Heat Controller Air Conditioner HDG User Manual

INSTALLATION  
INSTRUCTIONS  
Air Handler  
HDG Series  
1.5 to 5 Ton  
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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  
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
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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 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 result-  
ing 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 in-  
stallation, adjustment, service or maintenance possibly resulting in fire, electrical shock, property  
damage, personal injury or death.  
3
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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 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  
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
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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 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
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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 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
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HDG Series Air Handler  
INSTALLATION INSTRUCTIONS  
Heat Controller, Inc.  
NOTE: 24” CLEARANCE IS REQUIRED IN THE FRONT  
OF THE UNIT FOR FILTER AND COIL MAINTENANCE.  
3.1 Unit Dimensions  
ELECTRICAL CONNECTIOS  
MAY EXIT TOP OR EITHER SIDE  
SUPPLY AIR  
HIGH VOLTAGE CONNECTION 7/8”,  
FLANGES ARE PROVIDED  
FOR FIELD INSTALLATION  
1-3/8”, 1-3/4” DIAMETER KNOCK OUTS  
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)  
UPFLOW UNIT SHOWN;  
UNIT MAY BE INSTALLED UPFLOW, DOWNFLOW,  
HORIZONTAL RIGHT, OR LEFT AIR SUPPLY.  
Fig. 1 Dimensions  
Dimensional Data  
Dimensions  
Unit Weight lbs. [kg]  
Unit Height  
in. [mm]  
Unit Weight  
in. [mm]  
Unit Lenght  
in. [mm]  
Supply Duct  
“A” in [mm]  
Model Size  
HDG18  
HDG 24  
HDG 30  
HDG36  
HDG42  
HDG48  
HDG60  
Net  
Shipping  
41 3/8" [1050]  
41 3/8" [1050]  
41 3/8" [1050]  
46 1/2" [1180]  
46 1/2" [1180]  
54 1/2” [1385]  
54 1/2” [1385]  
18 1/8" [460]  
18 1/8" [460]  
18 1/8" [460]  
19 5/8" [500]  
19 5/8" [500]  
22” [560]  
20 1/2" [520]  
20 1/2" [520]  
20 1/2" [520]  
20 5/8" [550]  
20 5/8" [550]  
24" [610]  
16" [406]  
16" [406]  
106 [48]  
106 [48]  
119 [54]  
141 [64]  
141 [64]  
171 [78]  
171 [78]  
119 [54]  
119 [54]  
132 [60]  
156 [71]  
156 [71]  
187 [85]  
187 [85]  
16" [406]  
18" [456]  
18" [456]  
19 1/2[496]  
19 1/2[496]  
22” [560]  
24" [610]  
7
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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 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  
5/16  
2-13/16  
1-1/4  
5/16  
1-3/8  
2-15/16  
2-15/16  
Fig.2CoilConnectionDimensions  
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
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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.  
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 mount-  
ing 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 compart-  
ment 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
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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  
DRAIN CONNECTION  
VAPOR LINE 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  
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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 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 re-  
moved 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  
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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 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.  
5.3 GROUNDING  
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  
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HDG Series Air Handler  
INSTALLATION INSTRUCTIONS  
Heat Controller, Inc.  
5.4 Electrical Data– BLOWER ONLY, NO ELECTRIC HEAT  
MINIMUM  
CIRCUIT  
MAXIMUM  
CIRCUIT  
CIRCUIT  
Model  
Voltage  
HP  
1/8  
1/5  
1/4  
1/2  
1/2  
1/2  
3/4  
RPM  
580  
701  
872  
794  
882  
845  
963  
SPEEDS  
AMPS.  
0.68  
0.95  
1.48  
1.63  
1.80  
2.11  
AMPACITY  
PROTECTOR  
HDG18  
HDG24  
HDG30  
HDG36  
HDG42  
HDG48  
HDG60  
208/230-1-60  
208/230-1-60  
208/230-1-60  
208/230-1-60  
208/230-1-60  
208/230-1-60  
208/230-1-60  
3
3
3
3
3
3
3
1
1.5  
2
15(A)  
15(A)  
15(A)  
15(A)  
15(A)  
15(A)  
15(A)  
3
3
3
2.79  
3
5.5 Electrical Data– ELECTRIC HEAT  
Minimum Minimum Maximum Maximum  
Circuit Circuit Circuit Circuit  
Ampacity Ampacity Protection Protection  
Air  
Handler  
Model  
Heater Heater  
kW kW  
(208V) (240V)  
Circuit  
Amps  
Circuit  
Amps  
Heater  
Model No.  
Motor  
PH/Hz  
(208V) (240V) Ampacity  
(208V)  
23.5  
34.8  
46  
(240V)  
26.9  
40  
(208V)  
(240V)  
7800-505-1D  
3.8  
5.6  
7.5  
3.8  
5.6  
7.5  
3.8  
5.6  
7.5  
3.8  
5.6  
7.5  
11  
5
7.5  
10  
5
18.1  
27.1  
36.1  
18.1  
27.1  
36.1  
18.1  
27.1  
36.1  
18.1  
27.1  
36.1  
54.2  
72.2  
18.1  
27.1  
36.1  
54.2  
72.2  
18.1  
27.1  
36.1  
54.2  
72.2  
18.1  
27.1  
36.1  
54.2  
72.2  
20.8  
31.3  
41.7  
20.8  
31.3  
41.7  
20.8  
31.3  
41.7  
20.8  
31.3  
41.7  
62.5  
83.3  
20.8  
31.3  
41.7  
62.5  
83.3  
20.8  
31.3  
41.7  
62.5  
83.3  
20.8  
31.3  
41.7  
62.5  
83.3  
0.68  
0.68  
0.68  
0.95  
0.95  
0.95  
1.48  
1.48  
1.48  
1.63  
1.63  
1.63  
1.63  
1.63  
1.80  
1.80  
1.80  
1.80  
1.80  
2.11  
2.11  
2.11  
2.11  
2.11  
2.79  
2.79  
2.79  
2.79  
2.79  
25  
30  
HDG18 7800-508-1D  
7800-510-1D  
1Ph/60Hz  
35  
45  
53  
50  
60  
7800-505-1D  
23.8  
35.1  
46.4  
24.5  
35.8  
47  
27.3  
40.3  
53.3  
27.9  
41  
25  
30  
HDG24 7800-508-1D  
7800-510-1D  
7.5  
10  
5
1Ph/60Hz  
1Ph/60Hz  
40  
45  
50  
60  
7800-505-1D  
25  
30  
HDG30 7800-508-1D  
7800-510-1D  
7.5  
10  
5
40  
45  
54  
50  
60  
7800-505-1D  
24.7  
35.9  
47.2  
69.8  
92.4  
24.9  
36.2  
47.4  
70  
28.1  
41.1  
54.2  
80.2  
106.3  
28.3  
41.4  
54.4  
80.4  
106.5  
28.7  
41.7  
54.8  
80.8  
106.9  
29.6  
42.6  
55.6  
81.7  
107.7  
25  
30  
7800-508-1D  
7.5  
10  
15  
20  
5
40  
45  
HDG36 7800-510-1D  
7800-515-1D  
1Ph/60Hz  
1Ph/60Hz  
1Ph/60Hz  
1Ph/60Hz  
50  
55  
70  
90  
7800-520-1D  
15  
100  
25  
125  
30  
7800-505-1D  
3.8  
5.6  
7.5  
11  
7800-508-1D  
7.5  
10  
15  
20  
5
40  
45  
HDG42 7800-510-1D  
7800-515-1D  
50  
60  
80  
90  
7800-520-1D  
15  
92.6  
25.3  
36.5  
47.8  
70.4  
93  
100  
30  
125  
30  
7800-505-1D  
3.8  
5.6  
7.5  
11  
7800-508-1D  
7.5  
10  
15  
20  
5
40  
45  
HDG48 7800-510-1D  
7800-515-1D  
50  
60  
80  
90  
7800-520-1D  
15  
100  
30  
125  
30  
7800-505-1D  
3.8  
5.6  
7.5  
11  
26.1  
37.4  
48.7  
71.2  
93.8  
7800-508-1D  
7.5  
10  
15  
20  
40  
45  
HDG60 7800-510-1D  
7800-515-1D  
50  
60  
80  
90  
7800-520-1D  
15  
100  
125  
13  
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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  
Number Speed  
0 [0]  
551  
440  
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  
RPM  
509  
518  
120  
0.62  
622  
580  
143  
0.68  
-
462  
595  
393  
679  
116.3  
0.61  
506  
731  
136.3  
0.67  
--  
345  
726  
280  
781  
---  
-
----  
Low  
Watts 122.4  
-
116.8  
0.62  
577  
109.9  
0.61  
443  
106.2  
0.60  
400  
812  
---  
Amps  
CFM  
RPM  
0.62  
661  
518  
-
---  
-
---  
-
640  
770  
---  
HDG18 Middle  
Watts 145.2  
-
140.8  
0.68  
133.6  
0.67  
131.2  
0.66  
590  
894  
232  
1.16  
453  
840  
146.3  
0.75  
613  
---  
Amps  
CFM  
0.69  
--  
-
---  
--  
550  
487  
940  
400  
975  
RPM  
Watts  
Amps  
CFM  
--  
--  
--  
911  
High  
Low  
--  
--  
--  
229.5  
224.4  
1.14  
217.4  
1.12  
--  
--  
--  
1.15  
646  
528  
623  
591  
-
592  
650  
163  
553  
728  
157.5  
0.77  
733  
790  
211.4  
0.94  
--  
506  
790  
---  
RPM  
-
-
---  
Watts 169.4  
166.4  
0.78  
802  
151.3  
0.76  
681  
---  
Amps  
CFM  
0.79  
815  
658  
218  
0.96  
--  
-
0.78  
771  
---  
-
---  
RPM  
Watts  
Amps  
CFM  
701  
-
743  
841  
888  
203  
0.92  
780  
919  
---  
HDG24 Middle  
216.6  
0.95  
-
214.4  
0.95  
207.4  
0.93  
---  
-
---  
--  
695  
607  
515  
RPM  
Watts  
Amps  
CFM  
--  
--  
--  
956  
986  
1014  
High  
--  
--  
--  
262.6  
1.21  
690  
902  
258  
1.19  
788  
954  
279  
256.4  
250.1  
243  
--  
--  
--  
.181  
.171  
.15  
962  
729  
315  
1.39  
1094  
809  
334  
1.46  
1374  
910  
440  
1.94  
913  
754  
304  
1.35  
1043  
845  
325  
1.43  
1311  
937  
886  
798  
298  
1.32  
1012  
859  
319  
1.40  
1268  
947  
419  
1.86  
870  
809  
292  
1.30  
988  
885  
315  
813  
858  
280  
1.26  
927  
911  
303  
1.35  
1164  
972  
398  
1.79  
750  
873  
269  
1.22  
861  
932  
290  
1.30  
1084  
989  
381  
1.74  
-
-
-
RPM  
Watts  
Amps  
CFM  
-
-
-
Low  
-
-
-
-
-
-
-
-
-
RPM  
Watts  
Amps  
CFM  
-
-
-
-
-
-
HDG30 Middle  
1.38  
1240  
954  
413  
1.26  
996  
1004  
366  
1.68  
-
-
-
910  
1018  
352  
1.63  
828  
1033  
340  
1.60  
744  
1043  
331  
1.56  
RPM  
Watts  
Amps  
High  
427  
1.90  
1.84  
continued on next page  
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HDG Series Air Handler  
INSTALLATION INSTRUCTIONS  
Heat Controller, Inc.  
CFM (Watts)  
External Static Pressure-Inches W.C. [kPa]  
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]  
Model  
Number Speed  
Motor  
0 [0]  
1129  
642  
CFM  
RPM  
Watts  
Amps  
CFM  
RPM  
Watts  
Amps  
CFM  
RPM  
Watts  
Amps  
CFM  
RPM  
Watts  
Amps  
CFM  
RPM  
Watts  
Amps  
CFM  
RPM  
Watts  
Amps  
CFM  
RPM  
Watts  
Amps  
CFM  
RPM  
Watts  
Amps  
CFM  
RPM  
Watts  
Amps  
CFM  
RPM  
Watts  
Amps  
CFM  
RPM  
Watts  
Amps  
CFM  
RPM  
Watts  
Amps  
1088  
675  
312  
1061  
706  
306  
1040  
732  
301  
988  
771  
289  
941  
817  
269  
819  
853  
254  
-
-
-
-
-
-
-
-
-
Low  
322  
1.54  
1317  
776  
1.52  
1268  
810  
1.51  
1237  
841  
1.50  
1217  
874  
1.47  
1157  
905  
1.42  
1111  
935  
1.39  
1027  
966  
-
-
-
-
-
-
-
-
-
HDG36 Middle  
360  
354  
1.67  
1581  
883  
451  
2.20  
1203  
775  
385  
1.68  
1431  
865  
416  
1.81  
1682  
941  
348  
345  
1.65  
1518  
906  
438  
2.17  
1161  
808  
371  
1.62  
1379  
893  
401  
1.75  
1618  
955  
478  
2.08  
1374  
769  
335  
323  
309  
-
-
-
-
-
-
1.69  
1643  
868  
1.66  
1544  
895  
1.63  
1446  
931  
1.60  
1356  
955  
1.57  
1261  
978  
1123  
1013  
371  
2.03  
915  
1028  
356  
1.99  
812  
1050  
343  
1.96  
High  
463  
443  
429  
415  
401  
2.22  
1239  
738  
2.18  
1178  
797  
2.14  
1117  
844  
360  
1.57  
1319  
915  
2.12  
1070  
872  
2.09  
1000  
905  
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
Low  
HDG42 Middle  
High  
396  
376  
345  
327  
1.73  
1480  
843  
1.64  
1399  
882  
1.52  
1259  
937  
1.44  
1187  
959  
430  
407  
388  
375  
359  
1.87  
1738  
921  
1.77  
1639  
949  
1.69  
1548  
970  
1.63  
1477  
985  
445  
1.94  
1247  
833  
1.57  
1378  
1002  
431  
1.89  
1180  
864  
1286  
1016  
412  
1.81  
--  
1042  
1042  
373  
1.65  
908  
1059  
354  
1.58  
508  
493  
2.15  
1427  
732  
376  
486  
460  
2.22  
1471  
694  
2.12  
1395  
753  
2.01  
1316  
803  
-
-
-
--  
--  
Low  
381  
372  
370  
364  
357  
349  
1.66  
1729  
790  
1.64  
1678  
817  
1.63  
1646  
833  
1.62  
1625  
845  
470  
1.61  
1558  
876  
.581  
1491  
898  
.550  
1402  
920  
--  
--  
--  
--  
-
-
-
HDG48 Middle  
485  
477  
473  
460  
451  
240  
2.14  
2045  
895  
2.12  
1992  
920  
627  
2.09  
1951  
932  
2.08  
1928  
938  
612  
.782  
1688  
856  
552  
2.54  
2006  
943  
2.06  
1847  
956  
2.03  
1763  
972  
1.99  
1677  
987  
--  
-
1563  
1002  
546  
.572  
--  
--  
--  
--  
--  
1450  
1015  
528  
1317  
1030  
507  
.450  
High  
641  
617  
596  
582  
566  
2.86  
1786  
830  
584  
2.64  
2140  
917  
2.82  
1740  
843  
569  
2.59  
2071  
930  
630  
2.81  
2276  
976  
2.82  
1709  
849  
560  
2.55  
2039  
938  
.732  
1630  
890  
.682  
1562  
921  
.642  
1489  
942  
.522  
-
-
-
-
-
-
-
-
Low  
536  
516  
497  
2.58  
1932  
957  
2.42  
1799  
970  
2.37  
1677  
990  
--  
--  
--  
HDG60 Middle  
645  
623  
617  
602  
585  
569  
2.87  
2357  
964  
754  
3.34  
2.78  
2225  
982  
718  
3.22  
2.76  
2188  
990  
710  
2.71  
2100  
1001  
693  
2.65  
2004  
1012  
673  
2.59  
1902  
1022  
650  
1764  
1032  
630  
2.91  
1554  
1042  
607  
1393  
1063  
575  
2.71  
High  
733  
3.27  
3.19  
3.12  
3.05  
2.98  
2.83  
15  
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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 wire to the M2 terminal  
Terminal  
M2  
M1  
Fan  
Fan speed  
Blue B  
lack  
Red  
Medium  
Red  
Blue  
Black  
Blue  
High  
Low  
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 dramati-  
cally 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  
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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 run in unconditioned spaces must be insulated and covered with a vapor barrier. Fi-  
brous ductwork may be used if constructed and installed in accordance with SMACNA Construction Stan-  
dard 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  
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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 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 be-  
ing damaged by torch flames. After the refrigerant connections are made, seal the gap around the con-  
nections 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  
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.  
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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 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 tef-  
lon 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  
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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:  
HDG18FB-1A  
HDG24FB-1A  
HDG30FB-1A  
HDG36FB-1A  
HDG42FB-1A  
HDG48FB-1A  
HDG60FB-1A  
Heat Pumps  
HRG18S-1D  
HRG24S-1D  
HRG30S-1D  
HRG36S-1D  
HRG42S-1D  
HRG48S-1D  
HRG60S-1D  
Piston Size  
0.052 inch  
0.058 inch  
0.065 inch  
0.068 inch  
0.080 inch  
0.090 inch  
0.108 inch  
Scroll Compressor Condenser Applications**  
Air Handler:  
HDG18FB-1A  
HDG24FB-1A  
HDG30FB-1A  
HDG36FB-1A  
HDG42FB-1A  
HDG48FB-1A  
HDG60FB-1A  
Condeners  
RSG18S-1D  
RSG24S-1D  
RSG30S-1D  
RSG36S-1D  
RSG42S-1D  
RSG48S-1D  
RSG60S-1D  
Piston Size  
0.052 inch  
0.058 inch  
0.065 inch  
0.073 inch  
0.077 inch  
0.105 inch  
0.097 inch  
Rotary Compressor Condenser Applications**  
Air Handler:  
HDG18FB-1A  
HDG24FB-1A  
HDG30FB-1A  
Condeners  
RSG18R-1D  
RSG24R-1D  
RSG30R-1D  
Piston Size  
0.054 inch  
0.061 inch  
0.065 inch  
*PISTON REQUIRED FOR THIS APPLICATION IS FACTORY INSTALLED.  
**PISTON REQUIRED FOR THIS APPLICATION IS NOT FACTORY INSTALLED, REQUIRES  
FIELD CONVERSION.  
20  
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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 RE-  
DUCE 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  
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Heat Controller, Inc.  
INSTALLATION INSTRUCTIONS  
HDG Series Air Handler  
10.0 FILTER INSTALLATION DIMENSIONS  
FILTER RAILS  
U
N
I
T
M
U
S
T
B
E
S
L
I
G
H
T
L
Y
I
N
C
L
I
N
E
D
FILTER COVER  
MANUAL BOLT  
“H”  
NOTE:  
Air Filter is NOT factory supplied  
Fig. 7: External Filter Base  
DIMENSIONAL DATA  
MODEL  
*
Return length  
FILTER SIZE  
IN [mm]  
Return width  
"W" IN [mm] "D" IN [mm] "H" IN [mm]  
"B" IN  
"A" IN  
HDG 18/24/30  
HDG 36/42  
HDG 48/60  
16x20 [406x508]  
18x20 [457x508]  
20x22 [508x559]  
14.8  
16.3  
18.8  
16.8[426]  
18.3[466]  
20.7[526]  
20.4[518]  
21.6[548]  
23.9[608]  
1[25.4]  
1[25.4]  
1[25.4]  
19.6  
20.8  
23  
* 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  
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HDG Series Air Handler  
INSTALLATION INSTRUCTIONS  
Heat Controller, Inc.  
11.0 Wiring 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
C
G
R
C
Y
INDOOR UNIT  
OUTDOOR UNIT  
Fig. 8: Typical Thermostat Wiring for Cooling-Only Models  
W2  
B
C
R
Y
G
THERMOSTAT  
w1  
R
C
B
G
D
RY  
C
INDOOR UNIT  
OUTDOOR UNIT  
Fig. 9: Typical Thermostat Wiring for Heat Pump Models  
23  
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Heat Controller, Inc.  
INSTALLATION INSTRUCTIONS  
HDG Series Air Handler  
Fig. 10: Indoor Unit Wiring Diagram for A/C Systems and H/P Systems  
24  
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HDG Series Air Handler  
INSTALLATION INSTRUCTIONS  
Heat Controller, Inc.  
BLACK  
C
1
C
W2  
W2  
W1  
0
WHITE  
BLACK  
PCB  
1
W1  
WHITE  
0
RED  
BLACK  
12 GA 1015 600V 105 C  
14 GA 1015 600V 105 C  
18 GA 1015 600V 105 C  
L1  
L1  
L2  
L2  
L1  
L1  
L2  
L2  
FIELD WIRING PER LOCAL CODE  
20kW HEAT KIT  
BLACK  
C
1
C
W2  
W2  
W1  
0
1
WHITE  
BLACK  
PCB  
W1  
WHITE  
0
RED  
BLACK  
12 GA 1015 600V 105 C  
14 GA 1015 600V 105 C  
18 GA 1015 600V 105 C  
L1  
L1  
L1  
L1  
L2  
L2  
L2  
L2  
FIELD WIRING PER LOCAL CODE  
CB2(63A)  
CB1(32A  
15kW HEAT KIT  
12 GA 1015 600V 105 C  
14 GA 1015 600V 105 C  
18 GA 1015 600V 105 C  
7.5kW HEAT KIT  
10kW HEAT KIT  
7.5kW CB1 50A  
10kW CB1 63A  
FIELD WIRING PER LOCAL CODE  
GREEN  
1
C
BLACK  
WHITE  
PCB  
W1  
0
12 GA 1015 600V 105 C  
14 GA 1015 600V 105 C  
5kW HEAT KIT  
18 GA 1015 600V 105 C  
FIELD WIRING PER LOCAL CODE  
GREEN  
1
C
BLACK  
WHITE  
PCB  
W1  
0
Fig. 11: Indoor Unit Wiring Diagram for Electric Heat  
25  
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05/2011  
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