Heat Controller HDG48, HDG42, HDG30, HDG60, HDG24, HDG36, HDG User Manual

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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

HDG Series Air Handler

INSTALLATION INSTRUCTIONS

Heat Controller, Inc.

Table of Contents

 

 

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

1

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

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

F = Front Return

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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

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 possible 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 resulting 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 installation, adjustment, service or maintenance possibly resulting in fire, electrical shock, property damage, personal injury or death.

3

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 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.

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

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

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 horizontal 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

HDG Series Air Handler

INSTALLATION INSTRUCTIONS

 

Heat Controller, Inc.

3.1 Unit Dimensions

OF THE UNIT FOR FILTER AND COIL MAINTENANCE.

 

 

NOTE: 24” CLEARANCE IS REQUIRED IN THE FRONT

ELECTRICAL CONNECTIOS

 

 

 

 

 

MAY EXIT TOP OR EITHER SIDE

 

 

SUPPLY AIR

 

 

 

 

 

 

 

 

 

7/8”,

 

 

FLANGES ARE PROVIDED

HIGHVOLTAGELTAGECONNECTION 7/8”,

 

 

1-3/8”, 1-3/4”

KNOCK

 

 

FOR FIELD INSTALLATION

1-23/64”, 1-23/32”DIAMETERKNOCK OUTOUTS

 

 

 

 

 

5

 

 

W

 

 

0

16

 

 

 

1

 

A

 

 

 

 

 

 

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)

Fig. 1 Dimensions

Dimensional Data

UPFLOW UNIT SHOWN;

UNIT MAY BE INSTALLED UPFLOW, DOWNFLOW, HORIZONTAL RIGHT, OR LEFT AIR SUPPLY.

 

 

Dimensions

 

Unit Weight lbs. [kg]

 

Unit Height

Unit Weight

Unit Lenght

Supply Duct

 

 

Model Size

in. [mm]

in. [mm]

in. [mm]

“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]

7

Heat Controller, Inc.

INSTALLATION INSTRUCTIONS

HDG Series Air Handler

 

 

 

4.0Applications

4.1Vertical 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

2-15/16

Fig.22CoilCoilConnectionDimensionsDimensions

5/16

2-13/16

1-1/4

5/16 1-3/8

2-15/16

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

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 releases 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 mounting 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 compartment 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

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

REAR WATER CATCHER

TOP AIR STOP

HORIZONTAL ADAPTER KIT

FRONT WATER

CATCHER

VAPOR LINE CONNECTION

AUXILIARY HORIZONTAL

DRAIN 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

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 removed 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

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.

5.3GROUNDING

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

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

963

3

2.79

3

15(A)

5.5 Electrical Data– ELECTRIC HEAT

 

 

 

 

 

 

 

 

Minimum

Minimum

Maximum

Maximum

Air

 

Heater

Heater

 

Circuit

Circuit

 

Circuit

Circuit

Circuit

Circuit

Handler

Heater

kW

kW

 

Amps

Amps

Motor

Ampacity

Ampacity

Protection

Protection

Model

Model No.

(208V)

(240V)

PH/Hz

(208V)

(240V)

Ampacity

(208V)

(240V)

(208V)

(240V)

 

7800-505-1D

3.8

5

 

18.1

20.8

0.68

23.5

26.9

25

30

HDG18

7800-508-1D

5.6

7.5

1Ph/60Hz

27.1

31.3

0.68

34.8

40

35

45

 

7800-510-1D

7.5

10

 

36.1

41.7

0.68

46

53

50

60

 

7800-505-1D

3.8

5

 

18.1

20.8

0.95

23.8

27.3

25

30

HDG24

7800-508-1D

5.6

7.5

1Ph/60Hz

27.1

31.3

0.95

35.1

40.3

40

45

 

7800-510-1D

7.5

10

 

36.1

41.7

0.95

46.4

53.3

50

60

 

7800-505-1D

3.8

5

 

18.1

20.8

1.48

24.5

27.9

25

30

HDG30

7800-508-1D

5.6

7.5

1Ph/60Hz

27.1

31.3

1.48

35.8

41

40

45

 

7800-510-1D

7.5

10

 

36.1

41.7

1.48

47

54

50

60

 

7800-505-1D

3.8

5

 

18.1

20.8

1.63

24.7

28.1

25

30

 

7800-508-1D

5.6

7.5

 

27.1

31.3

1.63

35.9

41.1

40

45

HDG36

7800-510-1D

7.5

10

1Ph/60Hz

36.1

41.7

1.63

47.2

54.2

50

55

 

7800-515-1D

11

15

 

54.2

62.5

1.63

69.8

80.2

70

90

 

7800-520-1D

15

20

 

72.2

83.3

1.63

92.4

106.3

100

125

 

7800-505-1D

3.8

5

 

18.1

20.8

1.80

24.9

28.3

25

30

 

7800-508-1D

5.6

7.5

 

27.1

31.3

1.80

36.2

41.4

40

45

HDG42

7800-510-1D

7.5

10

1Ph/60Hz

36.1

41.7

1.80

47.4

54.4

50

60

 

7800-515-1D

11

15

 

54.2

62.5

1.80

70

80.4

80

90

 

7800-520-1D

15

20

 

72.2

83.3

1.80

92.6

106.5

100

125

 

7800-505-1D

3.8

5

 

18.1

20.8

2.11

25.3

28.7

30

30

 

7800-508-1D

5.6

7.5

 

27.1

31.3

2.11

36.5

41.7

40

45

HDG48

7800-510-1D

7.5

10

1Ph/60Hz

36.1

41.7

2.11

47.8

54.8

50

60

 

7800-515-1D

11

15

 

54.2

62.5

2.11

70.4

80.8

80

90

 

7800-520-1D

15

20

 

72.2

83.3

2.11

93

106.9

100

125

 

7800-505-1D

3.8

5

 

18.1

20.8

2.79

26.1

29.6

30

30

 

7800-508-1D

5.6

7.5

 

27.1

31.3

2.79

37.4

42.6

40

45

HDG60

7800-510-1D

7.5

10

1Ph/60Hz

36.1

41.7

2.79

48.7

55.6

50

60

 

7800-515-1D

11

15

 

54.2

62.5

2.79

71.2

81.7

80

90

 

7800-520-1D

15

20

 

72.2

83.3

2.79

93.8

107.7

100

125

13

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 performance 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

Model

Motor

 

Number

Speed

 

 

 

CFM

 

Low

RPM

 

Watts

 

 

 

 

Amps

 

 

CFM

HDG18

Middle

RPM

Watts

 

 

 

 

Amps

 

 

CFM

 

High

RPM

 

Watts

 

 

 

 

Amps

 

 

CFM

 

Low

RPM

 

Watts

 

 

 

 

Amps

 

 

CFM

HDG24

Middle

RPM

Watts

 

 

 

 

Amps

 

 

CFM

 

High

RPM

 

Watts

 

 

 

 

Amps

 

 

CFM

 

Low

RPM

 

Watts

 

 

 

 

Amps

 

 

CFM

HDG30

Middle

RPM

Watts

 

 

 

 

Amps

 

 

CFM

 

High

RPM

 

Watts

 

 

 

 

Amps

CFM (Watts)

External Static Pressure-Inches W.C. [kPa]

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]

551

509

-

462

393

345

280

---

 

 

440

518

-

595

679

726

781

----

 

 

122.4

120

-

116.8

116.3

109.9

106.2

---

 

 

0.62

0.62

-

0.62

0.61

0.61

0.60

---

 

 

661

622

-

577

506

443

400

---

 

 

518

580

-

640

731

770

812

---

 

 

145.2

143

-

140.8

136.3

133.6

131.2

---

 

 

0.69

0.68

-

0.68

0.67

0.67

0.66

---

 

 

--

 

--

 

--

 

590

550

487

400

--

 

--

 

--

 

894

911

940

975

--

 

--

 

--

 

232

229.5

224.4

217.4

--

 

--

 

--

 

1.16

1.15

1.14

1.12

646

623

-

592

553

506

453

---

 

 

528

591

-

650

728

790

840

---

 

 

169.4

166.4

-

163

157.5

151.3

146.3

---

 

 

0.79

0.78

-

0.78

0.77

0.76

0.75

---

 

 

815

802

-

771

733

681

613

---

 

 

658

701

-

743

790

841

888

---

 

 

218

216.6

-

214.4

211.4

207.4

203

---

 

 

0.96

0.95

-

0.95

0.94

0.93

0.92

---

 

 

--

 

--

 

--

 

780

695

607

515

--

 

--

 

--

 

919

956

986

1014

--

 

--

 

--

 

262.6

256.4

250.1

243

--

 

--

 

--

 

1.21

.181

.171

.15

962

913

886

870

813

750

690

-

-

-

729

754

798

809

858

873

902

-

-

-

315

304

298

292

280

269

258

-

-

-

1.39

1.35

1.32

1.30

1.26

1.22

1.19

-

-

-

1094

1043

1012

988

927

861

788

-

-

-

809

845

859

885

911

932

954

-

-

-

334

325

319

315

303

290

279

-

-

-

1.46

1.43

1.40

1.38

1.35

1.30

1.26

-

-

-

1374

1311

1268

1240

1164

1084

996

910

828

744

910

937

947

954

972

989

1004

1018

1033

1043

440

427

419

413

398

381

366

352

340

331

1.94

1.90

1.86

1.84

1.79

1.74

1.68

1.63

1.60

1.56

 

 

 

 

 

 

 

 

 

 

continued on next page

14

HDG Series Air Handler

INSTALLATION INSTRUCTIONS

Heat Controller, Inc.

 

 

 

Model Motor

Number Speed

CFM

Low RPM

Watts

Amps

CFM

HDG36 Middle RPM

Watts

Amps

CFM

High RPM

Watts

Amps

CFM

Low RPM

Watts

Amps

CFM

HDG42 Middle RPM

Watts

Amps

CFM

High RPM

Watts

Amps

CFM

Low RPM

Watts

Amps

CFM

HDG48 Middle RPM

Watts

Amps

CFM

High RPM

Watts

Amps

CFM

Low RPM

Watts

Amps

CFM

HDG60 Middle RPM

Watts

Amps

CFM

High RPM

Watts

Amps

CFM (Watts)

External Static Pressure-Inches W.C. [kPa]

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]

1129

1088

1061

1040

988

941

819

-

-

-

642

675

706

732

771

817

853

-

-

-

322

312

306

301

289

269

254

-

-

-

1.54

1.52

1.51

1.50

1.47

1.42

1.39

-

-

-

1317

1268

1237

1217

1157

1111

1027

-

-

-

776

810

841

874

905

935

966

-

-

-

360

354

348

345

335

323

309

-

-

-

1.69

1.67

1.66

1.65

1.63

1.60

1.57

-

-

-

1643

1581

1544

1518

1446

1356

1261

1123

915

812

868

883

895

906

931

955

978

1013

1028

1050

463

451

443

438

429

415

401

371

356

343

2.22

2.20

2.18

2.17

2.14

2.12

2.09

2.03

1.99

1.96

1239

1203

1178

1161

1117

1070

1000

-

-

-

738

775

797

808

844

872

905

-

-

-

396

385

376

371

360

345

327

-

-

-

1.73

1.68

1.64

1.62

1.57

1.52

1.44

-

-

-

1480

1431

1399

1379

1319

1259

1187

-

-

-

843

865

882

893

915

937

959

-

-

-

430

416

407

401

388

375

359

-

-

-

1.87

1.81

1.77

1.75

1.69

1.63

1.57

-

-

-

1738

1682

1639

1618

1548

1477

1378

1286

1042

908

921

941

949

955

970

985

1002

1016

1042

1059

508

493

486

478

460

445

431

412

373

354

2.22

2.15

2.12

2.08

2.01

1.94

1.89

1.81

1.65

1.58

1471

1427

1395

1374

1316

1247

1180

--

 

-

694

732

753

769

803

833

864

--

 

-

381

376

372

370

364

357

349

--

 

-

1.66

1.64

1.63

1.62

1.61

.581

.550

 

--

 

1729

1678

1646

1625

1558

1491

1402

--

 

-

790

817

833

845

876

898

920

--

 

-

485

477

473

470

460

451

240

--

 

-

2.14

2.12

2.09

2.08

2.06

2.03

1.99

--

 

-

2045

1992

1951

1928

1847

1763

1677

1563

1450

1317

895

920

932

938

956

972

987

1002

1015

1030

641

627

617

612

596

582

566

546

528

507

2.86

2.82

2.82

.782

.732

.682

.642

.572

.522

.450

1786

1740

1709

1688

1630

1562

1489

--

 

-

830

843

849

856

890

921

942

--

 

-

584

569

560

552

536

516

497

--

 

-

2.64

2.59

2.55

2.54

2.58

2.42

2.37

--

 

-

2140

2071

2039

2006

1932

1799

1677

--

 

-

917

930

938

943

957

970

990

--

 

-

645

630

623

617

602

585

569

--

 

-

2.87

2.81

2.78

2.76

2.71

2.65

2.59

--

 

-

2357

2276

2225

2188

2100

2004

1902

1764

1554

1393

964

976

982

990

1001

1012

1022

1032

1042

1063

754

733

718

710

693

673

650

630

607

575

3.34

3.27

3.22

3.19

3.12

3.05

2.98

2.91

2.83

2.71

15

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

M1

M2

Fan speed

Fan

Medium

Red

Blue B

lack

High

Black

Blue

Red

Low

Blue

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 dramatically 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

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. Fibrous ductwork may be used if constructed and installed in accordance with SMACNA Construction Standard 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

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 being damaged by torch flames. After the refrigerant connections are made, seal the gap around the connections 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

3" 3"

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

HDG Series Air Handler

INSTALLATION INSTRUCTIONS

Heat Controller, Inc.

The drain line should be insulated where necessary to prevent sweating and damage due to 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 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 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.

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

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:

Heat Pumps

Piston Size

HDG18FB-1A

HRG18S-1D

0.052 inch

HDG24FB-1A

HRG24S-1D

0.058 inch

HDG30FB-1A

HRG30S-1D

0.065 inch

HDG36FB-1A

HRG36S-1D

0.068 inch

HDG42FB-1A

HRG42S-1D

0.080 inch

HDG48FB-1A

HRG48S-1D

0.090 inch

HDG60FB-1A

HRG60S-1D

0.108 inch

Scroll Compressor Condenser Applications**

Air Handler:

Condeners

Piston Size

HDG18FB-1A

RSG18S-1D

0.052 inch

HDG24FB-1A

RSG24S-1D

0.058 inch

HDG30FB-1A

RSG30S-1D

0.065 inch

HDG36FB-1A

RSG36S-1D

0.073 inch

HDG42FB-1A

RSG42S-1D

0.077 inch

HDG48FB-1A

RSG48S-1D

0.105 inch

HDG60FB-1A

RSG60S-1D

0.097 inch

Rotary Compressor Condenser Applications**

Air Handler:

Condeners

Piston Size

HDG18FB-1A

RSG18R-1D

0.054 inch

HDG24FB-1A

RSG24R-1D

0.061 inch

HDG30FB-1A

RSG30R-1D

0.065 inch

*PISTON REQUIRED FOR THIS APPLICATION IS FACTORY INSTALLED.

**PISTON REQUIRED FOR THIS APPLICATION IS NOT FACTORY INSTALLED, REQUIRES FIELD CONVERSION.

20

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 REDUCE 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

Heat Controller, Inc.

INSTALLATION INSTRUCTIONS

HDG Series Air Handler

10.0 FILTER INSTALLATION DIMENSIONS

R

 

 

 

 

 

E

 

 

 

 

 

T

 

 

 

 

 

U

 

 

 

 

 

R

 

 

 

 

 

N AI

O

“A”

 

 

R

 

 

 

PE

 

 

 

 

 

 

 

 

 

 

NI

 

 

 

 

 

N

 

 

“D”

 

G D

H

 

 

 

 

 

E

 

 

 

 

 

P

 

 

 

 

 

T

 

FILTER RAILS

“H”

FILTER COVER

 

MANUAL BOLT

” “B

” “W

NOTE:

NOTE:

Air Filter is NOT factory supplied

Air filter is factory supplied (optional)

Fig..7:6 ExternalXTERNALFilterFILTERBaseBASE

DIMENSIONAL DATA

MODEL

FILTER SIZE*

"W" IN [mm]

"D" IN [mm]

"H" IN [mm]

Return width

Return length

 

IN [mm]

 

 

 

"A" IN

"B" IN

HDG 18/24/30

16x20 [406x508]

16.8[426]

20.4[518]

1[25.4]

19.6

14.8

HDG 36/42

18x20 [457x508]

18.3[466]

21.6[548]

1[25.4]

20.8

16.3

HDG 48/60

20x22 [508x559]

20.7[526]

23.9[608]

1[25.4]

23

18.8

* 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

HDG Series Air Handler

INSTALLATION INSTRUCTIONS

Heat Controller, Inc.

 

 

 

11.0Wiring 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

 

 

YE LLO W

 

GREEN

R ED

BLACK

BLACK

G

R

C

Y

C

INDOOR UNIT

OUTDOOR UNIT

Fig. 8: Typical Thermostat Wiring for Cooling-Only Models

W2

 

 

 

 

 

 

 

 

 

B

 

 

 

 

 

 

 

 

 

C

 

 

 

 

 

 

 

 

 

R

 

 

 

 

 

 

 

 

 

Y

 

 

 

 

 

 

 

 

 

G

GREEN

 

BLACK

WHITE

 

BLACK

YELLOW

BLUE

PURPLE

THERMOSTAT

RED

RED

 

 

 

 

 

 

 

 

 

 

G

R

C

w1

RY

 

C

B

D

 

INDOOR UNIT

 

OUTDOOR UNIT

 

Fig. 9: Typical Thermostat Wiring for Heat Pump Models

23

Heat Controller, Inc.

INSTALLATION INSTRUCTIONS

HDG Series Air Handler

 

 

 

Fig. 10: Indoor Unit Wiring Diagram for A/C Systems and H/P Systems

24

HDG Series Air Handler

INSTALLATION INSTRUCTIONS

Heat Controller, Inc.

 

 

 

 

 

BLACK

C

1

 

CN6

C

 

 

W2

 

 

W2

 

 

0

 

 

WHITE

PCB

 

W1

 

 

 

 

CN8

CN3

BLACK

 

 

 

 

 

1

 

 

 

 

 

 

 

 

 

 

 

W1

0

 

 

WHITE

 

 

 

 

 

RED

 

 

 

 

 

BLACK

 

12 GA 1015 600V 105 C

 

 

 

 

14 GA 1015 600V 105 C

 

 

 

 

18 GA 1015 600V 105 C

 

 

 

 

FIELD WIRING PER LOCAL CODE

20kW HEAT KIT

 

 

 

6 8 2 46 8

2

L1

L2

GREEN

L1

L2

L1

L2

 

L1

L2

 

 

BLACK

C

1

 

CN6

C

 

W2

 

PCB

 

 

0

W2

WHITE

W1

 

 

CN8 CN3

 

BLACK

 

 

 

 

 

 

 

 

 

 

W1

0

 

 

 

WHITE

 

 

 

 

RED

 

 

 

 

 

BLACK

 

12 GA 1015 600V 105 C

 

 

 

14 GA 1015 600V 105 C

 

 

 

18 GA 1015 600V 105 C

 

 

 

FIELD WIRING PER LOCAL CODE

15kW HEAT KIT

 

 

 

8

 

246

 

68

4

 

2

L1

L1

CB1(32A

L2 L2

GREEN

L1 L1

L2

L2

CB2(63A)

7.5kW HEAT KIT

10kW HEAT KIT

 

 

CN6

C

BLACK

1

PCB

 

W1

WHITE

0

 

 

 

 

 

 

 

CN8

CN3

 

 

 

12 GA 1015 600V 105 C 14 GA 1015 600V 105 C 18 GA 1015 600V 105 C FIELD WIRING PER LOCAL CODE

68

4

 

2

7.5kW CB1 50A

 

10kW CB1 63A

 

GREEN

 

 

L2

L2

 

L1

L1

 

 

RED

KBLAC

5kW HEAT KIT

 

PCB

CN6

C

BLACK

1

 

 

 

 

W1

WHITE

0

 

 

 

 

 

CN8

CN3

 

 

 

 

12 GA 1015 600V 105 C

 

14 GA 1015 600V 105 C

 

18 GA 1015 600V 105 C

 

FIELD WIRING PER LOCAL CODE

68

4

 

2

 

GREEN

 

L2

L2

 

L1

L1

 

 

RED

KBLAC

Fig. 11: Indoor Unit Wiring Diagram for Electric Heat

25

05/2011