INSTALLATION, OPERATION & MAINTENANCE MANUAL Residential Packaged Geothermal Heat Pump HEV/H Series 2 to 5 Tons Heat Controller, Inc. • 1900 Wellworth Ave. • Jackson, MI 49203 • (517)787-2100 • www.heatcontroller.
Installation, Operation & Maintenance HEV/H SERIES Heat Controller, Inc. Table of Contents Model Nomenclature.............................................................................................3 Safety Instructions.................................................................................................4 Pre-Installation......................................................................................................5 Physical Data.....................................................
HEV/H SERIES Heat Controller, Inc.
Installation, Operation & Maintenance HEV/H SERIES Safety Warnings, cautions and notices appear throughout this manual. Read these items carefully before attempting any installation, service or troubleshooting of the equipment. Heat Controller, Inc. 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.
Heat Controller, Inc. GENERAL HEV/HINFORMATION SERIES Installation, Operation & Maintenance Inspection 6. Loosen compressor bolts on units equipped with Upon receipt of the equipment, carefully check the shipmentINFORMATION compressor spring vibration isolation until the GENERAL against the bill of lading. Make sure all units have been compressor rides freely on the springs. Remove Inspection 6. shipping Loosen compressor received. Inspect the packaging of each unit, and inspect restraints.
HEV/H SERIES Installation, Operation & Maintenance Heat Controller, Inc. Physical Data Model 024 030 Compressor (1 Each) Factory Charge HFC-410a, oz [kg] 036 042 048 060 84 Copeland UltraTech Two-Stage Scroll 49 48 48 70 80 1/2 [373] 1/2 [373] 1/2 [373] 3/4 [559] 3/4 [559] 1 [746] 9x7 [229 x 178] 9x7 [229 x 178] 9x8 [229 x 203] 9x8 [229 x 203] 10 x 10 [254 x 254] 11 x 10 [279 x 254] 1” 1” 1” 1” 1” 1” 1” 1” 1” 1” 1” 1” Air Coil Dimensions (H x W), in [mm] 20 x 17.
HEV/H SERIES Heat Controller, Inc. Installation, Operation & Maintenance HE - Vertical Upflow Dimensional Data Overall Cabinet Vertical Upflow Model A Width B Depth C Height 024-030 in cm 22.4 56.9 22.4 56.9 40.5 102.9 036-042 in cm 22.4 56.9 26.0 66.0 46.5 118.1 048 -060 in cm 25.4 64.5 29.3 74.4 50.5 128.3 Water Connections - Standard Units Vertical Upflow Model 1 2 3 4 5 D Loop In E Loop Out Cond. HWG In HWG Out F G H Loop Water FPT HWG FPT 024 - 030 in cm 3.8 9.
HEV/H SERIES Installation, Operation & Maintenance Heat Controller, Inc. HE - Vertical Upflow Dimensional Data Return Connection Standard Deluxe Filter Frame (+/- 0.10 in, +/- 2.5mm) Discharge Connection Duct Flange Installed (+/- 0.10 in, +/- 2.5mm) Vertical Upflow Model M Left Return N O Supply Width P Supply Depth Q Right Return R S Return Depth T Return Height U 024 - 030 in cm 7.4 18.8 4.2 10.7 13.9 35.3 14.0 35.6 6.7 17.0 2.2 5.6 18.0 45.7 18.0 45.7 1.0 2.
Heat Controller, Inc. HEV/H SERIES 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. Vertical units are typically installed in a mechanical room or closet.
HEV/H SERIES Installation, Operation & Maintenance 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.
Heat Controller, Inc. HEV/H SERIES Installation, Operation & Maintenance VERTICAL 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. Horizontal units are typically installed above a false ceiling or in a ceiling plenum.
HEV/H SERIES Installation, Operation & Maintenance Heat Controller, Inc.
Heat Controller, Inc. HEV/H SERIES Installation, Operation & Maintenance FIELD CONVERSION OF AIR DISCHARGE Overview - Horizontal units can be field converted between side (straight) and back (end) discharge using the instructions below. Figure 8: 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 HEV/H SERIES Heat Controller, Inc. WATER CONNECTION INSTALLATION 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. which holds the male pipe end against the rubber gasket, and seals the joint.
HEV/H SERIES Heat Controller, Inc. Installation, Operation & Maintenance GROUND-LOOP HEAT PUMP APPLICATIONS pressure is reached. Open the return valve and a pressure surge will be sent through the loop to help purge air pockets from the piping system. 4. Notice the drop in fluid level in the flush cart tank when the return valve is shut off. If air is adequately purged from the system, the level will drop only 1-2 inches (2.5 - 5 cm) in a 10” (25 cm) diameter PVC flush tank (about a half gallon [2.
HEV/H SERIES Installation, Operation & Maintenance Heat Controller, Inc. 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 Open Loop - Ground Water Systems Typical open loop piping is shown in Figure 13. 14. Shut off valves should be included for ease of servicing.
HEV/H SERIES Heat Controller, Inc. Installation, Operation & Maintenance GROUND-WATER HEAT PUMP APPLICATIONS Flow Regulation Flow regulation can be accomplished by two methods. One method of flow regulation involves simply adjusting the ball valve or water control valve on the discharge line. Measure the pressure drop through the unit heat exchanger, and determine flow rate from Table Tables10C. 8. Since Since the pressure is constantly varying, two pressure gauges may be needed.
HEV/H SERIES Installation, Operation & Maintenance Heat Controller, Inc. WATER QUALITY STANDARDS Table 3: Water Quality Standards Water Quality Parameter Heat Exchanger Material Closed Loop 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 All - pH < 7.
Heat Controller, Inc. HEV/H SERIES Installation, Operation & Maintenance 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 temperature for the HWG.
Installation, Operation & Maintenance HEV/H SERIES 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. 20 Heat Controller, Inc.
HEV/H SERIES Heat Controller, Inc. ! WARNING! ! The HWG pump is fully wired from the factory.
HEV/H SERIES Installation, Operation & Maintenance Heat Controller, Inc. ELECTRICAL - LINE VOLTAGE Electrical - Line Voltage All field installed wiring, including electrical ground, must comply with the National Electrical Code as well as all applicable local codes. Refer to the unit electrical data for fuse sizes. Consult wiring diagram for field connections that must be made by the installing (or electrical) contractor.
HEV/H SERIES Heat Controller, Inc. Installation, Operation & Maintenance ELECTRICAL - POWER WIRING Power Connection Line voltage connection is made by connecting the incoming line voltage wires to the “L” side of the contactor as shown in Figures 18. Consult Table 4 for correct fuse size. 208 Volt Operation All residential 208-230 Volt units are factory wired for 230 Volt operation.
HEV/H SERIES Installation, Operation & Maintenance Heat Controller, Inc.
HEV/H SERIES Heat Controller, Inc. Installation, Operation & Maintenance ELECTRICAL - LOW VOLTAGE WIRING C Y1 Figure 24: Taco Series 500 Valve Wiring Accessory Connections A terminal paralleling the compressor contactor coil has been provided on the DXM2 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.
HEV/H SERIES Installation, Operation & Maintenance Heat Controller, Inc. ELECTRICAL - THERMOSTAT WIRING Thermostat Installation Thermostat Installation The thermostat shouldshould be located on an interior in awall in The thermostat be located on an wall interior largeraroom, away from supply duct drafts. DO NOT locate larger room, away from supply duct drafts. DO NOT the thermostat in areas subject to sunlight, drafts or on locate the thermostat in areas subject to sunlight, drafts external walls.
Heat Controller, Inc. HEV/H SERIES Installation, Operation & Maintenance ECM BLOWER CONTROL The ECM fan is controlled directly by the DXM2 control board that converts thermostat inputs and CFM settings to signals used by the ECM motor controller. To take full advantage of the ECM motor features, a communicating or conventional multi-stage thermostat should be used (2-stage heat/2-stage cool or 3-stage heat/2-stage cool). rpm at blower start up. This creates a much quieter blower start cycle.
HEV/H SERIES Installation, Operation & Maintenance Heat Controller, Inc. BLOWER PERFORMANCE DATA Table 6: ECM Blower Performance Data Table Residential Units Only Airflow in CFM with wet coil and clean air filter Model 024 030 036 042 048 060 Max ESP (in. wg) 0.75 0.5 0.6 0.6 0.75 0.
HEV/H SERIES Heat Controller, Inc.
Installation, Operation & Maintenance HEV/H SERIES Heat Controller, Inc. DXM2 CONTROLS DXM2 Control - For detailed control information, see DXM2 Application, Operation and Maintenance (AOM) manual. On = Stage 1. Off = Stage 2. 1.3 - Thermostat type (heat pump or heat/cool): DIP 1.3 provides selection of thermostat type. Heat pump or heat/ cool thermostats can be selected.
HEV/H SERIES Heat Controller, Inc. Installation, Operation & Maintenance DXM2 CONTROLS 2.4 - Accessory2 relay personality: DIP 2.4 provides selection of ACC 2 relay personality (relay operation/characteristics). See Table 7a for description of functionality. 2.5 - Accessory2 relay personality: DIP 2.5 provides selection of ACC 2 relay personality (relay operation/characteristics). See Table 7a for description of functionality. 2.6 - Accessory2 relay personality: DIP 2.
HEV/H SERIES Installation, Operation & Maintenance Heat Controller, Inc. DXM2 CONTROLS 5" DXM2 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 compressorP1 will follow a 5 to 80 second random start delay.
HEV/H SERIES Heat Controller, Inc. Installation, Operation & Maintenance DXM2 CONTROLS Table 8: Nominal resistance at various temperatures Temp (°C) Temp (°F) Resistance (kOhm) Temp (°C) Temp (°F) DXM2 Thermostat Details Thermostat Compatibility – Most heat pump and heat/cool thermostats can be used with the DXM2, as well as ClimateMaster communicating thermostats. Resistance (kOhm) Anticipation Leakage Current – Maximum leakage current for “Y1” is 50 mA and for “W” is 20mA.
HEV/H SERIES Installation, Operation & Maintenance 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 – Voltage utilization shall comply with AHRI standard 110, voltage range A.
HEV/H SERIES Heat Controller, Inc. Starting/Commissioning Conditions Table 9b: Commissioning Limits Commissioning Limits Air Limits Min. ambient air, DB Rated ambient air, DB Max. ambient air, DB Min. entering air, DB/WB Rated entering air, DB/WB Max. entering air, DB/WB Water Limits Min. entering water Normal entering water Max. entering water Normal Water Flow Cooling HE Series Heating 45°F [7°C] 80.6° [27°C] 110° [43°C] 50/45°F [10/7°C] 80.6/66.
Installation, Operation & Maintenance HEV/H SERIES Heat Controller, Inc. UNIT START-UP AND OPERATING CONDITIONS Unit and System Checkout BEFORE POWERING SYSTEM, please check the following: operate in the proper sequence. � Low water temperature cutout: Verify that low water temperature cut-out controls are set properly (LT1 - JW3). � Miscellaneous: Note any questionable aspects of the installation. UNIT CHECKOUT � Shutoff valves: Insure that all isolation valves are open.
Heat Controller, Inc. HEV/H SERIES Installation, Operation & Maintenance UNIT START-UP PROCEDURE Note: Units have a five minute time delay in the control circuit that can be eliminated on the CXM control board as shown below in Figure 30. See controls description for details. c. Verify that the compressor is on and that the water flow rate is correct by measuring pressure drop through the heat exchanger using the P/T plugs and comparing to Table 10C. 8. d.
HEV/H SERIES Installation, Operation & Maintenance Heat Controller, Inc. UNIT OPERATING CONDITIONS Table 10: HE Coax Water Pressure Drop Model GPM Table 11: Water Temperature Change Through Heat Exchanger Pressure Drop (psi) 30°F 50°F 70°F 90°F 024 3.0 4.5 6.0 3.7 6.1 12.8 2.4 4.3 10.0 1.9 3.4 8.6 1.8 3.2 8.0 030 3.8 5.6 7.5 1.5 3.1 4.7 1.1 2.3 3.5 1.0 2.0 3.0 0.9 1.9 2.8 036 4.5 6.8 9.0 2.6 4.1 7.6 1.2 2.5 5.7 0.8 2.0 4.8 0.8 1.9 4.3 042 5.3 7.9 10.5 2.5 4.9 7.3 1.7 3.7 5.
HEV/H SERIES Heat Controller, Inc. Installation, Operation & Maintenance UNIT OPERATING CONDITIONS Table 13: HE Series Typical Unit Operating Pressures and Temperatures 024 Full Load Cooling - without HWG active Entering Water Temp °F Water Flow GPM/ton 30* 1.5 2.25 3 50 70 90 110 Suction Pressure PSIG Discharge Pressure PSIG Superheat Subcooling Water Temp Drop °F Full Load Heating - without HWG active Air Temp Drop °F DB 1.5 2.25 3 1.5 2.25 3 1.5 2.
HEV/H SERIES Installation, Operation & Maintenance Heat Controller, Inc. UNIT OPERATING CONDITIONS Table 13: HE Series Typical Unit Operating Pressures and Temperatures: Continued 042 Full Load Cooling - without HWG active Entering Water Temp °F Water Flow GPM/ton Suction Pressure PSIG Discharge Pressure PSIG 30* 1.5 2.25 3 50 1.5 2.25 3 121-131 120-130 120-130 230-250 200-240 164-184 10-15 11-16 11-16 10-15 8-13 6-11 20.5-22.5 15.2-17.2 9.8-11.8 70 1.5 2.
Heat Controller, Inc. HEV/H SERIES Installation, Operation & Maintenance PREVENTIVE MAINTENANCE Water Coil Maintenance (Direct ground water applications only) If the system is installed in an area with a known high mineral content (125 P.P.M. or greater) in the water, it is best to establish a periodic maintenance schedule with the owner so the coil can be checked regularly. Consult the well water applications section of this manual for a more detailed water coil material selection.
Installation, Operation & Maintenance HEV/H SERIES Heat Controller, Inc. TROUBLESHOOTING General If operational difficulties are encountered, perform the preliminary checks below before referring to the troubleshooting charts. • Verify that the unit is receiving electrical supply power. • Make sure the fuses in the fused disconnect switches are intact.
HEV/H SERIES Heat Controller, Inc. Installation, Operation & Maintenance DXM2 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.
HEV/H SERIES Installation, Operation & Maintenance FUNCTIONAL TROUBLESHOOTING Fault Main Power Problems HPWS LP/LOC Fault-Code 3 Low Pressure/Loss of Charge LT1 Fault - Code 4 Water Low Temperature Htg Clg Possible Cause X Green status LED off X Reduced or no water flow in cooling X Water t emperature out of range in Bring water temp within design parameters cooling Reduced or no air flow in heating X Air t emperature out of range in heating Bring return air temp within design parameters X
Incorrect blower selection Low Air Coil Pressure Fault (ClimaDry) Code 11 X Check for dirty air filter and clean or replace Reduced or no air flow in cooling Check fan motor operation and airflow restrictions or ClimaDry Too high of external static - check static vs blower table Too much cold vent air - bring entering air temp within Air temperature out of range design parameters HEV/H SERIES Heat Controller, Inc.
Packaged Unit Refrigeration Schematic Rev. 3/04 _____________________________________ Antifreeze: ________________________ Installation, Customer: Operation & Maintenance HEV/H SERIES Heat Controller, Inc.
Heat Controller, Inc.
