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INSTALLATION
INSTRUCTIONS
Air Handler
HDG Series
1.5 to 5 Ton
Heat Controller, Inc. • 1900 Wellworth Ave. • Jackson, MI 49203 • (517)787-2100 • www.heatcontroller.com
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HDG Series Air Handler INSTALLATION INSTRUCTIONS Heat Controller, Inc. Table of Contents 1.0 NOMENCLATURE ...............................................................................................................2 2.0 SAFETY ................................................................................................................................3 3.0 GENERAL ............................................................................................................................6
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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 1 = 208/230V 1 Phase 60Hz A = Hydronic Air Handler 2 = 208/230V 3 Phase 60Hz F = Front Return 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 BTU
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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 symb
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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 produc
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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
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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 desire
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W A HDG Series Air Handler INSTALLATION INSTRUCTIONS Heat Controller, Inc. NOTE: 24” CLEARANCE IS REQUIRED IN THE FRONT 3.1 Unit Dimensions OF THE UNIT FOR FILTER AND COIL MAINTENANCE. ELECTRICAL CONNECTIOS MAY EXIT TOP OR EITHER SIDE SUPPLY AIR HIGH VOLTAGE CONNECTION 7/8”, HIGH VOLTAGE CONNECTION 7/8”, FLANGES ARE PROVIDED 1-3/8”, 1-3/4” DIAMETER KNOCK OUTS 1-23/64”, 1-23/32” DIA KNOCK OUTS FOR FIELD INSTALLATION LOW VOLTAGE CONNECTION BREAKER SWITCH (FOR ELECTRIC HEATER ONLY) H VAPOR LI
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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
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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.
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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 VAPOR LINE CONNECTION DRAIN CONNECTION LIQUID LINE CONNECTION VERTICAL DRAIN PAN PRIMARY DR
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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 SP
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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 ai
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HDG Series Air Handler INSTALLATION INSTRUCTIONS Heat Controller, Inc. 5.4 Electrical Data– BLOWER ONLY, NO ELECTRIC HEAT MINIMUM MAXIMUM CIRCUIT CIRCUIT CIRCUIT Model Voltage HP RPM SPEEDS AMPS. AMPACITY PROTECTOR HDG18 208/230-1-60 1/8 580 3 0.68 1 15(A) HDG24 208/230-1-60 1/5 701 3 0.95 1.5 15(A) HDG30 208/230-1-60 1/4 872 3 1.48 2 15(A) HDG36 208/230-1-60 1/2 794 3 1.63 3 15(A) HDG42 208/230-1-60 1/2 882 3 1.80 3 15(A) HDG48 208/230-1-60 1/2 845 3 2.11 3 15(A) HDG60 208/230-1-60 3/4 96
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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
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HDG Series Air Handler INSTALLATION INSTRUCTIONS Heat Controller, Inc. CFM (Watts) External Static Pressure-Inches W.C. [kPa] Model Motor Number Speed 0 [0] 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 1129 1088 1061 1040 988 941 819 - - - RPM 642 675 706 732 771 817 853 - - - Low Watts 322 312 306 301 289 269 254 - - - Amps 1.54 1.52 1.51 1.50 1.47 1.42 1.39 - - - CFM 1317 1268 1237 1217 1157 1111 1027 - - - RPM 776 810 841 874 905 935 966 - -
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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 w
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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
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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
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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 comple
