Heat Controller HAG, IOM HAG 06-15-09 Quick Start Manual

A. Introduction

1

Heat Controller, Inc., Air Handlers come in a variety of models and

sizes for upow or horizontal use and when combined with cool-

ing coils, are ready for air conditioning and heat pump applications.
These instructions are primarily to assist qualied individuals trained
and experienced in the proper installation of this type of equipment.

B. Rules for Safe Installation and Operation

1. Read these rules and the instructions carefully. Failure

to follow the rules and the instructions could cause a
malfunction of the unit, and a possible safety hazard.
Keep these instructions nearby the unit for future

reference.

2. This unit has been designed and manufactured to comply

with National Codes; however, it is the installer’s
responsibility to install this unit to comply with

prevailing codes and regulations. Heat Controller, Inc.,

assumes no responsibility for units installed in violation

of any code or regulation.

3. Before servicing, ALWAYS SHUT OFF
ELECTRICITY TO THE UNIT. This will prevent any

electrical shocks.

4. Ground the unit to prevent electric shock. All electrical

wiring should be in accordance with the National

Electrical Code.

5. Duct work must be installed in accordance with the

standards of the National Fire Protection Association
(NFPA) for the installation of Air Conditioning, Warm
Air Heating and Ventilating Systems (NFPA 90A and
90B). The air distribution duct system should be sized for

0.2 inches of static pressure. See National Environmental

Systems Contractors Association Manual K for duct

sizing recommendations. Ductwork in non-conditioned
spaces must be insulated to prevent formation of
condensate and for maximum operating efciency.

6. The safety testing agency label appearing on the unit

covers the unit and factory installed coil(s) only. It does
not cover any other equipment.

7. Exterior surface of cabinet may sweat when unit is installed

in non-conditioned space such as attic or garage. Installer
must provide protection such as full size auxiliary drain
pan on all units installed in non-conditioned space such as

attic or garage type installations to prevent damage from

condensation. It is recommended that units installed in
non-conditioned space be insulated on the outside with 1”
thick berglass with the vapor barrier on the outside.

8. While designed to operate quietly when properly installed,

several steps should be taken to insure this. Use of
isolation pads when mounting unit, exible duct collars
for discharge, and use of acoustical duct liners are all
good installation practices that promote quiet operation.

9. Cabinet insulation is rated for R=4.2 (standard). Some

jurisdictions require R=6.0 on installations in non­conditioned space. Add insulation 1” thick to exterior of
air handler to comply in these jurisdictions, putting the
vapor barrier on the outside.

C. Unpacking the Unit

The unit should be unpacked on receipt and if damage is found,
a claim should be made immediately to the shipping carrier. This
is the responsibility of the entity receiving the equipment. The air

handler is completely assembled, as received. Electric power, ther-

mostat wiring, refrigerant piping and duct connections are needed
to complete an installation. Additionally, a drain connection will
be needed.
Check the rating plate for unit size, voltage, phase etc. to make
sure unit meets your requirements.

D. Physical Installation

MINIMUM CLEARANCES

These units have a 0” minimum clearance to combustible materi-

als rating from all cabinet surfaces. The unit should be installed
with serviceability clearance of 30” from the front of the unit. The
unit can be serviced entirely from the front, including replacing the
lter. Be sure and route primary and secondary drain connections
so as not to obstruct lter replacement.

ARRANGEMENT

Unit is shipped from the factory arranged to be installed in a verti-

cal upow or horizontal right to left airow position (standard) or
eld convertible to a horizontal left to right airow position.

Upow Application

In an upow installation the discharge outlet is at the top. Care
should be taken to ensure unit is level to permit proper condensate

drainage. Normal upow installation will be in a basement or clos-

et. If installed in a closet, the closet should have a platform framed
in, with an opening on top of the platform centered in the closet.

Connect the supply air outlet to a discharge air plenum. Install re-

turn air grilles from outside the closet to space below the platform.
Platform must be at least 10” above the oor. Run all supply and
return ductwork in accordance with local codes.

Horizontal application

Horizontal application will normally be used in an attic or crawl
space. This type installation requires a return air duct be attached
to the air handler inlet. The opposite end of the return air duct
is attached to a return air lter grille through the ceiling or wall.
Remove lter from unit if lter grill is used. The unit is shipped in
right to left conguration.

CAUTION

A “P” trap must be installed in the coil

drain line! Cap unused drain ttings.

WARNING

To ensure unit will not interfere with drains and

refrigerant lines, modication must be made

prior to installing these lines..

FOR LEFT TO RIGHT APPLICATIONS.

1. Remove and set aside front panels.

2. Remove the coil support bracket (4-screws).

3. Remove horizontal drain pan retaining clip (1-screw).

2

4. Carefully remove coil assembly and bottom drain pan.

5. Move horizontal drain pan from left hand side of coil to
right side.

6. Install modied coil assembly back into unit.

7. Reinstall coil support bracket and horizontal drain pan

retaining clip.

8. Determine drain holes being used and reposition knockout

caps.

9. Reinstall doors.

CAUTION

IT IS MANDATORY TO USE AN

EMERGENCY AUXILIARY DRAIN PAN

WITH ANY COIL OR AIR HANDLER

INSTALLED IN AN ATTIC OR ABOVE A

FINISHED CEIING!

E. Electric Furnace

Optional electric heating packages are available, see the unit label

for various sizes.

* See Electric Heater Kit Specications Table

F. Power Wiring

Refer to the unit’s nameplate for specic electrical data.

CAUTION

DISCONNECT POWER AT MAIN FUSE OR CIRCUIT

BREAKER DISTRIBUTION PANEL BEFORE WIRING

UNIT TO PREVENT SHOCK OR FIRE HAZARD.

Use copper conductors only. Tighten all wire connectors.

Refer to unit nameplate for minimum circuit ampacity. For correct
wire size, refer to the National Electrical Code. Use 75˚C minimum
wire in unit wiring compartment.

NOTE: SEE UNIT FOR COMPLETE WIRING DIAGRAM

LOCATED ON BLOWER HOUSING.

G. Control Wiring

Field connections are made to the low voltage terminal strip.
Consult installation instructions provided with accessory items
for specic information on control wiring. Use 18 AWG minimum
copper control conductors for control wiring up to 50 feet between
units. 16 AWG control conductors are recommended for lengths up
to 100 feet. Class 2 wiring is acceptable. Do not short control leads.
Transformer burn-out will result. Set thermostat heat anticipator at

0.15 amps for air handler.

Terminal number 4 on the (FR) fan relay is the cooling blower
speed and terminal number 6 on the (FR) is the heating blower

speed.

I. Refrigerant Piping

All air handlers have DX refrigerant cooling coils installed, liquid
and suction piping should be sized in accordance with condensing
unit manufacturer’s recommendations. An adapter (by others) may
be required to make the transition between the line set and the
coil connector. The evaporator coil has sweat copper connections.
The suction line is a swaged solder cup connection. The liquid line
connection is made to a tail piece portion of the TXV. Remove the
nut on the inlet to the expansion valve and place it on the tail piece
prior to brazing the liquid line. DO NOT connect the tail piece
to the TXV until the liquid line has been brazed to the tail piece.
Refrigerant lines should be soldered with silver solder or other
high temperature brazing alloy. Dry nitrogen must ow through the
refrigerant lines during the brazing operation to prevent oxidation.

J. Refrigerant Flow Control

As shipped, the TXV installed on the A-coil is for the nominal
capacity of a 13 SEER matched with Heat Controller, Inc.,
condensing units. The TXV is for use on an R-410A system. For
other refrigerants, contact the factory. TXV has a built-in check
valve for reverse ow and is suitable for heat pump operation. All
are externally equalized with non-adjustable superheat and have
15% bleed. Hard start capability for outdoor units is not normally
required when a 15% bleed valve is used. The external equalizer
line attached to the TXV has a female are nut and is attached to
the suction line at the coil. Install the TXV bulb to the suction line
using the bulb clamp furnished with the kit. The bulb should be
installed on a horizontal run of the suction line if possible. On a
line less than 7/8” OD, the bulb may be installed on top of the line.
With 7/8” OD or over, the bulb should be installed in a position of
about 4 or 8 o’clock. If the bulb installation is made on a vertical
run, the bulb should be located at least 6 inches from any bend
and on the tubing side opposite the plane of the bend. On vertical
bulb installations, the bulbs should be positioned with the bulb
capillary tube at the top. The bulb must be insulated using thermal
insulation to protect it from the effects of the surrounding ambient

temperature.

H. Blower Motor

Units are equipped with a three-speed blower motor. Two factory­selected motor speed leads are connected to the fan relay (FR) to
provide automatic speed change for heating and cooling airow
volumes. The pre-selected motor speeds would normally not have
to be changed in the eld. All HAH models contain a post purge
timer (TDR) that delays the blower turning off at the end of the
cooling cycle, this improves energy efciency.