Heat Controller HTV Series Installation, Operation & Maintenance Manual
Htv/htd/hth series two-stage geothermal heat pumps 2 to 6 tons
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- Page 1 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.com...
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Page 2: Table Of Contents
Model Nomenclature – Two Stage Geothermal Heat Pump 4 5 6 0 2 4 0 1 A L K Supply Air Flow & Series Motor Configuration HT = Heat Controller Two Stage Supply Configuration Motor Down Configuration Back V = Vertical Up Flow... - Page 3 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 Warnings, cautions and notices appear throughout this manual. moderate injury or product or property damage.
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Page 4: Storage
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES General Information Inspection Locate and verify any hot water generator (HWG), hanger, Upon receipt of the equipment, carefully check the shipment or other accessory kit located in the compressor section or against the bill of lading. -
Page 5: General Information
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES General Information Mounting Horizontal Units Horizontal Unit Location Units are not designed for outdoor installation. Locate the unit in Horizontal units have hanger kits pre-installed from the factory an INDOOR area that allows enough space for service personnel as shown in Figure 1. -
Page 6: Horizontal Installation
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Horizontal Installation 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... -
Page 7: Field Conversion Of Air Discharge
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Field Conversion of Air Discharge Overview - Horizontal units can be fi eld converted between side Figure 4: Left Return Side to Back (straight) and back (end) discharge using the instructions below. -
Page 8: Duct System Installation
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. -
Page 9: Vertical Installation
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. -
Page 10: Series
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Vertical Installation Sound Attenuation for Vertical Units - Sound attenuation is Condensate Piping for Vertical Units - Vertical units utilize a achieved by enclosing the unit within a small mechanical room condensate hose inside the cabinet as a trapping loop;... -
Page 11: Water Connection Installation
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Water Connection Installation The female locking ring is threaded onto the pipe threads which External Flow Controller Mounting The Flow Controller can be mounted beside the unit as shown holds the male pipe end against the rubber gasket, and seals the in Figure 12. - Page 12 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 Low temperature protection should be maintained to 15°F [9°C] from the earth loop piping before operation. Flush the loop with a below the lowest expected entering loop temperature.
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Page 13: Open Loop - Ground Water Systems
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Ground-Loop Heat Pump Applications Table 2: Antifreeze Percentages by Volume Minimum Temperature for Low Temperature Protection Type 10°F 15°F 20°F 25°F [-12.2°C] [-9.4°C] [-6.7°C] [-3.9°C] Methanol Propylene Glycol Ethanol* * Must not be denatured with any petroleum based product... - Page 14 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 CAUTION! typically a brass fi tting with an orifi ce of rubber or plastic material that is designed to allow a specifi...
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Page 15: Water Quality Standards
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Water Quality Standards Table 3: Water Quality Standards Water Quality Closed Open Loop and Recirculating Well Parameter Material Recirculating 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 pH <... -
Page 16: Hot Water Generator
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Hot Water Generator The HWG (Hot Water Generator) or desuperheater option Electric water heaters are recommended. If a gas, propane, or provides considerable operating cost savings by utilizing excess oil water heater is used, a second preheat tank must be installed heat energy from the heat pump to help satisfy domestic hot (Figure 15). - Page 17 Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Hot Water Generator ANTI-SCALD Installation COLD WATER VALVE PIPING The HWG is controlled by two sensors and a microprocessor SUPPLY control. One sensor is located on the compressor discharge CONNECTIONS CHECK VALVE line to sense the discharge refrigerant temperature.
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Page 18: Series
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Hot Water Generator Warning! The HWG pump Is fully wired from the factory. Use insure maximum utilization of the heat available from the extreme caution when working around the microprocessor refrigeration system and conserve the most energy. On tanks... -
Page 19: Electrical - Line Voltage
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 CAUTION! Use only copper conductors for fi eld installed shock, open the power supply disconnect switch and secure it electrical wiring. -
Page 20: Electrical - Line Voltage
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Electrical - Line Voltage Figure 16: HT Single Phase Line Voltage WARNING! Field Wiring WARNING! Disconnect electrical power source to prevent injury or death from electrical shock. CAUTION! CAUTION! Use only copper conductors for fi eld installed electrical wiring. -
Page 21: Electrical - Low Voltage Wiring
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Electrical - Low Voltage Wiring Thermostat Connections Low Water Temperature Cutout Selection The thermostat should be wired directly to the CXM board The CXM control allows the eld selection of low water (or (units with PSC fan). -
Page 22: Accessory Connections
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Electrical - Low Voltage Wiring Accessory Connections Figure 23 illustrates piping for two-stage solenoid valves. Review A terminal paralleling the compressor contactor coil has been fi gures 20-22 for wiring of stage one valve. Stage two valve should provided on the CXM control. -
Page 23: Electrical - Thermostat Wiring
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Electrical - Thermostat Wiring Figure 24: Units With Optional ECM Fan. CAUTION! Connection to ECM Control CAUTION! Many units are installed with a factory or eld ATP32U04 Thermostat supplied manual or electric shut-off valve. DAMAGE... -
Page 24: Ecm Blower Control
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES ECM Blower Control The ECM fan is controlled by an interface board that converts operating in the normal mode, the cooling airfl ow settings thermostat inputs and fi eld selectable CFM settings to signals are determined by the cooling tap setting above. -
Page 25: Series
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES ECM Blower Control Table 5: ECM Board Tap Settings Cooling settings: TT, TS Units HT Units Heating settings: TT, TS Units HT Units Aux/Emerg Heat settings: TT, TS Units* HT Units... -
Page 26: Blower Data
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES HT Series ECM Blower Performance Data Residential Units Only Airfl ow in CFM with wet coil and clean air fi lter Dehumid Cooling Mode Heating Mode Aux/ Mode Model Motor Range... -
Page 27: Cxm Controls
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 NOTE: Some CXM controls only have a 2 position DIP switch and Maintenance (AOM) manual (part #97B0003N12). -
Page 28: Safety Features - Cxm Control
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES CXM Controls fault. The FP2 input is bypassed for the initial 120 seconds of a Safety Features – CXM Control compressor run cycle. FP2 is set at the factory for one try. Therefore, The safety features below are provided to protect the compressor, the control will go into lockout mode once the FP2 fault has occurred. - Page 29 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 fi rst time after power-up that there is a call for compressor, the compressor will follow a 5 to 80 second random start delay.
- Page 30 Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES CXM Controls Table 7: Nominal resistance at various temperatures CXM Thermostat Details Thermostat Compatibility - Most all heat pump thermostats can Resistance Resistance Temp (ºC) Temp (ºF) Temp (ºC) Temp (ºF) be used with the CXM control.
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Page 31: Unit Commissioning And Operating Conditions
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES 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). -
Page 32: Unit Start-Up And Operating Conditions
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Unit Start-Up and Operating Conditions Low water temperature cutout: Verify that low water Unit and System Checkout temperature cut-out controls are set properly BEFORE POWERING SYSTEM, please check the following: (FP1 - JW3). - Page 33 Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Unit Start-Up Procedure pressure drop across the heat exchanger versus the data WARNING! in Tables 9a through 9b. Heat of rejection (HR) can be calculated and compared to catalog data capacity pages.
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Page 34: Coax Pressure Drop Tables
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Unit Operating Conditions Table 9a: HT Coax Water Pressure Drop Pressure Drop (psi) Model 30°F 50°F 70°F 90°F 12.0 11.3 12.0 15.0 10.5 12.8 14.0 17.0 Table 10: Water Temperature Change Through Heat Exchanger... -
Page 35: Series
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Unit Operating Conditions Table 11: HT Series Typical Unit Operating Pressures and Temperatures HT024 TE026 Full Load Cooling - without HWG active Full Load Heating - without HWG active Entering Water... -
Page 36: Unit Operating Conditions
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 Full Load Cooling - without HWG active Full Load Heating - without HWG active Entering... -
Page 37: Performance Data
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Performance Data — HT 024 - Full Load 850 CFM Nominal (ISO Rated) Airfl ow Cooling, 950 CFM Nominal (ISO Rated) Airfl ow Heating Performance capacities shown in thousands of Btuh Cooling - EAT 80/67°F... - Page 38 Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Performance Data — HT 036 - Full Load 1250 CFM Nominal (ISO Rated) Airfl ow Cooling, 1250 CFM Nominal (ISO Rated) Airfl ow Heating Performance capacities shown in thousands of Btuh Cooling - EAT 80/67°F...
- Page 39 Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Performance Data — HT 048 - Full Load 1550 CFM Nominal (ISO Rated) Airfl ow Cooling, 1650 CFM Nominal (ISO Rated) Airfl ow Heating Performance capacities shown in thousands of Btuh Cooling - EAT 80/67°F...
- Page 40 Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Performance Data — HT 060 - Full Load 1825 CFM Nominal (ISO Rated) Airfl ow Cooling, 2050 CFM Nominal (ISO Rated) Airfl ow Heating Performance capacities shown in thousands of Btuh Cooling - EAT 80/67°F...
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Page 41: Performance Data
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Performance Data — HT 070 - Full Load 1950 CFM Nominal (Rated) Airfl ow Cooling, 2100 CFM Nominal (Rated) Airfl ow Heating Performance capacities shown in thousands of Btuh Cooling - EAT 80/67°F Heating - EAT 70°F... -
Page 42: Preventive Maintenance
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Preventive Maintenance months to minimize the problem. The condensate pan may also Water Coil Maintenance (Direct ground water applications only) - If the system is installed need to be cleaned periodically to insure indoor air quality. The in an area with a known high mineral content (125 P.P.M. -
Page 43: Troubleshooting
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Troubleshooting CXM Troubleshooting Process Flowchart/Functional General If operational diffi culties are encountered, perform the preliminary Troubleshooting Chart The “CXM Functional Troubleshooting Process Flowchart” checks below before referring to the troubleshooting charts. -
Page 44: Cxm Process Flow Chart
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. CXM Functional... -
Page 45: Functional & Performance Troubleshooting
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Functional Troubleshooting Fault Htg Clg Possible Cause Solution Check line voltage circuit breaker and disconnect. Check for line voltage between L1 and L2 on the contactor. Main power problems Green Status LED Off Check for 24VAC between R and C on CXM/DXM' Check primary/secondary voltage on transformer. -
Page 46: Series
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Performance Troubleshooting Performance Troubleshooting Htg Clg Possible Cause Solution Dirty fi lter Replace or clean. Check for dirty air fi lter and clean or replace. Reduced or no air fl ow in heating Check fan motor operation and airfl... -
Page 47: Troubleshooting Form
Installation, Operation & Maintenance Heat Controller, Inc. HTV/HTD/HTH SERIES Troubleshooting Form Look up pressure drop in I.O.M. or spec. catalog to determine flow rate. Look up pressure drop in I.O.M. or spec. catalog to determine flow rate. ________ Note: Never connect refrigerant gauges during startup procedures. Conduct water-side analysis using P/T ports to determine water fl... -
Page 48: Revision History
*97B00 97B00??????? 01-2013...