heater package as shown in Fig. 7 using 4 screws (item 9). Do not tighten all the way down. 11. Fasten the heater support bracket (item 7) to the indoor/ outdoor divider panels as shown in Fig. 7, using 4 screws (item 9). 12. Insert 2 screws (item 9) in the holes on the top support. Tighten these screws 3 or 4 turns. 13. Place connector(s) (item 16 or 17, depending on accessory package) and plug button (item 21) (depending on accessory package) in the holes located in the connector bracket (item 6) as shown in Fig Place varnish cloth (item 18) in the opening of the connector. Electrical washer (item 22) is required too, if electrical connector (item 16) is used. 14. Slide the connector bracket over the wires connected to the heater package. 15. Fasten the connector bracket (item 6) to the heater package top support, using 2 screws (item 9). 16. Slip the flange of the electric heater cover (item 4) under the heads of the screws that were installed in Step 10. Tighten the screws another 3 or 4 turns, but do not tighten them all the way down. This will ease removal of the cover if servicing is required at a later date. 17. Fasten the connector bracket (item 6) to the cover (item 4) using 2 screws (item 9). See Fig. 7. Tighten the electrical connector (item 16 or 17) around the wires so that they are held firmly in place. 18. Replace the air baffle that was removed in Step Place connector (item 16 or 17, depending on accessory package) and plug button (item 21) in the correct holes located on the top and on the bottom of the electric heat control box (item 2) as shown in Fig Use varnish cloth (item 18) in the opening of whichever connector was used. NOTE: Electrical washer (item 22) must be used if connector (item 16) is used. 20. Mount electric heat control box (item 2) to the face of the air baffle as shown in Fig. 7, using 6 screws (item 9). 21. Run wires connected to heater package through the connector in the bottom of the electric heat control box. Connect them to the heater contactors as shown in Fig Note that the wires attached to the heater package have markers (1, 2, 3, etc.) which indicate and locate contactor connections. For example, a wire marked 1 is to be connected to contactor 1. 12

13 NOTE: Numbers indicate items referenced in Table 3. Numbers in ( ) indicate quantity of parts required. Fig.7 Typical Mounting on 558F 13

14 FB Fuse Block FU Fuse HC Heater Contactor HR Heater Relay LEGEND HTB Heater Terminal Block PL Plug PLR4 Connector Assembly TB Terminal Block NOTE: Numbers indicate items referenced in Table 3. Numbers in ( ) indicate quantity of parts required. Fig. 8 Wiring Diagram, 108 kw Accessory Electric Heat Package, Applied to Models 558F ; 460 V 14

15 LEGEND FB Fuse Block FU Fuse HC Heater Contactor HR Heater Relay HTB Heater Terminal Block PL Plug PLR4 Connector Assembly TB Terminal Block NOTE: Numbers indicate items referenced in Table 3. Numbers in ( ) indicate quantity of parts required. Fig. 9 Wiring Diagram, 90 kw Accessory Electric Heat Package, Applied to Models 558F240; 460 V 15

16 FB Fuse Block FU Fuse HC Heater Contactor HR Heater Relay LEGEND HTB Heater Terminal Block PL Plug PLR4 Connector Assembly TB Terminal Block NOTE: Numbers indicate items referenced in Table 3. Numbers in ( ) indicate quantity of parts required. Fig. 10 Wiring Diagram, 90 kw Accessory Electric Heat Package, Applied to Models 558F ; 208/230 V 16

17 FB Fuse Block FU Fuse HC Heater Contactor HR Heater Relay LEGEND HTB Heater Terminal Block PL Plug PLR4 Connector Assembly TB Terminal Block NOTE: Numbers indicate items referenced in Table 3. Numbers in ( ) indicate quantity of parts required. Fig. 11 Wiring Diagram, 36 kw Accessory Electric Heat Package, Applied to Models 558F ; 208/230 and 460 V 17

18 FB Fuse Block FU Fuse HC Heater Contactor HR Heater Relay LEGEND HTB Heater Terminal Block PL Plug PLR4 Connector Assembly TB Terminal Block NOTE: Numbers indicate items referenced in Table 3. Numbers in ( ) indicate quantity of parts required. Fig. 12 Wiring Diagram, 18 kw Accessory Electric Heat Package, Applied to Models 558F ; 208/230 and 460 V 18

19 22. Remove the plug button from the hole on the partition separating the electric heat section of the unit from the outdoor section, and install connector, 2 varnish cloths and electrical washers (item 17, 18, and 42) in this hole. See Fig Remove main control box access cover and install heater relay(s) (item 8) as shown in Fig Use 2 screws (item 11) to fasten each relay. The wires that connect to the heater relay(s) are already in the main control box. Connect them as shown. 24. If a terminal block (item 3) is supplied with the heater package, remove the existing block (TB1 or field power terminal block) from the main control box. Replace it with item 3 from the accessory package. Fasten it to the back panel of the control box using either the original screws or use 4 screws (item 11). 25. Place the power wires that were fastened to the load side of the terminal block just replaced on the studs of the replacement terminal block. Remove the access door frame with the main control box attached to gain access to the area behind the control box. 26. There are 2 holes in the bottom of the main control box that accept the electrical connector (item 16). These holes are used for entry of the electric heat wire harness into the main control box. Remove the plug button(s) from the appropriate hole(s) as shown in Fig Install connector and varnish cloth (items 16 and 18) in the hole(s) as shown in Fig Connect the wires of the harness (items 25, 27, 29, or 30, depending on the accessory package) which run between the main control box and the electric heat control box, to the studs of the replacement terminal block (item 3) or the existing terminal block (ring terminal end of harness). If the existing terminal block was changed, use locknut (item 13) to tighten ring terminals on the ends of the wires to the studs on the terminal block. If the block has not been changed, use the nuts from the original terminal block to fasten the wires to the studs. 29. Run the other end of the harness through the connector and varnish cloth installed in Step 27, and the connector and varnish cloth installed in Step Run the harness to the top of the electric heat control box. 31. Feed the wire harness through the connector in the top of the electric heat control box installed in Step 19. Connect the pigtails of the harness to the fuse block on medium- and low-heat packages as shown in Fig. 11 and 12. On high-heat packages, connect the ring terminals on the end of the harness to the studs on the terminal block in the electric heat control box. 32. Run wire harness(es) (item 24A) through the connector installed in the bottom of the electric heat control box, and connect to heater contactor(s) as shown in Fig Run the other end of the wire harness(es) (item 24A) through the connector in the connector bracket (item 6) and into the electric heater. Connect wires as shown in Fig Plug the quick-connect end of connector assembly (item 23) into the bottom of the main control box as shown in Fig Feed the wires from this connector assembly through the connector (item 17) installed in the partition that separates the indoor section of the unit from the outdoor section. 36. Tighten the connector (item 17) in the indoor/outdoor partition so that the wires are held firmly in place. 37. Bring the wires down through the electrical connector in the bottom of the control box. Tighten the connector so that the wires are held firmly in place. 38. Fasten the wires to the correct heater contactor terminals as shown in Fig Secure the harness installed in Steps to the wires of the connector assembly (item 23) using wire ties (item 15). Do this in the outdoor section of the unit as shown in Fig Check that all wiring connections are tight. Reinstall main control box. 41. Check that the supply power wiring is sufficient to handle the load. The unit informative plate has the necessary data for determining this. The upper section of the informative plate has the MCA (Minimum Circuit Amps) and MOCP (Maximum Overcurrent Protection) values for the cooling portion of the unit. The lower section has the same information for the heating section. 42. Match the accessory package model number on the heater packing crate with one of the accessory model numbers from the lower portion of the informative plate to determine suitability of power wiring for handling the unit electrical load. Once the heater package has been identified, mark the appropriate space on the lower section of the informative plate. 43. Note the MCA and MOCP values for the heater package and connect properly sized power wiring. Reconnect original wires if suitable. Replace main control box access cover. Close and secure main control box access door as well as any others that are open. 44. Apply power to unit. Set thermostat to call for heat, and check heating effect at supply air ducts. 19

20 Copyright 1994 Carrier Corporation CATALOG NO. BDP

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