MrCool PRODIRECT Series Operating instructions

Installation & Owner’s
Manual
PRODIRECT™ SERIES
Air Handler HAH140*C
Copyright © 2021 MRCOOL, LLC
Thank you for choosing MRCOOL. Please read this manual carefully before installation and keep it for future reference.
Due to updates and constantly improving performance, the information and instructions within this
manual are subject to change without notice. Please visit www.mrcool.com/documentation to
ensure you have the latest version of this manual.
Version Date: 2-22-21

These instructions are intended as an aid for qualified,
licensed service personnel for proper installation,
adjustment, and operation of this unit. Read these
instructions thoroughly before attempting installation
or operation. Failure to follow these instructions may
result in improper installation, adjustment, service or
maintenance possibly resulting in fire, electrical shock,
property damage, personal injury or death.
mrcool.com
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INSTALLATION AND OWNER’S MANUAL
Table of Contents
INDOOR SPLIT-SYSTEM UNIT MODELS: UP TO 18 SEER 1.5 TO 5 TONS
1 SAFETY
2 GENERAL
3 UNIT DIMENSIONS
4 VERTICAL UPFLOW
5 VERTICAL DOWNFLOW
6 HORIZONTAL
7 ELECTRICAL WIRING
8 POWER WIRING
9 CONTROL WIRING
10 GROUNDING
11 ELECTRICAL DATA
12 REFRIGERANT CONNECTIONS
13 EXPANSION VALVE + PISTON
14 CONDENSATE DRAIN TUBING
15 AIR FILTER (not factory-installed)
16 FILTER INSTALLATION DIMENSIONS
17 WIRING DIAGRAM
18 ELECTRIC WIRING GAUGE
19 ELECTRIC HEAT KIT INSTALLATION (Optional)
20 TROUBLESHOOTING
2
4
5
6
6
7
9
9
9
9
10
10
11
12
13
14
15
18
19
20

Disconnect all power to unit before installing or servicing. More
than one disconnect switch may be required to de-energize the
equipment. Hazardous voltage can cause severe personal injury or
death.
If removal of the blower assembly is required, all disconnect
switches supplying power to the equipment must be de-energized
and locked (if not in sight of unit), so the field power wires can be
safely removed from the blower assembly. Failure to do so can
cause electrical shock, resulting in personal injury or death.
Because of possible damage to equipment or personal injury,
installation, service, and maintenance should only be performed
by trained, qualified service personnel. Consumer service is
recommended only for filter cleaning/replacement. Never
operate the unit with the access panels removed.
These instructions are intended as an aid to qualified,
licensed service personnel for proper installation, adjustment,
and operation of this unit. Read these instructions thoroughly
before attempting installation or operation. Failure to follow these
instructions may result in improper installation, adjustment,
service or maintenance possibly resulting in fire, electrical shock,
property damage, personal injury or death.
This document is customer property and needs to remain with this unit. These instructions do not
cover all of the different variations between systems, nor does it provide for every possible
contingency that can arise during installation. All phases of this installation must comply with
NATIONAL, STATE, AND LOCAL CODES. This manual could change without expressed written
notice. Visit mrcool.com/documentation for the latest versions.
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1 SAFETY
This is a safety alert symbol. When you see this symbol on labels or in manuals, be
alert to the potential for personal injury.
This is an attention alert symbol. When you see this symbol on labels or in manuals,
be alert to the potential for personal injury.

PROPOSITION 65: This appliance contains fiberglass insulation.
All manufacturer products meet current federal OSHA Guidelines
for safety. California Proposition 65 warnings are required for
certain products, which are not covered by the OSHA standards.
California’s Proposition 65 requires warnings for products sold in
California that contain or produce any of the over 900 listed
chemicals known to the State of California to cause cancer or birth
defects. These include, fiberglass insulation, lead contained in
brass, and combustion products from natural gas.
All “new equipment” shipped for sale in California will have labels
stating that the product contains and/or produces Proposition 65
chemicals. Although we have not changed our processes, having
the same label on all our product facilitates manufacturing and
shipping. We cannot always know “when, or if” products will be
sold in the California market.
You may receive inquiries from customers about chemicals found
in, or produced by, some of our heating and air-conditioning
equipment, or found in natural gas used with some of our
products. Listed below are those chemicals and substances
commonly associated with similar equipment in our industry and
other manufacturers.
• Glass Wool (Fiberglass) Insulation
• Carbon Monoxide (CO)
• Formaldehyde
• Benzene
More details are available at the websites for OSHA (Occupational
Safety and Health Administration), at www.osha.gov and the
State of California’s OEHHA
(Office of Environmental Health Hazard Assessment), at
www.oehha.org. Consumer education is important since the
chemicals and substances on the list are found in our daily lives.
Most consumers are aware that products present safety and
health risks, when improperly used, handled and maintained.
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Make sure the blower motor support is
tight, which is secured by 3-motor mount
bolts. Then check to see if the wheel is
secured to motor shaft before operating
unit.
The unit must be properly and permanently grounded. Failure to
do so could result in electrical shock causing personal injury or
death.

The first 3 feet (36 inches) of the supply air plenum and ductwork
must be constructed of sheet metal as required by NFPA 90B. The
supply air plenum or duct must also have a solid sheet metal
bottom directly under the unit with no openings, registers or
flexible air ducts located in it.
If flexible supply air ducts are used, they can only be located in
the vertical walls of the rectangular plenum and must be a
minimum of 6 inches from the solid bottom. The metal plenum of
the duct may be connected to the combustible floor base, if not, it
must be connected to the unit supply duct that is exposed to the
supply air opening from the downflow unit. Exposing combustible
(non-metal) material to the supply opening of a downflow unit
can cause a fire, resulting in property damage, personal injury, or
death.
Exception warning to downflow:
Installations on a concrete floor slab, with supply air plenum and
ductwork completely encased, must use at least 2 inches of
concrete (See NFPA 90A).
The unit can be positioned for bottom return air in the upflow position, left and right return in the
horizontal position, or top return in downflow position.
This Air Handler provides the flexibility for installation in any upflow, downflow, or horizontal
application. The direct drive motors provide a selection of air volumes to match any application. The
3-Speed motors can be adjusted to provide air flow to meet desired applications.
Top and side power control wiring, and accessible screw terminals for control wiring, all combine to
make the installation easy, and minimize installation cost. Please contact your local distributor (Refer to
Fig.1).
The appliance is only intended to supply conditioned air to one room.
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2 GENERAL

ELECTRICAL CONNECTIONS CAN
EXIT THE TOP, OR EITHER SIDE, OF
THE UNIT
3 UNIT DIMENSIONS
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UNIT LENGTH
Table 1

5 VERTICAL DOWNFLOW
IMPORTANT NOTE
4 VERTICAL UPFLOW
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1) Vertical Upflow configuration is the factory set on all models (see Fig 1)
2) If a side return air opening is required, field fabricate a return air plenum with an opening large
enough to supply unit and strong enough to support unit weight.
3) If return air is to be ducted, install duct flush with floor. Use fireproof resilient gasket 1/8 in. to 1/4
in. thick between the ducts, unit, and floor. Set unit on the floor over the opening.
Conversion to Vertical Downflow: A vertical upflow unit may be converted to vertical downflow.
Remove the door and indoor coil and reinstall 180 degrees from its original position (Refer to Fig. 3).
IMPORTANT: To comply with certification agencies and the National Electric Code for horizontal right
application, the circuit breaker(s) on field-installed electric heater kits must be re-installed, per the
procedure below, so that the breaker switch ”on” position and marking is up and, ”off” position and
marking is down.
To rotate breaker(s): Rotate one breaker set (circuit) at a time, starting with the one on the right.
Loosen both lugs on the load side of the breaker (make sure that wires are identified and are
reinstalled into proper breaker). Wires are bundled with wire ties, one bundle going to the right lug
and one bundle going to the left lug.
Torque applied to drain connections should not exceed 15 ft. lbs. (Refer to Fig.1 & 2).

•Using a screwdriver, lift the blue plastic tab with hole away from breaker until breaker releases from
mounting opening.
•With breaker held in hand, rotate breaker so that the ”on” position is up, and ”off” position is down (with
unit in planned vertical mounting position). Insert right wire bundle into top right breaker lug, ensuring all
strands of all the wires are inserted fully into lug, and no wire insulation is in the lug.
•Tighten lug as tight as possible while holding circuit breaker. Check wires and make sure each wire is
secure and none are loose. Repeat for left wire bundle in left top circuit breaker lug.
•Replace breaker by inserting the breaker mounting tab, opposite of the white pull tab in opening, hook
mounting tab over edge in opening.
•Using a screwdriver, pull the blue tab with hole away from breaker while setting that side of breaker into
the the opening. When breaker is in place, release tab, which will lock circuit breaker into location in
opening.
•Repeat above operation for remaining breaker(s) (if more than one is provided).
•Replace single point wiring jumper bar, if it is used, on line side of breaker and tighten securely.
•Double check wires and lugs to make sure all are secure and tight. Check to make sure unit wiring to
circuit breaker load lugs match that shown on the unit wiring diagram.
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When using the unit with the electrical heater, the switch on the
front of the panel is only used for the electrical heater.
Horizontal right is the default factory configuration for the units.
Conversion to Horizontal: A vertical upflow unit may be converted to horizontal left by removing indoor
coil assembly and reinstalling coil as shown for left hand air supply. And reinstall coil in unit as shown for
left hand air supply.
•Rotate unit into the downflow position, with the coil compartment on top and the blower compartment
on bottom (Refer to Fig. 3).
•Reinstall the indoor coil 180° from the original position. Ensure the retaining channel is fully engaged with
the coil rail (Refer to Fig. 3).
•Secondary drain pan kits are recommended when the unit is configured for the horizontal position over a
finished ceiling and/or living space.
Horizontal units must be configured for right hand air supply or
left hand air supply. Horizontal drain pan must be located under
indoor coil. Failure to use the drain pan can result in property
damage.
Conversion in Horizontal Direction: Horizontal right-hand supply can be changed to horizontal left-hand
supply by removing the indoor coil and reinstalling 180 ° from the original position.
6 HORIZONTAL

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HAH14018 HAH14024 HAH14030 HAH14036 HAH14042 HAH14048 HAH14060
InWC
InWC
0.10 0.10 0.15 0.15 0.15 0.20 0.20
CFM(hi/mi/lo)
723/610/500938/804/7381204/1060/9191376/1235/11611562/1385/1208 1695/1574/1434 1695/1574/1434
0.18 0.18 0.23 0.23 0.23 0.28 0.28
CFM(hi/mi/lo)
1364/1229/8491595/1366/12562046/1955/15622340/2100/19742480/2430/2074 2882/2676/2437 2882/2676/2437
Indoor external
static pressure
Indoor air flow
14SEER AHU
Market Model
Indoor air flow
Indoor external
static pressure
Table 2

It is important that proper electrical power is available for connection to the unit model being installed.
Please refer to the unit nameplate, wiring diagram, and electrical data in the installation instructions.
• If required, install a branch circuit disconnect of adequate size, located within sight of, and readily
accessible to the unit.
• IMPORTANT: After the Electric Heater is installed, units may be equipped with one, two, or three 30/60
amp. circuit breakers. These breaker(s) protect the internal wiring in the event of a short circuit and also
serve as a disconnect. Circuit breakers installed within the unit do not provide overcurrent protection of
the supply wiring and therefore may be sized larger than the branch circuit protection.
• Supply circuit power wiring must be 167°F (75°C) minimum copper conductors only. Refer to the
Electrical Data In this section for ampacity, wire size, and circuit protector requirement. Supply circuit
protective devices may be either fuses or “HACR” type circuit breakers.
• Power wiring may be connected to either the right side, left side, or top. Concentric knockouts are
provided for connection of power wiring to unit.
• Power wiring is connected to the power terminal block in unit electric cabinet.
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IMPORTANT: Class 2 low voltage control wiring should not be run in conduit with main power wiring and
must be separated from power wiring, unless class 1 wire of proper voltage rating is used.
• Low voltage control wiring should be 18 Awg. color-coded. For lengths longer than 100 ft., 16 Awg. wire
should be used.
• See wiring diagrams attached to indoor and outdoor sections to be connected.
• Make sure, after installation, separation of control wiring and power wiring has been maintained.
The unit must be properly and permanently grounded. Failure to
do so can result In electrical shock causing personal injury or
death.
• Grounding may be accomplished by grounding metal conduit when installed in accordance with
electrical codes to the unit cabinet.
• Grounding may also be accomplished by attaching ground wire(s) to ground lug(s) provided in the unit
wiring compartment.
• Ground lug(s) are located close to wire entrance on left side of the unit (upflow). Lug(s) may be moved
to marked locations near wire entrance on right side of the unit (upflow). If alternate location is more
convenient.
• Use of multiple supply circuits require grounding of each circuit to lug(s) provided in unit.
8 POWER WIRING
9 CONTROL WIRING
10 GROUNDING
7 ELECTRICAL WIRING
Field wiring must comply with the National Electric Code and any applicable local ordinance.
Disconnect all power to unit before installing or servicing. More
than one disconnect switch may be required to de-energize the
equipment. Hazardous voltage can cause severe personal injury
or death.

The air distribution system has the greatest effect on airflow. The duct system is totally controlled by
the contractor. For this reason, the contractor should use only industry-recognized procedures.
Heat pump systems require a specified airflow. Each ton of cooling requires between 350 and 450
cubic feet of air per minute (CFM), or 400 CFM nominally. Duct design and construction should be
carefully done. System performance can be lowered dramatically through bad planning or
workmanship.
Air supply diffusers must be selected and located carefully. They must be sized and positioned to
deliver treated air along the perimeter of the space. If they are too small for their intended airflow,
they become noisy. If they are not located properly, they can create drafts. Return air grilles must be
properly sized to carry air back to the blower. If they are too small, they also cause noise.
The installers should balance the air distribution system to ensure proper, quiet airflow to all rooms in
the home. This ensures a comfortable living space. An air velocity meter or airflow hood can give a
reading of system CFM.
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11 ELECTRICAL DATA
Table 3
Keep the coil connections sealed until refrigerant connections are made. See the Installation
Instructions for the outdoor unit for details on line sizing, tubing installation, and charging information.
Coil is shipped with “No charge”. Evacuate the system before charging with refrigerant.
Install refrigerant tubing so that it does not block service access to the front of the unit.
Nitrogen should flow through the refrigerant lines while brazing.
Use a brazing shield to protect the cabinet’s paint, and a wet rag to protect the rubber grommet from
being damaged by torch flames. After the refrigerant connections are made, seal the gap around the
connections with a pressure sensitive gasket.
12 REFRIGERANT CONNECTIONS

13 EXPANSION VALVE + PISTON INFORMATION
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Model Piston
18K 801600300100
036
24K 801600300085
045
30K 801600300102
055
36K 801600300085
045
42K 801600300102
055
48K 801600300088
065
60K 801600300089
075
One Way Valve
BOM
Piston (14 SEER Heat Pump)
The length of warm wire should be L2≥
Balance tube length L1≥
A：Outlet inner diameter
B：Inlet diameter
C：Length from outlet center to bottom of valve body
D：Length from inlet center to bottom of valve body
E：Length from outlet center to valve body center
F：Length from inlet center to valve body center
G：Length between the center of the adjustable screw and the back of the valve body
H：Length between the center of valve body and bottom of valve body
L1：Balance tube length
L2：Warm wire length
BOM Model
NO. Remark
18/24/30/36/42K
Unit
Emerson
Emerson
Thermal Expansion Valve (14 SEER Heat Pump)
48/60K
One Way Valve
One Way Valve
One Way Valve
One Way Valve
One Way Valve
One Way Valve

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DO NOT OVERTIGHTEN DRAIN FITTING
TOWARD DRAIN CONNECTION
UNIT MUST BE SLIGHTLY INCLINED
14 CONDENSATE DRAIN TUBING
IMPORTANT
1. When making drain fitting connections to the drain pan, use a thin layer of Teflon paste, silicone, or
Teflon tape and install. Hand-tighten the fittings.
2. When making drain fitting connections to drain pan, do not overtighten. Over tightening fittings can split
pipe connections on the drain pan.
(Continued on next page)

• Install drain lines so they do not block service access to front of the unit. A minimum clearance of 2 feet (24 inches) is
required for filter, coil or blower removal, and service access.
• Make sure unit is level or pitched slightly toward primary drain connection so that water will drain completely from
the pan (Refer to Fig. 5)
• Use a drain line sized properly to match size of condensate drain pan.
• All drain lines must be pitched downward and away from the unit with a minimum of 1/8 in. per foot of line to
ensure proper drainage.
•Do not connect condensate drain line to a closed or open sewer pipe. Run condensate to an open drain or run line
to a safe outdoor area.
• The drain line should be insulated where necessary to prevent sweating and damage from condensate forming on
the outside surface of the line.
• Make provisions for disconnecting and cleaning of the primary drain line should it become necessary. Install a 3 inch
trap in the primary drain line as close to the unit as possible. Make sure that the top of the trap is below the
connection to the drain pan to allow complete drainage of pan (Refer to Fig. 5).
• Auxiliary drain line should be run to a place where it will be noticeable if it begins to drain. Homeowner should be
warned that a problem exists if water should begin running from the auxiliary drain line.
• Plug the unused drain connection with the plugs provided in the parts bag, using a thin layer of teflon paste, silicone,
or teflon tape to form a water tight seal.
• Test condensate drain pan and drain line after installation is complete. Pour water into drain pan, enough to fill
drain trap and line. Check to make sure drain pan is draining completely, no leaks are found in drain line fittings, and
water is draining from the termination of the primary drain line.
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• An external filter, or other means of filtration, is required. Units should be sized for a maximum of 300
feet/min. air velocity, or what is recommended for the filter type installed.
Filter application and placement are critical to airflow, which may affect the heating and cooling system
performance. Reduced airflow can shorten the life of the system’s major components, such as motor,
limits, elements, heat relays, evaporator coil, or compressor. Consequently, we recommend that the return
air duct system have only one filter location. For systems with a return air filter grill or multiple filter grills,
they can have a filter installed at each of the return air openings.
If adding high efficiency filters or electronic air filtration systems, it is very important that the air flow is not
reduced. If air flow is reduced, the overall performance and efficiency of the unit will be reduced. It is
strongly recommended that a profesional installation technician is contacted to ensure these filtration
systems are installed correctly.
IMPORTANT: DO NOT DOUBLE FILTER THE RETURN AIR DUCT SYSTEM. DO NOT FILTER THE SUPPLY
AIR DUCT SYSTEM. THIS WILL CHANGE THE PERFORMANCE OF THE UNIT AND REDUCE AIRFLOW.
Do not operate the system without filters. A portion of the dust
entrained in the air may temporarily lodge in the duct runs and
at the supply registers. Any circulated dust particles could be
heated and charred by contact with the air handler elements.
This residue could soil ceilings, walls, drapes, carpets, and other
articles in the house. Soot damage may occur with filters in place,
when certain types of candles, oil lamps, or standing pilots are
burned.
15 AIR FILTER (NOT FACTORY-INSTALLED)

1. Tear down the two bolts marked A and B, remove the cover for air filter (Refer to Fig. 6).
2. Hold the edge of the air filter and extract out .
3. Clean the air filter. A vacuum cleaner or pure water may be used to clean the air filter. If the dust
accumulation is too heavy, use soft a brush and mild detergent to clean it and allow it to dry out in cool
place.
16 FILTER INSTALLATION DIMENSIONS
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AIR FILTER REMOVAL
Table 4

17 WIRING DIAGRAMS
Thermostat Wiring - 6 Conductor | 18 Guage | Low Voltage
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Control Wiring for A/C Systems only
Control Wiring for Heat Pump Systems
W1
W1
A C

1. To avoid the electrical shock, please connect the air conditioner with the ground lug. The main power
plug in the air conditioner has been joined with the ground wiring, please do not change it freely.
2. Use a dedicated circuit.
3. Do not pull the power wiring hard.
4.When connecting the air conditioner with the ground, observe the local codes.
5. If necessary, use the power fuse, circuit breaker, or the corresponding scale ampere.
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High Voltage Wiring
Applicable to 18k, 24k, 30k, 36k, 42k of 13-14 SEER
Applicable to 48K of 13-14 SEER

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Applicable to 60K of 13-14 SEER
Wiring Diagram to Adjust Blower Volume Speed
To adjust blower speed, use the diagram below to wire according to the desired speed:
CN12 is the air volume output port. The air volume is adjusted by connecting the wires with different
speeds for the motor to the port CN12. Regardless of the high, medium or low wind speeds, it is only
connected to CN12. Do not adjust CN13.
Black = High
Red = Medium
Blue = Low

Signal Line
Signal Line
Signal Line
Signal Line
18 ELECTRIC WIRING GAUGE
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NOTE: The cross-section areas of wires or lines should not be less than the corresponding
line measurements listed in the table below; Besides, if the power wires from the unit are
quite long, please choose the windings with larger cross-section area to guarantee the
normal power supply.
Table 5
Table 6