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Summary of Contents for Heat Controller HP Series
- Page 1 INSTALLATION, OPERATION & MAINTENANCE MANUAL Residential Packaged Geothermal Heat Pump HP Series to 5 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
HP SerieS Installation, Operation & Maintenance Heat Controller, Inc. Table of Contents Model Nomenclature ....................2 Safety Instructions ....................3 Pre-Installation......................4 Physical Data......................5 Horizontal Unit Dimensions ................6-7 Vertical Unit Dimensions..................8-9 Horizontal Installation ..................10-13 Vertical Installation..................14-15 Water Connection Installation ................16 Ground-Loop Heat Pump Applications ............16-18 Ground-Water Heat Pump Applications ............18-19... -
Page 3: Model Nomenclature
4 5 6 TRH/TRV HPH/HPV 0 3 6 MODEL TYPE SUPPLY AIR OPTIONS HP = HEAT CONTROLLER RESIDENTIAL 410A B = BACK DISCHARGE, HORIZONTAL ONLY T = TOP DISCHARGE, VERTICAL ONLY S = STRAIGHT DISCHARGE, HORIZONTAL ONLY CONFIGURATION H = HORIZONTAL... -
Page 4: Safety Instructions
HP SerieS Installation, Operation & Maintenance Heat Controller, Inc. Safety CAUTION: Indicates a potentially hazardous situation or Warnings, cautions and notices appear throughout this an unsafe practice, which if not avoided could result in manual. Read these items carefully before attempting any minor or moderate injury or product or property damage. -
Page 5: Pre-Installation
If not filed within 15 days, the freight company this IOM. with the carrier. Notify Heat Controller of all damage within section. can deny the claim without recourse. Note: It is the 9. -
Page 6: Physical Data
HP SerieS Installation, Operation & Maintenance Heat Controller, Inc. Physical Data HP Series Compressor (1 Each) Rotary Scroll Factory Charge R410A (oz) PSC Fan Motor & Blower Fan Motor Type/Speeds PSC/3 PSC/3 PSC/3 PSC/3 PSC/3 PSC/3 PSC/3 Fan Motor (hp) -
Page 7: Horizontal Unit Dimensions
HP SerieS Heat Controller, Inc. Installation, Operation & Maintenance HP - Horizontal Dimensional Data Unit Hanger Detail Model 018-030 48.3[122.9] 24.6[59.7] 19.3[49.0] 036-042 53.3[135.4] 24.6[62.5] 19.3[49.0] 048-060 68.0[172.7] 27.6[70.1] 23.3[59.2] 7. Source water and optional HWG connections are 1” swivel... - Page 8 HP SerieS Installation, Operation & Maintenance Heat Controller, Inc. HP - Horizontal Dimensional Data Overall Cabinet Electrical Knockouts Horizontal Model Horizontal Width Length Height 1/2” 1/2” 3/4” Model 22.4 48.3 17.5 Power 56.9 122.7 44.5 Voltage Voltage Supply 024 - 22.4...
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Page 9: Vertical Unit Dimensions
HP SerieS Heat Controller, Inc. Installation, Operation & Maintenance HP - Vertical Upflow Dimensional Data Overall Cabinet Vertical uplflow Model Width Depth Height 22.4 22.4 40.5 018 - 030 56.9 56.9 102.9 22.4 25.4 46.5 036 - 042 56.9 64.5 118.1... - Page 10 HP SerieS Installation, Operation & Maintenance Heat Controller, Inc. HP - Vertical Upflow Dimensional Data Discharge Connection Return Connection Duct Flange Installed (+/- 0.10 in, +/- 2.5mm) Using Return Air Opening Vertical Model Supply Supply Return Return Width Depth Depth Height 14.0...
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Page 11: Horizontal Installation
HP SerieS Heat Controller, Inc. Installation, Operation & Maintenance HORIZONTAL INSTALLATION NOTICE! Failure to remove shipping brackets Mounting Horizontal Units Horizontal units have hanger kits pre-installed from the from spring-mounted compressors will cause factory as shown in figure 1. Figure 3 shows a typical excessive noise, and could cause component horizontal unit installation. - Page 12 HP SerieS Installation, Operation & Maintenance Heat Controller, Inc. HORIZONTAL INSTALLATION Figure 3: Typical Horizontal Unit Installation 3/8" [10mm] threaded rods (by others) Return Air Thermostat Stainless steel braid hose Wiring with integral "J" swivel Power Wiring Optional Balancing Valve...
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Page 13: Field Conversion Of Air Discharge
HP SerieS Heat Controller, Inc. Installation, Operation & Maintenance FIELD CONVERSION OF AIR DISCHARGE Figure 4: Left Return Side to Back Overview Horizontal units can be field converted between Remove Screws Water side (straight) and back (end) discharge using the Connection End instructions below. -
Page 14: Horizontal Installation
����������� too short to cause drainage problems. However, the HP SerieS Installation, Operation & Maintenance Heat Controller, Inc. in the direction of flow to insure that the connection will horizontal run of the condensate line should be pitched �������� ������������������... -
Page 15: Vertical Installation
HP SerieS Heat Controller, Inc. Installation, Operation & Maintenance 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 16: Vertical Installation
HP SerieS Installation, Operation & Maintenance Heat Controller, Inc. VERTICAL INSTALLATION Sound Attenuation for Vertical Units Condensate Piping – Vertical Units Sound attenuation is achieved by enclosing the unit Vertical units utilize a condensate hose inside the within a small mechanical room or a closet. Additional cabinet as a trapping loop;... -
Page 17: Water Connection Installation
HP SerieS Heat Controller, Inc. Installation, Operation & Maintenance WATER CONNECTION INSTALLATION External Flow Controller Mounting which holds the male pipe end against the rubber The Flow Controller can be mounted beside the unit gasket, and seals the joint. HAND TIGHTEN ONLY! DO as shown in Figure 12. - Page 18 HP SerieS Installation, Operation & Maintenance Heat Controller, Inc. GROUND-LOOP HEAT PUMP APPLICATIONS pressure is reached. Open the return valve and a temperature, the leaving loop temperature would be 25 to pressure surge will be sent through the loop to help 22°F [-4 to -6°C] and freeze protection should be at 15°F...
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Page 19: Ground-Water Heat Pump Applications
HP SerieS Heat Controller, Inc. Installation, Operation & Maintenance GROUND-LOOP HEAT PUMP APPLICATIONS Figure 12: Typical Ground-Loop Application Flow Controller Unit Power Disconnect Insulated Hose Kit Thermostat Wiring P/T Plugs Air Pad or Extruded polystyrene insulation board GROUND-WATER HEAT PUMP APPLICATIONS... - Page 20 HP SerieS Installation, Operation & Maintenance Heat Controller, Inc. GROUND-WATER HEAT PUMP APPLICATIONS Expansion Tank and Pump Flow Regulation Use a closed, bladder-type expansion tank to minimize Flow regulation can be accomplished by two methods. mineral formation due to air exposure. The expansion...
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Page 21: Water Quality Standards
HP SerieS Heat Controller, Inc. Installation, Operation & Maintenance WATER QUALITY STANDARDS Table 3: Water Quality Standards Water Quality Heat Closed Loop Open Loop and Recirculating Well Exchanger Parameter Recirculating Material Scaling Potential - Primary Measurement Above the given limits, scaling is likely to occur. Scaling indexes should be calculated using the limits below. -
Page 22: Hot Water Generator
HP SerieS Installation, Operation & Maintenance Heat Controller, Inc. Dual element electric water heaters are recommended. If a gas, propane, oil or electric water heater with a single element is used, a second preheat storage tank is recommended to insure a usuable entering water... - Page 23 HP SerieS Heat Controller, Inc. Installation, Operation & Maintenance SCALD VALVE AT THE HOT WATER STORAGE TANK WITH SUCH VALVE PROPERLY SET TO CONTROL WATER TEMPERATURES DISTRIBUTED TO ALL HOT WATER OUTLETS AT A TEMPERATURE LEVEL THAT PREVENTS SCALDING OR BURNS.
- Page 24 HP SerieS Installation, Operation & Maintenance Heat Controller, Inc. WARNING! The HWG pump is fully wired from the factory. Use extreme caution when working around the mircoprocessor control as it contains line voltage connections that presents a shock hazard that can cause severe injury or death!
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Page 25: Electrical Data
HP SerieS Heat Controller, Inc. Installation, Operation & Maintenance ELECTRICAL - LINE VOLTAGE Electrical - Line Voltage � WARNING! � All field installed wiring, including electrical ground, must comply with the National Electrical Code as well as all WARNING! To avoid possible injury or death applicable local codes. -
Page 26: Field Wiring
HP SerieS Installation, Operation & Maintenance Heat Controller, Inc. ELECTRICAL - POWER WIRING Blower Speed Selection Power Connection PSC (Permanent Split Capacitor) blower fan speed can Line voltage connection is made by connecting the be changed by moving the blue wire on the fan motor incoming line voltage wires to the “L”... - Page 27 HP SerieS Heat Controller, Inc. Installation, Operation & Maintenance ELECTRICAL - LOW VOLTAGE WIRING Thermostat Connections Low Water Temperature Cutout Selection The thermostat should be wired directly to the CXM The CXM control allows the field selection of low water board.
- Page 28 HP SerieS Installation, Operation & Maintenance Heat Controller, Inc. ELECTRICAL - LOW VOLTAGE WIRING Figure 24: Taco Series 500 Valve 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.
- Page 29 CXM. Practically thermostat may in certain cases need to be sealed to any heat pump thermostat will work with Heat Controller prevent erroneous temperature measurement. Position units, provided it has the correct number of heating and the thermostat back plate against the wall so that it cooling stages.
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Page 30: Blower Performance Data
HP SerieS Installation, Operation & Maintenance Heat Controller, Inc. Blower Performance Data Airflow (cfm) at External Static Pressure (in. wg) Rated Model Speed Airflow 0.00 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0.40 0.45 0.50 0.60 0.70 0.80 0.90 1.00... -
Page 31: Wiring Diagrams
HP SerieS Heat Controller, Inc. Installation, Operation & Maintenance Wiring Diagram... -
Page 32: Wiring Diagrams
HP SerieS Installation, Operation & Maintenance Heat Controller, Inc. Wiring Diagram... -
Page 33: Cxm Controls
HP SerieS Heat Controller, Inc. Installation, Operation & Maintenance CXM CONTROLS CXM Control DIP switch 3: Not Used. For detailed control information, see CXM Electronic Heat DIP switch 4: DDC Output at EH2 - provides selection for Pump Control Application, Operation and Maintenance DDC operation. - Page 34 HP SerieS Installation, Operation & Maintenance Heat Controller, Inc. CXM CONTROLS Safety Features – CXM Control compressor run cycle to be recognized as a FP2 fault. The safety features below are provided to protect The FP2 input is bypassed for the initial 60 seconds of a the compressor, heat exchangers, wiring and other compressor run cycle.
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Page 35: Cxm Controls
HP SerieS Heat Controller, Inc. Installation, Operation & Maintenance 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. - Page 36 HP SerieS Installation, Operation & Maintenance Heat Controller, Inc. Table 9a: Operating Limits HP Series Operating Limits Cooling Heating Air Limits Min. ambient air, DB 45°F [7°C] 39°F [4°C] Rated ambient air, DB 80.6° [27°C] 68° [20°C] Max. ambient air, DB 110°...
- Page 37 HP SerieS Heat Controller, Inc. Installation, Operation & Maintenance Starting/Commissioning Conditions Table 9b: Commissioning Limits HP Series Commissioning Limits Cooling Heating Air Limits Min. ambient air, DB 45°F [7°C] 39°F [4°C] Rated ambient air, DB 80.6° [27°C] 68° [20°C] Max. ambient air, DB 110°...
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Page 38: Unit Starting And Operating Conditions
HP SerieS Installation, Operation & Maintenance Heat Controller, Inc. UNIT STARTING AND OPERATING CONDITIONS Unit and System Checkout � System controls: Verify that system controls function BEFORE POWERING SYSTEM, please check the following: and operate in the proper sequence. � Low water temperature cutout: Verify that low water... - Page 39 HP SerieS Heat Controller, Inc. Installation, Operation & Maintenance UNIT START-UP PROCEDURE Note: Units have a five minute time delay in the compressor is operating. Air temperature rise should control circuit that can be eliminated on the CXM be between 20°F and 30°F [11°C and 17°C].
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Page 40: Unit Operating Conditions
OPERATING CONDITIONS HP SerieS Installation, Operation & Maintenance Heat Controller, Inc. Table 9: Water Temperature Change Through Unit Operating Conditions Heat Exchanger 0°F Table 9: Water Temperature Change Through Heat Exchanger ������������� ������������� ��������������������� ������� ������� ��������������������������������������������� ������ ����� �����������������������������������������... - Page 41 HP SerieS Heat Controller, Inc. Installation, Operation & Maintenance Unit Operating Conditions Table 13: HP Series Typical Unit Operating Pressures and Temperatures...
- Page 42 HP SerieS Installation, Operation & Maintenance Heat Controller, Inc. Unit Operating Conditions Table 13: HP Series Typical Unit Operating Pressures and Temperatures continued...
- Page 43 HP SerieS Heat Controller, Inc. Installation, Operation & Maintenance Unit Operating Conditions Table 13: HP Series Typical Unit Operating Pressures and Temperatures continued...
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Page 44: Preventive Maintenance
HP SerieS Installation, Operation & Maintenance Heat Controller, Inc. PREVENTIVE MAINTENANCE Water Coil Maintenance Condensate Drain (Direct ground water applications only) In areas where airborne bacteria may produce a “slimy” If the system is installed in an area with a known high substance in the drain pan, it may be necessary to treat mineral content (125 P.P.M. -
Page 45: Troubleshooting
HP SerieS Heat Controller, Inc. Installation, Operation & Maintenance TROUBLESHOOTING General Test Mode If operational difficulties are encountered, perform Test mode can be entered for 20 minutes by shorting the preliminary checks below before referring to the the test pins. The CXM board will automatically exit test troubleshooting charts. -
Page 46: Cxm Process Flow Chart
HP SerieS Installation, Operation & Maintenance Heat Controller, Inc. 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. -
Page 47: Functional Troubleshooting
HP SerieS Heat Controller, Inc. Installation, Operation & Maintenance FUNCTIONAL TROUBLESHOOTING Fault Htg Clg Possible Cause Solution Main power Problems Green Status LED Off Check Line Voltage circuit breaker and disconnect Check for line voltage between L1 and L2 on the contactor... -
Page 48: Performance Troubleshooting
HP SerieS Installation, Operation & Maintenance Heat Controller, Inc. FUNCTIONAL TROUBLESHOOTING Check G wiring at heat pump. Jumper G and R for fan Only Compressor Runs Thermostat wiring operation. Jumper G and R for fan operation. Check for Line voltage Fan motor relay across BR contacts. - Page 49 Packaged Unit Refrigeration Schematic Rev. 3/04 Customer: _____________________________________ Antifreeze: ________________________ HP SerieS Heat Controller, Inc. Installation, Operation & Maintenance Model#: ________________________ Serial#: ________________ Loop type: _______________ TROUBLESHOOTING FORM Complaint: ________________________________________________________________________ HEATING CYCLE ANALYSIS - °F SUCTION COIL °F °F COMPRESSOR...
- Page 50 03/2010 04/2009...
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