Heat Controller HTD 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 HTV/HTD/HTH Series T wo-Stage Geothermal Heat Pumps 2 to 6 T ons[...]

2 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc. Model Breakdown Model Nomenclature – T wo Stage Geothermal Heat Pump HT = Heat Controller T wo Stage C 0 2 4 C 1 0 1 A L K 4 5 6 7 8 91 0 1 1 1 2 1 3 1 4 024 Unit Size 036 Return Air Flow Configura tion Vol t age C = CXM Controls B = Efficiency Upgrade C = Micro[...]

3 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc.  W ARNING!   W ARNING!   CAUTION!  W ARNING! T o avoid the release of refrigerant into the atmosphere, the refrigerant circuit of this unit must be serviced only by technicians who meet local, state, and federal pro fi ciency requirements. CAUTI[...]

4 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc. General Information Inspection Upon receipt of the equipment, carefully check the shipment against the bill of lading. Make sure all units have been received. Inspect the packaging of each unit, and inspect each unit for damage. Insure that the carrier makes prope[...]

5 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc. General Information Mounting Horizontal Units Horizontal units have hanger kits pre-installed fr om the factory as shown in Figure 1. Figur e 3 shows a typical horizontal unit installation. Horizontal heat pumps are typically suspended above a ceiling or within a [...]

6 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc. Horizontal Installation ERWKHUV ERWKHUV 7KHUPRVWDW :LULQJ : DWHU,Q : DWHU2XW 2SWLRQDO%DODQFLQJ9 DOYH %DOO9 DOYHZLWKRSWLRQDO LQWHJUDO37SOXJ 6WDLQOHVVVWHHOEUDLGKRVH ZLWKLQWHJUDO- VZLY[...]

7 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc. 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 e r Connection End Supply Duct Return Air Wat e r Connection End [...]

8 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc. ರ ರ ರ * Some units include a painted drain connection. Using a threaded pipe or similar device to clear any excess paint accumulated inside this fitting may ease final drain line installation. ರ3HU )RRW Figure 6: Horizon[...]

9 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc. V ertical Installation Figure 7: V ertical Unit Mounting Figure 8: T ypical V ertical Unit Installation Using Ducted Return Air $LU3DGRUH[WUXGHG SROVWUHQHLQVXODWLRQERDUG Flexib le canvas duct connector to reduce noise and vibration Use turning van[...]

10 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc. V ertical Installation Return Air Inlet Figure 9: V ertical Sound Attenuation ರ ರ ರ * Some units include a painted drain connection. Using a threaded pipe or similar device to clear any excess paint accumulated inside this fitting may e[...]

11 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc. W ater Connection Installation External Flow Controller Mounting The Flow Controller can be mounted beside the unit as shown in Figure 12. Review the Flow Contr oller installation manual for more details. Gasket Swivel Nut Stainless steel snap ring Brass Adaptor [...]

12 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc. Ground-Loop Heat Pump Applications most areas to pr event freezing. All air and debris must be removed from the earth loop piping befor e operation. Flush the loop with a high volume of water at a minimum velocity of 2 fps (0.6 m/s) in all piping. The steps below[...]

13 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc. T able 2: Antifreeze Percentages by V olume Ground-Loop Heat Pump Applications GROUND-W A TER HEA T PUMP APPLICA TIONS Open Loop - Ground W ater Systems T ypical open loop piping is shown in Figure 13. Shut of f valves should be included for ease of servicing. Bo[...]

14 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc. $LU3DGRU ([WUXGHG SROVWUHQH LQVXODWLRQERDUG 8QLW3 RZHU 'LVFRQQHFW 7KHUPRVWDW :LULQJ 3UHVVXUH 7D Q N 6KXW2II 9D O Y H %RLOHU 'UDLQV )ORZ 5HJXODWRU :DWHU,Q : DWHU2XW :D W H U &RQWURO 9D O Y H 2SWLRQDO )LOWHU 373OXJV Figure[...]

15 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc. W ater Quality Standards 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 Met[...]

16 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc. Electric water heaters are r ecommended. If a gas, propane, or oil water heater is used, a second preheat tank must be installed (Figure 15). If the electric water heater has only a single center element, the dual tank system is recommended to insur e a usable en[...]

17 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc. Hot W ater Generator 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 Ä ciently above the water temperature. Once the HWG has satis[...]

18 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc. W ar ning! The HWG pump Is fully wired from the factory . Use extreme caution when working ar ound the microprocessor control as it contains line voltage connections that pr esents a shock hazard that can cause sever e injury or death! The heat pump, water piping[...]

19 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc. Electrical - Line V oltage  W ARNING!   CAUTION!  W ARNING! T o 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! Use only copper conductors [...]

20 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc. Electrical - Line V oltage Electrical - Line V oltage All fi eld 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 [...]

21 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc. Electrical - Low V oltage Wiring Low voltage Ä eld wiring for units with ECM fan Low voltage Ä eld wiring for units with PSC F AN (ECM board will not be present) Figure 19: FP1 Limit Setting CXM PCB JW3-FP1 jumper should be clipped for low temperature operation[...]

22 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc. Electrical - Low V oltage Wiring Figure 20: Accessory Wiring Accessory Connections A terminal paralleling the compressor contactor coil has been provided on the CXM control. T erminal “A” is designed to control accessory devices, such as water valves. Note: T[...]

23 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc. Electrical - Thermostat Wiring Figure 24: Units With Optional ECM Fan. Figure 25: T ypical Thermostat 2 Heat/1 Cool (PSC Fan) Thermostat Installation The thermostat should be located on an interior wall in a lar ger room, away fr om supply duct drafts. DO NOT loc[...]

24 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc. ECM Blower Control The ECM fan is controlled by an interface board that converts thermostat inputs and fi eld selectable CFM settings to signals used by the ECM motor controller . Units manufactured before July 2005 have version I (P/N 69243707). Units manufactu[...]

25 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc. ECM Blower Control T able 5: ECM Board T ap Settings Y GGGGR W O Y2 Y1 G R C Y2 Y1 G O W C R DH AL1 A A AL1 SW1 SW2 SW3 SW4 SW5 SW6 SW7 SW8 SW9 OFF ON G DEHUM CFM TB1 J1 S1 Thermostat Input LEDs CFM Counter 1 flash per 100 CFM ECM Motor Low V oltage Connector 1/4[...]

26 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc. HT Series ECM Blower Performance Data Air fl ow in CFM with wet coil and clean air fi lter Residential Units Only Model Max ESP (in. wg) Fan Motor (hp) Range Cooling Mode Dehumid Mode Heating Mode Fan Only Mode Aux/ Emerg Mode Stg 1 Stg 2 Stg 1 Stg 2 Stg 1 Stg [...]

27 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc. CXM Control For detailed control information, see CXM Application, Operation and Maintenance (AOM) manual (part #97B0003N12). Field Selectable Inputs T est mode: T est mode allows the service technician to check the operation of the control in a timely manner . B[...]

28 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc. CXM Controls Safety Features – CXM Control The safety features below ar e pr ovided to protect the compressor , heat exchangers, wiring and other components from damage caused by operation outside of design conditions. Anti-short cycle protection: The contr ol [...]

29 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc. CXM Control Start-up Operation The control will not operate until all inputs and safety contr ols are checked for normal conditions. The compr essor will have a 5 minute anti-short cycle delay at power -up. The fi rst time after power -up that there is a call fo[...]

30 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc. CXM Controls CXM Thermostat Details Thermostat Compatibility - Most all heat pump thermostats can be used with the CXM control. However Heat/Cool stats are NOT compatible with the CXM. Anticipation Leakage Current - Maximum leakage current for "Y" is 50[...]

31 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc. Unit Commissioning And Operating Conditions T able 8a: 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 conde[...]

32 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc. Unit Start-Up and Operating Conditions Unit and System Checkout BEFORE POWERING SYSTEM, please check the following: UNIT CHECKOUT  Balancing/shutoff valves: Insur e that all isolation valves are open and water control valves ar e wired.  Line voltage and wi[...]

33 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc. Unit Start-Up Procedure pressur e drop across the heat exchanger versus the data in T ables 9a through 9b. Heat of r ejection (HR) can be calculated and compared to catalog data capacity pages. The formula for HR for systems with water is as follows: HR = TD x GP[...]

34 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc. Unit Operating Conditions T able 10: W ater T emperature Change Through Heat Exchanger    Antifreeze T ype Antifreeze % Cooling Heating WPD Corr . Fct. EWT 30°F EWT 90°F EWT 30°F T otal Cap Sens Cap Power H[...]

35 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc. Unit Operating Conditions TE026 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 Rise °F Air T emp Drop °F DB[...]

36 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc. Unit Operating Conditions TE064 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 Rise °F Air T emp Drop °F DB[...]

37 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc. Performance Data — HT 024 - Full Load 850 CFM N o m ina l (ISO R ated ) A i r ow C oo l ing , 950 CFM N o m ina l (ISO R ated ) A i r ow Heating P e rf o rm an c e c a p a c ities shown in thousands o f B tuh EWT °F C oo l ing - EA T 80/67°F Heating - E[...]

38 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc. Performance Data — HT 036 - Full Load Operation not recommended 1250 CFM N o m ina l (ISO R ated ) A i r ow C oo l ing , 1250 CFM N o m ina l (ISO R ated ) A i r ow Heating P e rf o rm an c e c a p a c ities shown in thousands o f B tuh EWT °F C oo l ing[...]

39 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc. Performance Data — HT 048 - Full Load 1550 CFM N o m ina l (ISO R ated ) A i r ow C oo l ing , 1650 CFM N o m ina l (ISO R ated ) A i r ow Heating P e rf o rm an c e c a p a c ities shown in thousands o f B tuh EWT °F C oo l ing - EA T 80/67°F Heating -[...]

40 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc. Performance Data — HT 060 - Full Load 1825 CFM N o m ina l (ISO R ated ) A i r ow C oo l ing , 2050 CFM N o m ina l (ISO R ated ) A i r ow Heating P e rf o rm an c e c a p a c ities shown in thousands o f B tuh EWT °F C oo l ing - EA T 80/67°F Heating -[...]

41 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc. Performance Data — HT 070 - Full Load 1950 CFM N o m ina l (R ated ) A i r ow C oo l ing , 2100 CFM N o m ina l (R ated ) A i r ow Heating P e rf o rm an c e c a p a c ities shown in thousands o f B tuh EWT °F C oo l ing - EA T 80/67°F Heating - EA T 70[...]

42 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc. Preventive Maintenance W ater Coil Maintenance (Direct gr ound 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[...]

43 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc. General If operational dif fi culties are encountered, perform the pr eliminary checks below before r eferring to the troubleshooting charts. • V erify that the unit is receiving electrical supply power . • Make sure the fuses in the fused disconnect switche[...]

44 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc. See “ Does not Operate in Clg” See “ Only Comp Runs” Start Did Unit Attempt to Start? Did Unit Lockout at Start-up? Unit Short Cycles? Only Fan Runs? Only Compressor Runs? Did unit lockout after a period of operation? Does unit operate in cooling? Unit is[...]

45 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc. Functional T roubleshooting Fault Htg Clg Possible Cause Solution Main power problems XX Green Status LED Off Check line voltage circuit breaker and disconnect. Check for line voltage between L1 and L2 on the contactor . Check for 24V AC between R and C on CXM/DX[...]

46 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc. Performance T roubleshooting Performance T roubleshooting Htg Clg Possible Cause Solution Insuf fi cient capacity/ Not cooling or heating XX Dirty fi lter Replace or clean. X Reduced or no air fl ow in heating Check for dirty air fi lter and clean or replace.[...]

47 Installation, Operation & Maintenance HTV/HTD/HTH SERIES Heat Controller , Inc. T roubleshooting Form 3DFNDJHG8QLW 5HIULJHUDWLRQ6FK HPDWLF 5H Y &XVWR P HUBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBB $QW LI UH H]HBBBBBBBBBBBBBBBBBBBBBBBB 0RGH O BBBBBBBBBBBBBBBBBBBBBBBB 6HULDO ?[...]

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