Heatcontroller HBH 6-10 T User Manual
Installation, Operation
& Maintenance Manual
Commercial Horizontal Packaged
Water Source Heat Pump:
HBH Series
6-10 Tons
Heat Controller, Inc. • 1900 Wellworth Ave. • Jackson, MI 49203 • (517)787-2100 • www.heatcontroller.com
IOM Manual HBH SERIES Heat Controller, Inc.
Table of Contents
Model Nomenclature ....................................2
Storage...........................................................3
Pre-Installation ..............................................3
Physical Data .................................................5
Horizontal Installation ...................................6
Field Conversion of Air Discharge ................8
Horizontal Installation-Condensate Piping .....10
Duct System Installation .............................10
Piping Installation ...................................... 11
Water-Loop Applications ............................ 12
Ground-Loop Applications ......................... 13
Open Loop-Ground Water Systems ........... 15
Water Quality Standards .............................17
Water Valve Wiring ......................................21
Thermostat Wiring ...................................... 22
Typical Wiring Diagrams ............................. 23
CXM Controls ...............................................24
Safety Features .......................................... 25
Blower Adjustment ......................................27
Tensioning V-Belt Drives ............................ 28
Blower Sheave Information ....................... 29
Blower Performance Tables ....................... 30
Unit Starting and Operating Conditions .... 35
Piping System Cleaning and Flushing ...... 36
Unit Starting and Operating Conditions .....37
Unit Start-Up Procedure ............................. 38
Electrical-Line Voltage ................................ 18
Power Wiring ............................................... 20
Electrical-Low Voltage Wiring......................21
Low Water Temperature Cutout Selection .21
Unit Operating Conditions ......................... 39
Preventative Maintenance ..........................41
Functional Troubleshooting ....................... 42
Refrigerant Circuit Diagrams ..................... 44
1
Heat Controller, Inc. HBH SERIES IOM Manual
Heat Controller OEM Price List
HBH Large Compact Horizontal Units
Entering Water Temperature Range: 20 - 120° F (-6. 7 - 48.9° C)
Horizontal Sizes 072 - 120
HBH Large Model Structure
The basic unit price includes sealed heat pump refrigerant circuit and
•
Reversing Valve
- 4-way, pilot operated, solenoid activated in
air handler within cabinetry, filter, and a factory installed hanger kit on
cooling.
horizontal units.
•
Water to Refrigerant Coil
- Tube-in-tube, convoluted copper inner
•
Cabinetry
- Compact design - galvanized steel construction -
water tube.
FPT water connections, high and low voltage knockouts - filter
and filter brackets. All horizontal units have field convertible discharge
•
Refrigerant to Air Coil
- Lanced aluminum fins on rifled copper
air patterns, no extra parts required.
tubes.
•
Standard Controls
- CXM Controller, loss of charge switch, high
• Blower Motor
- Belt drive with adjustable sheave, single blower and
pressure switch, water coil low temperature cutout, lockout safety
single blower motor.
circuit reset at thermostat or disconnect, LED fault indication,
five minute anti-short cycle, random start, high and low voltage
•
Application
- Units can be applied in WLHP, GW HP or GLHP
protection, condensate overflow protection, dry contact for alarm.
applications.
• Compressor
- High efficiency scroll compressor - overload
• Field Connections
- For supply, return and condensate can be made
protected.
on either side (plug opposite side). Condensate connection on end
opposite compressor end.
• Refrigerant Circuit
- Dual refrigerant circuit. Thermostatic
expansion valve’s for refrigerant metering, copper tubing
interconnecting all components - sealed & tested non-ozone
depleting, HFC-410A refrigerant circuit with high and low-side
Schrader ports.
Model Nomenclature
3
Basic Unit Description:
R-410A refrigerant circuit with high and low-side
2
IOM Manual HBH SERIES Heat Controller, Inc.
General Information
Safety
Warnings, cautions and notices appear throughout this
manual. Read these items carefully before attempting any
installation, service or troubleshooting of the equipment.
DANGER: Indicates an immediate hazardous situation,
which if not avoided will result in death or serious injury.
DANGER labels on unit access panels must be observed.
WARNING: Indicates a potentially hazardous situation,
which if not avoided could result in death or serious injury.
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.
NOTICE: Notication of installation, operation or
maintenance information, which is important, but which is
not hazard-related.
� WARNING! �
WARNING!
!
WARNING! To 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 prociency requirements.
CAUTION!
!
� CAUTION! �
CAUTION! To avoid equipment damage, DO NOT use
these units as a source of heating or cooling during the
construction process. The mechanical components and
lters will quickly become clogged with construction dirt and
debris, which may cause system damage.
!
!
WARNING!
!
� WARNING! �
WARNING! All refrigerant discharged from this unit must be
recovered WITHOUT EXCEPTION. Technicians must follow
industry accepted guidelines and all local, state, and federal
statutes for the recovery and disposal of refrigerants. If a
compressor is removed from this unit, refrigerant circuit oil will
remain in the compressor. To avoid leakage of compressor oil,
refrigerant lines of the compressor must be sealed after it is
removed.
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 proper notation of any shortages or damage on all
copies of the freight bill and completes a common carrier
inspection report. Concealed damage not discovered
during unloading must be reported to the carrier within
15 days of receipt of shipment. If not led within 15 days,
the freight company can deny the claim without recourse.
Note: It is the responsibility of the purchaser to le all
necessary claims with the carrier. Notify your equipment
supplier of all damage within fteen (15) days of shipment.
Storage - Equipment should be stored in its original
packaging in a clean, dry area. Store units in an upright
position at all times.
Unit Protection - Cover units on the job site with either the
original packaging or an equivalent protective covering.
Cap the open ends of pipes stored on the job site. In areas
where painting, plastering, and/or spraying has not been
completed, all due precautions must be taken to avoid
physical damage to the units and contamination by foreign
material. Physical damage and contamination may prevent
proper start-up and may result in costly equipment clean-up.
!
Examine all pipes, ttings, and valves before installing
any of the system components. Remove any dirt or debris
found in or on these components.
3
Heat Controller, Inc. HBH SERIES IOM Manual
General Information
Pre-Installation - Installation, Operation, and Maintenance
instructions are provided with each unit. Horizontal
equipment is designed for installation above false ceiling or
in a ceiling plenum. Other unit congurations are typically
installed in a mechanical room. The installation site chosen
should include adequate service clearance around the unit.
Before unit start-up, read all manuals and become familiar
with the unit and its operation. Thoroughly check the system
before operation.
Prepare units for installation as follows:
1. Compare the electrical data on the unit nameplate
with ordering and shipping information to verify that
the correct unit has been shipped.
2. Keep the cabinet covered with the original packaging
until installation is complete and all plastering,
painting, etc. is nished.
3. Verify refrigerant tubing is free of kinks or dents and
that it does not touch other unit components.
4. Inspect all electrical connections. Connections must
be clean and tight at the terminals.
5. Remove any blower support packaging (water-to-air
units only).
CAUTION!
direction of rotation veried at start-up. Verication is achieved by
checking compressor Amp draw. Amp draw will be substantially
lower compared to nameplate values. Additionally, reverse rotation
results in an elevated sound level compared to correct rotation.
Reverse rotation will result in compressor internal overload trip
within several minutes. Verify compressor type before proceeding.
CAUTION! DO NOT store or install units in corrosive
environments or in locations subject to temperature or
humidity extremes (e.g., attics, garages, rooftops, etc.).
Corrosive conditions and high temperature or humidity can
signicantly reduce performance, reliability, and service life.
Always move and store units in an upright position. Tilting
units on their sides may cause equipment damage.
CAUTION! CUT HAZARD - Failure to follow this caution
may result in personal injury. Sheet metal parts may have
sharp edges or burrs. Use care and wear appropriate
protective clothing, safety glasses and gloves when
handling parts and servicing heat pumps.
� CAUTION! �
CAUTION!
!
All three phase scroll compressors must have
CAUTION!
� CAUTION! �
!
CAUTION!
!
� CAUTION! �
!
!
!
6. Some airow patterns are eld convertible (horizontal
units only). Locate the airow conversion section of
this IOM.
7. Locate the package of hanger grommets (shipped
inside of the blower outlet) and retain for use with the
hanger brackets when mounting the unit.
4
IOM Manual HBH SERIES Heat Controller, Inc.
Unit Physical Data
HBH Series (60 Hz)
Model 072 096 120
Compressor Quantity Scroll
Number of Circuits (Compressors) 2
Factory Charge HFC-410a (oz) [kg] per circuit 60 [1.70] 76 [2.15] 80 [2.27]
Blower Motor
Blower Motor Quantity 1
Standard Motor (hp) [kw] 1 [0.75] 2 [1.49] 3 [2.24]
Large Motor (hp)[KW] (2)[1.49] 3[2.24] 5[3.73]
Blower
No. of Blowers 1
Blower Wheel Size D x W (in0 [cm] 12 x 12 [30.48 x 30.48]
Water Connection Size
FPT (in) [mm] 1-1/4" [31.8] 1-1/2" [38.1]
Coax Volume
Volume (US Gallons) [liters] 1.62 [6.13] 1.81 [6.85] 2.40 [9.08]
Condensate Connection Size
FPT (in) [mm] 3/4" [19.1]
Air Coil Data
Air Coil Dimensions H x W (in) [cm] 20 x 54 [50.8 x 137.16] 20 x 64 [50.8 x 162.56]
Air Coil Total Face Area (ft2) [m2] 7.5 [0.70] 8.9 [0.83]
Air Coil Tube Size (in) [cm] 3/8" [0.953]
Air Coil Fin Spacing (fpi) [ns per cm] 14 [5.5]
Air Coil Number of Rows 3
Miscellaneous Data
Filter Standard - 1" [25.4mm] Throwaway (qty)
(in) [cm]
Weight - Operating (lbs) [kg] 586 [265.8] 644 [292.1] 698 [316.6]
Weight - Packaged (lbs) [kg] 626 [283.9] 684 [310.3] 738 [334.8]
All units have grommet compressor mountings, and 1/2" & 1-3/4" electrical knockouts.
(QTY.4) 16 x20 [40.64 x 50.80]
Unit Maximum Water Working
Pressure
Base Unit 500 [3445]
HBH Corner Weights
Weight - Operating (lbs) [kg] 586 [265.8] 644 [292.1] 698 [316.6]
Weight - Packaged (lbs) [kg] 626 [283.9] 684 [310.3] 738 [334.8]
Weight - Corner - Control box/Compressor side (lbs) [kg] 235 [106.6] 254 [115.2] 271 [122.9]
Weight - Corner - Compressor side (lbs) [kg] 101 [45.8] 120 [54.4] 137 [62.1]
Weight - Corner - Blower side side (lbs) [kg] 180 [81.6] 190 [86.2] 200 [90.7]
Weight - Corner - Air Coil side (lbs) [kg] 70 [31.8] 80 [36.3] 90 [40.8]
Max Pressure PSIG [kPa]
HBH072 HBH096 HBH120
5
Heat Controller, Inc. HBH SERIES IOM Manual
Horizontal 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. 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). Consideration should
be given to access for easy removal of the lter and
access panels. Provide sufcient room to make water,
electrical, and duct connection(s). Allow 3 feet (91 cm)
clearance for servicing unit through all access panels.
If the unit is located in a conned space, such as a closet,
provisions must be made for return air to freely enter the
space by means of a louvered door, etc. Any access panel
screws that would be difcult to remove after the unit is
installed should be removed prior to setting the unit. Refer
to Figure 3 for an illustration of a typical installation. Refer
to unit submittal data or engineering design guide for
dimensional data.
Conform to the following guidelines when selecting
unit location:
1. Provide a hinged access door in concealed-spline
or plaster ceilings. Provide removable ceiling
tiles in T-bar or lay-in ceilings. Refer to horizontal
unit dimensions for specic series and model in
unit submittal data. Size the access opening to
accommodate the service technician during the
removal or replacement of the compressor and the
removal or installation of the unit itself.
2. Provide access to hanger brackets, water valves
and ttings. Provide screwdriver clearance to
access panels, discharge collars and all electrical
connections.
3. DO NOT obstruct the space beneath the unit with
piping, electrical cables and other items that prohibit
future removal of components or the unit itself.
4. Use a manual portable jack/lift to lift and support the
weight of the unit during installation and servicing.
Mounting Horizontal Units - Horizontal units have hanger
kits pre-installed from the factory as shown in Figure 1.
Figure 3 shows a typical horizontal unit installation.
Horizontal heat pumps are typically suspended above a
ceiling or within a soft using eld supplied, threaded rods
sized to support the weight of the unit.
Use four (4) eld supplied threaded rods and factory
provided vibration isolators to suspend the unit. Hang the
unit clear of the oor slab above and support the unit by
the mounting bracket assemblies only. DO NOT attach the
unit ush with the oor slab above.
Pitch the unit toward the drain as shown in Figure 2 to
improve the condensate drainage.
Figure 1: Hanger Bracket
3/8" [10mm] Threaded
Rod (by others)
Vibration Isolator
(factory supplied)
Washer
(by others)
Double Hex Nuts
(by others)
Figure 2: Horizontal Unit Pitch
1/4" [6.4mm] pitch
for drainage
The installation of water source heat pump units and all
associated components, parts and accessories which
make up the installation shall be in accordance with
the regulations of ALL authorities having jurisdiction
and MUST conform to all applicable codes. It is the
responsibility of the installing contractor to determine and
comply with ALL applicable codes and regulations.
Drain
Connection
6
IOM Manual HBH SERIES Heat Controller, Inc.
(by others)
Thermostat
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 rods
Flexible Duct
Connector
HORIZONTAL INSTALLATION
Figure 3: Typical Horizontal Unit Installation
BSP
A
A
F
G
E
D
BSP
RIGHT RETURN STRAIGHT DISCHARGE
1
EAP
2 CAP
CAP
2
FRONT
CBP
1
5
4
LEGEND
CAP=Compressor Access Panel
CBP=Control Box Panel
BSP=Blower Service Panel
EAP=Expansion Valve Access panel
1=Water Outlet 1-1/4Ó FPT (072-096) 1-1/2Ó FPT (120)
2=Water Inlet 1-1/4Ó FPT (072-096) 1-1/2Ó FPT (120)
3=Condensate 3/4Ó FPT
4=High Voltage 1-1/8Ó [2.9cm] KO
5=Low Voltage 7/8Ó [2.2cm] KO
SERVICE ACCESS
3Õ (91 cm.) TYPICAL
ALL CONFIGURATIONS
NOTES FOR LEGEND:
1. Access is required for all removable panels and installer should take care to comply with
all building codes and allow adequate clearance for future field service.
2. Water inlet and water outlet connections are available on either side (left or right) of the
unit. Qty (2x) MPT Plugs are shipped loose in a plastic bag tied to the water leg in front of
the unit. Installer must plug water inlet/outlet side not being connected to.
3. Condensate drain is available on end opposite compressor.
4. Electrical access is available on either side (left or right) of the front.
5. Electric box is on right side. It can be field converted to left side. Conversion should only
be attempted by qualified service technician.
Horizontal Installation
Figure 3: Typical Horizontal Unit Installation
BSP
CBP
Unit
Power
EAP
CAP
Ball valve with optional
integral P/T plug
Water Out
Building
Water In
Loop
Stainless steel braid hose
with integral ÒJÓ swivel
Balancing Valve
CAP
Optional
Air Coil be cleaned before start-up. A 10% solution of dishwasher
detergent and water is recommended for both sides of the
coil. A thorough water rinse should follow. UV based antibacterial systems may damage e-coated air coils.
To obtain maximum performance, the air coil should
Optional Low Pressure Drop Water
Control Valve
(can be internally mounted
on some models)
Notice! Installation Note - Ducted Return: Many horizontal
WSHPs are installed in a return air ceiling plenum
application (above ceiling). Vertical WSHPs are commonly
installed in a mechanical room with free return (e.g. louvered
door). Therefore, lter rails are the industry standard and
are included on Heat Controller commercial heat pumps
for the purposes of holding the lter only. For ducted return
applications, the lter rail must be removed and replaced
with a duct ange or lter rack. Canvas or exible connectors
should also be used to minimize vibration between the unit
and ductwork.
7
Heat Controller, Inc. HBH SERIES IOM Manual
Step 1
Step 2
Step 3
Step 4
Move motor clips to
other side on bracket
Remove motor
and blower sheave
Loosen 2 motor slide nuts, raise
slide assembly, remove belt.
Remove blower panel
and access panel
Return air
Front
Adjusting bolt - used
to raise or lower motor
slide assembly.
Remove 4
motor bolts
Step 1
Step 3
Step 4
Remove motor
and blower sheave
Remove blower panel
and access panel
Return air
Front
Adjusting bolt - used
to raise or lower motor
slide assembly.
Remove 4
motor bolts
Step 3
Remove motor
and blower sheave
Adjusting bolt - used
to raise or lower motor
slide assembly.
Remove 4
motor bolts
Field Conversion of Air Discharge
discharge for either right or left return conguration is the
WARNING!
!
� 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 or
conversion.
Overview -
Horizontal units can be eld converted
!
between straight (side) and back (end) discharge using
the instructions below.
Note: It is not possible to eld convert return air between left
or right return models due to the necessity of refrigeration
copper piping changes.
Preparation - Field conversion must be completed on
the ground. If the unit is already hung it should be taken
down for the eld conversion. Place in a well-lighted area.
Conversion should only be attempted by a qualied service
technician.
same. In some cases, it may be possible to rotate the entire
unit 180 degrees if the return air connection needs to be on
the opposite side. Note that rotating the unit will move the
piping to the other end of the unit.
Figure 4: Left Return Side Discharge to Back
Side to Back Discharge Conversion
1. Remove back panel and side access panel
2. Loosen 2 motor slide nuts, raise motor slide
assembly and remove belt and motor sheave.
3. Remove blower sheave. Remove motor bolts and
carefully remove motor.
4. Remove 2 motor clips and reattach to opposite side.
5. Unbolt (3 per side) complete housing assembly.
6. Rotate complete assembly into new position. Locate
over mounting holes in base, reattach using 3 bolts
per side.
7. Mount motor, motor sheave, blower sheave and
belt. Make sure wires are not pinched and not over
sharp edges. Adjust motor downward to tighten belt.
Raise or lower motor slide assembly with adjusting
bolt and retighten 2 slide nuts. Check for correct
tension (See Tensioning V-Belt Drives page). Rewire
motor (at contactor) for correct rotation. Spin blower
wheel to insure wheel is not obstructed.
8. Replace 2 panels.
Back to Side Discharge Conversion - If the discharge is
changed from back to side, use above instruction noting that
illustrations will be reversed.
Left vs. Right Return - It is not possible to eld convert
return air between left or right return models due to the
necessity of refrigeration copper piping changes. However,
the conversion process of side to back or back to side
Figure 4 Continued on Following Page
8
Step 1
Step 3
Step 4
Move motor clips to
other side on bracket
Remove motor
and blower sheave
Loosen 2 motor slide nuts, raise
slide assembly, remove belt.
Remove blower panel
and access panel
Remove (3x) per slide
1/4-20 UNC bolts
Return air
Step 5
Motor motor, motor sheave,
blower sheave and belt
Step 7
Front
Adjusting bolt - used
to raise or lower motor
slide assembly.
Remove 4
motor bolts
Step 4
Move motor clips to
other side on bracket
Loosen 2 motor slide nuts, raise
slide assembly, remove belt.
Remove blower panel
and access panel
Remove (3x) per slide
1/4-20 UNC bolts
Step 5
Step 6
Rotate entire blower housing ASM to rest at back end of the unit. Locate
housing holes and bolt down using previous 1/4-20 UNC bolts (3x) ea. side.
Motor motor, motor sheave,
blower sheave and belt
Step 7
Step 8
Put blower panel
Return air
Front
Return air
Adjusting bolt - used
to raise or lower motor
slide assembly.
Remove 4
motor bolts
Step 3
Step 4
Move motor clips to
other side on bracket
Remove motor
and blower sheave
Motor motor, motor sheave,
blower sheave and belt
Step 7
Adjusting bolt - used
to raise or lower motor
slide assembly.
Remove 4
motor bolts
Step 4
Move motor clips to
other side on bracket
and blower sheave
Motor motor, motor sheave,
blower sheave and belt
Step 7
Step 8
Put blower panel
and access panel back on
Return air
Front
Return air
Adjusting bolt - used
to raise or lower motor
slide assembly.
Remove 4
motor bolts
Step 4
Move motor clips to
other side on bracket
Adjusting bolt - used
to raise or lower motor
slide assembly.
Remove 4
motor bolts
IOM Manual HBH SERIES Heat Controller, Inc.
Field Conversion of Air Discharge
Figure 4 Continued: Left Return Side Discharge to Back
9
Heat Controller, Inc. HBH SERIES IOM Manual
*3/4" FPT
Trap Depth
1.5" [38mm]
Min 1.5"
[38mm]
1/4" per foot
(21mm per m)
drain slope
3/4" PVC or
Copper by others
Rev.: 4/30/10B
Vent
* 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.
Horizontal Installation
Figure 5: Right Return Side Discharge to Back
RIGHT RETURN SIDE DISCHARGE
CBP
RETURN AIR
Drain
Horizontal Units Condensate Piping - Pitch the unit
toward the drain as shown in Figure 2 to improve the
condensate drainage. Insure that unit pitch does not cause
condensate leaks inside the cabinet.
FRONT
RIGHT RETURN END DISCHARGE
FRONT
CBP
RETURN AIR
Drain
Always vent the condensate line when dirt or air can
collect in the line or a long horizontal drain line is required.
Also vent when large units are working against higher
external static pressure than other units connected to
the same condensate main since this may cause poor
drainage for all units on the line. WHEN A VENT IS
INSTALLED IN THE DRAIN LINE, IT MUST BE LOCATED
AFTER THE TRAP IN THE DIRECTION OF THE
CONDENSATE FLOW.
Figure 6: Horizontal Condensate Connection
Install condensate trap at each unit with the top of the trap
positioned below the unit condensate drain connection as
shown in Figure 6. Design the depth of the trap (waterseal) based upon the amount of ESP capability of the
blower (where 2 inches [51mm] of ESP capability requires
2 inches [51mm] of trap depth). As a general rule, 1-1/2
inch [38mm] trap depth is the minimum.
Each unit must be installed with its own individual trap and
connection to the condensate line (main) or riser. Provide
a means to ush or blow out the condensate line. DO NOT
install units with a common trap and/or vent.
Duct System Installation
Duct System Installation - Proper duct sizing and design
is critical to the performance of the unit. The duct system
should be designed to allow adequate and even airow
through the unit during operation. Air ow through the unit
MUST be at or above the minimum stated airow for the
unit to avoid equipment damage. Duct systems should
be designed for quiet operation. Refer to Figure 3 for
horizontal duct system details or gure 8 for vertical duct
system details. A exible connector is recommended for
both discharge and return air duct connections on metal
duct systems to eliminate the transfer of vibration to the
duct system. To maximize sound attenuation of the unit
CAUTION!
!
� CAUTION! �
CAUTION! Ensure condensate line is pitched toward drain
1/4” per foot [21mm per m] of run.
!
blower, the supply and return plenums should include
internal berglass duct liner or be constructed from
ductboard for the rst few feet. Application of the unit to
uninsulated ductwork in an unconditioned space is not
recommended, as the unit’s performance may be adversely
affected.
At least one 90° elbow should be included in the supply
duct to reduce air noise. If air noise or excessive air ow is
a problem, the blower speed can be changed. For airow
charts, consult submittal data for the series and model of the
specic unit.
10
IOM Manual HBH SERIES Heat Controller, Inc.
Swivel
Piping Installation
If the unit is connected to existing ductwork, a previous
check should have been made to ensure that the ductwork
has the capacity to handle the airow required for the unit.
If ducting is too small, as in the replacement of a heating
only system, larger ductwork should be installed. All existing
ductwork should be checked for leaks and repaired as
necessary.
Installation of Supply and Return Piping
Follow these piping guidelines.
1. Install a drain valve at the base of each supply and
return riser to facilitate system ushing.
2. Install shut-off / balancing valves and unions at each
unit to permit unit removal for servicing.
3. Place strainers at the inlet of each system
circulating pump.
4. Select the proper hose length to allow slack
between connection points. Hoses may vary in
length by +2% to -4% under pressure.
5. Refer to Table 1. Do not exceed the minimum
bend radius for the hose selected. Exceeding
the minimum bend radius may cause the hose to
collapse, which reduces water ow rate. Install an
angle adapter to avoid sharp bends in the hose
when the radius falls below the required minimum.
Optional pressure-rated hose assemblies designed
specically for use with Heat Controller units are available.
Similar hoses can be obtained from alternate suppliers.
Supply and return hoses are tted with swivel-joint ttings at
one end to prevent kinking during installation.
Refer to Figure 7 for an illustration of a typical supply/return
hose kit. Adapters secure hose assemblies to the unit and
risers. Install hose assemblies properly and check regularly
to avoid system failure and reduced service life.
CAUTION!
!
� CAUTION! �
CAUTION! Corrosive system water requires corrosion
resistant ttings and hoses, and may require water
treatment.
CAUTION!
!
� CAUTION! �
CAUTION! Do not bend or kink supply lines or hoses.
CAUTION!
!
� CAUTION! �
CAUTION!
Piping must comply with all applicable codes.
!
!
!
Insulation is not required on loop water piping except
where the piping runs through unheated areas, outside the
building or when the loop water temperature is below the
minimum expected dew point of the pipe ambient conditions.
Insulation is required if loop water temperature drops
below the dew point (insulation is required for ground loop
applications in most climates).
Pipe joint compound is not necessary when Teon® thread
tape is pre-applied to hose assemblies or when ared-end
connections are used. If pipe joint compound is preferred,
use compound only in small amounts on the external pipe
threads of the tting adapters. Prevent sealant from reaching
the ared surfaces of the joint.
Note: When anti-freeze is used in the loop, insure that it is
compatible with the Teon tape or pipe joint compound that
is applied.
Maximum allowable torque for brass ttings is 30 ft-lbs [41
N-m]. If a torque wrench is not available, tighten nger-tight
plus one quarter turn. Tighten steel ttings
as necessary.
Table 1: Metal Hose Minimum Bend Radii
Hose Diameter Minimum Bend Radii
1/2" [12.7mm] 2-1/2" [6.4cm]
3/4" [19.1mm] 4" [10.2cm]
1" [25.4mm] 5-1/2" [14cm]
1-1/4" [31.8mm] 6-3/4" [17.1cm]
1-1/2" [38.1 mm] 8.5" [216mm]
Notice! Do not allow hoses to rest against structural building
components. Compressor vibration may be transmitted
through the hoses to the structure, causing unnecessary
noise complaints.
Figure 7: Supply/Return Hose Kit
Rib Crimped
Length
(2 ft [0.6m] Length Standard)
Brass
Fitting
Brass
Fitting
MPT
11
Heat Controller, Inc. HBH SERIES IOM Manual
(by others)
Thermostat
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 rods
Flexible Duct
Connector
HORIZONTAL INSTALLATION
Figure 3: Typical Horizontal Unit Installation
Water-Loop Heat Pump Applications
Commercial Water Loop Applications -
Commercial systems typically include a number of units
connected to a common piping system. Any unit plumbing
maintenance work can introduce air into the piping system;
therefore air elimination equipment is a major portion of the
mechanical room plumbing. In piping systems expected to
utilize water temperatures below 50°F [10°C], 1/2” (13mm)
closed cell insulation is required on all piping surfaces to
eliminate condensation (extended range units required).
Metal to plastic threaded joints should never be used due to
their tendency to leak over time. All commercial class units
include low temperature-soldered bracket-supported IPT
water connections, which do not require a backup wrench.
Teon tape thread sealant is recommended to minimize
internal fouling of the heat exchanger. Do not over tighten
connections and route piping so as not to interfere with
service or maintenance access. Hose kits are available
from Heat Controller in different congurations as shown
in Figure 8 for connection between the unit and the piping
system. Depending upon selection, hose kits may include
shut off valves, P/T plugs for performance measurement,
high pressure stainless steel braided hose, “Y” type strainer
with blow down valve, and/or “J” type swivel connection.
Balancing valves and an external low pressure drop solenoid
valve for use in variable speed pumping systems may also
be included in the hose kit.
The piping system should be ushed to remove dirt, piping
chips, and other foreign material prior to operation (see
“Piping System Cleaning and Flushing Procedures” in this
manual). The ow rate is usually set between 2.25 and 3.5
gpm per ton [2.9 and 4.5 l/m per kW] of cooling capacity.
Heat Controller recommends 3 gpm per ton [3.9 l/m per kW]
for most applications of water loop heat pumps. To insure
proper maintenance and servicing, P/T ports are imperative
for temperature and ow verication, as well as performance
checks.
Water loop heat pump (cooling tower/boiler) systems
typically utilize a common loop, maintained between 60 90°F [16 - 32°C]. The use of a closed circuit evaporative
cooling tower with a secondary heat exchanger between the
tower and the water loop is recommended. If an open type
cooling tower is used continuously, chemical treatment and
ltering will be necessary.
Figure 8: Typical Water-Loop Application
BSP
EAP
Optional
Balancing Valve
Stainless steel braid hose
with integral ÒJÓ swivel
CAP
Optional Low Pressure Drop Water
Control Valve
(can be internally mounted
on some models)
CBP
CAP
Ball valve with optional
integral P/T plug
Water Out
Water In
Unit
Power
Building
Loop
Low Water Temperature Cutout Setting
- CXM Control
When antifreeze is selected, the FP1
jumper (JW3) should be clipped to
select the low temperature (antifreeze
10°F [-12.2°C]) set point and avoid
nuisance faults (see “Low Water
Temperature Cutout Selection” in this
manual).
Note: Low water temperature operation
requires extended range equipment.
12
IOM Manual HBH SERIES Heat Controller, Inc.
Ground-Loop Heat Pump Applications
CAUTION!
!
� CAUTION! �
CAUTION! The following instructions represent industry
accepted installation practices for closed loop earth coupled
heat pump systems. Instructions are provided to assist the
contractor in installing trouble free ground loops. These
instructions are recommendations only. State/provincial
and local codes MUST be followed and installation MUST
conform to ALL applicable codes. It is the responsibility of
the installing contractor to determine and comply with ALL
applicable codes and regulations.
CAUTION!
!
� CAUTION! �
CAUTION! Ground loop applications require extended range
equipment and optional refrigerant/water circuit insulation.
Pre-Installation -
all existing underground utilities, piping, etc. Install loops
for new construction before sidewalks, patios, driveways,
and other construction has begun. During construction,
accurately mark all ground loop piping on the plot plan
as an aid in avoiding potential future damage to the
installation.
Piping Installation - The typical closed loop ground
source system is shown in Figure 9. All earth loop piping
materials should be limited to polyethylene fusion only for
in-ground sections of the loop. Galvanized or steel ttings
should not be used at any time due to their tendency to
corrode. All plastic to metal threaded ttings should be
avoided due to their potential to leak in earth coupled
applications. A anged tting should be substituted. P/T
plugs should be used so that ow can be measured using
the pressure drop of the unit heat exchanger.
Earth loop temperatures can range between 25 and
110°F [-4 to 43°C]. Flow rates between 2.25 and 3 gpm
per ton [2.41 to 3.23 l/m per kW] of cooling capacity is
recommended in these applications.
Prior to installation, locate and mark
!
!
Test individual horizontal loop circuits before backlling.
Test vertical U-bends and pond loop assemblies prior to
installation. Pressures of at least 100 psi [689 kPa] should
be used when testing. Do not exceed the pipe pressure
rating. Test entire system when all loops are assembled.
Flushing the Earth Loop - Upon completion of system
installation and testing, ush the system to remove all
foreign objects and purge to remove all air.
Antifreeze - In areas where minimum entering loop
temperatures drop below 40°F [5°C] or where piping will
be routed through areas subject to freezing, antifreeze
is required. Alcohols and glycols are commonly used as
antifreeze; however your local sales manager should be
consulted for the antifreeze best suited to your area. Low
temperature protection should be maintained to 15°F [9°C]
below the lowest expected entering loop temperature. For
example, if 30°F [-1°C] is the minimum expected entering
loop temperature, the leaving loop temperature would be
25 to 22°F [-4 to -6°C] and low temperature protection
should be at 15°F [-10°C]. Calculation is as follows:
30°F - 15°F = 15°F [-1°C - 9°C = -10°C].
All alcohols should be premixed and pumped from
a reservoir outside of the building when possible or
introduced under the water level to prevent fumes.
Calculate the total volume of uid in the piping system.
Then use the percentage by volume shown in table 2 for
the amount of antifreeze needed. Antifreeze concentration
should be checked from a well mixed sample using a
hydrometer to measure specic gravity.
Low Water Temperature Cutout Setting - CXM Control
When antifreeze is selected, the FP1 jumper (JW3)
should be clipped to select the low temperature
(antifreeze 10°F [-12.2°C]) set point and avoid nuisance
faults (see “Low Water Temperature Cutout Selection”
in this manual).
Note: Low water temperature operation requires
extended range equipment.
Table 2: Antifreeze Percentages by Volume
Type
Methanol
100% USP food grade Propylene Glycol
Ethanol*
* Must not be denatured with any petroleum based product
10°F [-12.2°C] 15°F [-9.4°C] 20°F [-6.7°C] 25°F [-3.9°C]
25%
38%
29%
Minimum Temperature for Low Temperature Protection
21%
25%
25%
13
16%
22%
20%
10%
15%
14%
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