Heat Controller HTV Series Guía

Heat Controller, Inc. • 1900 Wellworth Ave. • Jackson, MI 49203 • (517)787-2100 • www.heatcontroller.com

INSTALLATION, OPERATION

& MAINTENANCE

HTV/HTD/HTH Series

Two-Stage

Geothermal Heat Pumps

2 to 6 Tons

HTV/HTD/HTH SERIES Heat Controller, Inc.

Model Breakdown

Model Nomenclature – Two Stage Geothermal Heat Pump

Heat Controller GeoMax 2 nGeothermal Heat Pump Systems

H = Horizontal

J = Cupro-Nickel

P = Back

W = Straight

Table of Contents

Model Nomenclature .................................................... 1

Storage........................................................................... 3

Pre-Installation .............................................................. 3

Physical Data................................................................. 4

Duct System Installation............................................... 5

Vertical Unit Location................................................. 5-7

Horizontal Unit Location ..........................................8-11

Piping Installation ................................................. 12-13

Ground Loop Applications .....................................14-16

Open Loop-Ground Water Systems .......................17-18

Hot Water Generator..............................................19-21

Water Quality Standards............................................. 22

Electrical-Line Voltage................................................. 23

Power Wiring................................................................ 24

Electrical-Low Voltage Wiring...................................... 25

Low Water Temperature Cutout Selection................. 25

Water Valve Wiring .................................................26-27

Thermostat Wiring....................................................... 28

ECM Blower Control .............................................. 29-30

Electrical Wiring Schematics...................................... 31

CXM Controls ......................................................... 32-35

Unit Start-Up and Operating Conditions ...............36-37

Unit and System Checkout Procedure ..................37-38

Unit Start-Up Procedure........................................ 38-40

Coax Pressure Drop Table .......................................... 40

Operating Pressures ..............................................41-42

Preventative Maintenance.................................... 43-44

Functional and Performance Troubleshooting .... 45-49

Heat Controller, Inc. HTV/HTD/HTH SERIES

WARNING! Verify refrigerant type

before proceeding. Units are

shipped with R-410A refrigerant.

The R-410A application and service

manual should be read and

understood before attempting to

service refrigerant circuits with

R-410A.

SAFETY

Warnings, cautions and notices appear

throughout this manual. Read these items

carefully before attempting any installation,

service or troubleshooting of the

equipment.

DANGER: Indicates an immediate

hazardous situation, which if not avoided

will result in death or serious injury.

DANGER labels on unit access panels

must be observed.

WARNING: Indicates a potentially

hazardous situation, which if not avoided

could result in death or serious injury.

⌧ WARNING! ⌧

WARNING! To avoid the release of

refrigerant into the atmosphere, the

refrigerant circuit of this unit must be

serviced only by technicians who

meet local, state and federal

proficiency requirements.

⌧ WARNING! ⌧

WARNING! All refrigerant

discharged from this unit must be

recovered WITHOUT EXCEPTION.

Technicians must follow industry

accepted guidelines and all local,

state, and federal statutes for the

recovery and disposal of refrigerants.

If a compressor is removed from this

unit, refrigerant circuit oil will remain

in the compressor. To avoid leakage

of compressor oil, refrigerant lines of

the compressor must be sealed after

it is removed.

⌧ WARNING! ⌧

CAUTION! To avoid equipment

damage, DO NOT use these units as

a source of heating or cooling during

the construction process. The

mechanical components and filters

will quickly become clogged with

construction dirt and debris, which

may cause system damage.

⌧ CAUTION! ⌧

NOTICE: Notification of installation,

operation or maintenance information,

which is important, but which is not

hazard-related.

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.

WARNING! Verify refrigerant type

before proceeding. Units are

shipped with R-410A refrigerant.

The R-410A application and service

manual should be read and

understood before attempting to

service refrigerant circuits with

R-410A.

SAFETY

Warnings, cautions and notices appear

throughout this manual. Read these items

carefully before attempting any installation,

service or troubleshooting of the

equipment.

DANGER: Indicates an immediate

hazardous situation, which if not avoided

will result in death or serious injury.

DANGER labels on unit access panels

must be observed.

WARNING: Indicates a potentially

hazardous situation, which if not avoided

could result in death or serious injury.

⌧ WARNING! ⌧

WARNING! To avoid the release of

refrigerant into the atmosphere, the

refrigerant circuit of this unit must be

serviced only by technicians who

meet local, state and federal

proficiency requirements.

⌧ WARNING! ⌧

WARNING! All refrigerant

discharged from this unit must be

recovered WITHOUT EXCEPTION.

Technicians must follow industry

accepted guidelines and all local,

state, and federal statutes for the

recovery and disposal of refrigerants.

If a compressor is removed from this

unit, refrigerant circuit oil will remain

in the compressor. To avoid leakage

of compressor oil, refrigerant lines of

the compressor must be sealed after

it is removed.

⌧ WARNING! ⌧

CAUTION! To avoid equipment

damage, DO NOT use these units as

a source of heating or cooling during

the construction process. The

mechanical components and filters

will quickly become clogged with

construction dirt and debris, which

may cause system damage.

⌧ CAUTION! ⌧

NOTICE: Notification of installation,

operation or maintenance information,

which is important, but which is not

hazard-related.

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.

HTV/HTD/HTH SERIES Heat Controller, Inc.

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.

Concealed damage not discovered during

unloading must be reported to the carrier

within 15 days of receipt of shipment. If

not filed within 15 days, the freight

company can deny the claim without

recourse.Note:It is the responsibility of

the purchaser to file all necessary claims

with the carrier. Notify your equipment

supplier of all damage within 15 days of

shipment.

STORAGE

Equipment should be stored in its original

packaging in a clean, dry area. Store units

in an upright position at all times. Stack

units a maximum of 3 units high.

UNIT PROTECTION

Cover units on the job site with either the

original packaging or an equivalent

protective covering. Cap the open ends of

pipes stored on the job site. In areas

where painting, plastering, and/or spraying

has not been completed, all due

precautions must be taken to avoid

physical damage to the units and

contamination by foreign material.

Physical damage and contamination may

prevent proper start-up and may result in

costly equipment clean-up. Examine all

pipes, fittings, and valves before installing

any of the system components. Remove

any dirt or debris found in or on these

components.

PRE-INSTALLATION

This Installation, Operation, and

Maintenance manual is provided with each

unit. Units are typically installed in a

mechanical room. The installation site

chosen should include adequate service

clearance around the unit. Before unit

start-up, read all manuals and become

familiar with the unit and its operation.

Thoroughly check the system before

operation.

Prepare units for installation as follows:

1. Compare the electrical data on the unit

nameplate with ordering and shipping

information to verify that the correct unit

has been shipped.

2. Keep the cabinet covered with the

original packaging until installation is

complete and all plastering, painting,

etc. is finished.

3. Verify refrigerant tubing is free of kinks

or dents and that it does not touch other

unit components.

4. Inspect all electrical connections.

Connections must be clean and tight at

the terminals.

5. Remove any blower support packaging.

6. Loosen compressor bolts on units

equipped with compressor spring

vibration isolation until the compressor

rides freely on the springs. Remove

shipping restraints.

7. REMOVE COMPRESSOR SUPPORT

PLATE 1/4” SHIPPING BOLTS (2 on

each side) TO MAXIMIZE VIBRATION

AND SOUND ATTENUATION.

General Information

Heat Controller, Inc. HTV/HTD/HTH SERIES

General Information

All units have TXV devices, 1/2” and 3/4” electrical knockouts.

GENERAL INFORMATION

CAUTION! DO NOT store or install

units in corrosive environments or in

locations subject to temperature or

humidity extremes (e.g., attics, rooftops,

etc.). Corrosive conditions and high

temperature or humidity can significantly

reduce performance, reliability, and service

life. Always move and store units in an

upright position. Tilting units on their

sides may cause equipment damage.

CAUTION! CUT HAZARD

Failure to follow this caution may result in

personal injury. Sheet metal parts may

have sharp edges or burrs. Use care and

wear appropriate protective clothing, safety

glasses and gloves when handling parts

and servicing heat pumps.

CAUTION! CAUTION!

NOTICE! Failure to remove shipping brackets from spring-mounted compressors will

cause excessive noise, and could cause component failure due to added vibration.

Model 24 36 48 60

Compressor (1 Each) Two-Stage Scroll

Factory Charge R410A (oz) 58 78 81 144

ECM Fan Motor & Blower

Fan Motor (hp) ½ ½ 1 1

Blower Wheel Size (dia x w) - (in) 9 x 7 11 x 10 11 x 10 11 x 10

Water Connection Size

Swivel (in) 1 1 1 1

HWG Connection Size

Swivel (in) 1 1 1 1

Coax Volume

Volume (US Gallons) 0.760.921.241.56

Vertical Upflow

Air Coil Dimensions (h x w) - (in) 28 x 20 28 x 25 32 x 25 36 x 25

Standard Filter - 1”

Throwaway, qty (in)

1 - 28 x 24 1 - 28 x 30 2 - 16 x 30 1 - 16 x 20

1 - 20 x 30

Weight - Operating, (lbs) 266327416443

Weight - Packaged, (lbs) 276337426453

All units have spring compressor mountings, TXV devices, and all units have ½” and ¾” electrical knockouts.

GeoMax2 TWO-STAGE HTV/HTD SERIES (60 Hz Only)

UNIT PHYSICAL DATA

156

11 x 10

36 x 25

443

453

1.56

1 - 16 x 20

1 - 20 x 30



UNIT PHYSICAL DATA

TWO STAGE HTV/HTD/HTH SERIES (60Hz Only)

Model 24 36 48 60 70

Compressor (1 Each) Two-Stage Scroll

Factory Charge R410A (oz) 58 78 81 144 156

ECM Fan Motor & Blower

Fan Motor (hp) 1/21/21 1 1

Blower Wheel Size (dia x w) - (in) 9 x 7 11 x 10 11 x 10 11 x 10 11 x 10

Water Connection Size

Swivel (in) 1 1 1 1 1

HWG Connection Size

Swivel (in) 1 1 1 1 1

Coax Volume

Volume (US Gallons) 0.76 0.92 1.24 1.56 1.56

Vertical Upow/Downow

Air Coil Dimensions (h x w) - (in) 28 x 20 28 x 25 32 x 25 36 x 25 36 x 25

Standard Filter - 2” Pleated

HERV11, Quantity - in x in

1-24 x 28 1-28 x 30 1-30 x 32 1-30 x 36

1-30 x 36

Weight - Operating, (lbs) 266 327 416 443 443

Weight -Packaged, (lbs) 276 337 426 453 453

Horizontal

Air Coil Dimensions (H x W), in 18 x 31 20 x 35 20 x 40 20 x 45 20 x 45

Standard Filter - 2” Pleated

MERV11, Quantity - in x in

2 - 18 x 18 1 - 12 x 20

1 - 20 x 25

1 - 18 x 20

1 - 20 x 24

2 - 20 x 24 2 - 20 x 24

Weight - Operating, lbs 266 327 416 443 443

Weight - Packaged, lbs 276 337 426 453 453

HTV/HTD/HTH SERIES Heat Controller, Inc.

Duct System Installation

DUCT SYSTEM INSTALLATION

Proper duct sizing and design is critical to the

performance of the unit. The duct system

should be designed to allow adequate airflow

through the unit during operation. Air flow

through the unit MUST be at or above the

minimum stated airflow for the unit to avoid

equipment damage. Duct systems should

be designed for quiet operation. Refer to

Figure 2 for vertical duct system details. A

flexible connector is recommended for both

discharge and return air duct connections on

metal duct systems to eliminate the transfer

of vibration to the duct system. To maximize

sound attenuation of the unit blower, the

supply and return plenums should include

internal fiberglass duct liner or be

constructed from ductboard for the first few

feet. Application of the unit to uninsulated

ductwork in an unconditioned space is not

recommended as the unit’s performance will

be adversely affected.

At least one 90° elbow should be included in

the supply duct to reduce air noise. If air

noise or excessive air flow is a problem, the

blower speed can be changed. For airflow

charts, consult Engineering Design Guide for

the specific unit.

If the unit is connected to existing ductwork, a

previous check should have been made to

insure that the ductwork has the capacity to

handle the airflow required for the unit. If

ducting is too small, as in the replacement of

a heating only system, larger ductwork

should be installed. All existing ductwork

should be checked for leaks and repaired as

necessary.

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. 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). Consideration should be

given to access for easy removal of the

filter and access panels. Provide

sufficient room to make water, electrical,

and duct connection(s).

If the unit is located in a confined space,

such as a closet, provisions must be

made for return air to freely enter the

space by means of a louvered door, etc.

Any access panel screws that would be

difficult to remove after the unit is

installed should be removed prior to

setting the unit. Refer to Figures 1 and

2 for typical installation illustrations.

Refer to Engineering Design Guide for

dimensional data.

1. Install the unit on a piece of rubber,

neoprene or other mounting pad

material for sound isolation. The

pad should be at least 3/8” to 1/2” in

thickness. Extend the pad beyond

all four edges of the unit.

INSTALLATION

Heat Controller, Inc. HTV/HTD/HTH SERIES

INSTALLATION

2. Provide adequate clearance for filter

replacement and drain pan cleaning.

Do not block filter access with piping,

conduit or other materials. Refer to

unit submittal data or Engineering

Design Guide for dimensional data.

3. Provide access for fan and fan motor

maintenance and for servicing the

compressor and coils without removing

the unit.

4. Provide an unobstructed path to the

unit within the closet or mechanical

room. Space should be sufficient to

allow removal of the unit, if necessary.

5. In limited side access installations,

pre-removal of the control box side

mounting screws will allow control box

removal for future servicing.

6. Provide access to water valves and

fittings and screwdriver access to the

unit side panels, discharge collar and

all electrical connections.

Figure 1: Unit Mounting

Figure 2: Typical Unit Installation

Using Ducted Return Air

Internally insulate supply duct of first 15’

each way to reduce noise

Use turning vanes in supply transition

Flexible canvas duct connector to

reduce noise and vibration

Rounded return transition

Internally insulate return transition

duct to reduce noise

or Engineering Design Guide for

dimensional data.

HTV/HTD/HTH SERIES Heat Controller, Inc.

INSTALLATION

SOUND ATTENUATION

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 3. Install a sound

bae as illustrated to reduce line-of

sight sound transmitted through

return air grilles.

2. Mount the unit on a rubber or

neoprene isolation pad to minimize

vibration transmission to the building

structure.

CONDENSATE PIPING

These units utilizea condensate hose

inside the cabinet as a trapping loop;

therefore an external trap is not

necessary. Figure 4A shows typical

condensate connections. Figure 4B

illustrates the internal trap for a typical

vertical heat pump. Each unit must be

installed with its own individual vent

(where necessary) and a means to ush

or blow out the condensate drain line.

Do not install units with a common trap

and/or vent.

Figure 4A: Condensate Drain Air

Figure 3: Vertical Sound Attenuation

Figure 4B: Internal Condensate Trap

NOTICE! Units with clear plastic drain

lines should have regular maintenance

(as required) to avoid buildup of debris,

especially in new construction.

Heat Controller, Inc. HTV/HTD/HTH SERIES

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. Horizontal units

are typically installed above a false ceiling or in a ceiling

plenum. 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). Consideration should be given to access for easy

removal of the lter and access panels. Provide sufcient

room to make water, electrical, and duct connection(s).

If the unit is located in a conned space, such as a closet,

provisions must be made for return air to freely enter the

space by means of a louvered door, etc. Any access panel

screws that would be difcult to remove after the unit is

installed should be removed prior to setting the unit. Refer

to Figure 3 for an illustration of a typical installation. Refer to

unit specications catalog for dimensional data.

Conform to the following guidelines when selecting

unit location:

Provide a hinged access door in concealed-spline or

plaster ceilings. Provide removable ceiling tiles in T-bar

or lay-in ceilings. Refer to horizontal unit dimensions for

specic series and model in unit specications catalog.

Size the access opening to accommodate the service

technician during the removal or replacement of the

compressor and the removal or installation of the unit

itself.

Provide access to hanger brackets, water valves and

ttings. Provide screwdriver clearance to access panels,

discharge collars and all electrical connections.

3. DO NOT obstruct the space beneath the unit with

piping, electrical cables and other items that prohibit

future removal of components or the unit itself.

4. Use a manual portable jack/lift to lift and support the

weight of the unit during installation and servicing.

The installation of water source heat pump units and all

associated components, parts and accessories which

make up the installation shall be in accordance with the

regulations of ALL authorities having jurisdiction and MUST

conform to all applicable codes. It is the responsibility of

the installing contractor to determine and comply with ALL

applicable codes and regulations.

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 heat pumps are typically suspended above a

ceiling or within a soft using eld supplied, threaded rods

sized to support the weight of the unit.

Use four (4) eld supplied threaded rods and factory

provided vibration isolators to suspend the unit. Hang the

unit clear of the oor slab above and support the unit by the

mounting bracket assemblies only. DO NOT attach the unit

ush with the oor slab above.

Pitch the unit toward the drain as shown in Figure 2 to

improve the condensate drainage. On small units (less

than 2.5 tons/8.8kW) ensure that unit pitch does not cause

condensate leaks inside the cabinet.

Drain

Connection

1/4" [6.4mm] pitch

for drainage

Figure 1: Hanger Bracket

Figure 2: Horizontal Unit Pitch

3/8" [10mm] Threaded

Rod (by others)

Vibration Isolator

(factory supplied)

Washer

(by others)

Double Hex Nuts

(by others)

Varilla Roscada de 3/8"

(fabricada por terceros)

Arandela

(fabricada por terceros)

Tuercas Hexagonales

Dobles (por terceros)

Instale los Tornillos como

se Indica en el Diagrama

La longitud de este tornillo

debe ser de solamente 1/2” para evitar daños

Aislador de Vibraciones

(para codificación por color y

notas de instalación, consulte

las instrucciones de

instalación del soport

e colgador)

HTV/HTD/HTH SERIES Heat Controller, Inc.

HORIZONTAL INSTALLATION

(by others)

Cableado

del termostato

Válvula compensadora opcional

Salida de agua

Entrada de agua

Válvula invertida opcional para

control de baja presión de agua

(puede montarse en forma interna)

Válvula a bola con tapón

P/T integrado opcional

Manguera trenzada de

acero inoxidable con accesorio

giratorio en “J”

Circuito

de edificación

Disyuntor de

energía de la unidad

(fabricado por terceros)

Alimentación

de energía de

la unidad

Conducto de alimentación

aislado con un codo (mínimo)

de 90 grados para reducir el

ruido del aire

Retorno de

aire

Aire de alimentación

Cableado de

alimentación

de energía

Varillas Roscadas de 3/8"

(fabricadas por terceros)

Colgador

de la unidad

Thermostat

Wiring

Optional Balancing Valve

Water In

Water Out

Optional Low Pressure Drop Water

Control Valve

(can be internally mounted

on some models)

Ball Valve with optional

integral P/T plug

Stainless steel braid hose

with integral "J" swivel

Building

Loop

Unit Power

Disconnect

Power Wiring

Insulated supply duct with

at least one 90 deg elbow

to reduce air noise

Return Air

Supply Air

Unit Hanger

3/8" [10mm] threaded rods

Unit Power

Flexible Duct

Connector

Figure 3: Typical Horizontal Unit Installation

Air Coil

To obtain maximum performance, the air coil should be

cleaned before start-up. A 10% solution of dishwasher

detergent and water is recommended for both sides

of the coil. A thorough water rinse should follow. UV

based anti-bacterial systems may damage e-coated

air coils.

NOTICE! Failure to remove shipping brackets from

spring-mounted compressors will cause excessive

noise, and could cause component failure due to

added vibration.

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