Heat Controller Hdg Quick Start Guide

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2014-07-19

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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

Heat Controller, Inc.

HDG Series Air Handler

INSTALLATION INSTRUCTIONS

1.0 Nomenclature

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.

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.

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

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).

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

HDG Series Air Handler

Heat Controller, Inc.

INSTALLATION INSTRUCTIONS

3.1 Unit Dimensions

NOTE: 24” CLEARANCE IS REQUIRED IN THE FRONT
OF THE UNIT FOR FILTER AND COIL MAINTENANCE.

ELECTRICAL CONNECTIOS
MAY EXIT TOP OR EITHER SIDE

SUPPLY AIR

HIGH
HIGH VOLTAGE
VOLTAGE CONNECTION
CONNECTION 7/8”,
7/8”,
1-3/8”,
1-3/4”
DIAMETER
KNOCK
OUTS
1-23/64”,
1-23/32”
DIA KNOCK
OUTS

FLANGES ARE PROVIDED
FOR FIELD INSTALLATION
5 16

LOW VOLTAGE CONNECTION
BREAKER SWITCH
(FOR ELECTRIC HEATER ONLY)

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)
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]

Net

Shipping

HDG18

41 3/8" [1050]

18 1/8" [460]

20 1/2" [520]

16" [406]

106 [48]

119 [54]

HDG 24

41 /8" [1050]

18 /8" [460]

20 /2" [520]

16" [406]

106 [48]

119 [54]

HDG 30

41 /8" [1050]

18 /8" [460]

20 /2" [520]

16" [406]

119 [54]

132 [60]

HDG36

46 /2" [1180]

19 /8" [500]

20 /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]

/2” [496]
19 1/2” [496]

171 [78]

187 [85]

171 [78]

187 [85]

Model Size

3
3

1
1

1
1
5

HDG48

54 1/2” [1385]

22” [560]

24" [610]

HDG60

54 1/2” [1385]

22” [560]

24" [610]
7

Heat Controller, Inc.

HDG Series Air Handler

INSTALLATION INSTRUCTIONS

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

Fig.22Coil
Connection
Dimensions
Fig.
Coil
Connection
Dimensions

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.

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.

Heat Controller, Inc.

HDG Series Air Handler

INSTALLATION INSTRUCTIONS

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
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

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.

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.

HDG Series Air Handler

Heat Controller, Inc.

INSTALLATION INSTRUCTIONS

5.4 Electrical Data– BLOWER ONLY, NO ELECTRIC HEAT
Model

Voltage

RPM

SPEEDS

CIRCUIT
AMPS.

MINIMUM
CIRCUIT
AMPACITY

MAXIMUM
CIRCUIT
PROTECTOR

HDG18

208/230-1-60

1/8

580

0.68

15(A)

HDG24

208/230-1-60

1/5

701

0.95

1.5

15(A)

HDG30

208/230-1-60

1/4

872

1.48

15(A)

HDG36

208/230-1-60

1/2

794

1.63

15(A)

HDG42

208/230-1-60

1/2

882

1.80

15(A)

HDG48

208/230-1-60

1/2

845

2.11

15(A)

HDG60

208/230-1-60

3/4

963

2.79

15(A)

5.5 Electrical Data– ELECTRIC HEAT
Air
Handler
Model
HDG18

HDG24

HDG30

HDG36

HDG42

HDG48

HDG60

Heater
Model No.

Heater
kW
(208V)

Heater
kW
(240V)

7800-505-1D

3.8

7800-508-1D

5.6

7.5

7800-510-1D

7.5

7800-505-1D

3.8

7800-508-1D

5.6

7.5

7800-510-1D

7.5

7800-505-1D

3.8

7800-508-1D

5.6

7.5

7800-510-1D

7.5

7800-505-1D

3.8

7800-508-1D

5.6

7800-510-1D

7.5

7800-515-1D

7800-520-1D

7800-505-1D

Minimum
Circuit
Motor
Ampacity
Ampacity
(208V)

Minimum Maximum Maximum
Circuit
Circuit
Circuit
Ampacity Protection Protection
(240V)
(208V)
(240V)

Circuit
Amps
(208V)

Circuit
Amps
(240V)

18.1

20.8

0.68

23.5

26.9

27.1

31.3

0.68

34.8

36.1

41.7

0.68

18.1

20.8

0.95

23.8

27.3

27.1

31.3

0.95

35.1

40.3

36.1

41.7

0.95

46.4

53.3

18.1

20.8

1.48

24.5

27.9

27.1

31.3

1.48

35.8

36.1

41.7

1.48

18.1

20.8

1.63

24.7

28.1

7.5

27.1

31.3

1.63

35.9

41.1

36.1

41.7

1.63

47.2

54.2

62.5

1.63

69.8

80.2

72.2

83.3

1.63

92.4

106.3

100

125

3.8

18.1

20.8

1.80

24.9

28.3

7800-508-1D

5.6

7.5

27.1

31.3

1.80

36.2

41.4

7800-510-1D

7.5

36.1

41.7

1.80

47.4

54.4

7800-515-1D

54.2

62.5

1.80

80.4

7800-520-1D

72.2

83.3

1.80

92.6

106.5

100

125

7800-505-1D

3.8

18.1

20.8

2.11

25.3

28.7

7800-508-1D

5.6

7.5

27.1

31.3

2.11

36.5

41.7

7800-510-1D

7.5

36.1

41.7

2.11

47.8

54.8

7800-515-1D

54.2

62.5

2.11

70.4

80.8

7800-520-1D

72.2

83.3

2.11

106.9

100

125

7800-505-1D

3.8

18.1

20.8

2.79

26.1

29.6

7800-508-1D

5.6

7.5

27.1

31.3

2.79

37.4

42.6

7800-510-1D

7.5

36.1

41.7

2.79

48.7

55.6

7800-515-1D

54.2

62.5

2.79

71.2

81.7

7800-520-1D

72.2

83.3

2.79

93.8

107.7

100

125

PH/Hz
1Ph/60Hz

1Ph/60Hz

Heat Controller, Inc.

HDG Series Air Handler

INSTALLATION INSTRUCTIONS

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

CFM (Watts)
Model
Number

Motor
Speed

Low

HDG18

Middle

High

Low

HDG24

Middle

High

Low

HDG30

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

Middle

High

0 [0]

0.1 [.02]

0.16 [.04]

0.2 [.05]

0.3 [.07]

0.4 [.10]

0.5 [.12]

0.6 [.15]

CFM

551

509

462

393

345

280

---

RPM

440

518

595

679

726

781

----

Watts

122.4

120

116.8

116.3

109.9

106.2

---

Amps

0.62

0.61

0.60

---

CFM

661

622

577

506

443

400

---

RPM

518

580

640

731

770

812

---

Watts

145.2

143

140.8

136.3

133.6

131.2

---

Amps

0.69

0.68

0.67

0.66

---

CFM

590

RPM

Watts

0.7 [.17]

0.8 [.20]

550

487

400

894

911

940

975

232

229.5

224.4

217.4

1.14

1.12

Amps

1.16

1.15

CFM

646

623

592

553

506

453

---

RPM

528

591

650

728

790

840

---

Watts

169.4

166.4

163

157.5

151.3

146.3

---

Amps

0.79

0.78

0.77

0.76

0.75

---

CFM

815

802

771

733

681

613

---

RPM

658

701

743

790

841

888

---

Watts

218

216.6

214.4

211.4

207.4

203

---

Amps

0.96

0.95

0.94

0.93

0.92

---

CFM

780

695

607

515

RPM

919

956

986

1014

Watts

262.6

256.4

250.1

243

Amps

1.21

.181

.171

.15

CFM

962

913

886

870

813

750

690

RPM

729

754

798

809

858

873

902

Watts

315

304

298

292

280

269

258

Amps

1.39

1.35

1.32

1.30

1.26

1.22

1.19

CFM

1094

1043

1012

988

927

861

788

RPM

809

845

859

885

911

932

954

Watts

334

325

319

315

303

290

279

Amps

1.46

1.43

1.40

1.38

1.35

1.30

1.26

CFM

1374

1311

1268

1240

1164

1084

996

910

828

744

RPM

910

937

947

954

972

989

1004

1018

1033

1043

Watts

440

427

419

413

398

381

366

352

340

331

Amps

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

Heat Controller, Inc.

INSTALLATION INSTRUCTIONS
CFM (Watts)

Model
Number

Low

HDG36

Middle

High

Low

HDG42

Middle

High

Low

HDG48

Middle

High

Low

HDG60

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

Motor
Speed

Middle

High

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

0 [0]
1129
642
322
1.54
1317
776
360
1.69
1643
868
463
2.22
1239
738
396
1.73
1480
843
430
1.87
1738
921
508
2.22
1471
694
381
1.66
1729
790
485
2.14
2045
895
641
2.86
1786
830
584
2.64
2140
917
645
2.87
2357
964
754
3.34

0.1 [.02]
1088
675
312
1.52
1268
810
354
1.67
1581
883
451
2.20
1203
775
385
1.68
1431
865
416
1.81
1682
941
493
2.15
1427
732
376
1.64
1678
817
477
2.12
1992
920
627
2.82
1740
843
569
2.59
2071
930
630
2.81
2276
976
733
3.27

0.16 [.04]
1061
706
306
1.51
1237
841
348
1.66
1544
895
443
2.18
1178
797
376
1.64
1399
882
407
1.77
1639
949
486
2.12
1395
753
372
1.63
1646
833
473
2.09
1951
932
617
2.82
1709
849
560
2.55
2039
938
623
2.78
2225
982
718
3.22

0.2 [.05]
1040
732
301
1.50
1217
874
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
370
1.62
1625
845
470
2.08
1928
938
612
.782
1688
856
552
2.54
2006
943
617
2.76
2188
990
710
3.19
15

0.3 [.07]
988
771
289
1.47
1157
905
335
1.63
1446
931
429
2.14
1117
844
360
1.57
1319
915
388
1.69
1548
970
460
2.01
1316
803
364
1.61
1558
876
460
2.06
1847
956
596
.732
1630
890
536
2.58
1932
957
602
2.71
2100
1001
693
3.12

0.4 [.10]
941
817
269
1.42
1111
935
323
1.60
1356
955
415
2.12
1070
872
345
1.52
1259
937
375
1.63
1477
985
445
1.94
1247
833
357
.581
1491
898
451
2.03
1763
972
582
.682
1562
921
516
2.42
1799
970
585
2.65
2004
1012
673
3.05

0.5 [.12]
819
853
254
1.39
1027
966
309
1.57
1261
978
401
2.09
1000
905
327
1.44
1187
959
359
1.57
1378
1002
431
1.89
1180
864
349
.550
1402
920
240
1.99
1677
987
566
.642
1489
942
497
2.37
1677
990
569
2.59
1902
1022
650
2.98

0.6 [.15]
1123
1013
371
2.03
1286
1016
412
1.81
----

0.7 [.17]
915
1028
356
1.99
1042
1042
373
1.65

0.8 [.20]
812
1050
343
1.96
908
1059
354
1.58
-

-----1563
1002
546
.572
--------1764
1032
630
2.91

1450
1015
528
.522

1554
1042
607
2.83

1317
1030
507
.450
1393
1063
575
2.71

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

Fan

Medium

Red

Blue B

lack

High

Black

Blue

Red

Low

Blue

Red

Black

Fan speed

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.

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.

Heat Controller, Inc.

HDG Series Air Handler

INSTALLATION INSTRUCTIONS

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
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.

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.

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.

Heat Controller, Inc.

HDG Series Air Handler

INSTALLATION INSTRUCTIONS

10.0 FILTER INSTALLATION DIMENSIONS

FILTER RAILS

UNIT MUST BE SLIGH TLY INCLINED

“H”

FILTER COVER

MANUAL BOLT

AIR “
OP A”
EN
ING

“D

”

”
“B
DE

”
“W

NOTE:

AirAir
Filter
factory
supplied
filterisisNOT
factory
supplied
(optional)
Fig.
Filter
Base
Fig.7:
6 External
EXTERNAL
FILTER
BASE
DIMENSIONAL DATA
MODEL

FILTER SIZE*
IN [mm]

HDG 18/24/30

16x20 [406x508]

16.8[426]

20.4[518]

1[25.4]

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]

18.8

"W" IN [mm] "D" IN [mm] "H" IN [mm]

Return width Return length
"B" IN
"A" IN
19.6

* 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.

14.8

HDG Series Air Handler

Heat Controller, Inc.

INSTALLATION INSTRUCTIONS

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

YELLO W

BLACK

R ED

GREE N

INDOOR UNIT

OUTDOOR UNIT

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

W2
B
C
R
Y

INDOOR UNIT

OUTDOOR UNIT

Fig. 9: Typical Thermostat Wiring for Heat Pump Models

PURPLE

BLUE

YELLOW

BLACK

RED

WHITE

BLACK

RED

THERMOSTAT

GREEN

Heat Controller, Inc.

INSTALLATION INSTRUCTIONS

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

HDG Series Air Handler

Heat Controller, Inc.

INSTALLATION INSTRUCTIONS

WHITE

2 4

CN6
CN8

1
0

BLACK

CN3

PCB

C
W2

WHITE

2 46 8

BLACK
C
W2
W1

RED

BLACK

FIELD WIRING PER LOCAL CODE

GREEN

14 GA 1015 600V 105 C
18 GA 1015 600V 105 C

GREEN

12 GA 1015 600V 105 C

20kW HEAT KIT

CN6

W2
W1

WHITE

1
0

1
W1

WHITE

2 4

BLACK

CN3

CN8

PCB

C
W2

2 46 8

BLACK
C

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

CB2(63A)

15kW HEAT KIT

WHITE

BLACK

GREEN

RED

CN8

CN3

PCB

CN6

FIELD WIRING PER LOCAL CODE

7.5kW CB1 50A
10kW CB1 63A

BLACK

12 GA 1015 600V 105 C
14 GA 1015 600V 105 C
18 GA 1015 600V 105 C

L1 L2

7.5kW HEAT KIT
10kW HEAT KIT

CB1(32A

12 GA 1015 600V 105 C

5kW HEAT KIT

14 GA 1015 600V 105 C
18 GA 1015 600V 105 C

GREEN

RED

Fig. 11: Indoor Unit Wiring Diagram for Electric Heat
25

BLACK

L1 L2

WHITE

BLACK

6 8

CN3

CN8

PCB

CN6

FIELD WIRING PER LOCAL CODE

05/2011
04/2009

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Manifest Link Form              : ReferenceStream, ReferenceStream
Manifest Placed X Resolution    : 300.00, 72.00
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Manifest Placed Resolution Unit : Inches, Inches
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Manifest Reference Document ID  : xmp.did:B047FCB2A6B2DE11BA3DA1B2D42BC347, uuid:C5B7FCD095F3DD11BC07C1B437698E05
Doc Change Count                : 11340
Format                          : application/pdf
Producer                        : Adobe PDF Library 9.0
Trapped                         : False
Page Count                      : 27
Creator                         : Adobe InDesign CS4 (6.0)

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Heat Controller Hdg Quick Start Guide

HDG36 to the manual 19a91e28-d068-4721-875b-ba0cf652761d

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