Heatcontroller HWCG60T0A User Manual

INSTALLATION, OPERATION

& MAINTENANCE MANUAL

Multi-Position Air Handler

Hydronic Heat with PSC Motor

HWCGxxT0A

Heat Controller • 1900 Wellworth Ave. • Jackson, MI 49203 • [phone] • www.heatcontroller.com

Multi-Position Air Handler with Hydronic Heat with PSC Motor HWCGxxT0A Heat Controller

REQUI RE D

Safety Instruction

Potential safety hazards are alerted using symbol.
The symbol is used in conjunction with terms that
indicate the intensity of the hazard.

WARNING

This symbol indicates a potentially
hazardous situation which if not avoided, could result in
serious injury, property damage, product damage or
death.

CAUTION

This symbol indicates a potentially
hazardous situation which if not avoided, may result in
moderate injury or property damage.

WARNING

individuals meeting the requirements specified by
NATE may use this information. Property and
product damage or personal injury hazard may
occur without such background.

WARNING

disconnected prior to servicing. Failure to do so may
cause personal injury or property damage.

WARNING

ured to permit installation in accordance with local and
national building codes. It is the installer’s responsibility
to ensure that product is installed in strict compliance
with national and local codes. Manufacturer takes no
responsibility for damage (personal, product or property)
caused due to installations violating regulations. In
absence of local/state codes, refer to National Electric

Code NFPA 90A & 90B Uniform Mechanical Code
(CEC or CSA for Canadian Installations).

WARNING

enclosed area, such as a garage or utility room with any
Carbon Monoxide producing devices (i.e. automobile,
space heater, water heater etc.) ensure that the
enclosed area is properly ventilated.

CAUTION

accessories should be used when installing or modifying
this unit unless it is so noted in these instructions. Some
localities may require a licensed installer/service
personnel.

WARNING

installations.

Certified technicians or those

All power sources should be

Product designed and manufact-

When this unit is installed in an

Only factory authorized kits and

Unit is not approved for outdoor

WARNING

The unit is designed for operation
with 108/120 V, single phase, 60 Hz power supply.
Manufacturer will not be reponsible for damages caused
due to modification of the unit to operate with alternative
power sources.

Inspection

On receiving the product, visually inspect it for any major
shipping related damages. Shipping damages are the
carrier’s responsibility. Inspect the product labels to
verify that the model number and options are in
accordance with your order. Manufacturer will not accept
damage claims for incorrectly shipped product.

Installation Preparation

Read all the instructions in this guideline carefully while
paying special attention to the WARNING and CAUTION
alerts. If any of the instructions are unclear; clarify with
certified technicians. Gather all the tools needed for
successful installation of the unit prior to beginning the
installation.

This unit is designed for zero clearance installation on
three sides and adequate clearance to provide access
for serivce in the front. A min of 2.5 – 3.5 feet clearance
is recommended on the front end.

If the unit is to be installed in garages, warehouses or
other areas where they may be subjected to physical
damage, adequate protective barriers must be installed.
Unit MUST be installed 18” away from source of ignition.

If the unit is located in high humidity areas like attics or
unconditioned garage; the air handler casing might
experience nuisance sweating. In such installation
scenarios, wrapping the casing with a 2” fiberglass
insulation with vapor barrier SHOULD be used.

The drain lines must be installed with ¼” per foot pitch to
provide free drainage. A condensate trap MUST be
installed on the primary drain line to ensure proper
drainage of the condensate. The trap must be installed
in the drain line below the bottom of the drain pan.
Figure 1 illustrates the typical drain trap installation

DRAI N
CONNECTI ON

2" MINI MUM

FLEXIBLE

TUBI NG- HOSE

OR PIPE

A POSITIVE

LIQUID SEAL IS

Figure.1. Typical drain line trap set up

3" MINI MU

2

Heat Controller Multi-Position Air Handler with Hydronic Heat with PSC Motor HWCGxxT0A

Ductwork

Duct systems should be installed in accordance with
standards for air-conditioning systems, National Fire
Protection Association Pamphlet No. 90A or 90B. They
should be sized in accordance with National
Environmental System Contractors Association Manual
K, or whichever is applicable.

On any job, non-flammable flexible collars should be
used for the return air and discharge connections to
prevent transmission of vibration. Although these units
have been specially designed for quiet vibration-free
operation, air ducts can act as soundboards can, if
poorly installed, amplify the slightest vibration to the
annoyance level.

All main supply and return air drops should be properly
size as determined by the designer of the duct system
and should not necessarily be the size of the duct flange
openings of the unit.

When installing a central air return grille in or near the
living space, it is advisable to design the ductwork so
that the grille is not in direct line with the opening in the
unit. One or two elbows and acoustical duct liner will
also assure a quieter installation and system.

It is recommended that wherever supply and return air
sheet metal duct pass through unconditioned areas, they
be insulated to prevent excessive heat loss during
heating operation. When applied in conjunction with
summer air conditioning, sheet metal duct routed
through unconditioned areas should be insulated and
have an outside vapor barrier to prevent formation of
condensation.

Installation

CAUTION

sized. The tonnage of the outdoor unit should never
exceed the tonnage of this unit.

WARNING

dry nitrogen pre-charge. Release the pressure through
the Schrader valve test port prior to installation. If
holding pressure is not present, return coil to distributor
for exchange.

Clean coil fins with degreasing agent or mild detergent
and rinse fins clean prior to installation.

All connection joints should be burr-free and clean. Not
removing the burr and cleaning may increase chances of
a leak. It is recommended to use a pipe cutter to remove
the spun closed end of the suction line.

To avoid damage to grommets (where present), remove
these prior to brazing by sliding over the lines. Use a
quenching cloth or allow the lines to cool before
reinstalling the grommets.

Ensure that the unit is adequately

The coil was manufactured with

WARNING

Prior to connecting the water
(hydronic) coil, make sure that the hot water supply is
turned off. Water from the heater could be extremely hot
and might result in burns and other personal injury along
with equipment damage. Ensure that proper saftey gear
is being used prior to making connections.

CAUTION

Only lead free solder should be
used to connect water (hydronic) coil to the hot water
source.

CAUTION

Some coils may include a
Schrader valve on the suction manifold. Ensure that the
Schrader valve and valve core (where present) are
protected from heat to prevent leakage.

Metering Device

Coils use a TXV of metering device. Instructions below
are for the metering device. Ensure that the instructions
are thoroughly read and understood.

TXV Coils:

WARNING

MUST be protected from overheating during brazing.
The sensing bulb and TXV body must be covered using
a quench cloth or wet cloth when brazing. Pointing the
brazing flame away from the valve and sensing bulb
provide partial protection only.

CAUTION

compatible with the refrigerant used in the outdoor
system (R22 or R410A). TXV caps are painted green for
R22 or pink for R410A. In absence of color, the caps will
be marked with the compatible refrigerant.

CAUTION

according to the capacity of the outdoor unit. Failure to
install the right valve can lead to poor performance and
possible compressor damage.

TXV Bulb Mounting

The orientation and location of the TXV bulb has a major
influence on the system performance.

CAUTION

direct contact with the suction/vapor line. Gap between
the bulb and tube should be avoided. Failure to eliminate
gaps will impair the proper functioning of the TXV valve.

It is recommended that the TXV bulb be installed parallel
to the ground (in a horizontal plane). The bulb position
should be above and between 4 o’clock and 8 o’clock.

3

The sensing bulb and TXV body

Ensure that the TXV selected is

The valves should be sized

Ensure that the TXV bulb is in

Multi-Position Air Handler with Hydronic Heat with PSC Motor HWCGxxT0A Heat Controller

Fig. 2 shows the recommended position for the TXV bulb
installation in the horizontal plane.

The TXV sensing bulb SHOULD be mounted using the
metal clamp provided. In order to obtain a good
temperature reading and correct superheat control, the
TXV sensing bulb must conform to ALL of the following
criteria:

1) The sensing bulb must be in direct and
continous contact with the suction line

2) The sensing bulb should be mounted
horizontally on the suction line.

3) The sensing bulb must be mounted above and
between the 4 and 8 o’clock position on the
circumference of the suction line.

4) The sensing bulb must be insulated from outside
air.

SUCTION/VAPOR LINE

METAL STRAP

TXV BULB POSI TION
4 O'CLOCK OR
8 O'CLOCK

Fig.2. Recommended location of the TXV bulb in a
horizontal orientation

The mounting location and insulation guards the sensing
bulb from false reading due to hot outside air or liquid
refrigerant formed inside the suction/vapor line.

As recommended earlier, the TXV sensing bulb should
be mounted in a horizontal plane in relation to the
suction/vapor line. However, in case such a mounting is
not feasible and the sensing bulb has to be mounted
vertically; then place the bulb as shown in Fig.3.

Fig.3. Sensing bulb mounted in a vertical orientation

4

CAUTION

If the TXV sensing bulb is mounted
vertically; the capillary MUST be directed upwards. The
bulb must be mounted on the wall opposite to that being
directly hit by the refrigerant and oil leaving the
distributor tubes.

Field – Installed Expansion Valve Coils

Remove the valve identification sticker from the valve
and place it adjacent to the model number on unit name
plate.

When installing an expansion valve, it is not necessary
to remove all the access panels and slide the coil out of
the housing.

1) Disassemble the flowrator body using two
wrenches. Unscrew the body with a counter­clockwise motion.

2) Replace the white Teflon seal in place (located
between the halves).

3) Remove the existing flowrator piston using a
small wire or pick.

4) Inspect the TXV box to confirm that the valve is
compatible with the refrigerant in the system.

5) Remove the valve from the box and note the
location of the inlet side (threaded male port)
and the outlet side (female swivel nut port).

6) After ensuring that the white Teflon seal is still in
place inside the flowrator body, screw the
female swivel nut onto the flowrator body.

7) Place the attachment nut on the liquid line.

8) Braze the stub-out portion to the liquid line and

let cool.

WARNING

joint while hot. Touching it may cause sever burns.

9) Remove the additional white Teflon seal ring
from the box and place on the shoulder just
inside the inlet port. Screw the nut attached to
the stub-out portion of the flowrator body onto
the inlet port of the TXV.

10) Tighten all connections taking care to use proper

Some coils come with a Schrader valve on the suction
line. If a Schrader port is present

Coils without Schrader Ports

back up.

11) Remove valve stem from the Schrader port
mounted on the suction line

12) Screw flare nut on TXV equalization tube in to
the Schrader valve stem

11) Locate a convenient spot on the suction line
and punch a ¼” hole with a pick or other suitable
tool.

Do not attempt to touch the braze

Heat Controller Multi-Position Air Handler with Hydronic Heat with PSC Motor HWCGxxT0A

CAUTION

enter suction manifold.

12) Insert TXV equalizer tube approximately 3/8”
into the hole and apply solder to seal.

Fig.4 shows the components of a typical TXV assembly

TXV BULB

Fig.4. Components of a typical TXV assembly

CAUTION

valve may require the use of a hard-start kit. Follow the
outdoor unit manufacturer’s guidelines.

Do NOT drill a hole as chips will

DISTRIBUTOR

TEFLON O- RINGS

TAIL PIECE

Using a non-bleed expansion

Air handler orientation

This unit can be installed in vertical or right horizontal
position without modifications. In case of a counterflow
application, the horizontal drain pan MUST be removed.
Fig. 5 shows the various orientations this air handler can
be installed in.

CAUTION

horizontal orientation; an auxiliary drain pan MUST be
provided by the installer and placed under the entire unit
with a separate drain line that is properly sloped and
terminated in an area visible to the home owner. The
auxiliary pans provide extra protection to the area under
the unit should the primary and secondary drain plug up
and overflow. As expressed in our product warranty;

failure to follow this installation requirment will void
the product warranty. The drains from the auxiliary

drain pan must be installed according to the local
building codes.

When the unit is used in an

Fig.5. Various airflow orientation

Horizontal Left-hand Installation

• With Air Handler in vertical position remove all
access panels.

• Remove horizontal drain pan from right hand
side. Disconnect any drain connections.

• Relocate the removed horizontal drain pan on to
the left side and reconnect the drain
connections.

• “P” traps must be installed on primary and
secondary drains of the horizontal drain pan.

• Reinstall all access panels to the unit.

Fig.6. Air flow direction in Horizontal Left application

5