Heat Controller HEV/H manual

Heat Controller , Inc. • 1900 Wellworth A ve. • Jackson, MI 49203 • (517)787-2100 • www .heatcontroller .com INST ALLA TION, OPERA TION & MAINTEN ANCE MANU AL Residential Packaged Geothermal Heat Pump HEV/H Series 2 to 5 T ons[...]

2 Installation, Operation & Maintenance HEV/H SERIES Heat Controller , Inc. Model Nomenclature ............................................................................................ 3 Safety Instructions ................................................................................................ 4 Pre-Installation.....................[...]

3 Heat Controller , Inc. HEV/H SERIES Installation, Operation & Maintenance UNIT NOMENCLA TURE DENTIAL CLASS UNITS COME ST ANDARD w/75 V A TRANSFORMER NLESS STEEL DRAIN P AN, LOOP PUMP , HWG CONNECTIONS, MOTOR, AND TWO STAGE SCROLL COMPRESSORS. S ARE P AINTED POLAR ICE. s HEV ch T able HEH HeatController H E H B 0 3 6 D 1 0 0 A L B 1 2 3 4 5 6 [...]

4 Installation, Operation & Maintenance HEV/H SERIES Heat Controller , Inc. W ARNING! V erify refrigerant type before proceeding. Units are shipped with R-22 refrigerant. W ARNING! T o av oid the release of refrigerant into the atmosphere, the refrigerant circuit of this unit must be ser viced only b y technicians who meet local, state, and f e[...]

5 Heat Controller , Inc. HEV/H SERIES Installation, Operation & Maintenance GENERAL INFORMA TION Inspection Upon receipt of the equipment, carefully check the shipment against the bill of lading. Make sure all units ha ve been received. Inspect the packaging of each unit, and inspect each unit f or damage. Insure that the carr ier mak es proper[...]

6 Installation, Operation & Maintenance HEV/H SERIES Heat Controller , Inc. PHYSICAL DA T A Model 024 030 036 042 048 060 Compressor (1 Each) Copeland UltraT ech T wo-Stage Scroll Factory Charge HFC-410a, oz 51 48 54 70 80 84 ECM Fan Motor & Blower Fan Motor , hp [W] 1/2 [373] 1/2 [373] 1/2 [373] 3/4 [559] 3/4 [559] 1 [746] Blower Wheel Siz[...]

7 Heat Controller , Inc. HEV/H SERIES Installation, Operation & Maintenance Notes: 1. While clear access to all removable panels is not required, installer should take care to comply with all building codes and allow adequate clearance for future fi eld service. 2. Front & Side access is preferred for service access. However , all componen[...]

8 Installation, Operation & Maintenance HEV/H SERIES Heat Controller , Inc. HE - VERTICAL UPFLOW DIMENSIONAL DA T A Residential Filter Rack Shown Access Panels T op View-Left Return U R S Isometric View Left Return Left View - Air Coil Opening T C Power Supply 3/4" [19.1 mm] HV Knockout Low V oltage 1/2" [12.7 mm] L V Knockout Low V o[...]

9 Heat Controller , Inc. HEV/H SERIES Installation, Operation & Maintenance VER TICAL INST ALLA TION Flexib le canvas duct connector to reduce noise and vibration Use turning vanes in supply transition Internally insulate supply duct for first 4’ [1.2m] each way to reduce noise Internally insulate retur n transition duct to reduce noise Round[...]

10 Installation, Operation & Maintenance HEV/H SERIES Heat Controller , Inc. VER TICAL I N Sound Attenuation f or V ertical Units Sound attenuation is achie ved b y enclosing the unit within a small mechanical room or a closet. Additional measures f or sound control include the f ollowing: 1. Mount the unit so that the return air inlet is 90° [...]

11 Heat Controller , Inc. HEV/H SERIES Installation, Operation & Maintenance VERTICAL INST ALLA TION Drain Connection 1/4” (6.4mm) pi per foot for drai Figure 5: Hanger Bracket Figure 6: Horizontal Unit Pitch >PP@7KUHDGHG 5RGERWKHUV 9LEUDWLRQ,VRODWRU IDFWRUVXSSOLHG : DVKHU ERWKHUV[...]

12 Installation, Operation & Maintenance HEV/H SERIES Heat Controller , Inc. HORIZONT AL INST ALLA TION (by others) (by others) Thermostat Wiring Water In Water Out Ball V alves Unit Power Disconnect Power Wiring Insulated supply duct with at least one 90 deg elbow to reduce air noise Return Air Supply Air Unit Hanger 3/8" [10mm] threaded [...]

13 Heat Controller , Inc. HEV/H SERIES Installation, Operation & Maintenance 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 Wat er Connection End Supply Duct Return Air Wat er Connection End Drain R[...]

14 Installation, Operation & Maintenance HEV/H SERIES Heat Controller , Inc. W A TER CONNECTION INST ALLA TION External Flow Contr oller Mounting The Flow Controller can be mounted beside the unit as shown in Figure 12. Review the Flo w Controller installation manual f or more details. W ater Connections-Residential HR Models Models utilize s w[...]

15 Heat Controller , Inc. HEV/H SERIES Installation, Operation & Maintenance GR OUND-LOOP HEA T PUMP APPLICA TIONS T ab le 3. Antifreez e P ercentages by V olume T ype Minimum T emperature f or F reeze Protection 10°F [-12.2 °C] 15°F [-9.4 °C] 20°F [-6.7 °C] 25°F [-3.9 °C] Methanol 25% 21% 16% 10% 100% USP f ood grade Prop ylene Glycol [...]

16 Installation, Operation & Maintenance HEV/H SERIES Heat Controller , Inc. Un i t Power D i sconnect Flow Controller Insulated Hose K i t P/T Plugs Thermostat W i r i ng A i r Pad or Extruded polystyrene i nsulat i on board Figure 12: T ypical Ground-Loop Application GR OUND-LOOP HEA T PUMP APPLICA TIONS GR OUND-W A TER HEA T PUMP APPLICA TIO[...]

17 Heat Controller , Inc. HEV/H SERIES Installation, Operation & Maintenance A i r P ad or Extruded polystyrene i nsulat i on board Un i t P ower D i sconnect Thermostat W i r i ng Pressure T ank Shut-Off V alve Bo i ler Dra i ns Flow Regulator W ater In W ater Out W ater Control V alve Opt i onal F i lter P/T Plugs Expansion T ank and Pump Use[...]

18 Installation, Operation & Maintenance HEV/H SERIES Heat Controller , Inc. W A TER QU ALITY ST AND ARDS T able 3: W ater Quality Standards W ater Quality Parameter HX Material Closed Recir culating Open Loop and Recir culating Well Scaling Potential - Primary Measurement pH/Calcium Har dness All - pH < 7.5 and Ca Har dness <100ppm Metho[...]

19 Heat Controller , Inc. HEV/H SERIES Installation, Operation & Maintenance HOT W A TER GENERA TOR Insulated water lines - 5/8” OD, 50 ft maximum (one way) [16mm OD, 15 meters maximum] Upper element to 130°F [54°C] (or owner preference) Cold Inlet Hot Outlet to house Powered Water Heater Cold Inlet from Domestic supply Hot Outlet Unpowered[...]

20 Installation, Operation & Maintenance HEV/H SERIES Heat Controller , Inc. HOT W A TER GENERA TOR The micropr ocessor control monitors the refrigerant and water temperatures to determine when to operate the HWG. The HWG will operate any time the refrigerant temperatur e is suf fi ciently above the water temperature. Once the HWG has satis ?[...]

21 Heat Controller , Inc. HEV/H SERIES Installation, Operation & Maintenance HOT W A TER GENERA TOR The heat pump, water piping, pump, and hot water tank should be located where the ambient temperatur e does not fall below 50°F [10°C]. Keep water piping lengths at a minimum. DO NOT use a one way length greater than 50 ft. (one way) [15 m]. Se[...]

22 Installation, Operation & Maintenance HEV/H SERIES Heat Controller , Inc. Electrical Data - ELECTRICAL - LINE V OL T A GE W ARNING! T o av oid possible injur y or death due to electrical shock, open the pow er supply disconnect s witch and secure it in an open position during installation. CA UTION! Use only copper conductors f or field ins[...]

23 Heat Controller , Inc. HEV/H SERIES Installation, Operation & Maintenance ELECTRICAL - PO WER WIRING Figure 18: HR Single Phase Line V oltage Field Wiring Tran s former CXM Control Contactor -CC BR Low Voltage Connector CB L2 L1 Un i t Power Supply See electr i cal table for breaker s i ze Grnd Capacitor P ower Connection Line voltage connec[...]

24 Installation, Operation & Maintenance HEV/H SERIES Heat Controller , Inc. ELECTRICAL - L O Figure 21: Low V oltage Field Wiring Thermostat Connections The thermostat should be wired directly to the CXM board. See “Electr ical – Thermostat” f or specific ter minal connections. Rev .: 3/24/00 BR Contactor - CC Capacitator Loop PB1 HWG P[...]

25 Heat Controller , Inc. HEV/H SERIES Installation, Operation & Maintenance ELECTRICAL - LO W V OL T A GE WIRING U fsnjobm!Tusjq U zqjdbm X bufs W bmwf D B 35W BD Figure 23: Accessory Wiring Figure 24: T aco Series 500 V alve Wiring C C Thermostat Y1 1 2 3 Y1 AV M T aco V alve Heater Switch Figure 25: T aco ESP V alve Wiring Accessory Connecti[...]

26 Installation, Operation & Maintenance HEV/H SERIES Heat Controller , Inc. ELECTRICAL - THERMOST A T WIRING Figure 24: T ypical Thermostat 2 Heat/1 Cool Thermostat Installation The thermostat should be located on an interior wall in a lar ger room, away fr om supply duct drafts. DO NOT locate the thermostat in areas subject to sunlight, draft[...]

27 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 . T o take full advantage of the ECM motor features, a communicating multi-stage thermostat shou[...]

28 Installation, Operation & Maintenance HEV/H SERIES Heat Controller , Inc. T able 6: ECM Blower Performance Data T able Air fl ow in CFM with wet coil and clean air fi lter Model Max ESP (in. wg) Fan Motor (hp) Range Cooling Mode Dehumid Mode Heating Mode Fan Only Mode Aux/ Emerg Mode Stg 2 Stg 1 Stg 2 Stg 1 Stg 2 Stg 1 024 0.75 1/2 Default[...]

29 Heat Controller , Inc. HEV/H SERIES Installation, Operation & Maintenance WIRING DIAGRAM Communicating T -stat, 3Heat/2 cool t-stat and 2Heat/1 Cool T -stat HG[...]

30 Installation, Operation & Maintenance HEV/H SERIES Heat Controller , Inc. DXM2 Control DXM2 is the next generation in controls is capable of 2-way communication between itself and smart components, like the communicating thermostat, fan motor and con fi guration/ diagnostic tool. For most residential applications, con fi guration, monitori[...]

31 Heat Controller , Inc. HEV/H SERIES Installation, Operation & Maintenance DXM2 LA YOUT AND CONNECTIONS P1 Alarm Relay Comp Relay O Y1 Y2 W G C R AL1 24Vdc EH1 EH2 P6 R C Off On JW3 A OVR ESD C R NSB AL2 JW1 Acc1 Relay Acc2 Relay H COM1 NC1 NO1 COM2 NC2 NO2 P3 CO RV RV LT1 LT1 LT2 LT2 LP LP HP HP P7 Status Fault R R CC CCG CO S1 S2 1 12 1 4 e[...]

32 Installation, Operation & Maintenance HEV/H SERIES Heat Controller , Inc. UNIT COMMISSIONING AND OPERA TING CONDITIONS T able 9a: Building Operating Limits 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 condensati[...]

33 Heat Controller , Inc. HEV/H SERIES Installation, Operation & Maintenance Commissioning Limits Cooling Heating 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 45°F [7°C] 80.6° [27°C] 1 10° [43°C] 50/45°F [10/7°C] 80.6/66.2°F [...]

34 Installation, Operation & Maintenance HEV/H SERIES Heat Controller , Inc. UNIT ST ART -UP AND OPERA TING CONDITIONS Unit and System Checkout BEFORE POWERING SYSTEM, please check the following: UNIT CHECKOUT  Shutoff valves: Insur e that all isolation valves are open.  Line voltage and wiring: V erify that voltage is within an acceptabl[...]

35 Heat Controller , Inc. HEV/H SERIES Installation, Operation & Maintenance W ARNING! When the disconnect s witch is closed, high v oltage is present in some areas of the electrical panel. Ex ercise caution when working with energized equipment. UNIT ST ART -UP PROCEDURE CA UTION! V erify that ALL water control v alv es are open and allow wate[...]

36 Installation, Operation & Maintenance HEV/H SERIES Heat Controller , Inc. UNIT OPERA TING CONDITIONS T able 1 1: W ater T emperature Change Through Heat Exchanger 9 - 12 20 - 26 4 - 8 10 - 17 Antifreeze T ype Antifreeze % Cooling Heating WPD Corr . Fct. EWT 30°F EWT 90°F EWT 30°F T otal Cap Sens Cap Power Htg Cap Power W ater 0 1.000 1.00[...]

37 Heat Controller , Inc. HEV/H SERIES Installation, Operation & Maintenance UNIT OPERA TING CONDITIONS T able 13: HE Series T ypical Unit Operating Pressures and T emperatures 024 Full Load Cooling - without HWG active Full Load Heating - without HWG active Entering Water T emp °F Water Flow GPM/ton Suction Pressure PSIG Discharge Pressure PS[...]

38 Installation, Operation & Maintenance HEV/H SERIES Heat Controller , Inc. UNIT OPERA TING CONDITIONS 048 Full Load Cooling - without HWG active Full Load Heating - without HWG active Entering Water T emp °F Water Flow GPM/ton Suction Pressure PSIG Discharge Pressure PSIG Superheat Subcooling Water T emp Drop °F Air T emp Drop °F DB Suctio[...]

39 Heat Controller , Inc. HEV/H SERIES Installation, Operation & Maintenance PREVENTIVE MAINTENANCE W ater 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 w ater , it is best to establish a periodic maintenance schedule with the own[...]

40 Installation, Operation & Maintenance HEV/H SERIES Heat Controller , Inc. General If operational dif fi culties are encounter ed, perform the preliminary checks below befor e referring to the troubleshooting charts. • V erify that the unit is receiving electrical supply power . • Make sure the fuses in the fused disconnect switches ar e[...]

41 Heat Controller , Inc. HEV/H SERIES Installation, Operation & Maintenance DXM2 PROCESS FLOW CHART  W ARNING!  W ARNING! HAZARDOUS VOL T AGE! DISCONNECT ALL ELECTRIC POWER INCLUDING REMOTE DISCONNECTS BEFORE SERVICING. Failure to disconnect power befor e servicing can cause severe personal injury or death. See “ Does not Operate in Cl[...]

42 Installation, Operation & Maintenance HEV/H SERIES Heat Controller , Inc. FUNCTIONAL TROUBLESHOOTING Fault Htg Clg Possible Cause Solution Main Power Pr oblems X X Green status LED off Check Line V oltage circuit breaker and disconnect Check for line voltage between L1 and L2 on the contactor Check for 24V AC between R and C on DXM Check pri[...]

43 Heat Controller , Inc. HEV/H SERIES Installation, Operation & Maintenance FUNCTIONAL TROUBLESHOOTING (CONT .) No Fault Code Shown X X No compressor operation See 'Only Fan Operates' X X Compressor overload Check and replace if necessary X X Control boar d Reset power and check operation Unit Short Cycles X X Dirty air filter Check [...]

44 Installation, Operation & Maintenance HEV/H SERIES Heat Controller , Inc. TR OUBLESHOO TING FORM COAX COMPRESSOR DISCHARGE SUCTION HW G COOLI NG CYCL E ANAL YS IS - COAX COMPRESSOR DISCHARGE SUCTION HW G HE AT I NG C YC LE ANAL YS IS - PSI SA T PSI SA T ° F ° F AIR COIL ° F ° F FP2 : HEA T ING LIQUID LINE ° F EXP ANSION VA LV E AIR COIL[...]

45 Heat Controller , Inc. HEV/H SERIES Installation, Operation & Maintenance[...]

4/22/13 *97B0016N11* 97B0016N1 1 Date Page # Description 22 April, 13 All 024, 036 Rev B Info Added Revision History[...]