INSTALLATION, OPERATION & MAINTENANCE MANUAL HTV/HTD/HTH Series Two-Stage Geothermal Heat Pumps 2 to 6 Tons Heat Controller, Inc. • 1900 Wellworth Ave. • Jackson, MI 49203 • (517)787-2100 • www.heatcontroller.
Installation, Operation & Maintenance Heat Controller, Inc.
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Safety CAUTION: Indicates a potentially hazardous situation or an unsafe practice, which if not avoided could result in minor or moderate injury or product or property damage. Warnings, cautions and notices appear throughout this manual. Read these items carefully before attempting any installation, service, or troubleshooting of the equipment.
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES General Information Inspection Upon receipt of the equipment, carefully check the shipment against the bill of lading. Make sure all units have been received. Inspect the packaging of each unit, and inspect each unit for damage. Insure that the carrier makes proper notation of any shortages or damage on all copies of the freight bill and completes a common carrier inspection report.
Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller, Inc. General Information Mounting Horizontal Units Horizontal units have hanger kits pre-installed from the factory as shown in Figure 1. Figure 3 shows a typical horizontal unit installation. Horizontal Unit Location Units are not designed for outdoor installation. Locate the unit in an INDOOR area that allows enough space for service personnel to perform typical maintenance or repairs without removing unit from the ceiling.
Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller, Inc.
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Field Conversion of Air Discharge Overview - Horizontal units can be field converted between side (straight) and back (end) discharge using the instructions below. Figure 4: Left Return Side to Back Remove Screws Water Connection End Note: It is not possible to field convert return air between left or right return models due to the necessity of refrigeration copper piping changes.
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Horizontal Installation Condensate Piping Figure 6: Horizontal Condensate Connection Condensate Piping – Horizontal Units Pitch the unit toward the drain as shown in Figure 2 to improve the condensate drainage. On small units (less than 2.5 tons/8.8 kW), insure that unit pitch does not cause condensate leaks inside the cabinet.
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Vertical Installation Figure 7: Vertical Unit Mounting Vertical Unit Location Units are not designed for outdoor installation. Locate the unit in an INDOOR area that allows enough space for service personnel to perform typical maintenance or repairs without removing unit from the mechanical room/closet. Vertical units are typically installed in a mechanical room or closet.
Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller, Inc. Vertical Installation Sound Attenuation for Vertical Units - Sound attenuation is achieved by enclosing the unit within a small mechanical room or a closet. Additional measures for sound control include the following: 1. Mount the unit so that the return air inlet is 90° to the return air grille. Refer to Figure 9. Install a sound baffle as illustrated to reduce line-of sight sound transmitted through return air grilles. 2.
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Water Connection Installation The female locking ring is threaded onto the pipe threads which holds the male pipe end against the rubber gasket, and seals the joint. HAND TIGHTEN ONLY! DO NOT OVERTIGHTEN! External Flow Controller Mounting The Flow Controller can be mounted beside the unit as shown in Figure 12. Review the Flow Controller installation manual for more details.
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Ground-Loop Heat Pump Applications most areas to prevent freezing. All air and debris must be removed from the earth loop piping before operation. Flush the loop with a high volume of water at a minimum velocity of 2 fps (0.6 m/s) in all piping. The steps below must be followed for proper flushing. 1. Fill loop with water from a garden hose through the flush cart before using the flush cart pump to insure an even fill. 2.
Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller, Inc. Ground-Loop Heat Pump Applications Table 2: Antifreeze Percentages by Volume Type Methanol Propylene Glycol Ethanol* Minimum Temperature for Low Temperature Protection 10°F [-12.2°C] 15°F [-9.4°C] 20°F [-6.7°C] 25°F [-3.
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Ground-Water Heat Pump Applications mounted on the outlet of the water control valve. The device is typically a brass fitting with an orifice of rubber or plastic material that is designed to allow a specified flow rate. On occasion, flow control devices may produce velocity noise that can be reduced by applying some back pressure from the ball valve located on the discharge line.
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Water Quality Standards Table 3: Water Quality Standards Water Quality Parameter HX Material Closed Recirculating Open Loop and Recirculating Well Scaling Potential - Primary Measurement Above the given limits, scaling is likely to occur. Scaling indexes should be calculated using the limits below pH/Calcium Hardness Method All - pH < 7.
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Hot Water Generator The HWG (Hot Water Generator) or desuperheater option provides considerable operating cost savings by utilizing excess heat energy from the heat pump to help satisfy domestic hot water requirements. The HWG is active throughout the year, providing virtually free hot water when the heat pump operates in the cooling mode or hot water at the COP of the heat pump during operation in the heating mode.
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Hot Water Generator Installation The HWG is controlled by two sensors and a microprocessor control. One sensor is located on the compressor discharge line to sense the discharge refrigerant temperature. The other sensor is located on the HWG heat exchanger’s “Water In” line to sense the potable water temperature.
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Hot Water Generator Warning! The HWG pump Is fully wired from the factory. Use extreme caution when working around the microprocessor control as it contains line voltage connections that presents a shock hazard that can cause severe injury or death! insure maximum utilization of the heat available from the refrigeration system and conserve the most energy.
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Electrical - Line Voltage WARNING! CAUTION! WARNING! To avoid possible injury or death due to electrical shock, open the power supply disconnect switch and secure it in an open position during installation. CAUTION! Use only copper conductors for field installed electrical wiring. Unit terminals are not designed to accept other types of conductors.
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Electrical - Line Voltage Figure 16: HT Single Phase Line Voltage Field Wiring WARNING! WARNING! Disconnect electrical power source to prevent injury or death from electrical shock. CAUTION! CAUTION! Use only copper conductors for field installed electrical wiring. Unit terminals are not designed to accept other types of conductors.
Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller, Inc. Electrical - Low Voltage Wiring Thermostat Connections The thermostat should be wired directly to the CXM board (units with PSC fan). Units with optional ECM motor include factory wiring from the CXM board to the ECM interface board. Thermostat wiring for these units should be connected to the ECM interface board. Figure 18 shows wiring for TT/ TS units with PSC or optional ECM motor.
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Electrical - Low Voltage Wiring Accessory Connections A terminal paralleling the compressor contactor coil has been provided on the CXM control. Terminal “A” is designed to control accessory devices, such as water valves. Note: This terminal should be used only with 24 Volt signals and not line voltage. Terminal “A” is energized with the compressor contactor. See Figure 20 or the specific unit wiring diagram for details.
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Electrical - Thermostat Wiring Figure 24: Units With Optional ECM Fan. ѥ CAUTION! ѥ Connection to ECM Control CAUTION! Many units are installed with a factory or ¿eld supplied manual or electric shut-off valve. DAMAGE WILL OCCUR if shut-off valve is closed during unit operation.
Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller, Inc. ECM Blower Control The ECM fan is controlled by an interface board that converts thermostat inputs and field selectable CFM settings to signals used by the ECM motor controller. Units manufactured before July 2005 have version I (P/N 69243707). Units manufactured after July 2005 have version II (P/N 17B0019N01). Fan speeds are selected with jumpers for version I or via a nine position DIP switch for version II.
Installation, Operation & Maintenance Heat Controller, Inc.
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES HT Series ECM Blower Performance Data Residential Units Only Airflow in CFM with wet coil and clean air filter Model 024 026 036 038 048 049 060 064 072 070 Fan Motor (hp) Range 1.0 1/2 0.9 1.0 0.7 0.7 1/2 1 1 1 Dehumid Mode Cooling Mode Max ESP (in.
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES CXM Controls On = EH2 Normal. Off = DDC Output at EH2. CXM Control For detailed control information, see CXM Application, Operation and Maintenance (AOM) manual (part #97B0003N12). NOTE: Some CXM controls only have a 2 position DIP switch package. If this is the case, this option can be selected by clipping the jumper which is in position 4 of SW1.
Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller, Inc. CXM Controls fault. The FP2 input is bypassed for the initial 120 seconds of a compressor run cycle. FP2 is set at the factory for one try. Therefore, the control will go into lockout mode once the FP2 fault has occurred. Safety Features – CXM Control The safety features below are provided to protect the compressor, heat exchangers, wiring and other components from damage caused by operation outside of design conditions.
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES CXM Controls CXM Control Start-up Operation The control will not operate until all inputs and safety controls are checked for normal conditions. The compressor will have a 5 minute anti-short cycle delay at power-up. The first time after power-up that there is a call for compressor, the compressor will follow a 5 to 80 second random start delay.
Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller, Inc. CXM Controls Table 7: Nominal resistance at various temperatures Temp (ºC) Temp (ºF) -17.8 -17.5 -16.9 -12 -11 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 0.0 0.5 1.5 10.4 12.2 14.0 15.8 17.6 19.4 21.2 23.0 24.8 26.6 28.4 30.2 32.0 33.8 35.6 37.4 39.2 41.0 42.8 44.6 46.4 48.2 50.0 51.
Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller, Inc. Unit Commissioning And Operating Conditions Operating Limits Environment – Units are designed for indoor installation only. Never install units in areas subject to freezing or where humidity levels could cause cabinet condensation (such as unconditioned spaces subject to 100% outside air). Power Supply – A voltage variation of +/– 10% of nameplate utilization voltage is acceptable.
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Unit Start-Up and Operating Conditions Low water temperature cutout: Verify that low water temperature cut-out controls are set properly (FP1 - JW3). Miscellaneous: Note any questionable aspects of the installation. Unit and System Checkout BEFORE POWERING SYSTEM, please check the following: UNIT CHECKOUT Balancing/shutoff valves: Insure that all isolation valves are open and water control valves are wired.
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Unit Start-Up Procedure 6. 7. 8. 9. pressure drop across the heat exchanger versus the data in Tables 9a through 9b. Heat of rejection (HR) can be calculated and compared to catalog data capacity pages. The formula for HR for systems with water is as follows: HR = TD x GPM x 500, where TD is the temperature difference between the entering and leaving water, and GPM is the flow rate in U.S.
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Unit Operating Conditions Table 9a: HT Coax Water Pressure Drop Model GPM Pressure Drop (psi) 30°F 50°F 70°F 90°F 024 026 2.3 3.0 3.4 4.5 6.0 0.7 1.1 1.3 2.0 3.1 0.4 0.7 0.9 1.4 2.3 0.4 0.6 0.8 1.2 1.9 0.5 0.7 0.8 1.2 1.8 038 036 3.0 4.5 6.0 6.8 9.0 1.5 2.6 3.8 4.5 6.9 0.9 1.7 2.7 3.2 5.2 0.8 1.5 2.3 2.7 4.4 0.9 1.5 2.2 2.6 4.1 048 049 4.5 6.0 6.8 9.0 12.0 1.5 2.6 3.8 4.5 6.9 0.6 1.1 1.4 2.5 4.2 0.5 1.
Installation, Operation & Maintenance Heat Controller, Inc.
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Unit Operating Conditions Table 11: HT Series Typical Unit Operating Pressures and Temperatures: Continued TE064 HT060 Entering Water Water Flow Temp GPM/ton °F Suction Pressure PSIG Full Load Cooling - without HWG active Water Temp Superheat Subcooling Rise °F Discharge Pressure PSIG 30* 1.5 2.25 3 50 1.5 2.25 3 128-138 126-136 125-135 238-258 222-242 205-225 16-21 21-26 26-31 14-19 13-18 12-17 20.5-22.5 14.9-16.
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Performance Data — HT 024 - Full Load 850 CFM Nominal (ISO Rated) Airflow Cooling, 950 CFM Nominal (ISO Rated) Airflow Heating Performance capacities shown in thousands of Btuh Cooling - EAT 80/67°F EWT °F GPM WPD PSI FT 40 50 60 70 80 90 100 110 120 TC SC kW EER HR LWT HWC Operation not recommended 20 30 CFM Heating - EAT 70°F 3.0 3.0 4.5 4.5 6.0 6.0 3.0 3.0 4.5 4.5 6.0 6.0 3.0 3.0 4.5 4.5 6.0 6.
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Performance Data — HT 036 - Full Load 1250 CFM Nominal (ISO Rated) Airflow Cooling, 1250 CFM Nominal (ISO Rated) Airflow Heating Performance capacities shown in thousands of Btuh Cooling - EAT 80/67°F EWT °F GPM WPD PSI FT 40 50 60 70 80 90 100 110 120 TC SC kW EER HR LWT HWC Operation not recommended 20 30 CFM Heating - EAT 70°F 4.5 4.5 6.8 6.8 9.0 9.0 4.5 4.5 6.8 6.8 9.0 9.0 4.5 4.5 6.8 6.8 9.0 9.
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Performance Data — HT 048 - Full Load 1550 CFM Nominal (ISO Rated) Airflow Cooling, 1650 CFM Nominal (ISO Rated) Airflow Heating Performance capacities shown in thousands of Btuh Cooling - EAT 80/67°F EWT °F GPM WPD PSI FT 40 50 60 70 80 90 100 110 120 TC SC kW EER HR LWT HWC Operation not recommended 20 30 CFM Heating - EAT 70°F 6.0 6.0 9.0 9.0 12.0 12.0 6.0 6.0 9.0 9.0 12.0 12.0 6.0 6.0 9.0 9.0 12.
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Performance Data — HT 060 - Full Load 1825 CFM Nominal (ISO Rated) Airflow Cooling, 2050 CFM Nominal (ISO Rated) Airflow Heating Performance capacities shown in thousands of Btuh Cooling - EAT 80/67°F EWT °F GPM WPD PSI FT 20 30 40 50 60 70 80 90 100 110 120 CFM TC SC kW EER Heating - EAT 70°F HR LWT HWC Operation not recommended 7.5 7.5 11.3 11.3 15.0 15.0 7.5 7.5 11.3 11.3 15.0 15.0 7.5 7.5 11.3 11.
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Performance Data — HT 070 - Full Load 1950 CFM Nominal (Rated) Airflow Cooling, 2100 CFM Nominal (Rated) Airflow Heating Performance capacities shown in thousands of Btuh Cooling - EAT 80/67°F EWT °F GPM WPD PSI FT 20 30 40 50 60 70 80 90 100 110 120 CFM TC SC kW EER Heating - EAT 70°F HR LWT HWC Operation not recommended 8.5 8.5 12.8 12.8 17.0 17.0 8.5 8.5 12.8 12.8 17.0 17.0 8.5 8.5 12.8 12.8 17.
Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller, Inc. Preventive Maintenance months to minimize the problem. The condensate pan may also need to be cleaned periodically to insure indoor air quality. The condensate drain can pick up lint and dirt, especially with dirty filters. Inspect the drain twice a year to avoid the possibility of plugging and eventual overflow.
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Troubleshooting CXM Troubleshooting Process Flowchart/Functional Troubleshooting Chart The “CXM Functional Troubleshooting Process Flowchart” is a quick overview of how to start diagnosing a suspected problem, using the fault recognition features of the CXM board.
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES CXM Process Flow Chart WARNING! WARNING! HAZARDOUS VOLTAGE! DISCONNECT ALL ELECTRIC POWER INCLUDING REMOTE DISCONNECTS BEFORE SERVICING. Failure to disconnect power before servicing can cause severe personal injury or death.
Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller, Inc. Functional Troubleshooting Fault Main power problems HP Fault Code 2 Htg Clg Possible Cause Air temperature out of range in heating Overcharged with refrigerant Bad HP Switch Insufficient charge X Compressor pump down at start-up Check charge and start-up water flow.
Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller, Inc. Performance Troubleshooting Performance Troubleshooting Htg Clg Possible Cause X X Solution Dirty filter Replace or clean. Reduced or no air flow in heating Check fan motor operation and airflow restrictions. Check for dirty air filter and clean or replace. X Too high of external static. Check static vs. blower table. Check for dirty air filter and clean or replace.
Installation, Operation & Maintenance Heat Controller, Inc.
*97B00 * 97B00??????? 01-2013