Heat Controller HDG18 User manual

Heat Controller, Inc. • 1900 Wellworth Ave. • Jackson, MI 49203 • (517)787-2100 • www.heatcontroller.com

INSTALLATION

INSTRUCTIONS

Air Handler

HDG Series

1.5 to 5 Ton

HDG Series Air Handler INSTALLATION INSTRUCTIONS Heat Controller, Inc.

1.0 NOMENCLATURE ...............................................................................................................2

2.0 SAFETY................................................................................................................................3

3.0 GENERAL ............................................................................................................................6

3.1 UNIT DIMENSIONS......................................................................................................7

4.0 APPLICATIONS ...................................................................................................................8

4.1 VERTICAL UPFLOW. ...................................................................................................8

4.2 VERTICAL DOWNFLOW..............................................................................................8

4.3 HORIZONTAL...............................................................................................................9

4.4 INSTALLATION IN AN UNCONDITIONED SPACE .................................................... 11

5.0 ELECTRICAL WIRING....................................................................................................... 11

5.1 POWER WIRING........................................................................................................ 11

5.2 CONTROL WIRING....................................................................................................12

5.3 GROUNDING .............................................................................................................12

5.4 ELECTRICAL DATA....................................................................................................13

6.0 AIRFLOW PERFORMANCE..............................................................................................14

7.0 DUCTWORK ......................................................................................................................17

8.0 REFRIGERANT CONNECTIONS ......................................................................................18

8.1 CONDENSATE DRAIN TUBING ................................................................................18

8.2 FLOW RATER PISTON CHANGE ..............................................................................19

9.0 AIR FILTER (not factory-installed) ..................................................................................21

10.0 FILTER INSTALLATION DIMENSIONS ..........................................................................22

10.0 WIRE DIAGRAMS............................................................................................................23

Table of Contents

Heat Controller, Inc. INSTALLATION INSTRUCTIONS HDG Series Air Handler

These instructions are intended as an aid to qualied 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 instruction may result in improper

installation,adjustment, service or maintenance possibly resulting in re, electrical shock,

property damage, personal injury or death.

H D G 18 F B - 1 A

H = DX Air Handler

A = Hydronic Air Handler

F = Front Return

Design Series

R-410A Refrigerant

18 = 18,000 BTUH

24 = 24,000 BTUH

30 = 30,000 BTUH

36 = 36,000 BTUH

42 = 42,000 BTUH

48 = 48,000 BTUH

60 = 60,000 BTUH

F = Flowrater (Piston)

T = TXV

V = TXV w/ ECM Drive

Condenser/Heat Pump Matching Guide:

H = Heat Pump

C = Air Conditioner

B = Both A/C & H/P use

1 = 208/230V 1 Phase 60Hz

2 = 208/230V 3 Phase 60Hz

Warning

1.0 Nomenclature

A = Revision

Code

NOTE: Not all model congurations are available. The nomenclature exists for future product line development. Consult

your local distributor or Heat Controller’s customer service department regarding available options.

HDG Series Air Handler INSTALLATION INSTRUCTIONS Heat Controller, Inc.

This document is customer property and is to remain with this unit.

These instructions do not cover all the different variations systems nor does it provide for every pos-

sible contingency to be met in connection with installtion.

All phases of this installation must comply with NATIONAL STATE AND LOCAL CODES. If additional

information is required please contact your local distributor.

2.0 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.

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 server 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 eld power wires can

be safely removed from the blower assembly. Failure to do so can cause electrical shock result-

ing in personal injuring or death.

Because of possible damage to equipment or personal injury, installation, service, and maintenance

should be performed by a trained, qualied service personnel. Consumer service is recommended

only for lter cleaning / replacement. Never operate the unit with the acess panels removed.

These instructions are intended as an aid to qualied, 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 in-

stallation, adjustment, service or maintenance possibly resulting in re, electrical shock, property

damage, personal injury or death.

Warning

Heat Controller, Inc. INSTALLATION INSTRUCTIONS HDG Series Air Handler

The unit must be permanently grounded. Failure to do so can result in electrical shock causing

personal injury or death.

PROPOSITION 65: This appliance contains berglass insulation. Respirable particles of

berglass are known to State of California to cause cancer.

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 over 600 listed chemicals known to the State of California to cause cancer or birth

defects such as berglass insulation, lead in brass, and combustion products from natural gas.

All “new equipment” shipped for sale in California will only have labels stating that the product

contains and /or produces Proposition 65 chemicals. We cannot always know “when, or if”

products will be sold in the California market, thus all products may not be labeled when their

nal destination is unknown.

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 (Ofce 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.

Make sure the blower motor support is tight (3-motor

mount bolts) then check to see if wheel is secured to

motor shaft before operating unit. To avoid electrical

shock, which can result in injury or death, use only the

screws furnished with the motor from the manufacturer.

Warning

BLOWER MOTOR BOLT

HDG Series Air Handler INSTALLATION INSTRUCTIONS Heat Controller, Inc.

Do not install this unit in manufactured (mobile) homes. Improper installation is more likely in

manufactured housing due to ductwork material, size, location and arrangement. Installations in

manufactured housing can cause re resulting in property damage, personal injury or death.

EXCEPTION: Manufactured housing installations are approved only with documentation by a

recognized inspection authority that veries that the installation has been made in compliance

with the instructions and all warnings have been observed.

Duct leaks can create an unbalanced system and draw pollutants such as direct, dust, fumes

and odors into the home causing property damage. Fumes and odors from toxic, volatile or

ammable chemicals, as well as automobile exhaust and carbon monoxide (CO), can be drawn

into the living space through leaking ducts and unbalanced duct systems causing personal injury

or death (see Figure 1).

• If air-moving equipment or ductwork is located in garages or off-garage storage areas, all joints,

seams, and openings in the equipment and duct must be sealed to limit the migration of toxic

fumes and odors including carbon monoxide from migrating into the living space.

• If air-moving equipment or ductwork is located in spaces containing fuel burning appliances

such as water heaters or boilers, all joints, seams and openings in the equipment and duct

must be sealed to prevent depressurization of the space and possible migration of combustion

byproducts including carbon monoxide into the living space.

When used in cooling applications, excessive sweating may occur when unit is installed in an

unconditioned space. This can result in property damage.

In compliance with recognized codes, it is recommended that an auxiliary drain pan be installed

under all evaporator coils or units containing evaporator coils that are located in any area of a

structure where damage to the building or building contents may occur as a result of an overow

of the coil drain pan or a stoppage in the primary condensate drain piping.

The rst 36 inches of supply air plenum and ductwork must be constructed of sheet metal as

required by NFPA 90B. The supply air plenum or duct must have a solid sheet metal bottom

directly under the unit with no openings, registers or exible air ducts located in it. If exible supply

air ducts are used they may be located only in the vertical walls of rectangular plenum, a minimum

of 6 inches from the solid bottom. Metal plenum of duct may be connected to the combustible oor

base, if not, it must be connected to the unit supply duct exposed to the supply air opening from the

downow unit. Exposing combustible (non-metal) material to the supply opening of a downow unit

can cause a re resulting in property damage, personal injury or death.

Exception warning to downow:

Installations on concrete oor slab with supply air plenum and ductwork completely encased

must be not less than 2 inches of concrete (See NFPA 90A).

Warning

Notice

Warning

Heat Controller, Inc. INSTALLATION INSTRUCTIONS HDG Series Air Handler

3.0 General

The unit can be positioned for bottom return air in the upow position, left and right return in the horizon-

tal position, top return in downow position.

This Air Handler provides the exibility for installation in any upow or downow horizontal application.

The direct drive motors provides a selection of air volume to match any application. 3-Speed motors

provide selections of air ow to meet desired applications.

Top and side power and control wiring, accessible screw terminals for control wiring all combine to

make the installation easy, and minimize installation cost. Please contact your local distributor.

See Fig. 1 on Pg. 7

HDG Series Air Handler INSTALLATION INSTRUCTIONS Heat Controller, Inc.

Model Size

Dimensions Unit Weight lbs. [kg]

Unit Height

in. [mm]

Unit Weight

in. [mm]

Unit Lenght

in. [mm]

Supply Duct

“A” in [mm] Net Shipping

HDG18 41 3/8" [1050] 18 1/8" [460] 20 1/2" [520] 16" [406] 106 [48] 119 [54]

HDG 24 41 3/8" [1050] 18 1/8" [460] 20 1/2" [520] 16" [406] 106 [48] 119 [54]

HDG 30 41 3/8" [1050] 18 1/8" [460] 20 1/2" [520] 16" [406] 119 [54] 132 [60]

HDG36 46 1/2" [1180] 19 5/8" [500] 20 5/8" [550] 18" [456] 141 [64] 156 [71]

HDG42 46 1/2" [1180] 19 5/8" [500] 20 5/8" [550] 18" [456] 141 [64] 156 [71]

HDG48 54 1/2” [1385] 22” [560] 24" [610] 19 1/2” [496] 171 [78] 187 [85]

HDG60 54 1/2” [1385] 22” [560] 24" [610] 19 1/2” [496] 171 [78] 187 [85]

UPFLOW UNIT SHOWN;

UNIT MAY BE INSTALLED UPFLOW, DOWNFLOW,

HORIZONTAL RIGHT, OR LEFT AIR SUPPLY.

516

SUPPLY AIR

FLANGES ARE PROVIDED

FOR FIELD INSTALLATION

ELECTRICAL CONNECTIOS

MAY EXIT TOP OR EITHER SIDE

HIGH VOLTAGE CONNECTION 7/8”,

1-23/64”, 1-23/32” DIA KNOCK OUTS

LOW VOLTAGE CONNECTION

BREAKER SWITCH

(FOR ELECTRIC HEATER ONLY)

VAPOR LINE CONNECTION COPPER (SWEAT)

LIQUID LINE CONNECTION COPPER (SWEAT)

AUXILIARY DRAIN CONNCECTION 3/4”

FEMALE PIPE THREAD (NPT)

AUXILIARY DRAIN CONNECTION 3/4”

FEMALE PIPE THREAD (NPT)

PRIMARY DRAIN CONNCETION 3/4”

FEMALE PIPE THREAD (NPT)

NOTE: 24” CLEARANCE IS REQUIRED IN THE FRONT

OF THE UNIT FOR FILTER AND COIL MAINTENANCE.

HIGH VOLTAGE CONNECTION 7/8”,

1-3/8”, 1-3/4” DIAMETER KNOCK OUTS

Fig. 1 Dimensions

3.1 Unit Dimensions

Dimensional Data

Heat Controller, Inc. INSTALLATION INSTRUCTIONS HDG Series Air Handler

1-9/16

2-15/16 5/16

2-15/16

1-3/8

1-1/4

5/16

2-13/16

Fig.2 Coil Connection Dimensions

4.0 Applications

4.1 Vertical Upow

• Vertical Upow conguration is the factory set on all models (see Fig 1).

• If a side return air opening is required, eld fabricate a return air plenum with an opening large enough

to supply unit and strong enough to support unit weight.

• If return air is to be ducted, install duct ush with oor. Use reproof resilient gasket 1/8 to 1/4 in. thick

between the ducts, unit and oor. Set unit on oor over opening.

IMPORTANT NOTE

Torque applied to drain connections should not exceed 15.ft.lbs.(see Fig.1&2)

Fig. 2 Coil Connection Dimensions

4.2 Vertical Downow

Conversion to Vertical Downow: A vertical upow unit may be converted to vertical downow.

Remove the door and indoor coil and reinstall 180° from original position. See Fig. 2~3.

IMPORTANT: To comply with certication agencies and the National Electric Code for horizontal

right application, the circuit breaker(s) on eld-installed electric heater kits must be re-installed per

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 identied

and are reinstalled into proper breaker).Wires are bundles with wire ties, one bundle going to

the right lug and one bundle going to the left lug.

Refrigerant Line

Connections

Drain

Connections

HDG Series Air Handler INSTALLATION INSTRUCTIONS Heat Controller, Inc.

• Using a screwdriver or pencil, lift blue plastic tab with hole away from breaker until breaker releas-

es from mounting opening.

• With breaker held in hand, rotate breaker so that “on” position is up, “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 wires are inserted fully into lug, and no wire insulation is in 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 breaker mounting tab opposite white pull tab in opening, hook mount-

ing tab over edge in opening.

• With screwdriver or pencil, pull blue tab with hole away from breaker while setting that side of

breaker into opening. When breaker is in place, release tab, locking 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.

4.3 HORIZONTAL

Horizontal right is the default factory conguration for the units.

Horizontal left isn’t the default factory conguration for the units.

Conversion to Horizontal: A vertical upow unit may be converted to horizontal right by removing indoor

coil assembly and reinstalling coil as shown for right hand air supply. And reinstall coil in unit as shown

for right hand air supply.

• Reinstall the indoor coil 180° from original position. Ensure the retaining channel is fully engaged

with the coil rail. See Fig. 3.

• Rotate unit into the downow position, with the coil compartment on top and the blower compart-

ment on bottom. See Fig. 3.

• Secondary drain pan kits are required when the unit is congured for the horizontal right position

over a nished ceiling and/or living space.

Caution

When using the unit with electrical heater, the switch is used only for electrical heater

on the front of panel.

This manual suits for next models

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