Heat Controller HTV Series Manual de instrucciones

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

INSTALLATION, OPERATION

& MAINTENANCE MANUAL

HTV/HTD/HTH Series

Two-Stage

Geothermal Heat Pumps

2 to 6 Tons

Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller, Inc.

Model Breakdown

Model Nomenclature – Two Stage Geothermal Heat Pump

HT = Heat Controller Two Stage

C0 2 4 C1 0 1 A L K

4 5 6 7

91011121314

024

Unit Size

036 Return Air Flow Configuration

Voltage

C = CXM

Controls

B = Efficiency Upgrade

C = Microchannel Air Coil on 036

Revision Level Heat Exchanger Options

Cabinet

Supply Air Flow &

Motor Configuration

1 2

Series

V = Vertical Up Flow

H = Horizontal

D = Vertical Down Flow

Configuration

L = Left Return

R = Right Return

Water Circuit Options

048

060

0 = Residential

1 = HWG w/Internal Pump

0 = None

Supply Configuration Motor

HTV

HTD

HTH

Top

Down

Back

Straight

ECM

070

1 = 208-230/30/1

A = Copper Water Coil, Coated Air Coil

J = Copro-Nickel Water Coil, Coated Air Coil

TABLE OF CONTENTS

Model Nomenclature ..........................................2

Storage...............................................................4

Pre-Installation....................................................4

Horizontal Installation.........................................5

Field Conversion of Air Discharge......................7

Duct System Installation.....................................8

Condensate Piping Installation...........................8

Vertical Installation........................................ 9-10

Water Connection Installation...........................11

Ground Loop Applications ...........................11-12

Open Loop - Ground Water Systems...............13

Water Quality Standards ..................................15

Hot Water Generator.................................. 16-18

Electrical - Line Voltage.............................. 19-20

Electrical - Low Voltage Wiring................... 21-22

Accessory Connections....................................22

Electrical - Thermostat Wiring ..........................23

ECM Blower Control................................... 24-25

Blower Data......................................................26

CXM Controls...................................................27

Safety Features – CXM Control.................. 28-30

Unit Commissioning

And Operating Conditions ................................31

Unit Start-Up and Operating Conditions...........32

Unit Start-Up Procedure...................................32

Coax Pressure Drop Tables..............................34

Unit Operating Conditions .......................... 35-36

Performance Data ...................................... 37-41

Preventive Maintenance...................................42

Troubleshooting................................................43

CXM Process Flow Chart.................................44

Functional & Performance

Troubleshooting.......................................... 45-46

Troubleshooting Form ......................................47

Refrigerant Circuit Diagram..............................47

Revision History................................................48

Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller, Inc.

 WARNING! 

 CAUTION! 

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.

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.

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.

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.

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.

NOTICE: Notiﬁcation of installation, operation or maintenance

information, which is important, but which is not hazard-related.

Installation, Operation & Maintenance 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 ﬁfteen

(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

Installation, Operation, and Maintenance instructions are

provided with each unit. Horizontal equipment is designed for

installation above false ceiling or in a ceiling plenum. Other unit

conﬁgurations 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 (water-to-air units

only).

6. Loosen compressor bolts on units equipped with compressor

grommet vibration isolation until the compressor rides freely

on the grommets.

7. Locate and verify any hot water generator (HWG), hanger,

or other accessory kit located in the compressor section or

blower section.

CAUTION! DO NOT store or install units in corrosive

environments or in locations subject to temperature or

humidity extremes (e.g., attics, garages, 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! 

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.

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 heat pumps are typically suspended above a ceiling or

within a sofﬁt using ﬁeld supplied, threaded rods sized to support

the weight of the unit.

Use four (4) ﬁeld supplied threaded rods and factory provided

vibration isolators to suspend the unit. Hang the unit clear of the

ﬂoor slab above and support the unit by the mounting bracket

assemblies only. DO NOT attach the unit ﬂush with the ﬂoor slab

above.

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

the condensate drainage. On small units (less than 8.8kW) ensure

that unit pitch does not cause condensate leaks inside the

cabinet.

Drain

Connection

1/4” (6.4mm) pitch

per foot for drainage

Figure 1: Hanger Bracket

Figure 2: Horizontal Unit Pitch

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 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 Figure 3 for an

illustration of a typical installation. Refer to unit speciﬁcations

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 speciﬁc

series and model in unit speciﬁcations 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 ﬁttings.

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.

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Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller, Inc.

Horizontal Installation

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Figure 3: Typical Horizontal Unit Installation

Air Coil -

To obtain maximum performance, the air coil should be

cleaned before start-up. A10% solution of dishwasher detergent

and water is recommended for both sides of the coil. Athorough

water rinse should follow.

Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller, Inc.

Water

Connection End

Return Air

Remove Screws

Water

Connection End

Return Air

Rotate

Move to Side

Side Discharge

Return Air

Water

Connection End

Discharge Air

Drain

Back Discharge

Replace Screws

Water

Connection End

Supply Duct

Return Air

Water

Connection End

Drain

Return Air

Discharge Air

Side Discharge

Back Discharge

Field Conversion of Air Discharge

Figure 5: Right Return Side to Back

Figure 4: Left Return Side to Back

Overview -

Horizontal units can be ﬁeld converted between side

(straight) and back (end) discharge using the instructions below.

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.

Preparation - It is best to ﬁeld convert the unit on the ground

before hanging. If the unit is already hung it should be taken down

for the ﬁeld conversion.

Side to Back Discharge Conversion

Place unit in well lit area. Remove the screws as shown in

Figure 4 to free top panel and discharge panel.

2. Lift out the access panel and set aside. Lift and rotate the

discharge panel to the other position as shown, being careful

with the blower wiring.

Check blower wire routing and connections for tension or

contact with sheet metal edges. Reroute if necessary.

4. Check refrigerant tubing for contact with

other components.

5. Reinstall top panel and screws noting that the location for

some screws will have changed.

6. Manually spin the fan wheel to ensure that the wheel is not

rubbing or obstructed.

7. Replace access panels.

Back to Side Discharge Conversion - If the discharge is changed

from back to side, use above instruction noting that illustrations will

be reversed.

Left vs. Right Return - It is not possible to ﬁeld convert return air

between left or right return models due to the necessity of refrigera-

tion copper piping changes. However, the conversion process of

side to back or back to side discharge for either right or left return

conﬁguration is the same. In some cases, it may be possible to

rotate the entire unit 180 degrees if the return air connection needs

to be on the opposite side. Note that rotating the unit will move the

piping to the other end of the unit.

Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller, Inc.

ರ

ರ

* Some units include a painted drain connection.

Using a threaded pipe or similar device to clear

any excess paint accumulated inside this fitting

may ease final drain line installation.

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Figure 6: Horizontal Condensate Connection

Horizontal Installation

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.

Install condensate trap at each unit with the top of the trap

positioned below the unit condensate drain connection as shown

in Figure 6. Design the depth of the trap (water-seal) based

upon the amount of ESP capability of the blower (where 2 inches

[51mm] of ESP capability requires 2 inches [51mm] of trap depth).

As a general rule, 1-1/2 inch [38mm] trap depth is the minimum.

Each unit must be installed with its own individual trap and

connection to the condensate line (main) or riser. Provide a

means to ﬂush or blow out the condensate line. DO NOT install

units with a common trap and/or vent.

Always vent the condensate line when dirt or air can collect in

the line or a long horizontal drain line is required. Also vent when

large units are working against higher external static pressure

than other units connected to the same condensate main since

this may cause poor drainage for all units on the line. WHEN A

VENT IS INSTALLED IN THE DRAIN LINE, IT MUST BE LOCATED

AFTER THE TRAP IN THE DIRECTION OF THE CONDENSATE

FLOW.

 CAUTION! 

Duct System Installation

The duct system should be sized to handle the design airﬂow

quietly. Refer to Figure 3 for horizontal duct system details or

ﬁgure 8 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

speciﬁcations catalog for the series and model of 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.

DUCT SYSTEM INSTALLATION

ondensate Pipin

CAUTION! Ensure condensate line is pitched toward drain

1/8 inch per ft [11mm per m] of run.

Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller, Inc.

Vertical Installation

Figure 7: Vertical Unit Mounting

Figure 8: Typical Vertical Unit Installation Using Ducted

Return Air

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Flexible canvas duct

connector to reduce

noise and vibration

Use turning vanes in

supply transition

Internally insulate supply

duct for first 1.2 m each way

to reduce noise

Internally insulate return

transition duct to reduce

noise

Rounded return

transition

Rev.: 6/2/09S

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 7 and 8

for typical installation illustrations. Refer to unit speciﬁcations

catalog for dimensional data.

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” [10mm] to 1/2” [13mm] in thickness. Extend

the pad beyond all four edges of the unit.

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 speciﬁcations 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. Provide access to water valves and ﬁttings and screwdriver

access to the unit side panels, discharge collar and all

electrical connections.

Downﬂow units may be installed directly on the ﬂoor. The

optional internal electric heat is rated for zero clearance to

combustible materials.

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.

Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller, Inc.

Vertical Installation

Return

Air Inlet

Figure 9: Vertical Sound Attenuation ರ

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Using a threaded pipe or similar device to clear

any excess paint accumulated inside this fitting

may ease final drain line installation.

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Figure 10a: Vertical Condensate Drain

Figure 10b: Vertical Internal Condensate Trap

Condensate Piping for Vertical Units - Vertical units utilize a

condensate hose inside the cabinet as a trapping loop; therefore

an external trap is not necessary. Figure 10a shows typical

condensate connections. Figure 10b 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 ﬂush

or blow out the condensate drain line. Do not install units with a

common trap and/or vent.

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.

Mount the unit on an Unit Isolation Pad to minimize vibration

transmission to the building structure. For more information on

Unit Isolation Pads, contact your distributor.

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