Bosch HK050-1XXX-RE User manual

TABLE OF CONTENTS
Introduction.......................................................... 2
Pre-Installation ..................................................... 2
Components List................................................... 2
Installation............................................................ 3
Packaged Units (CE/TAxxx-xVT,
CE/TAxxx-xHZ, CE/TAxxx-xCF) ............................ 3
Split Units (CE/TAxxx-xAV,
CE/TAxxx-xAH, TAxxx-xAC).................................. 6
CE-VT / HZ & TA-HZ (TA025-HZ excluded) Units..... 6
Units with 5, 7.5, or 10 kW Electrical
Heater Elements (HK050, HK075, HK100) .......... 8
Units with 15 or 20 kW Electrical
Heater Elements (HK150, HK200)....................... 8
Split Units (CE/TAxxx-xAV,
CE/TAxxx-xAH, TAxxx-xAC)................................ 10
TA-VT & TA025-HZ Units....................................... 10
Units with 5, 7.5, or 10 kW Electrical
Heater Elements (HK050, HK075, HK100) ........ 12
Units with 15 or 20 kW Electrical
Heater Elements (HK150, HK200)..................... 12
Electric Heater Electrical Data ............................ 14
Field Installed Electric Heater Kit Availability ...... 14
Typical Wiring Diagrams................................. 15-16
HK SERIES
ELECTRIC HEATER
PACKAGE
INSTALLATION INSTRUCTIONS
Revised 05-13
6 720 220 328

6 720 220 328 Subject to change without prior notice Revised 05-13
2HK Series
INTRODUCTION
Bosch HK Series Heater Package is a eld
installable electric resistance heater kit designed
for use with the CE and TA series heat pumps.
Caution
The HK series heater package requires separate
electrical service connection, independent from
the heat pump’s power supply. DO NOT wire the
heater elements into the same circuit as the
compressor.
Note:
• A heater collar is installed in the CE and TA
models, no need to order separately.
• The series heater packages are designed for
installation in the heat pump model published in
this document. Do not install this heater kit in a
heat pump not specied in this manual. Refer to
Table 3 on page 18 for compatibility.
• A heat pump thermostat with supplemental
electric heat feature is required to operate the
system when this kit is installed.
• 18 AWG wire will be needed to connect the
thermostat to the electrical box for the “W1” &
“EM” connections. See wiring diagrams at the
end of this manual.
Caution
Improper installation of the electric resistance
heater can result in severe injury or death due
to electrical shock or re.
Only trained and qualied personnel should
install, repair, or service this equipment.
All electrical service connection to the heater
must be done to National and local electrical
Standard & codes.
PRE-INSTALLATION
1. UNPACK the HK heater kit and inspect for
contents and condition. If any part or the kit
appears damaged (i.e.: broken heater elements,
damage relays) or missing, do not attempt to
install the kit. Contact your local distributor for
further help
2. Ensure that the heater kit package includes the
following components. Contact your local
distributor for further help.
COMPONENTS LIST:
The following components should be found in the
heater kit package:
a. Pre-wired heater electrical box
b. Heater elements pre-wired to the heater
electrical box
c. Heater element(s) protective metal cover
d. Wire harness pre-wired at one end (used only in
units in which a second electrical box is added)
e. New wiring diagram
f. Adhesive back electrical data label
g. Clear hardware accessory bag containing:
• Heater element mounting screws (4 for each
element bank)
• Heater element cover mounting screws (2 for
each cover)
• Two yellow wire nuts (used only for packaged
units; discard for split systems)
• Four electrical box mounting screws (used
only in units in which a second electrical box
is added)
Introduction
Table 1: Electric Heater Compatibilitytor Only)
Units 5kW 7.5 & 10 kW 15 kW 20 kW
TA025 ü ü x x
TA035 ü ü x x
TA049 ü ü ü ü
TA061 ü ü ü ü
TA071 ü ü ü ü
CE025 ü ü x x
CE035 ü ü x x
CE049 ü ü ü ü
CE061 ü ü ü ü
CE071 ü ü ü ü

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3
HK Series
h. 2 x 30 amp fuses + 2 x 60 amp fuses for 15kW
heater packages only
i. 4 x 60 amp fuses for 20kW heater packages
only
j. This installation manual
Caution
The heater element mounting screws and the
heater element cover mounting screws are the
same type of screw. Quantities used will depend
on the heater package type.
For technical assistance contact your local
distributor or Call Bosch Technical Support:
866-642-3198
3. Ensure following tools and supplies, needed
for installation, are available:
• Phillips screwdriver
• Small fl at head screwdriver
• 5/16” socket and a ratchet or drill
• Wire cutter
• Wire stripper
• 18 AWG wire (connect thermostat to the
electrical box)
• Torque Phillips head screwdriver
• Volt meter
INSTALLATION
Packaged Units (CE/TAxxx-xVT,
CE/TAxxx-xHZ, CE/TAxxx-xCF)
This section is for packaged units only. See
sections below for installation instructions for
split systems.
STEP 1: DISCONNECTING THE POWER:
a. Turn system to “OFF” from your Thermostat
b. Turn the power to the heat pump to “OFF” at
the unit’s disconnect switch or breaker panel.
c. Remove the access panel(s) from the unit
exposing the blower section and compressor
section of the packaged heat pump unit. Place
the panel mounting screws aside in a safe
place as they will need to be reused when
putting the panels back on.
STEP 2: Remove the heater collar cover plate(s) to
install the heater elements. (See Figure 1).
Figure #1 – Showing Collar mounted on blower housing,
element location and collar plate(s)
STEP 3: Identify retainer pins on the end of the
heater element(s). These pins are to be inserted in
holes visible in the back of the heater collar. This
stabilizes the heater element and prevents
vibration of the heater elements.
STEP 4: Slide the heater element(s) into the
mounting opening(s) on the heater collar, making
sure that the retainer pins engage in the holes in
the back of the collar.
Caution
It may be necessary to lower the blower in order
to complete this task.
When installing the heater elements into the
heater collar, ensure that the thermal overloads
are on the right side; this will be the “L1” side.
Secure each insert(s) with four of the supplied
sheet metal screws provided (See Figure 2).
Caution
It may be necessary to remove the line voltage
wires that are connected to the element(s) from
heater electrical box in order to complete
installation.
Remove the wires from heater contactor and
terminal block at “L1” only. If wires are removed
during installation, ensure that they are marked
Installation

6 720 220 328 Subject to change without prior notice Revised 05-13
4HK Series
for proper reconnection. When reconnecting the
line voltage wires to the contactor, apply 22 in-lbs
of torque.
STEP 5: Install the element cover over the heater
element(s). These are secured with a tab at one
end of the cover and two of the supplied sheet
metal screws at the other end (See Figure 2).
Ensure that heater wires are routed through the
plastic bushing on the heater element cover.
Figure #2 – With Collar removed insert heater element(s) (one
shown in this diagram), wires not shown in diagram.
Caution
Ensure unused slot is covered with a collar plate.
STEP 6: INSTALLING THE HEATER CONTROL BOX:
a. Vertical Units - Install the heater control box
between the unit corner posts at the top of the
blower section.
b. Horizontal Units (Straight through
con guration) - Mount the heater electrical box
in the rear of the unit, attached to the electrical
post on the opposite side of the blower.
c. Horizontal Units (End Blow Con guration)
- Mount the heater electrical box in the rear of
the unit, attached to the electrical post on the
opposite side of the blower motor.
The mounting holes for the heater box have been
pre-punched in the posts. Make sure no wires are
pinched between the metal parts. Connect or
reconnect wires from the heater element(s) as was
marked in step 4 or follow electrical wiring diagram
for corresponding model at the end of this manual.
STEP 7: Route the loose ends of the yellow, blue,
red, purple, and the two black wire leads from the
long side of the wire harness plug from the heater
electrical box to the heat pump electrical box in the
compressor compartment. Route these wires
through the access hole in the divider panel
together where the existing blower motor wires are
routed.
STEP 8: CONNECTING HIGH VOLTAGE WIRES
a. In the heat pump electrical box, disconnect the
two line voltage wires that connect the
transformer and blower motor to the “LINE 1”
side of the compressor contactor.
b. Cut the wire terminal off of the following wires
and strip off the insulation:
• One of the black wires from the wire harness
• The transformer wire disconnected in Step
8(a)
• The black blower motor wire disconnected in
Step 8(a)
c. Connect the three wires that were cut and
stripped in Step 8(b) together using a yellow
wire nut connector supplied with the kit.
Secure with electrical tape.
d. Disconnect the two line voltage wires that
connect the transformer and blower motor to
the “LINE2” side of the compressor contactor.
e. Cut the terminal connections off of the
following wires and strip off the insulation:
• The remaining black wire from the wire
harness
• The transformer wire disconnected in Step
8(d)
• The white blower motor wire disconnected in
Step 8(a)
Installation

6 720 220 328
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5
HK Series
f. Connect the three wires that were cut and
stripped in Step 8(e) together using a yellow
wire nut connector supplied with the kit.
Secure with electrical tape.
g. Reference Figure 3 and/or the appropriate
wiring diagram at the end of the manual to
ensure that all connections are correct.
Caution
Ensure that the wires are connected to the
correct matching terminal and all unused wires
are capped with a wire nut. Severe damage to
the unit, personal injury, or death can occur if
wires are not connected securely to the
correct terminal or loose wires come into
contact with the cabinet or other components.
STEP 9: CONNECTING LOW VOLTAGE WIRES
a. The four remaining wires on the long end of the
wire harness are low voltage wires (Yellow,
Purple, Red, and Blue). Connect these wires to
the motor control board according to Table 2.
Table 2r Only)
Heater Box Heat Pump Box
Yellow R
Blue C1
Red W1
Purple EM
b. Reference Figure 3 and/or the appropriate
wiring diagram at the end of this manual to
ensure that all connections have been made
and are correct.
STEP 10: THERMOSTAT WIRE CONNECTIONS
a. Ensure that two low voltage wires are available
from the thermostat to make the “W1” and
“EM” connections. If these wires are not
located, they will need to be pulled and routed
from the back of the thermostat to motor
control board in the heater electrical box.
Installation
Figure #3 – Electrical Heater wiring interface with Heat Pump Electrical Box

6 720 220 328 Subject to change without prior notice Revised 05-13
6HK Series
b. Strip the insulation off of the “W1” and “EM”
wires and insert into the thermostat control
wire block on the motor control board. Connect
the other end of the wires to the back of the
thermostat to the supplemental and emergency
heat terminals. Reference the user’s manual for
the thermostat for proper connection.
STEP 11: ROUTING NEW LINE VOLTAGE WIRES
FROM CIRCUIT BREAKER PANEL TO HEATER
ELECTRICAL BOX
a. Select the proper wire size based upon the
heater electrical load that the blower motor and
electric heater element(s) will require. Refer to
the data tag label that is included in the heater
kit or the electrical data at the end of this
manual. Ensure that all national and local
electrical codes are followed for installation,
wire sizing, and breaker sizing.
b. Select the proper breaker size based upon the
heater electrical load that the heat pump will
require. Refer to the data tag label that is
included in the heater kit or the electrical data
at the end of this manual.
c. Route the new line voltage wiring and the
ground wire from the circuit breaker panel to
the heat pump.
d. Use the knockout provided in the heat pump
corner post as the entry for the electrical
service wiring. A plastic bushing should be used
to protect the wire insulation from the metal
edge of the knockout.
e. Connect one of the line voltage wires to “L1”
terminal connection and the other line voltage
wire to “L2” terminal connection. Torque to 22
in-lbs.
STEP 12:Use the ground lug provided in the heater
control box to connect the  eld ground from the
power supply.
Caution
The heater electrical power provides service to
the unit’s Transformer, electrical heat element(s),
and blower motor only. The Compressor remains
on the original and now isolated circuit.
STEP 13: Remove the wiring diagram that is
adhered to the back side of the front panel. Replace
with the wiring diagram that was included with the
heater kit. Using spray adhesive glue is
recommended.
STEP 14: Place the adhesive back heater data label
next to the knockout in the post where the new
electrical service for the fan motor and heater
elements is entering the cabinet.
STEP 15: RESTORING POWER / TURNING ON THE
UNIT
a. Turn the disconnect switch or breaker switch to
the “ON” position for the compressor and for
the new separate circuit servicing the blower
motor and the heating elements.
b. Test the unit in “COOLING” and “HEATING” to
ensure that full functionality of the unit has
been restored.
c. Run the unit in heating mode with the heating
elements engaged for at least 10 minutes to
ensure the unit does not shut down due to any
temperature limiting device.
STEP 16: Install the cover on the heater electrical
box and reinstall the heat pump access panel(s)
with the screws that were set aside in Step 1.
Caution
Always contact your local distributor if there is
ever any doubt
SPLIT UNITS (CE/TAXXX-XAV,
CE/TAXXX-XAH, TAXXX-XAC)
This section is for CE vertical & horizontal split
units and TA horizontal (excluding the TA025) split
units only. See the section below for other split
systems or the section above relating to packaged
units.
CE-VT / HZ & TA-HZ (TA025-HZ
excluded) Units Covered in this Section
Within this range of the units, the electric heater kit
and the air handler will share a common electrical
box, therefore a single complete new electrical box
will be provided with the electrical heater kit.
Installation

6 720 220 328
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7
HK Series
STEP 1: DISCONNECT POWER:
Caution
Always disconnect electrical power to the air
handler and condensing section completely
from its electrical source prior to any servicing.
Caution
It is highly critical that all wires that are
disconnected within these steps are carefully
labeled so that reconnection is easy and accurate.
a. Turn the system to “OFF” from the unit’s
thermostat
b. Turn the power to the condensing section and
air handler section off at the unit’s disconnect
switch or breaker panel.
c. Remove the access panel from the front of the
air handler exposing the blower section. Place
the panel mounting screws aside in a safe place
as they will need to be reused when putting the
panels back on.
d. Unplug the blower motor communication
harness at the motor control board and set
aside for reconnection later.
e. The thermostat wires terminate at a common
connection block on the motor control board
inside the electrical box of the air handler.
Unplug the thermostat terminal block and set
aside for reconnection later.
f. Disconnect the line voltage wires from the
blower motor power terminal block from the
service side and the ground wire from the
ground lug in the air handler electrical box.
g. The low voltage wires from the condensing
section connect to a terminal block in the air
handler with ¼” insulated terminal
connections. Mark and disconnect these low
voltage wires from terminal connections; set
aside for reconnection later. The “C”, “R”, “O”,
“Y1”, & “Y2” should be labeled and
disconnected in this step.
h. All wires leading into the air handler’s electrical
box should now be disconnected at this point.
If any wires remain connected, go back through
the previous steps to ensure that all wires have
been properly labeled and disconnected before
proceeding.
i. Remove existing Electrical Box and set aside.
STEP 2: Remove the heater collar cover plate(s) to
install the heater elements. (See Figure 1).
Figure #1 – Showing Collar mounted on blower housing,
element location and collar plate(s)
STEP 3: Identify retainer pins on the end of the
heater element(s). These pins are to be inserted in
holes visible in the back of the heater collar. This
stabilizes the heater element and prevents
vibration of the heater elements.
STEP 4: Slide the heater element(s) into the
mounting opening(s) on the heater collar, making
sure that the retainer pins engage the holes in the
back of the collar.
Caution
It may be necessary to lower the blower in order
to complete this task.
When installing the heater elements into the heater
collar, ensure that the thermal overloads are on the
right side; this will be the “L1” side. Secure each
insert(s) with four of the supplied sheet metal
screws provided (See Figure 2).
Caution
It may be necessary to remove the line voltage
wires that are connected to the element(s) from
heater electrical box in order to complete
installation.
Installation

6 720 220 328 Subject to change without prior notice Revised 05-13
8HK Series
Remove the wires from heater contactor and
terminal block at “L1” only. If wires are removed
during installation, ensure that they are marked for
proper reconnection. When reconnecting the line
voltage wires to the contactor, apply 22 in-lbs of
torque.
STEP 5: Install the element cover over the heater
element(s). These are secured with a tab at one
end of the cover and two of supplied sheet metal
screws at the other end (See Figure 2). Ensure that
heater wires are routed through the plastic bushing
on the heater element cover.
Figure #2 – With Collar removed insert heater element(s) (one
shown in this diagram), wires not shown in diagram.
STEP 6: INSTALLING THE NEW ELECTRICAL BOX
a. Using the pre-punched holes in the two front
corner posts, fasten the new electrical box
provided in the electrical heater kit using the
four screws that were included with the heater
kit. Ensure no wires are pinched between any
metal parts.
b. If the wires from the heater elements were
disconnected from the contactor(s) and
terminal block at “L1” in Step 4, reconnect the
elements to the contactor(s) applying 22 in-lbs
of torque.
STEP 7: CONNECTING HIGH VOLTAGE WIRES
Caution
By adding electrical heaters, the electrical
demand may change quite signicantly. The
existing wires between the circuit panel and
the air handler may not be sufcient and may
need to be replaced. Verify the breaker is
appropriately sized for the new electrical load
also. See the data tag label that was included
with the heater kit or at the end of the manual
for the appropriate wire and breaker size for
the amount of electric heat that is being
installed. If the electrical load surpasses the
rating of the breaker and/or wire size, add a
separate circuit at the breaker panel, and run
new wire.
Units with 5, 7.5, or 10 kW Electrical
Heater Elements (HK050, HK075, HK100)
a. Reconnect the two line voltage wires that were
disconnected in Step 1(f) to the main power
terminal block in the heater/heat pump
electrical box.
b. Reconnect the ground wire that was
disconnected in Step 1(f) to the ground lug in
the heater/heat pump electrical box.
c. Reconnect the blower motor line voltage wires
to the terminal block that was disconnected in
Step 1(g). The black wire should connect to the
“L1” side, and the white wire should connect to
the “L2” side.
d. Reconnect the blower motor ground wire that
was disconnected in Step 1(g) to the ground lug
and tighten the screw.
e. Reference the appropriate wiring diagram at
the end of this manual to ensure that all
connections have been made and are correct.
Units with 15 or 20 kW Electrical Heater
Elements (HK150, HK200)
a. Reconnect the two line voltage wires that were
disconnected in Step 1(f) to the power fuse
block in the heater/heat pump electrical box.
Use the following torques when tightening the
line voltage wires:
Installation

6 720 220 328
Revised 05-13 Subject to change without prior notice
9
HK Series
Installation
• 0/2 AWG 120 in-lbs
• 8 AWG 40 in-lbs
• 10-14 AWG 35 in-lbs
b. Reconnect the ground wire that was
disconnected in Step 1(f) to the ground lug in
the heater/heat pump electrical box.
c. Ensure that all fuses are accounted for (2 x 30
amp + 2 x 60 amp for 15kW & 4 x 60 amp for
20kW), and are securely fastened in the fuse
block.
d. Reconnect the blower motor line voltage wires
block that was disconnected in Step 1(g) to the
fuse block using the male terminal connection
posts. The black wire should connect to the
“L1” side, and the white wire should connect to
the “L2” side.
f. Reconnect the blower motor ground wire that
was disconnected in Step 1(g) to the ground
lug and tighten the screw.
g. Reference the appropriate wiring diagram at
the end of the manual to ensure that all
connections have been made and are correct.
Caution
Ensure that the wires are connected to the
correct matching terminal and all unused wires
are capped with a wire nut. Severe damage to
the unit, personal injury, or death can occur if
wires are not connected securely to the correct
terminal or loose wires come into contact with
the cabinet or other components.
STEP 8: CONNECTING LOW VOLTAGE WIRES
a. The four remaining wires on the long end of the
wire harness are low voltage wires (Yellow,
Purple, Red, and Blue). Connect these wires to
the motor control board according to Table 2.
Table 2r Only)
Heater Box Heat Pump Box
Yellow R
Blue C1
Red W1
Purple EM
b. Reconnect the low voltage wires from the
condensing section to the terminal block in the
air handler that was removed in Step 1(g). The
“C”, “R”, “O”, “Y1”, & “Y2” should all be
connected in this step.
c. Reconnect the blower motor communication
harness that was disconnected in Step 1(d) to
the new motor control board.
d. Reconnect the thermostat wire terminal block
that was removed in Step 1(e) to the new motor
control board. If new motor control board is the
same as the old motor control board, the
original block that was removed in Step 1(e)
will t and reconnecting the thermostat wires
to the block will not be necessary.
STEP 9: THERMOSTAT WIRE CONNECTIONS
a. Ensure that two low voltage wires are available
from the thermostat to make the “W1” and
“EM” connections. If these wires are not
located, they will need to be pulled and routed
from the back of the thermostat to motor
control board in the heater electrical box.
b. Strip the insulation off of the “W1” and “EM”
wires and insert into the thermostat control
wire block on the motor control board. Connect
the other end of the wires to the back of the
thermostat to the supplemental and emergency
heat terminals. Reference the user’s manual for
the thermostat for proper connection.
STEP 10: Use the ground lug provided in the heater
control box to connect the eld ground from the
power supply.
STEP 11: Remove the wiring diagram that is
adhered to the back side of the front panel. Replace
with the wiring diagram that was included with the
heater kit. Using spray adhesive glue is
recommended.
STEP 12: Place the adhesive back heater data label
on top of the existing data tag as the new
information will replace the existing information.
STEP 13: RESTORING POWER / TURNING ON THE
UNIT

6 720 220 328 Subject to change without prior notice Revised 05-13
10 HK Series Installation
a. Turn on the disconnect switches or breaker
switches to the “ON” position for the
condensing section and the air handler.
b. Test the unit in “COOLING” and “HEATING” to
ensure that full functionality of the unit has
been restored.
c. Run the split system in heating mode with the
heating elements engaged for at least 10
minutes to ensure the unit does not shut down
due to any temperature limiting device.
STEP 14: Install the cover on the heater electrical
box and reinstall the air handler access panel(s)
with the screws that were set aside in Step 1(c).
Caution
Always contact your local distributor if there is
ever any doubt
SPLIT UNITS (CE/TAXXX-XAV,
CE/TAXXX-XAH, TAXXX-XAC)
TA-VT & TA025-HZ Units Covered in this
Section
Within this range of the units, the electric heater kit
will come with a separate heater electrical box to
be installed. The original air handler electrical box
will not be removed. Only some rewiring will be
required.
STEP 1: DISCONNECT POWER:
Caution
Always disconnect electrical power to the air
handler and condensing section completely
from its electrical source prior to any servicing.
Caution
It is highly critical that all wires that are
disconnected within these steps are carefully
labeled so that reconnection is easy and accurate.
a. Turn the system to “OFF” from the unit’s
thermostat
b. Turn the power to the condensing section and
air handler section off at the unit’s disconnect
switch or breaker panel.
c. Remove the access panel from the front of the
air handler exposing the blower section. Place
the panel mounting screws aside in a safe place
as they will need to be reused when putting the
panels back on.
d. Disconnect the line voltage wires from the
blower motor power terminal block from the
service side and the ground wire from the
ground lug in the air handler electrical box.
STEP 2: REMOVING THE AIR HANDLER
ELECTRICAL BOX:
a. Unplug the blower motor communication
harness at the motor control board and set
aside for reconnection later.
b. Disconnect the line voltage wiring from the
terminal block.
c. Disconnect ground wire from the ground lug.
d. The thermostat wires will terminate at a
common connection block on the motor control
board inside the electrical box of the air
handler. Unplug the thermostat terminal block
and set aside for reconnection later.
e. The low voltage wires from the condensing
section connect to the motor control board in
the air handler with ¼” insulated terminal
connections. Mark and disconnect these low
voltage wires from terminal connections; set
aside for reconnection later. The “C”, “R”, “O”,
“Y1”, & “Y2” should be labeled and
disconnected in this step.
f. All wires leading into the air handler’s electrical
box should now be loose at this point. If any
wires remain connected, go back through the
previous steps to ensure that all wires have
been properly labeled and disconnected before
proceeding.
g. Remove existing Electrical Box and set aside.
Retain the mounting screws as these will be
reused when reinstalling the air handler’s
electrical box.
STEP 3: Remove the heater collar cover plate(s) to
install the heater elements. (See Figure 1).

6 720 220 328
Revised 05-13 Subject to change without prior notice
11
HK Series
Installation
Figure #1 – Showing Collar mounted on blower housing,
element location and collar plate(s)
STEP 4: Identify retainer pins on the end of the
heater element(s). These pins are to be inserted in
holes visible in the back of the heater collar. This
stabilizes the heater element and prevents
vibration of the heater elements.
STEP 5: Slide the heater element(s) into the
mounting opening(s) on the heater collar, making
sure that the retainer pins engage the holes in the
back of the collar.
Caution
It may be necessary to lower the blower in order
to complete this task.
When installing the heater elements into the heater
collar, ensure that the thermal overloads are on the
right side; this will be the “L1” side. Secure each
insert(s) with four of the supplied sheet metal
screws provided (See Figure 2).
Caution
It may be necessary to remove the line voltage
wires that are connected to the element(s) from
heater electrical box in order to complete
installation.
Remove the wires from heater contactor and
terminal block at “L1” only. If wires are removed
during installation, ensure that they are marked for
proper reconnection. When reconnecting the line
voltage wires to the contactor, apply 22 in-lbs of
torque.
STEP 6: Install the element cover over the heater
insert(s). These are secured with a tab at one end
of the cover and two of the supplied sheet metal
screws at the other end (See Figure 2). Ensure that
heater wires are routed through the plastic bushing
on the heater element cover.
Figure #2 – With Collar removed insert heater element(s) (one
shown in this diagram), wires not shown in diagram.
STEP 7: REINSTALLING THE ELECTRICAL BOX AND
INSTALLING THE NEW HEATER ELECTRICAL BOX
a. Reinstall the original air handler electrical box
in the same location in which it was removed
from in Step 2-(g).
b. Reuse the mounting screws that were set aside
in Step 2-(g).
c. Using the pre-punched holes in the two front
corner posts underneath the air handler
electrical box, fasten the new heater electrical
box provided in the electrical heater kit using
the four mounting screws found in the clear
accessory bag. Ensure no wires are pinched
between any metal parts.
STEP 8: CONNECTING HIGH VOLTAGE WIRES

6 720 220 328 Subject to change without prior notice Revised 05-13
12 HK Series Installation
Caution
By adding electrical heaters, the electrical
demand may change quite signicantly. The
existing wires between the circuit panel and
the air handler may not be sufcient and may
need to be replaced. Verify the breaker is
appropriately sized for the new electrical load
also. See the data tag label that was included
with the heater kit or at the end of the manual
for the appropriate wire and breaker size for
the amount of electric heat that is being
installed. If the electrical load surpasses the
rating of the breaker and/or wire size, add a
separate circuit at the breaker panel, and run
new wire.
Units with 5, 7.5, or 10 kW Electrical
Heater Elements (HK050, HK075, HK100)
a. Reconnect the two line voltage wires that were
disconnected in Step 1(d) to the power
terminal block in the heater electrical box.
Torque to 22 in-lbs.
b. Reconnect the ground wire that was
disconnected in Step 1(d) to the ground lug in
the heater electrical box. Tighten with a
screwdriver.
c. There are two black wires connected to the
power terminal block in the heater electrical
box with female quick connection terminals.
Route these two wires from the heater
electrical box to the air handler electrical box.
Connect the two wires to the male quick
connection terminals on the blower motor
power terminal block . Ensure that the wire
from the heater electrical box that is connected
to “L1” side is also connected to “L1” side of
the blower motor terminal block in the air
handler electrical box and “L2” is connected to
“L2”.
d. Reference the appropriate wiring diagram at
the end of this manual to ensure that all
connections have been made and are correct.
Units with 15 or 20 kW Electrical Heater
Elements (HK150, HK200)
a. Reconnect the two line voltage wires that were
disconnected in Step 1(d) to the power fuse
block in the heater electrical box. Use the
following torques when tightening the line
voltage wires:
• 0/2 AWG 120 in-lbs
• 8 AWG 40 in-lbs
• 10-14 AWG 35 in-lbs
b. Reconnect the ground wire that was
disconnected in Step 1(d) to the ground lug in
the heater electrical box. Tighten with a
screwdriver.
c. Ensure that all fuses are accounted for (2 x 30
amp + 2 x 60 amp for 15kW & 4 x 60 amp for
20kW), and are securely fastened in the fuse
block.
d) There are two black wires connected to the
power fuse block in the heater electrical box
with female quick connection terminals. Route
these two wires from the heater electrical box
to the air handler electrical box. Connect the
two wires to the male quick connection
terminals on the blower motor power terminal
block. Ensure that the wire from the heater
electrical box that is connected to “L1” side is
also connected to “L1” side of the blower motor
terminal block in the air handler electrical box
and “L2” is connected to “L2”
e) Reference the appropriate wiring diagram at
the end of this manual to ensure that all
connections have been made and are correct.
Caution
Ensure that the wires are connected to the
correct matching terminal and all unused wires
are capped with a wire nut. Severe damage to
the unit, personal injury, or death can occur if
wires are not connected securely to the correct
terminal or loose wires come into contact with
the cabinet or other components.
STEP 9: CONNECTING LOW VOLTAGE WIRES
a. Reconnect the low voltage wires from the
condensing section to the motor control board
that was removed in Step 2(e). The “C”, “R”,
“O”, “Y1”, & “Y2” should all be connected in this
step.
b. Reconnect the blower motor communication
harness that was disconnected in Step 2(a) to
the motor control board.

6 720 220 328
Revised 05-13 Subject to change without prior notice
13
HK SeriesInstallation
c. Reconnect the thermostat wire terminal block
that was removed in Step 2(d) to the motor
control board.
d. There are four wire leads (Yellow, Purple, Red,
and Blue) with insulated female quick
connections attached at one end in the heater
electrical box. Route these wires from heater
electrical box to the air handler electrical box
and connect these wires to the motor control
board according to Table 2.
Table 2r Only)
Heater Box Heat Pump Box
Yellow R
Blue C1
Red W1
Purple EM
STEP 10: THERMOSTAT WIRE CONNECTIONS
a. Ensure that two low voltage wires are available
from the thermostat to make the “W1” and
“EM” connections. If these wires are not
located, they will need to be pulled and routed
from the back of the thermostat to motor
control board in the heater electrical box.
b. Strip the insulation off of the “W1” and “EM”
wires and insert into the thermostat control
wire block on the motor control board. Connect
the other end of the wires to the back of the
thermostat to the supplemental and emergency
heat terminals. Reference the user’s manual for
the thermostat for proper connection.
STEP 11: Use the ground lug provided in the heater
control box to connect the eld ground from the
power supply.
STEP 12: Remove the wiring diagram that is
adhered to the back side of the front panel. Replace
with the wiring diagram that was included with the
heater kit. Using a spray adhesive glue is
recommended.
STEP 13: Place the adhesive back heater data label
on top of the existing data tag as the new
information will replace the existing information.
STEP 14: RESTORING POWER AND TURNING ON
THE UNIT
a. Turn on the disconnect switch or breaker
switch to the “ON” position for the air handler.
b. Test the unit in “COOLING” and “HEATING” to
ensure that full functionality of the unit has
been restored.
c. Run the split system in heating mode with the
heating elements engaged for at least 10
minutes to ensure the unit does not shut down
due to any temperature limiting device.
STEP 15: Install the cover on the heater electrical
box and reinstall the air handler access panel(s)
with the screws that were set aside in Step 1(g).
Caution
Always contact your local distributor if there is
ever any doubt

6 720 220 328 Subject to change without prior notice Revised 05-13
14 HK Series Electric Heater Electrical Data
Table 3: Electric Heater Electrical Data
Heater
Model
kW Number
of Stages Hz Phase
Heater
Amps Circuit
Fuses
MCA* MOCP*
208 240 208 240 208 240 208 240
HK050-1XXX-RES 3.6 4.8 1 60 1 17.3 20.0 F1/F2 30.4 33.8 35 35
HK075-1XXX-RES 5.4 7.2 1 60 1 26.0 30.0 F1/F2 41.2 46.3 45 50
HK100-1XXX-RES 7.2 9.6 1 60 1 34.6 40.0 F1/F2 52.0 58.8 55 60
HK150-1XXX-RES
10.8 14.4 1 60 1 51.9 60.0 73.7 83.8 80 90
7.2 9.6 1 60 1 34.6 40.0 F1/F2 52.0 58.8 55 60
3.6 4.8 1 60 1 17.3 20.0 F3/F4 30.4 33.8 35 35
HK200-1XXX-RES
14.4 19.2 1 60 1 69.2 80.0 95.3 108.8 100 110
5.4 7.2 1 60 1 26.0 30.0 F1/F2 41.2 46.3 45 50
5.4 7.2 1 60 1 26.0 30.0 F3/F4 41.2 46.3 45 50
* The fan motor and electric heat elements should be rewired to be on the same circuit. MCA and MOCP
include 7 amps to accommodate for the additional motor load. 7 is the amp draw on a 1 HP motor.
Table 4: Field Installed Electric Heater Kit Availability
CE / TA Field Installed Electric Heater Kit Model Numbers
Unit
Model 5 kW 7.5 kW 10 kW 15 kW 20 kW Unit Model 5 kW 7.5 kW 10 kW 15 kW 20 kW
Vertical/
Counter
Flow
Packaged
Units
TA025 HK050-1001 HK075-1001 HK100-1001 X X CE025 HK050-1001 HK075-1001 HK100-1001 X X
TA035 HK050-1002 HK075-1002 HK100-1002 X X CE035 HK050-1001 HK075-1001 HK100-1001 X X
TA049 HK050-1002 HK075-1002 HK100-1002 HK150-1001 HK200-1001 CE049 HK050-1002 HK075-1002 HK100-1002 HK150-1001 HK200-1001
TA061 HK050-1002 HK075-1002 HK100-1002 HK150-1001 HK200-1001 CE061 HK050-1002 HK075-1002 HK100-1002 HK150-1001 HK200-1001
TA071 HK050-1002 HK075-1002 HK100-1002 HK150-1001 HK200-1001 CE071 HK050-1002 HK075-1002 HK100-1002 HK150-1001 HK200-1001
Horizontal
Packaged
Units
TA025 HK050-1004 HK075-1004 HK100-1004 X X CE025 HK050-1004 HK075-1004 HK100-1004 X X
TA035 HK050-1004 HK075-1004 HK100-1004 X X CE035 HK050-1004 HK075-1004 HK100-1004 X X
TA049 HK050-1004 HK075-1004 HK100-1004 HK150-1002 HK200-1002 CE049 HK050-1004 HK075-1004 HK100-1004 HK150-1002 HK200-1002
TA061 HK050-1004 HK075-1004 HK100-1004 HK150-1002 HK200-1002 CE061 HK050-1004 HK075-1004 HK100-1004 HK150-1002 HK200-1002
TA071 HK050-1004 HK075-1004 HK100-1004 HK150-1002 HK200-1002 CE071 HK050-1004 HK075-1004 HK100-1004 HK150-1002 HK200-1002
Vertical/
Counter
Flow Air
Handlers
TA025 HK050-1005 HK075-1005 HK100-1005 X X CE025 HK050-1007 HK050-1007 HK050-1007 X X
TA035 HK050-1005 HK075-1005 HK100-1005 X X CE035 HK050-1007 HK050-1007 HK050-1007 X X
TA049 HK050-1005 HK075-1005 HK100-1005 HK150-1005 HK200-1003 CE049 HK050-1007 HK050-1007 HK050-1007 HK150-1004 HK200-1005
TA061 HK050-1005 HK075-1005 HK100-1005 HK150-1005 HK200-1003 CE061 HK050-1007 HK050-1007 HK050-1007 HK150-1004 HK200-1005
TA071 HK050-1005 HK075-1005 HK100-1005 HK150-1005 HK200-1003 CE071 HK050-1007 HK050-1007 HK050-1007 HK150-1004 HK200-1005
Horizontal
Air
Handlers
TA025 HK050-1005 HK075-1005 HK100-1005 X X CE025 HK050-1007 HK050-1007 HK050-1007 X X
TA035 HK050-1006 HK075-1006 HK100-1006 X X CE035 HK050-1007 HK050-1007 HK050-1007 X X
TA049 HK050-1006 HK075-1006 HK100-1006 HK150-1003 HK200-1004 CE049 HK050-1007 HK050-1007 HK050-1007 HK150-1004 HK200-1005
TA061 HK050-1006 HK075-1006 HK100-1006 HK150-1003 HK200-1004 CE061 HK050-1007 HK050-1007 HK050-1007 HK150-1004 HK200-1005
TA071 HK050-1006 HK075-1006 HK100-1006 HK150-1003 HK200-1004 CE071 HK050-1007 HK050-1007 HK050-1007 HK150-1004 HK200-1005

6 720 220 328
Revised 05-13 Subject to change without prior notice
15
HK Series
Typical Wiring Diagrams
ELECTRIC HEAT DIAGRAM - HK SERIES HEATER PACKAGE
Heater Control Box For Packaged Units
Rewiring Fan Motor With Electric Heat

6 720 220 328 Subject to change without prior notice Revised 05-13
16 HK Series Typical Wiring Diagrams
ELECTRIC HEAT DIAGRAM - HK SERIES HEATER PACKAGE
Heater Control Box For 1 Or 2 Stage Air Handler Units
Rewiring Fan Motor With Electric Heat

6 720 220 328
Revised 05-13 Subject to change without prior notice
17
HK Series
Notes

6 720 220 328 Subject to change without prior notice Revised 05-13
18 HK Series Notes

6 720 220 328
Revised 05-13 Subject to change without prior notice
19
HK Series
Notes

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