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HDG30
User Manual
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Heat Controller HDG48, HDG42, HDG30, HDG60, HDG24 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
3.0 GENERAL ............................................................................................................................6
3.1 UNIT DIMENSIONS ......................................................................................................7
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
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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
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 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.
Condenser/Heat Pump Matching Guide:
H = Heat Pump
C = Air Conditioner
B = Both A/C & H/P use
Warning
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.
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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 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 eld 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, qualied service personnel. Consumer service is recommended only for lter cleaning / replacement. Never operate the unit with the acess panels removed.
Warning
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 in­stallation, adjustment, service or maintenance possibly resulting in re, electrical shock, property damage, personal injury or death.
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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 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.
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
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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 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.
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 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.
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 overow of the coil drain pan or a stoppage in the primary condensate drain piping.
Warning
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).
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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 upow position, left and right return in the horizon­tal 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
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HDG Series Air Handler INSTALLATION INSTRUCTIONS Heat Controller, Inc.
3.1 Unit Dimensions
ELECTRICAL CONNECTIOS MAY EXIT TOP OR EITHER SIDE
HIGH VOLTAGE CONNECTION 7/8”,
HIGH VOLTAGE CONNECTION 7/8”,
1-3/8”, 1-3/4” DIAMETER KNOCK OUTS
1-23/64”, 1-23/32” DIA KNOCK OUTS
LOW VOLTAGE CONNECTION
BREAKER SWITCH
(FOR ELECTRIC HEATER ONLY)
NOTE: 24” CLEARANCE IS REQUIRED IN THE FRONT
OF THE UNIT FOR FILTER AND COIL MAINTENANCE.
SUPPLY AIR
FLANGES ARE PROVIDED FOR FIELD INSTALLATION
5
6
1
0
1
W
A
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)
PRIMARY DRAIN CONNCETION 3/4” FEMALE PIPE THREAD (NPT)
Fig. 1 Dimensions
UPFLOW UNIT SHOWN; UNIT MAY BE INSTALLED UPFLOW, DOWNFLOW, HORIZONTAL RIGHT, OR LEFT AIR SUPPLY.
D
Dimensional Data
Dimensions Unit Weight lbs. [kg]
Unit Height
Model Size
in. [mm]
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
HDG60
54 1/2” [1385] 22” [560] 24" [610] 19
54 1/2” [1385] 22” [560] 24" [610] 19
Unit Weight
in. [mm]
Unit Lenght
in. [mm]
Supply Duct
“A” in [mm] Net Shipping
1
/2” [496] 171 [78] 187 [85]
1
/2” [496] 171 [78] 187 [85]
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Heat Controller, Inc. INSTALLATION INSTRUCTIONS HDG Series Air Handler
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)
Refrigerant Line
Connections
Drain Connections
1-9/16
5/16
2-13/16
1-1/4
5/16
2-15/16
Fig.2 Coil Connection Dimensions
Fig. 2 Coil Connection Dimensions
1-3/8
2-15/16
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.
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