Heat Controller HDG18 User manual

Heat Controller, Inc. • 1900 Wellworth Ave. • Jackson, MI 49203 • [phone] • www.heatcontroller.com
INSTALLATION
INSTRUCTIONS
Air Handler
HDG Series
1.5 to 5 Ton

HDG Series Air Handler INSTALLATION INSTRUCTIONS Heat Controller, Inc.
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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
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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.
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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
Warning
Warning
Warning

Heat Controller, Inc. INSTALLATION INSTRUCTIONS HDG Series Air Handler
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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
Warning
Warning
BLOWER MOTOR BOLT

HDG Series Air Handler INSTALLATION INSTRUCTIONS Heat Controller, Inc.
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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
Warning
Notice
Notice
Warning

Heat Controller, Inc. INSTALLATION INSTRUCTIONS HDG Series Air Handler
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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.
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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.
W
A
10
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)
H
D
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
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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.
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• 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.