INSTALLATION, OPERATION & MAINTENANCE MANUAL Residential Packaged Geothermal Heat Pump HP Series 11/2 to 5 Tons Heat Controller, Inc. • 1900 Wellworth Ave. • Jackson, MI 49203 • (517)787-2100 • www.heatcontroller.
Installation, Operation & Maintenance HP Series Heat Controller, Inc. Table of Contents Model Nomenclature.............................................................................................2 Safety Instructions.................................................................................................3 Pre-Installation......................................................................................................4 Physical Data......................................................
HP Series Heat Controller, Inc.
Installation, Operation & Maintenance HP 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 INFORMATION HP 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.
HP Series Installation, Operation & Maintenance Heat Controller, Inc. Physical Data HP Series Compressor (1 Each) Factory Charge R410A (oz) 018 024 030 036 Rotary 042 048 060 Scroll 43 43 48 50 70 74 82 PSC/3 PSC Fan Motor & Blower Fan Motor Type/Speeds PSC/3 PSC/3 PSC/3 PSC/3 PSC/3 PSC/3 Fan Motor (hp) 1/6 1/4 3/4 1/2 3/4 3/4 1 Blower Wheel Size (Dia x w) 8x7 9x7 9x7 9x8 9x8 10x10 11x10 .45 .286 .323 .323 .890 .738 .939 20x17.25 20x17.25 20x17.
HP Series Heat Controller, Inc. Installation, Operation & Maintenance HP - Vertical Upflow Dimensional Data Overall Cabinet Vertical uplflow Model A Width B Depth C Height 018 - 030 in cm 22.4 56.9 22.4 56.9 40.5 102.9 036 - 042 in cm 22.4 56.9 25.4 64.5 46.5 118.1 048 - 060 in cm 25.4 64.5 29.1 73.9 50.5 128.3 Water Connections - Standard Units 1 Vertical Upflow Model 2 Loop In D Loop In E Loop Out F Loop Out E 3 4 5 Cond.
HP Series Installation, Operation & Maintenance Heat Controller, Inc. HP - Vertical Upflow Dimensional Data Discharge Connection Duct Flange Installed (+/- 0.10 in, +/- 2.5mm) Vertical Model Return Connection Using Return Air Opening M N O Supply Width P Supply Depth Q R S Return Depth T Return Height U 018 - 030 in cm 7.2 18.3 4.2 10.7 14.0 35.6 14.0 35.6 5.4 13.7 2.2 5.6 18.4 46.7 20.3 51.6 1.1 2.8 036 - 042 in cm 7.2 18.3 6.0 15.2 14.0 35.6 14.0 35.6 5.2 13.2 2.1 5.
Heat Controller, Inc. HP 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.
HP 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.
HP Series Heat Controller, Inc. Installation, Operation & Maintenance 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.
Installation, Operation & Maintenance HP Series Heat Controller, Inc. 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.
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 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.
Installation, Operation & Maintenance HP Series Heat Controller, Inc. 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.
HP Series Heat Controller, Inc. Installation, Operation & Maintenance 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.
Installation, Operation & Maintenance HP Series 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 temperature for the HWG.
Heat Controller, Inc. HP 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.
Installation, Operation & Maintenance HP Series ! 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! 17 Heat Controller, Inc.
HP Series Heat Controller, Inc. Installation, Operation & Maintenance ELECTRICAL - LINE VOLTAGE � WARNING! � WARNING! To avoid possible injury or death due to electrical shock, open the power supply disconnect switch and secure it in an open position during installation. � CAUTION! � CAUTION! Use only copper conductors for field installed electrical wiring. Unit terminals are not designed to accept other types of conductors.
HP Series Installation, Operation & Maintenance Heat Controller, Inc. 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.
HP Series Heat Controller, Inc. Installation, Operation & Maintenance ELECTRICAL - LOW VOLTAGE WIRING Thermostat Connections The thermostat should be wired directly to the CXM board. See “Electrical – Thermostat” for specific terminal connections. Low Water Temperature Cutout Selection The CXM control allows the field selection of low water (or water-antifreeze solution) temperature limit by clipping jumper JW3, which changes the sensing temperature associated with thermistor FP1.
HP Series Installation, Operation & Maintenance Heat Controller, Inc. 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 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.
Heat Controller, Inc. HP Series Installation, Operation & Maintenance ELECTRICAL - THERMOSTAT WIRING Thermostat Installation The thermostat should be located on an interior wall in a larger room, away from supply duct drafts. DO NOT locate the thermostat in areas subject to sunlight, drafts or on external walls. The wire access hole behind the thermostat may in certain cases need to be sealed to prevent erroneous temperature measurement.
HP Series Installation, Operation & Maintenance Heat Controller, Inc. Blower Performance Data Model Fan Speed Rated Airflow Min CFM Airflow (cfm) at External Static Pressure (in. wg) 0.00 0.05 HI HPV018 MED 600 450 LOW 0.10 0.15 0.20 0.25 0.30 0.35 0.40 0.45 0.50 0.
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Installation, Operation & Maintenance HP Series Wiring Diagram 25 Heat Controller, Inc.
HP Series Heat Controller, Inc. Installation, Operation & Maintenance CXM CONTROLS CXM Control For detailed control information, see CXM Electronic Heat Pump Control Application, Operation and Maintenance Guide. Field Selectable Inputs Test mode: Test mode allows the service technician to check the operation of the control in a timely manner. By momentarily shorting the test terminals, the CXM control enters a 20 minute test mode period in which all time delays are sped up 15 times.
Installation, Operation & Maintenance HP Series Heat Controller, Inc. CXM CONTROLS Safety Features – CXM Control The safety features below are provided to protect the compressor, heat exchangers, wiring and other components from damage caused by operation outside of design conditions. Anti-short cycle protection: The control features a 5 minute anti-short cycle protection for the compressor. Note: The 5 minute anti-short cycle also occurs at power up.
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. The first time after power-up that there is a call for compressor, the compressor will follow a 5 to 80 second random start delay.
HP Series Installation, Operation & Maintenance Table 9a: Operating Limits Operating 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 HP Series Heating 45°F [7°C] 80.6° [27°C] 110° [43°C] 65/50°F [18/10°C] 80.6/66.2°F [27/19°C] 95/75°F [35/24°C] 39°F [4°C] 68° [20°C] 85° [29°C] 45°F [7.
HP 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 HP 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 HP Series Heat Controller, Inc. UNIT STARTING AND OPERATING CONDITIONS Unit and System Checkout BEFORE POWERING SYSTEM, please check the following: UNIT CHECKOUT � Balancing/shutoff valves: Insure that all isolation valves are open and water control valves are wired. � Line voltage and wiring: Verify that voltage is within an acceptable range for the unit and wiring and fuses/ breakers are properly sized. Verify that low voltage wiring is complete.
Heat Controller, Inc. HP 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.
OPERATING CONDITIONS 0°F .5 .7 .4 0.7 .6 .4 .6 2.7 .2 .0 .2 .1 .9 .7 .8 .6 .2 .3 .7 .1 .7 .2 .2 .5 .9 .9 0.4 6.1 .2 .5 .1 HP Series Installation, Operation & Maintenance Heat Controller, Inc.
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Installation, Operation & Maintenance HP Series Unit Operating Conditions Table 13: HP Series Typical Unit Operating Pressures and Temperatures continued 35 Heat Controller, Inc.
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Installation, Operation & Maintenance HP Series Heat Controller, Inc. 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.
Heat Controller, Inc. HP Series Installation, Operation & Maintenance 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. After completing the preliminary checks described above, inspect for other obvious problems such as leaking connections, broken or disconnected wires, etc.
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.
HP Series Heat Controller, Inc.
HP Series Installation, Operation & Maintenance Heat Controller, Inc. FUNCTIONAL TROUBLESHOOTING Only Compressor Runs X X Thermostat wiring Check G wiring at heat pump. Jumper G and R for fan operation. X X Fan motor relay Jumper G and R for fan operation. Check for Line voltage across BR contacts.
Packaged Unit Refrigeration Schematic Rev. 3/04 Customer: _____________________________________ Antifreeze: ________________________ Heat Controller, Inc.
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