INSTALLATION
INSTRUCTIONS
Air Handler
HDG Series
1.5 to 5 Ton
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Heat Controller, Inc.
INSTALLATION INSTRUCTIONS
HDG Series Air Handler
1.0 Nomenclature
H D G 18 F B - 1 A
A = Revision
Code
H = DX Air Handler
A = Hydronic Air Handler
F = Front Return
1 = 208/230V 1 Phase 60Hz
2 = 208/230V 3 Phase 60Hz
Design Series
Condenser/Heat Pump Matching Guide:
H = Heat Pump
C = Air Conditioner
B = Both A/C & H/P use
R-410A Refrigerant
F = Flowrater (Piston)
T = TXV
V = TXV w/ ECM Drive
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
NOTE: Not all model configurations are available. The nomenclature exists for future product line development. Consult
your local distributor or Heat Controller’s customer service department regarding available options.
Warning
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 instruction may result in improper
installation,adjustment, service or maintenance possibly resulting in fire, electrical shock,
property damage, personal injury or death.
2
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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.
Warning
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.
Warning
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 result-
ing in personal injuring or death.
Warning
Because of possible damage to equipment or personal injury, installation, service, and maintenance
should be performed by a trained, qualified service personnel. Consumer service is recommended
only for filter cleaning / replacement. Never operate the unit with the acess panels removed.
Warning
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 in-
stallation, adjustment, service or maintenance possibly resulting in fire, electrical shock, property
damage, personal injury or death.
3
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Heat Controller, Inc.
INSTALLATION INSTRUCTIONS
HDG Series Air Handler
Warning
The unit must be permanently grounded. Failure to do so can result in electrical shock causing
personal injury or death.
Warning
PROPOSITION 65: This appliance contains fiberglass insulation. Respirable particles of
fiberglass 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 fiberglass 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
final 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
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.
Warning
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.
BLOWER MOTOR BOLT
4
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HDG Series Air Handler
INSTALLATION INSTRUCTIONS
Heat Controller, Inc.
Warning
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 fire resulting in property damage, personal injury or death.
EXCEPTION: Manufactured housing installations are approved only with documentation by a
recognized inspection authority that verifies that the installation has been made in compliance
with the instructions and all warnings have been observed.
Warning
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
flammable 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.
Notice
When used in cooling applications, excessive sweating may occur when unit is installed in an
unconditioned space. This can result in property damage.
Notice
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 overflow
of the coil drain pan or a stoppage in the primary condensate drain piping.
Warning
The first 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 flexible air ducts located in it. If flexible 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 floor
base, if not, it must be connected to the unit supply duct 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 concrete floor slab with supply air plenum and ductwork completely encased
must be not less than 2 inches of concrete (See NFPA 90A).
5
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Heat Controller, Inc.
INSTALLATION INSTRUCTIONS
HDG Series Air Handler
3.0 General
The unit can be positioned for bottom return air in the upflow position, left and right return in the horizon-
tal position, top return in downflow position.
This Air Handler provides the flexibility for installation in any upflow or downflow horizontal application.
The direct drive motors provides a selection of air volume to match any application. 3-Speed motors
provide selections of air flow 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
6
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HDG Series Air Handler
INSTALLATION INSTRUCTIONS
Heat Controller, Inc.
NOTE: 24” CLEARANCE IS REQUIRED IN THE FRONT
OF THE UNIT FOR FILTER AND COIL MAINTENANCE.
3.1 Unit Dimensions
ELECTRICAL CONNECTIOS
MAY EXIT TOP OR EITHER SIDE
SUPPLY AIR
HIGH VOLTAGE CONNECTION 7/8”,
FLANGES ARE PROVIDED
FOR FIELD INSTALLATION
1-3/8”, 1-3/4” DIAMETER KNOCK OUTS
LOW VOLTAGE CONNECTION
BREAKER SWITCH
(FOR ELECTRIC HEATER ONLY)
H
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)
D
PRIMARY DRAIN CONNCETION 3/4”
FEMALE PIPE THREAD (NPT)
UPFLOW UNIT SHOWN;
UNIT MAY BE INSTALLED UPFLOW, DOWNFLOW,
HORIZONTAL RIGHT, OR LEFT AIR SUPPLY.
Fig. 1 Dimensions
Dimensional Data
Dimensions
Unit Weight lbs. [kg]
Unit Height
in. [mm]
Unit Weight
in. [mm]
Unit Lenght
in. [mm]
Supply Duct
“A” in [mm]
Model Size
HDG18
HDG 24
HDG 30
HDG36
HDG42
HDG48
HDG60
Net
Shipping
41 3/8" [1050]
41 3/8" [1050]
41 3/8" [1050]
46 1/2" [1180]
46 1/2" [1180]
54 1/2” [1385]
54 1/2” [1385]
18 1/8" [460]
18 1/8" [460]
18 1/8" [460]
19 5/8" [500]
19 5/8" [500]
22” [560]
20 1/2" [520]
20 1/2" [520]
20 1/2" [520]
20 5/8" [550]
20 5/8" [550]
24" [610]
16" [406]
16" [406]
106 [48]
106 [48]
119 [54]
141 [64]
141 [64]
171 [78]
171 [78]
119 [54]
119 [54]
132 [60]
156 [71]
156 [71]
187 [85]
187 [85]
16" [406]
18" [456]
18" [456]
19 1/2” [496]
19 1/2” [496]
22” [560]
24" [610]
7
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Heat Controller, Inc.
INSTALLATION INSTRUCTIONS
HDG Series Air Handler
4.0 Applications
4.1 Vertical Upflow
• Vertical Upflow configuration is the factory set on all models (see Fig 1).
• 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.
• If return air is to be ducted, install duct flush with floor. Use fireproof resilient gasket 1/8 to 1/4 in. thick
between the ducts, unit and floor. Set unit on floor over opening.
IMPORTANT NOTE
Torque applied to drain connections should not exceed 15.ft.lbs.(see Fig.1&2)
Refrigerant Line
Connections
Drain
Connections
1-9/16
5/16
2-13/16
1-1/4
5/16
1-3/8
2-15/16
2-15/16
Fig.2CoilConnectionDimensions
4.2 Vertical Downflow
Conversion to Vertical Downflow: A vertical upflow unit may be converted to vertical downflow.
Remove the door and indoor coil and reinstall 180° from original position. See Fig. 2~3.
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
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 bundles with wire ties, one bundle going to
the right lug and one bundle going to the left lug.
8
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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.
Caution
When using the unit with electrical heater, the switch is used only for electrical heater
on the front of panel.
4.3 HORIZONTAL
Horizontal right is the default factory configuration for the units.
Horizontal left isn’t the default factory configuration for the units.
Conversion to Horizontal: A vertical upflow 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 downflow 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 configured for the horizontal right position
over a finished ceiling and/or living space.
9
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Heat Controller, Inc.
INSTALLATION INSTRUCTIONS
HDG Series Air Handler
A
1:4
ENSURE THE RETAINING
CHANNEL IS FULLY ENGAGED
WITH THE COIL RAIL.
DETAIL A
RAILS
A
RAILS
Fig.3 VERTICAL DOWNFLOW & HORIZONTAL LEFT APPLICATIONS
(lower front service panel removed “view”.)
STRAPS
TOP AIR STOP
REAR WATER CATCHER
HORIZONTAL ADAPTER KIT
FRONT WATER
CATCHER
AUXILIARY HORIZONTAL
DRAIN CONNECTION
VAPOR LINE CONNECTION
LIQUID LINE CONNECTION
VERTICAL DRAIN PAN
PRIMARY DRAIN
CONNECTION
AUXILIARY UPFLOW/DOWNFLOW
DRAIN CONNECTION
The Max. resistant pressure of evaporator is up to 16MPa (2320PSI)
Fig.4 INDOOR COIL AND DRAIN PAN SET-UP
10
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HDG Series Air Handler
INSTALLATION INSTRUCTIONS
Heat Controller, Inc.
Caution
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 left-hand supply can be changed to horizontal
right-hand supply by removing the indoor coil and reinstalling 180° from original.
4.4 INSTALLATION IN AN UNCONDITIONED SPACE
IMPORTANT: There are two pairs of coil rails in the air handler for default and counter flow
application. If the air handler is installed in an unconditioned space, the two unused coil rails
should be removed to minimize air handler surface sweating. The coil rails can be easily re-
moved by taking off the 6 mounting screws from both sides of the cabinet.
5.0 ELECTRICAL WIRING
Field wiring must comply with the National Electric Code (C.E.C. in Canada) 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.
5.1 POWER WIRING
It is important that proper electrical power is available for connection to the unit model
being installed. See 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 serve as a disconnect. Circuit breakers installed within the
unit do not provide over-current 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. See
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, left side or top. Three 7/8”, 1-3/8”,
1-3/4” diameter concentric knockouts are provided for connection of power wiring to unit.
Power wiring is connected to the power terminal block in unit electric cabinet.
11
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Heat Controller, Inc.
INSTALLATION INSTRUCTIONS
HDG Series Air Handler
5.2 CONTROL WIRING
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.
•
Low voltage control connections are made to low voltage pigtails extending from top of air
handler (upflow position - see Figure 3). Connections for control wiring are made with wire
nuts. Control wiring knockouts (518 and 7/8) are also provided on the right and left side of
the unit for side connection.
•
•
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.
5.3 GROUNDING
Caution
The unit must be permanently grounded. FaIlure to do so can result In electrical shock
causing personal injury or death.
•
•
•
•
This product must be sufficiently ground in accordance with National Electric Code (C.E.C.
in Canada) and any applicable local ordinace.
Grounding may be accomplished by grounding metal conduit when installed in accord
ance 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 unit (up-flow). Lug(s) may
be moved to marked locations near wire entrance on right side of unit (upflow). If alternate
location is more convenient.
•
Use of multiple supply circuits require grounding of each circuit to lug(s) provided in unit.
12
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HDG Series Air Handler
INSTALLATION INSTRUCTIONS
Heat Controller, Inc.
5.4 Electrical Data– BLOWER ONLY, NO ELECTRIC HEAT
MINIMUM
CIRCUIT
MAXIMUM
CIRCUIT
CIRCUIT
Model
Voltage
HP
1/8
1/5
1/4
1/2
1/2
1/2
3/4
RPM
580
701
872
794
882
845
963
SPEEDS
AMPS.
0.68
0.95
1.48
1.63
1.80
2.11
AMPACITY
PROTECTOR
HDG18
HDG24
HDG30
HDG36
HDG42
HDG48
HDG60
208/230-1-60
208/230-1-60
208/230-1-60
208/230-1-60
208/230-1-60
208/230-1-60
208/230-1-60
3
3
3
3
3
3
3
1
1.5
2
15(A)
15(A)
15(A)
15(A)
15(A)
15(A)
15(A)
3
3
3
2.79
3
5.5 Electrical Data– ELECTRIC HEAT
Minimum Minimum Maximum Maximum
Circuit Circuit Circuit Circuit
Ampacity Ampacity Protection Protection
Air
Handler
Model
Heater Heater
kW kW
(208V) (240V)
Circuit
Amps
Circuit
Amps
Heater
Model No.
Motor
PH/Hz
(208V) (240V) Ampacity
(208V)
23.5
34.8
46
(240V)
26.9
40
(208V)
(240V)
7800-505-1D
3.8
5.6
7.5
3.8
5.6
7.5
3.8
5.6
7.5
3.8
5.6
7.5
11
5
7.5
10
5
18.1
27.1
36.1
18.1
27.1
36.1
18.1
27.1
36.1
18.1
27.1
36.1
54.2
72.2
18.1
27.1
36.1
54.2
72.2
18.1
27.1
36.1
54.2
72.2
18.1
27.1
36.1
54.2
72.2
20.8
31.3
41.7
20.8
31.3
41.7
20.8
31.3
41.7
20.8
31.3
41.7
62.5
83.3
20.8
31.3
41.7
62.5
83.3
20.8
31.3
41.7
62.5
83.3
20.8
31.3
41.7
62.5
83.3
0.68
0.68
0.68
0.95
0.95
0.95
1.48
1.48
1.48
1.63
1.63
1.63
1.63
1.63
1.80
1.80
1.80
1.80
1.80
2.11
2.11
2.11
2.11
2.11
2.79
2.79
2.79
2.79
2.79
25
30
HDG18 7800-508-1D
7800-510-1D
1Ph/60Hz
35
45
53
50
60
7800-505-1D
23.8
35.1
46.4
24.5
35.8
47
27.3
40.3
53.3
27.9
41
25
30
HDG24 7800-508-1D
7800-510-1D
7.5
10
5
1Ph/60Hz
1Ph/60Hz
40
45
50
60
7800-505-1D
25
30
HDG30 7800-508-1D
7800-510-1D
7.5
10
5
40
45
54
50
60
7800-505-1D
24.7
35.9
47.2
69.8
92.4
24.9
36.2
47.4
70
28.1
41.1
54.2
80.2
106.3
28.3
41.4
54.4
80.4
106.5
28.7
41.7
54.8
80.8
106.9
29.6
42.6
55.6
81.7
107.7
25
30
7800-508-1D
7.5
10
15
20
5
40
45
HDG36 7800-510-1D
7800-515-1D
1Ph/60Hz
1Ph/60Hz
1Ph/60Hz
1Ph/60Hz
50
55
70
90
7800-520-1D
15
100
25
125
30
7800-505-1D
3.8
5.6
7.5
11
7800-508-1D
7.5
10
15
20
5
40
45
HDG42 7800-510-1D
7800-515-1D
50
60
80
90
7800-520-1D
15
92.6
25.3
36.5
47.8
70.4
93
100
30
125
30
7800-505-1D
3.8
5.6
7.5
11
7800-508-1D
7.5
10
15
20
5
40
45
HDG48 7800-510-1D
7800-515-1D
50
60
80
90
7800-520-1D
15
100
30
125
30
7800-505-1D
3.8
5.6
7.5
11
26.1
37.4
48.7
71.2
93.8
7800-508-1D
7.5
10
15
20
40
45
HDG60 7800-510-1D
7800-515-1D
50
60
80
90
7800-520-1D
15
100
125
13
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Heat Controller, Inc.
INSTALLATION INSTRUCTIONS
HDG Series Air Handler
6.0 Airflow Performance
Airflow performance data is based on cooling performance with a coil and no filter in place. Select perfor-
mance table for appropriate unit size. Make sure external static applied to unit allows operation within the
minimum and maximum limits shown in table below for both cooling and electric heat operation.
Airflow Performance Data
CFM (Watts)
External Static Pressure-Inches W.C. [kPa]
Model
Motor
Number Speed
0 [0]
551
440
0.1 [.02] 0.16 [.04] 0.2 [.05] 0.3 [.07] 0.4 [.10] 0.5 [.12] 0.6 [.15] 0.7 [.17] 0.8 [.20]
CFM
RPM
509
518
120
0.62
622
580
143
0.68
-
462
595
393
679
116.3
0.61
506
731
136.3
0.67
--
345
726
280
781
---
-
----
Low
Watts 122.4
-
116.8
0.62
577
109.9
0.61
443
106.2
0.60
400
812
---
Amps
CFM
RPM
0.62
661
518
-
---
-
---
-
640
770
---
HDG18 Middle
Watts 145.2
-
140.8
0.68
133.6
0.67
131.2
0.66
590
894
232
1.16
453
840
146.3
0.75
613
---
Amps
CFM
0.69
--
-
---
--
550
487
940
400
975
RPM
Watts
Amps
CFM
--
--
--
911
High
Low
--
--
--
229.5
224.4
1.14
217.4
1.12
--
--
--
1.15
646
528
623
591
-
592
650
163
553
728
157.5
0.77
733
790
211.4
0.94
--
506
790
---
RPM
-
-
---
Watts 169.4
166.4
0.78
802
151.3
0.76
681
---
Amps
CFM
0.79
815
658
218
0.96
--
-
0.78
771
---
-
---
RPM
Watts
Amps
CFM
701
-
743
841
888
203
0.92
780
919
---
HDG24 Middle
216.6
0.95
-
214.4
0.95
207.4
0.93
---
-
---
--
695
607
515
RPM
Watts
Amps
CFM
--
--
--
956
986
1014
High
--
--
--
262.6
1.21
690
902
258
1.19
788
954
279
256.4
250.1
243
--
--
--
.181
.171
.15
962
729
315
1.39
1094
809
334
1.46
1374
910
440
1.94
913
754
304
1.35
1043
845
325
1.43
1311
937
886
798
298
1.32
1012
859
319
1.40
1268
947
419
1.86
870
809
292
1.30
988
885
315
813
858
280
1.26
927
911
303
1.35
1164
972
398
1.79
750
873
269
1.22
861
932
290
1.30
1084
989
381
1.74
-
-
-
RPM
Watts
Amps
CFM
-
-
-
Low
-
-
-
-
-
-
-
-
-
RPM
Watts
Amps
CFM
-
-
-
-
-
-
HDG30 Middle
1.38
1240
954
413
1.26
996
1004
366
1.68
-
-
-
910
1018
352
1.63
828
1033
340
1.60
744
1043
331
1.56
RPM
Watts
Amps
High
427
1.90
1.84
continued on next page
14
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HDG Series Air Handler
INSTALLATION INSTRUCTIONS
Heat Controller, Inc.
CFM (Watts)
External Static Pressure-Inches W.C. [kPa]
0.1 [.02] 0.16 [.04] 0.2 [.05] 0.3 [.07] 0.4 [.10] 0.5 [.12] 0.6 [.15] 0.7 [.17] 0.8 [.20]
Model
Number Speed
Motor
0 [0]
1129
642
CFM
RPM
Watts
Amps
CFM
RPM
Watts
Amps
CFM
RPM
Watts
Amps
CFM
RPM
Watts
Amps
CFM
RPM
Watts
Amps
CFM
RPM
Watts
Amps
CFM
RPM
Watts
Amps
CFM
RPM
Watts
Amps
CFM
RPM
Watts
Amps
CFM
RPM
Watts
Amps
CFM
RPM
Watts
Amps
CFM
RPM
Watts
Amps
1088
675
312
1061
706
306
1040
732
301
988
771
289
941
817
269
819
853
254
-
-
-
-
-
-
-
-
-
Low
322
1.54
1317
776
1.52
1268
810
1.51
1237
841
1.50
1217
874
1.47
1157
905
1.42
1111
935
1.39
1027
966
-
-
-
-
-
-
-
-
-
HDG36 Middle
360
354
1.67
1581
883
451
2.20
1203
775
385
1.68
1431
865
416
1.81
1682
941
348
345
1.65
1518
906
438
2.17
1161
808
371
1.62
1379
893
401
1.75
1618
955
478
2.08
1374
769
335
323
309
-
-
-
-
-
-
1.69
1643
868
1.66
1544
895
1.63
1446
931
1.60
1356
955
1.57
1261
978
1123
1013
371
2.03
915
1028
356
1.99
812
1050
343
1.96
High
463
443
429
415
401
2.22
1239
738
2.18
1178
797
2.14
1117
844
360
1.57
1319
915
2.12
1070
872
2.09
1000
905
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
Low
HDG42 Middle
High
396
376
345
327
1.73
1480
843
1.64
1399
882
1.52
1259
937
1.44
1187
959
430
407
388
375
359
1.87
1738
921
1.77
1639
949
1.69
1548
970
1.63
1477
985
445
1.94
1247
833
1.57
1378
1002
431
1.89
1180
864
1286
1016
412
1.81
--
1042
1042
373
1.65
908
1059
354
1.58
508
493
2.15
1427
732
376
486
460
2.22
1471
694
2.12
1395
753
2.01
1316
803
-
-
-
--
--
Low
381
372
370
364
357
349
1.66
1729
790
1.64
1678
817
1.63
1646
833
1.62
1625
845
470
1.61
1558
876
.581
1491
898
.550
1402
920
--
--
--
--
-
-
-
HDG48 Middle
485
477
473
460
451
240
2.14
2045
895
2.12
1992
920
627
2.09
1951
932
2.08
1928
938
612
.782
1688
856
552
2.54
2006
943
2.06
1847
956
2.03
1763
972
1.99
1677
987
--
-
1563
1002
546
.572
--
--
--
--
--
1450
1015
528
1317
1030
507
.450
High
641
617
596
582
566
2.86
1786
830
584
2.64
2140
917
2.82
1740
843
569
2.59
2071
930
630
2.81
2276
976
2.82
1709
849
560
2.55
2039
938
.732
1630
890
.682
1562
921
.642
1489
942
.522
-
-
-
-
-
-
-
-
Low
536
516
497
2.58
1932
957
2.42
1799
970
2.37
1677
990
--
--
--
HDG60 Middle
645
623
617
602
585
569
2.87
2357
964
754
3.34
2.78
2225
982
718
3.22
2.76
2188
990
710
2.71
2100
1001
693
2.65
2004
1012
673
2.59
1902
1022
650
1764
1032
630
2.91
1554
1042
607
1393
1063
575
2.71
High
733
3.27
3.19
3.12
3.05
2.98
2.83
15
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Heat Controller, Inc.
INSTALLATION INSTRUCTIONS
HDG Series Air Handler
Fan speed switch configurations:
1. All motors are shipped from the factory at medium speed as default.
2. To charge the fan speed to high speed:
• Connect the black wire to the fan terminal
• Connect the blue wire to the M1 terminal
• Connect the red wire to the M2 terminal
3. To charge the fan spped to low speed
• Connect the blue wire to the fan terminal
• Connect the red wire to the M1 terminal
• Connect the black wire to the M2 terminal
Terminal
M2
M1
Fan
Fan speed
Blue B
lack
Red
Medium
Red
Blue
Black
Blue
High
Low
Red
Black
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 dramati-
cally through bad planning or workmanship.
Air supply diffusers must be selected and located carefully. They must be sized and positoined to deliver
treated air along the perimerter of the space. If they are too small for their intended airflow, they become
noisy. If they are not located properly, they cause 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.
16
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HDG Series Air Handler
INSTALLATION INSTRUCTIONS
Heat Controller, Inc.
7.0 DUCTWORK
Field ductwork must comply with the National Fire Protection Association NFPA 90A, NFPA 90B and any
applicable local ordinance.
Warning
Do not, under any circumstances, connect return ductwork to any other heat producing device such
as fireplace insert, stove, etc. Unauthorized use of such devices may result in fire, carbon monoxide
poisoning, explosion, personal injury or property damage.
Sheet metal ductwork run in unconditioned spaces must be insulated and covered with a vapor barrier. Fi-
brous ductwork may be used if constructed and installed in accordance with SMACNA Construction Stan-
dard on Fibrous Glass Ducts. Ductwork must comply with National Fire Protection Association as tested by
U/L Standard 181 for Class I Air Ducts. Check local codes for requirements on ductwork and insulation.
•
Duct system must be designed within the range of external static pressure the unit is designed
to operate against. It is important that the system airflow be adequate. Make sure supply and
return ductwork, grills, special filters, accessories, etc. are accounted for in total resistance.
See airflow performance tables in this manual.
•
Design the duct system in accordance with “ACCA” Manual “D” Design for Residential Winter
and Summer Air Conditioning and Equipment Selection. Latest editions are available from:
“ACCA” Air Conditioning Contractors of America, 1513 16th Street, N.W., Washington, D.C.
20036. If duct system incorporates flexible air duct, be sure pressure drop Information (straight
length plus all turns) shown in “ACCA” Manual “D” is accounted for in system.
•
Supply plenum is attached to the 3/4” duct flanges supplied with the unit. Attach flanges
around the blower outlet.
IMPORTANT: If an elbow is included in the plenum close to the unit, it must not be smaller than the
dimensions of the supply duct flange on the unit.
•
IMPORTANT: The front flange on the return duct if connected to the blower casing must not
be screwed into the area where the power wiring is located. Drills or sharp screw points can
damage insulation on wires located inside unit.
•
Secure the supply and return ductwork to the unit flanges, using proper fasteners for the type
of duct used and tape the duct-to-unit joint as required to prevent air leaks.
17
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Heat Controller, Inc.
INSTALLATION INSTRUCTIONS
HDG Series Air Handler
8.0 REFRIGERANT CONNECTIONS
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 be-
ing damaged by torch flames. After the refrigerant connections are made, seal the gap around the con-
nections with pressure sensitive gasket.
8.1 CONDENSATE DRAIN TUBING
Consult local codes for specific requirements.
CONDENSATE DRAIN TRAP
DO NOT OPERATE UNIT WITHOUT
CONDENSATE DRAIN TRAP.
UNIT
DO NOT OVERTIGHTEN DRAIN FITTING
UNIT MUST BE SLIGHTLY INCLINED
TOWARD DRAIN CONNECTION
TO APPROVED DRAIN
Fig. 5 CONDENSATE DRAIN TRAP
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.
2.
When making drain fitting connections to drain pan, do not overtighten. Over tightening fittings
can split pipe connetions on the drain pan.
•
•
Install drain lines so they do not block service access to front of the unit. Minimum clearance of 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. (See Fig. 5)
• Do not reduce drain line size less than connection size provided on condensate drain pan.
• All drain lines must be pitched downward away from the unit a minimum of 1/8” 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.
18
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HDG Series Air Handler
INSTALLATION INSTRUCTIONS
Heat Controller, Inc.
• The drain line should be insulated where necessary to prevent sweating and damage due to conden-
sate forming on the outside surface of the line.
•
Make provisions for disconnecting and cleaning of the primary drain line should it become neces-
sary. 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 connection to the drain pan to allow complete drainage of pan (See Fig. 5).
• Auxiliary drain line should be run to a place where it will be noticeable if it becomes operational.
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 tef-
lon 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.
8.2 Flowrator Piston Change
In most applications, there is no need to change the piston (orifice). However, in some applications,
changing the piston size is required. If the application requires a different piston/flowrator, change the
piston in the distributor of indoor coil before installing the coil. See Table 1 for orifice size.
To change the piston, use following steps:
1. Remove cover panel.
2. Use Two wrenches.
Loosen one turn to release pressure. (High pressure gas)
3. After releasing pressure.
Loosen and carefully pull a part the two fittings to expose piston.
4. Remove factory installed piston and replace with recommended piston from Table 1 as shown in Fig.7.
5. Carefully reassemble assembly. (Hand tighten)
Be sure to use teflon tape on thread for a complete seal.
6. Hand tighten and make sure assembly is properly connected and then torque to 10-30 ft/lb.
NOTE: Be careful not to bend tubing
LIQUID LINE
PISTON
NUT
(MOMENT:15±2N.m)
Fig. 6: Flowrator Piston Change
19
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Heat Controller, Inc.
INSTALLATION INSTRUCTIONS
HDG Series Air Handler
Flowrator Piston Size Chart
NOTE: Pistons are factory installed for use with HRG-1D series heat pump. To use the
coil with a RSG-1D series condenser, a piston change may be required. Refer to table below.
Scroll Heat Pump Applications*
Air Handler:
HDG18FB-1A
HDG24FB-1A
HDG30FB-1A
HDG36FB-1A
HDG42FB-1A
HDG48FB-1A
HDG60FB-1A
Heat Pumps
HRG18S-1D
HRG24S-1D
HRG30S-1D
HRG36S-1D
HRG42S-1D
HRG48S-1D
HRG60S-1D
Piston Size
0.052 inch
0.058 inch
0.065 inch
0.068 inch
0.080 inch
0.090 inch
0.108 inch
Scroll Compressor Condenser Applications**
Air Handler:
HDG18FB-1A
HDG24FB-1A
HDG30FB-1A
HDG36FB-1A
HDG42FB-1A
HDG48FB-1A
HDG60FB-1A
Condeners
RSG18S-1D
RSG24S-1D
RSG30S-1D
RSG36S-1D
RSG42S-1D
RSG48S-1D
RSG60S-1D
Piston Size
0.052 inch
0.058 inch
0.065 inch
0.073 inch
0.077 inch
0.105 inch
0.097 inch
Rotary Compressor Condenser Applications**
Air Handler:
HDG18FB-1A
HDG24FB-1A
HDG30FB-1A
Condeners
RSG18R-1D
RSG24R-1D
RSG30R-1D
Piston Size
0.054 inch
0.061 inch
0.065 inch
*PISTON REQUIRED FOR THIS APPLICATION IS FACTORY INSTALLED.
**PISTON REQUIRED FOR THIS APPLICATION IS NOT FACTORY INSTALLED, REQUIRES
FIELD CONVERSION.
20
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HDG Series Air Handler
INSTALLATION INSTRUCTIONS
Heat Controller, Inc.
9.0 AIR FILTER (not factory-installed)
• 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 type filter 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, 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 installation of
these such 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 RE-
DUCE AIRFLOW .
Warning
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.
21
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Heat Controller, Inc.
INSTALLATION INSTRUCTIONS
HDG Series Air Handler
10.0 FILTER INSTALLATION DIMENSIONS
FILTER RAILS
U
N
I
T
M
U
S
T
B
E
S
L
I
G
H
T
L
Y
I
N
C
L
I
N
E
D
FILTER COVER
MANUAL BOLT
“H”
NOTE:
Air Filter is NOT factory supplied
Fig. 7: External Filter Base
DIMENSIONAL DATA
MODEL
*
Return length
FILTER SIZE
IN [mm]
Return width
"W" IN [mm] "D" IN [mm] "H" IN [mm]
"B" IN
"A" IN
HDG 18/24/30
HDG 36/42
HDG 48/60
16x20 [406x508]
18x20 [457x508]
20x22 [508x559]
14.8
16.3
18.8
16.8[426]
18.3[466]
20.7[526]
20.4[518]
21.6[548]
23.9[608]
1[25.4]
1[25.4]
1[25.4]
19.6
20.8
23
* Air filter is not factory installed. Filter rack is provided. Field supplied filters must be installed per recommended sizes.
AIR FILTER REMOVAL
1.Remove bolts manually, remove air filter recover, see in Fig 7;
2. Hold the edge of the air filter and extract out .
3. Replace the filter with a properly sized filter using the table above.
22
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HDG Series Air Handler
INSTALLATION INSTRUCTIONS
Heat Controller, Inc.
11.0 Wiring Diagram
1. To avoid the electrical shock, connect the air conditioner with the ground lug. The main power plug in
the air conditioner has been joined with the ground wiring, please don’t alter it.
2. The power socket is used as the air conditioner specially.
3. Don’t 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 or the circuit, breaker or the corresponding scale ampere.
THERMOSTAT
C
R
Y
G
C
G
R
C
Y
INDOOR UNIT
OUTDOOR UNIT
Fig. 8: Typical Thermostat Wiring for Cooling-Only Models
W2
B
C
R
Y
G
THERMOSTAT
w1
R
C
B
G
D
RY
C
INDOOR UNIT
OUTDOOR UNIT
Fig. 9: Typical Thermostat Wiring for Heat Pump Models
23
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Heat Controller, Inc.
INSTALLATION INSTRUCTIONS
HDG Series Air Handler
Fig. 10: Indoor Unit Wiring Diagram for A/C Systems and H/P Systems
24
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HDG Series Air Handler
INSTALLATION INSTRUCTIONS
Heat Controller, Inc.
BLACK
C
1
C
W2
W2
W1
0
WHITE
BLACK
PCB
1
W1
WHITE
0
RED
BLACK
12 GA 1015 600V 105 C
14 GA 1015 600V 105 C
18 GA 1015 600V 105 C
L1
L1
L2
L2
L1
L1
L2
L2
FIELD WIRING PER LOCAL CODE
20kW HEAT KIT
BLACK
C
1
C
W2
W2
W1
0
1
WHITE
BLACK
PCB
W1
WHITE
0
RED
BLACK
12 GA 1015 600V 105 C
14 GA 1015 600V 105 C
18 GA 1015 600V 105 C
L1
L1
L1
L1
L2
L2
L2
L2
FIELD WIRING PER LOCAL CODE
CB2(63A)
CB1(32A
15kW HEAT KIT
12 GA 1015 600V 105 C
14 GA 1015 600V 105 C
18 GA 1015 600V 105 C
7.5kW HEAT KIT
10kW HEAT KIT
7.5kW CB1 50A
10kW CB1 63A
FIELD WIRING PER LOCAL CODE
GREEN
1
C
BLACK
WHITE
PCB
W1
0
12 GA 1015 600V 105 C
14 GA 1015 600V 105 C
5kW HEAT KIT
18 GA 1015 600V 105 C
FIELD WIRING PER LOCAL CODE
GREEN
1
C
BLACK
WHITE
PCB
W1
0
Fig. 11: Indoor Unit Wiring Diagram for Electric Heat
25
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05/2011
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