Heatcontroller HBH 6-10 T User Manual

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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

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

Basic Unit Description:

R-410A refrigerant circuit with high and low-side

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: Notication 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 prociency 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.

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 congurations 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 veried at start-up. Verication 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

signicantly 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 airow patterns are eld convertible (horizontal units only). Locate the airow 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.

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

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 sufcient 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 conned 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 difcult 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 specic 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 soft 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

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

RIGHT RETURN STRAIGHT DISCHARGE

EAP

2 CAP

CAP

FRONT

CBP

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.

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 conguration 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 qualied 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

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

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 airow through the unit during operation. Air ow through the unit MUST be at or above the minimum stated airow 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 airow

charts, consult submittal data for the series and model of the

specic unit.

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 airow 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

specically 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 Teon® 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 Teon 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

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.

Teon 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 congurations 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 verication, 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.

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 backlling.

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 specic 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%

16% 22% 20%

10% 15% 14%

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

Ground-Loop Heat Pump Applications

Figure 9: Typical Ground-Loop Application

BSP

CBP

Unit

Power

EAP

CAP

Stainless steel braid hose

with integral ÒJÓ swivel

Optional

Balancing Valve

Ball valve with optional

integral P/T plug

Optional Low Pressure Drop Water

Control Valve

(can be internally mounted

on some models)

Water Out

Building

Loop

Water In

IOM Manual HBH SERIES Heat Controller, Inc.

Ground-Water Heat Pump Applications

Open Loop - Ground Water Systems - Typical open loop piping is shown in Figure 10. Shut off valves should be included for ease of servicing. Boiler drains or other valves

should be “tee’d” into the lines to allow acid ushing of the

heat exchanger. Shut off valves should be positioned to

allow ow through the coax via the boiler drains without allowing ow into the piping system. P/T plugs should

be used so that pressure drop and temperature can be measured. Piping materials should be limited to copper or PVC SCH80. Note: Due to the pressure and temperature extremes, PVC SCH40 is not recommended.

Water quantity should be plentiful and of good quality. Consult table 3 for water quality guidelines. The unit can be ordered with either a copper or cupro-nickel water heat exchanger. Consult Table 3 for recommendations. Copper is recommended for closed loop systems and open loop ground water systems that are not high in mineral content or corrosiveness. In conditions anticipating heavy scale formation or in brackish water, a cupro-nickel heat exchanger is recommended. In ground water situations where scaling could be heavy or where biological growth such as iron bacteria will be present, an open loop system is not recommended. Heat exchanger coils may over time lose heat exchange capabilities due to build up of mineral deposits. Heat exchangers must only be serviced by a

qualied technician, as acid and special pumping equipment

is required. Desuperheater coils can likewise become scaled and possibly plugged. In areas with extremely hard water, the owner should be informed that the heat exchanger

may require occasional acid ushing. In some cases, the

desuperheater option should not be recommended due to hard water conditions and additional maintenance required.

Water Quality Standards - Table 3 should be consulted for water quality requirements. Scaling potential should be assessed using the pH/Calcium hardness method. If the pH <7.5 and the calcium hardness is less than 100 ppm, scaling potential is low. If this method yields numbers out of range of those listed, the Ryznar Stability and Langelier Saturation indecies should be calculated. Use the appropriate scaling surface temperature for the application, 150°F [66°C] for direct use (well water/open loop) and DHW (desuperheater); 90°F [32°F] for indirect use. A monitoring plan should be implemented in these probable scaling situations. Other water quality issues such as iron fouling, corrosion prevention and erosion and clogging should be referenced in Table 3.

Expansion Tank and Pump - Use a closed, bladder-type expansion tank to minimize mineral formation due to air exposure. The expansion tank should be sized to provide at least one minute continuous run time of the pump using its drawdown capacity rating to prevent pump short cycling. Discharge water from the unit is not contaminated in any manner and can be disposed of in various ways, depending on local building codes (e.g. recharge well, storm sewer,

drain eld, adjacent stream or pond, etc.). Most local codes

forbid the use of sanitary sewer for disposal. Consult your local building and zoning department to assure compliance in your area.

Water Control Valve - Note the placement of the water control valve in Figure 10. Always maintain water pressure in the heat exchanger by placing the water control valve(s) on the discharge line to prevent mineral precipitation during the off-cycle. Pilot operated slow closing valves are recommended to reduce water hammer. If water hammer persists, a mini-expansion tank can be mounted on the piping to help absorb the excess hammer shock. Insure that the total ‘VA’ draw of the valve can be supplied by the unit transformer. For instance, a slow closing valve can draw up to 35VA. This can overload smaller 40 or 50 VA transformers depending on the other controls in the circuit. A typical pilot operated solenoid valve draws approximately 15VA (see Figure 14). Note the special wiring diagrams for slow closing valves (Figures 15 & 16).

Flow Regulation - Flow regulation can be accomplished

by two methods. One method of ow 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 ow rate from Tables

8a through 8e. Since the pressure is constantly varying, two pressure gauges may be needed. Adjust the valve

until the desired ow of 1.5 to 2 gpm per ton [2.0 to 2.6 l/m per kW] is achieved. A second method of ow control requires a ow control device mounted on the outlet of the water control valve. The device is typically a brass tting with an orice of rubber or plastic material that is designed to allow a specied ow rate. On occasion, ow control

devices may produce velocity noise that can be reduced by applying some back pressure from the ball valve located on the discharge line. Slightly closing the valve will spread the pressure drop over both devices, lessening the velocity noise. NOTE: When EWT is below 50°F [10°C], 2 gpm

per ton (2.6 l/m per kW) is required.

Heat Controller, Inc. HBH SERIES IOM Manual

Water Coil Low Temperature Limit Setting - For all open loop systems the 30°F [-1.1°C] FP1 setting (factory settingwater) should be used to avoid freeze damage to the unit. See “Low Water Temperature Cutout Selection” in this manual for details on the low limit setting.

Figure 10: Typical Open Loop/Well Application

Pressure

Flow

Tank

Regulator

Water Out

Water

Water In

Control

Valve

P/T Plugs

Shut-Off

Valve

Optional

Filter

Boiler

Drains

IOM Manual HBH SERIES Heat Controller, Inc.

Water Quality Standards

Table 3: Water Quality Standards

Water Quality

Parameter

Material

Closed

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

Method

All

pH < 7.5 and Ca Hardness <100ppm

Index Limits for Probable Scaling Situations - (Operation outside these limits is not recommended)

Scaling indexes should be calculated at 150°F [66°C] for direct use and HWG applications, and at 90°F [32°C] for indirect HX use. A monitoring plan should be implemented.

Ryznar Stability Index If >7.5 minimize steel pipe use.

Langelier Saturation Index

All

- 6.0 - 7.5

If <-0.5 minimize steel pipe use. Based upon 150°F [66°C] HWG and

-0.5 to +0.5

Direct well, 85°F [29°C] Indirect Well HX

Iron Fouling

Iron Fe2+(Ferrous) (Bacterial Iron potential)

Iron Fouling

All

(ferrous)>0.2 ppm with pH 6 - 8, O2<5 ppm check for iron bacteria.

If Fe

Above this level deposition will occur.

<0.2 ppm (Ferrous)

<0.5 ppm of Oxygen

Corrosion Prevention

Hydrogen Sulfide (H

Ammonia ion as hydroxide, chloride, nitrate and sulfate compounds

Maximum Chloride Levels

6 - 8.5

All

Copper - <20ppm NR NR

304 SS - <400 ppm <250 ppm <150 ppm 316 SS - <1000 ppm <550 ppm < 375 ppm

Titanium - >1000 ppm >550 ppm >375 ppm

Monitor/treat as

needed

- <0.5 ppm

- <150 ppm NR NR

Minimize steel pipe below 7 and no open tanks with pH <8

At H

S>0.2 ppm, avoid use of copper and copper nickel piping or HX's.

Copper alloy (bronze or brass) cast components are OK to <0.5 ppm.

50°F (10°C) 75°F (24°C) 100°F (38°C)

Rotten egg smell appears at 0.5 ppm level.

Maximum Allowable at maximum water temperature.

6 - 8.5

<0.5 ppm

Erosion and Clogging

<10 ppm of particles and a maximum velocity of 6 fps [1.8 m/s].

Particulate Size and Erosion

Notes:

• Closed Recirculating system is identified by a

• Recirculating open wells should observe the open recirculating design considerations.

• NR - Application not recommended.

• "-" No design Maximum.

All

Filtered for maximum 800 micron [800mm, 20 mesh] size.

closed pressurized piping system.

<10 ppm (<1 ppm "sandfree” for reinjection) of particles and a maximum velocity of 6 fps [1.8 m/s]. Filtered for maximum 800 micron [800mm, 20 mesh] size. Any particulate that is not removed can potentially clog components.

Rev.: 6/2/2010

Heat Controller, Inc. HBH SERIES IOM Manual

Electrical - Line Voltage

Electrical - Line Voltage - All 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 diagram for eld connections that must be made by the installing (or electrical) contractor. All nal electrical connections must be made with a length of exible conduit

to minimize vibration and sound transmission to the building.

General Line Voltage Wiring -

Be sure the available power is the same voltage and phase shown on the unit serial plate. Line and low voltage wiring must be done in accordance with local codes or the National Electric Code, whichever is applicable.

Transformer - All 208/230 voltage units are factory wired for 208 volt. If supply voltage is 230 volt, installer must rewire transformer. See wire diagram for connections.

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! Use only copper conductors for eld installed

electrical wiring. Unit terminals are not designed to accept other types of conductors.

WARNING!

� WARNING! �

CAUTION!

� CAUTION! �

Table 4a: HBH Series Electrical Data - (Standard 60Hz Units)

Model

072

096

120

Voltage

Code

Rated

Voltage

208-3-60 197/254 A, B, C 2 10.4 73.0 4.0 24.8 27.4 35

208-3-60 197/254 D, E 2 10.4 73.0 6.2 27.0 29.6 35

460-3-60 414/506 A, B, C 2 5.8 38.0 2.0 13.6 15.1 20

460-3-60 414/506 D, E 2 5.8 38.0 3.1 14.7 16.1 20

575-3-60 518/633 A, B, C 2 3.8 36.5 1.4 9.0 9.9 15

575-3-60 518/633 D, E 2 3.8 36.5 2.3 9.9 10.8 15

208-3-60 197/254 A, B, C 2 13.7 83.1 6.2 33.6 37.0 50

208-3-60 197/254 D, E 2 13.7 83.1 9.2 36.6 40.0 50

460-3-60 414/506 A, B, C 2 6.2 41.0 3.1 15.5 17.0 20

460-3-60 414/506 D, E 2 6.2 41.0 4.3 16.7 18.3 20

575-3-60 518/633 A, B, C 2 4.8 33.0 2.3 11.9 13.1 15

575-3-60 518/633 D, E 2 4.8 33.0 3.4 13.0 14.2 15

208-3-60 197/254 A, B, C 2 15.6 110.0 9.2 40.4 44.3 50

208-3-60 197/254 D, E 2 15.6 110.0 14.1 45.3 49.2 60

460-3-60 414/506 A, B, C 2 7.8 52.0 4.3 19.9 21.9 25

460-3-60 414/506 D, E 2 7.8 52.0 7.0 22.6 24.6 30

575-3-60 518/633 A, B, C 2 5.8 38.9 3.4 15.0 16.5 20

575-3-60 518/633 D, E 2 5.8 38.9 5.2 16.8 18.3 20

Voltage

Min Max

Blower Option

Compressor

QTY RLA LRA

Fan

Motor

FLA

Total

Unit

FLA

Min

Circuit

Amp

Max Fuse/ HACR

HACR circuit breaker in USA only All fuses Class RK-5

IOM Manual HBH SERIES Heat Controller, Inc.

Electrical - Power Wiring

Figure 11: TCH 072-120 Line Voltage Wiring

WARNING!

� WARNING! �

WARNING! Disconnect electrical power source to prevent

injury or death from electrical shock.

CAUTION!

� CAUTION! �

CAUTION! Use only copper conductors for eld installed

electrical wiring. Unit terminals are not designed to accept other types of conductors.

Electrical - Line Voltage - All 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 diagram for eld connections that must be made by the installing (or electrical) contractor. All nal electrical connections must be made with a length of exible conduit

to minimize vibration and sound transmission to the building.

Power

Block

General Line Voltage Wiring -

power is the same voltage and phase shown on the unit serial plate. Line and low voltage wiring must be done in accordance with local codes or the National Electric Code, whichever is applicable.

Power Connection - Line voltage connection is made by connecting the incoming line voltage wires to the “L” side of the power block as shown in Figure 11. Consult electrical data tables for correct fuse size.

Transformer - All 208/230 voltage units are factory wired for 208 volt. If supply voltage is 230 volt, installer must rewire transformer. See wire diagram for connections.

Be sure the available

Heat Controller, Inc. HBH SERIES IOM Manual

Electrical - Power & Low Voltage Wiring

ELECTRICAL - LOW VOLTAGE WIRING

Thermostat Connections - The thermostat should be wired directly to the CXM board. Figure 12 shows wiring for units. See “Electrical – Thermostat” (Figure 16) for

specic terminal connections.

Low Water Temperature Cutout Selection - The CXM

control allows the eld selection of low water (or water-

antifreeze solution) temperature limit by clipping jumper JW3, which changes the sensing temperature associated with thermistor FP1. Note that the FP1 thermistor is located on the refrigerant line between the coaxial heat exchanger and expansion device (TXV or cap tube). Therefore, FP1 is sensing refrigerant temperature, not water temperature, which is a better indication of how

water ow rate/temperature is affecting the refrigeration

circuit.

The factory setting for FP1 is for systems using water (30°F [-1.1°C] refrigerant temperature). In low water temperature (extended range) applications with antifreeze (most ground loops), jumper JW3 should be clipped as shown in Figure 13 to change the setting to 10°F [-12.2°C] refrigerant temperature, a more suitable temperature when using an antifreeze solution. All Heat Controller units operating with entering water temperatures below 59°F [15°C] must include the optional water/refrigerant circuit insulation package to prevent internal condensation.

Figure 12: HBH 072-120 Low Voltage Field Wiring

CXM1 Low

Voltage

Connector

CXM2

Figure 13: FP1 Limit Setting

JW3-FP1

jumper should

be clipped for

low temperature

CXM PCB

operation

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.

See the specic unit wiring diagram for details.

Low Voltage VA Ratings

Components In Unit VA

Typical Blower Contactor 6 - 9

Typical Reversing Valve Solenoid (2) 8 - 12

30A Compressor Contactor (2) 12 - 18

CXM board (2) 10 - 18

DXM board (2) 16 - 24

Units with CXM Remaing VA for Accessories

Units with DXM Remaing VA for Accessories

39 - 18

33 - 12

Standard transformer is 75VA.

Figure 14: Accessory Wiring

IOM Manual HBH SERIES Heat Controller, Inc.

Electrical - Low Voltage Wiring

Figure 15: Optional Motorized Water Valve Wiring

Switch

23B0040N01 for 072 and 096

or 23B0041N01 for 120 Valve

Thermostat

Water Solenoid Valves - An external solenoid valve(s) should be used on ground water installations to shut off

ow to the unit when the compressor is not operating. A

slow closing valve may be required to help reduce water hammer. Figure 14 shows typical wiring for a 24VAC external solenoid valve. This wiring should only be used if valve fully opens in 15 second. Figure 15 illustrates a typical slow closing water control valve wiring for Belimo valves. Slow closing valves take approximately

60 seconds to open (very little water will ow before 45

seconds). Once fully open, an end switch allows the compressor to be energized. Only relay or triac based electronic thermostats should be used with slow closing valves. When wired as shown, the slow closing valve will operate properly with the following notations:

1. The valve will remain open during a unit lockout.

2. The valve will draw approximately 25-35 VA through the “Y” signal of the thermostat.

Note: This valve can overheat the anticipator of an electromechanical thermostat. Therefore, only relay or triac based thermostats should be used.

Heat Controller, Inc. HBH SERIES IOM Manual

Connection to CXM Control

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. Position the thermostat back plate against the wall so that it appears level and so the thermostat wires protrude through

Figure 16: Thermostat Connection

ATP32U03 Thermostat

Compressor-Stage 1

Compressor-Stage 2

Reversing Valve

Fan

24Vac Hot

24Vac Com

CXM1

the middle of the back plate. Mark the position of the back plate mounting holes and drill holes with a 3/16” (5mm) bit. Install supplied anchors and secure plate to the wall. Thermostat wire must be 18 AWG wire. Wire the appropriate thermostat as shown in Figure 16 to the low voltage terminal strip on the CXM control board. Practically any heat pump thermostat will work with Heat Controller units, provided it has the correct number of heating and cooling stages.

CXM2

Field Wiring

Factory Wiring

IOM Manual HBH SERIES Heat Controller, Inc.

Typical Wiring Diagram - HBH Units with CXM

Heat Controller, Inc. HBH SERIES IOM Manual

Description of Operation LED Alarm Relay

Normal Mode On Open Normal Mode with UPS Warning On Cycle (closed 5 sec., Open 25 sec.) CXM is non-functional Off Open Fault Retry Slow Flash Open Lockout Fast Flash Closed Over/Under Voltage Shutdown Slow Flash Open (Closed after 15 minutes)

Test Mode - No fault in memory Flashing Code 1 Cycling Code 1

Test Mode - HP Fault in memory Flashing Code 2 Cycling Code 2

Test Mode - LP Fault in memory Flashing Code 3 Cycling Code 3

Test Mode - FP1 Fault in memory Flashing Code 4 Cycling Code 4

Test Mode - FP2 Fault in memory Flashing Code 5 Cycling Code 5

Test Mode - CO Fault in memory Flashing Code 6 Cycling Code 6

Test Mode - Over/Under shutdown in memory

Flashing Code 7 Cycling Code 7

Test Mode - UPS in memory Flashing Code 8 Cycling Code 8

Test Mode - Swapped Thermistor Flashing Code 9 Cycling Code 9

CXM Controls

CXM Control - For detailed control information, see CXM Application, Operation and Maintenance (AOM) manual (part # 97B0003N1)).

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. Upon entering

test mode, the status LED will ash a code representing the

last fault. For diagnostic ease at the thermostat, the alarm relay will also cycle during test mode. The alarm relay will cycle on and off similar to the status LED to indicate a code representing the last fault, at the thermostat. Test mode can be exited by shorting the test terminals for 3 seconds. Retry Mode: If the control is attempting a retry of a fault, the

status LED will slow ash (slow ash = one ash every 2

seconds) to indicate the control is in the process of retrying.

Field Conguration Options - Note: In the following eld conguration options, jumper wires should be clipped ONLY when power is removed from the CXM control.

Water coil low temperature limit setting: Jumper 3 (JW3-

FP1 Low Temp) provides eld selection of temperature limit

setting for FP1 of 30°F or 10°F [-1°F or -12°C] (refrigerant temperature). Not Clipped = 30°F [-1°C]. Clipped = 10°F [-12°C]. Air coil low temperature limit setting: Jumper 2 (JW2-FP2

Low Temp) provides eld selection of temperature limit

setting for FP2 of 30°F or 10°F [-1°F or -12°C] (refrigerant temperature). Note: This jumper should only be clipped

under extenuating circumstances, as recommended by the factory.

Not Clipped = 30°F [-1°C]. Clipped = 10°F [-12°C].

Alarm relay setting: Jumper 1 (JW1-AL2 Dry) provides eld

selection of the alarm relay terminal AL2 to be jumpered to 24VAC or to be a dry contact (no connection). Not Clipped = AL2 connected to R. Clipped = AL2 dry contact (no connection).

DIP switch 2: Stage 2 Selection - provides selection of whether compressor has an “on” delay. If set to stage 2, the compressor will have a 3 second delay before energizing. Also, if set for stage 2, the alarm relay will NOT cycle during test mode. On = Stage 1. Off = Stage 2

DIP switch 3: Not Used. DIP switch 4: DDC Output at EH2 - provides selection

for DDC operation. If set to “DDC Output at EH2,” the EH2 terminal will continuously output the last fault code of the controller. If set to “EH2 normal,” EH2 will operate as standard electric heat output. On = EH2 Normal. Off = DDC Output at EH2.

Note: Some CXM controls only have a 2 position DIP switch package. If this is the case, this option can be selected by clipping the jumper which is in position 4 of SW1.

Jumper not clipped = EH2 Normal. Jumper clipped = DDC Output at EH2. DIP switch 5: Factory Setting - Normal position is “On.” Do not change selection unless instructed to do so by the factory.

Table 6a: CXM LED And Alarm Relay Operations

DIP Switches - Note: In the following eld conguration options, DIP switches should only be changed when power is removed from the CXM control.

DIP switch 1: Unit Performance Sentinel Disable - provides

eld selection to disable the UPS feature.

On = Enabled. Off = Disabled.

-Slow Flash = 1 ash every 2 seconds

-Fast Flash = 2 ashes every 1 second

-Flash code 2 = 2 quick ashes, 10 second pause, 2 quick ashes, 10 second pause, etc.

-On pulse 1/3 second; off pulse 1/3 second

� CAUTION! �

CAUTION!

CAUTION! Do not restart units without inspection and remedy of faulting condition. Equipment damage may occur.

IOM Manual HBH SERIES Heat Controller, Inc.

Safety Features

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.

Random start: The control features a random start upon power up of 5-80 seconds. Fault Retry: In Fault Retry mode, the Status LED begins

slowly ashing to signal that the control is trying to recover

from a fault input. The control will stage off the outputs and then “try again” to satisfy the thermostat input call. Once the

thermostat input call is satised, the control will continue on

as if no fault occurred. If 3 consecutive faults occur without satisfying the thermostat input call, the control will go into “lockout” mode. The last fault causing the lockout will be stored in memory and can be viewed by going into test mode (CXM board). Note: FP1/FP2 faults are factory set at only one try.

Lockout: In lockout mode, the status LED will begin fast

ashing. The compressor relay is turned off immediately.

Lockout mode can be “soft” reset by turning off the thermostat (or satisfying the call). A “soft” reset keeps the fault in memory but resets the control. A “hard” reset (disconnecting power to the control) resets the control and erases fault memory.

Lockout with emergency heat: While in lockout mode, if W becomes active (CXM), emergency heat mode will occur.

High pressure switch: When the high pressure switch opens due to high refrigerant pressures, the compressor relay is de-energized immediately since the high pressure switch is in series with the compressor contactor coil. The high pressure fault recognition is immediate (does not delay for 30 continuous seconds before de-energizing the compressor). High pressure lockout code = 2

Example: 2 quick ashes, 10 sec pause, 2 quick ashes, 10

sec. pause, etc.

Low pressure switch: The low pressure switch must be open and remain open for 30 continuous seconds during “on” cycle to be recognized as a low pressure fault. If the low pressure switch is open for 30 seconds prior to compressor power up it will be considered a low pressure (loss of charge) fault. The low pressure switch input is bypassed for the initial 120 seconds of a compressor run cycle. Low pressure lockout code = 3

Water coil low temperature (FP1): The FP1 thermistor temperature must be below the selected low temperature limit setting for 30 continuous seconds during a compressor run cycle to be recognized as a FP1 fault. The FP1 input is bypassed for the initial 120 seconds of a compressor run cycle. FP1 is set at the factory for one try. Therefore, the control will go into lockout mode once the FP1 fault has occurred. FP1 lockout code = 4

Air coil low temperature (FP2): The FP2 thermistor temperature must be below the selected low temperature limit setting for 30 continuous seconds during a compressor run cycle to be recognized as a FP2 fault. The FP2 input is bypassed for the initial 60 seconds of a compressor run cycle. FP2 is set at the factory for one try. Therefore, the control will go into lockout mode once the FP2 fault has occurred. FP2 lockout code = 5

Condensate overow: The condensate overow sensor must sense overow level for 30 continuous seconds to be recognized as a CO fault. Condensate overow will be

monitored at all times. CO lockout code = 6

Over/under voltage shutdown: An over/under voltage condition exists when the control voltage is outside the range of 19VAC to 30VAC. Over/under voltage shut down is a self-resetting safety. If the voltage comes back within range for at least 0.5 seconds, normal operation is restored. This is not considered a fault or lockout. If the CXM is in over/under voltage shutdown for 15 minutes, the alarm relay will close. Over/under voltage shut down code = 7

Heat Controller, Inc. HBH SERIES IOM Manual

CXM Controls

Unit Performance Sentinel-UPS (patent pending): The UPS feature indicates when the heat pump is operating

inefciently. A UPS condition exists when:

a) In heating mode with compressor energized,

FP2 is greater than 125°F [52°C] for 30 continuous seconds, or:

b) In cooling mode with compressor energized,

FP1 is greater than 125°F [52°C] for 30 continuous seconds, or:

c) In cooling mode with compressor energized,

FP2 is less than 40°F [4.5°C] for 30 continuous seconds.

If a UPS condition occurs, the control will immediately go to UPS warning. The status LED will remain on as if the control is in normal mode. Outputs of the control, excluding LED and alarm relay, will NOT be affected by UPS. The UPS condition cannot occur during a compressor off cycle. During UPS warning, the alarm relay will cycle on and off. The cycle rate will be “on” for 5 seconds, “off” for 25 seconds, “on” for 5 seconds, “off” for 25 seconds, etc. UPS warning code = 8 Swapped FP1/FP2 thermistors: During test mode, the control monitors to see if the FP1 and FP2 thermistors are in the appropriate places. If the control is in test mode, the

control will lockout with code 9 after 30 seconds if: a) The compressor is on in the cooling mode and

the FP1 sensor is colder than the FP2 sensor, or:

b) The compressor is on in the heating mode and

the FP2 sensor is colder than the FP1 sensor.

Swapped FP1/FP2 thermistor code = 9.

Diagnostic Features - The LED on the CXM board advises the technician of the current status of the CXM control. The LED can display either the current CXM mode or the last fault in memory if in test mode. If there is no fault in memory,

the LED will ash Code 1 (when in test mode).

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 rst time after power-up

that there is a call for compressor, the compressor will follow a 5 to 80 second random start delay. After the random start delay and anti-short cycle delay, the compressor relay will be energized. On all subsequent compressor calls, the random start delay is omitted.

IOM Manual HBH SERIES Heat Controller, Inc.

Blower Adjustment

CAUTION!

� CAUTION! �

Always disconnect all power supply(s) to unit prior to making belt or sheave adjustments. Inadvertently starting of the motor can cause damage to the equipment and personal injury.

Airow and External Static Pressure

Selection Adjustment - The TCH Series is available with standard, low, and high static options. These options will substitute a different blower drive sheave for each static range. In addition certain static ranges (bold print in Tables 5a through 5k) may require the optional large fan motor. Please specify static range and motor horsepower when ordering. See model nomenclature.

Sheave Adjustment - The TCH Series is supplied with variable sheave drive on the fan motor to adjust for

differing airows at various ESP conditions. Select an airow requirement on the left side of the table, then move

horizontally to right under the required ESP. Note the sheave turns open, rpm and horsepower for that condition. Fully closed the sheave will produce the highest static capability (higher rpm). To adjust sheave position: loosen belt tension and remove belt, loosen set screw on variable sheave (on fan motor) and open sheave to desired position. Retighten set screw and replace belt and set belt tension as below.

Notes:

- Motor position should not need adjustment.

- Motor sheave position is at mid position of each

sheave. Thus the motor sheave is typically 2.5 turns open on a 5 turn sheave.

Special Note for AHRI Testing

The Units should be adjusted as follows for rated airow:

HBH072 - 2400cfm/2.5 turns and 0.57 in wg ESP HBH096 - 3200cfm/3.0 turns and 0.62 in wg ESP HBH120 - 4000cfm/3.0 turns and 0.59 in wg ESP

Belt Tensioning - An overly loose belt will, upon motor start, produce a slippage 'squeel' and cause premature

belt failure and or intermittent airow. An overly tight belt

can cause premature motor or blower bearing failure.

Belt Tensioning Procedure - HBH

1. Remove belt from motor sheave

2. Lift motor assembly

3. Loosen the 5/16" hex nuts on the grommet motor adjustment bolts (2 per bolt). To increase the belt tension loosen the top hex nut. To decrease the belt tension loosen the bottom hex nut.

4. Turn the bolts by hand to the desired position then tighten the 5/16" hex nuts ( 2 per bolt).

5. Lower the motor assembly

6. Install the belt

7. The belt should be tensioned tensioning gauge method such as the Browning Belt Tensioner to set proper belt tension (See next page).

Heat Controller, Inc. HBH SERIES IOM Manual

Tensioning V-Belt Drives

General rules of tensioning

1. Ideal tension is the lowest tension at which the belt will not slip under peak load conditions.

2. Check tension frequently during the first 24-48 hours of operation.

3. Over tensioning shortens belt and bearing life.

4. Keep belts free from foreign material which may cause slip.

5. Make V-drive inspection on periodic basis. Tension when slipping. Never apply belt dressing as this willl damage the belt and cause early failure.

Tension Measurement Procedure

1. Measure the belt span (see sketch).

2. Position bottom of the large “O” ring on the span scale at the measured belt span.

3. Set the small “O” ring on the deflection force scale to zero.

4. Place the tension checker squarely on one belt at the center of the belt span. Apply a force on the plunger and perpendicular to the belt span until the bottom of the large “O” ring is even with the top of the next belt or with the bottom of a straight edge laid across the sheaves.

5. Remove the tension checker and read the forct applied from the bottom of the small “O” ring on the deflection force scale.

6. Compare the force you have applied with the values given in the table below. The force should be between the minimum and maximum shown. The maximum value is shown for “New Belt” and new belts should be tensioned at this value to allow for expected tension loss. Used belts should be maintained at the minimum value as indicated in the table below.

NOTE: The ratio of deflection to belt span is 1:64.

Sheave Diameter - Inches

Smallest

Sheave

Cross

Section

A, AX

B, BX

Diameter

Range

3.0 - 3.6

3.8 - 4.8

5.0 - 7.0

3.4 - 4.2

4.4 - 5.6

5.8 - 8.6

RPM

Range

1000-2500 2501-4000

860-2500 2501-4000

Deflection Force - LBS

Super Gripbelts and

Unnotched Gripbands

Used

Belt

3.7

2.8

4.5

3.8

5.4

4.7

5.3

4.5

6.3

6.0

New

Belt

5.5

4.2

6.8

5.7

8.0

7.0

7.9

6.7

9.4

8.9

Belt Deflection Force

Gripnotch Belts and Notched Gripbands

Used

Belt

4.1

3.4

5.0

4.3

5.7

5.1

4.9

4.2

7.1

8.5

7.3

New

Belt

6.1

5.0

7.4

6.4

9.4

7.6

7.2

6.2

10.5

9.1

12.6

10.9

IOM Manual HBH SERIES Heat Controller, Inc.

Blower Sheave Information

Table 4a: HBH Blower Sheave and Belt Information

Model

120

Con󰘰guration

Return/Supply

Left or Right/

Straight or Back

Component

Blower Sheave BK67 X 1" BK85 X 1" BK67 X 1" BK67 X 1" BK67 X 1"

Motor Sheave 1VP34 X 7/8" 1VP34 X 7/8" 1VP44 X 7/8" 1VP34 X 7/8" 1VP44 X 7/8"

Motor 1HP 1HP 1HP 2HP 2HP

Belt B X 46 B X 50 B X 48 B X 46 B X 48

Blower Sheave BK67 X 1" BK77 X 1" BK62 X 1" BK67 X 1" BK62 X 1"

Motor Sheave 1VP40 X 7/8" 1VP34 X 7/8" 1VP44 X 7/8" 1VP40 X 7/8" 1VP44 X 7/8"

Motor 2HP 2HP 2HP 3HP 3HP

Belt B X 46 B X 48 B X 46 B X 46 B X 46

Blower Sheave BK67 X 1" BK67 X 1" BK67 X 1" BK67 X 1" BK67 X 1"

Motor Sheave 1VP44 X 7/8" 1VP34 X 7/8" 1VP50 X 7/8" 1VP44 X 1-1/8" 1VP50 X 1-1/8"

Motor 3HP 3HP 3HP 5HP 5HP

Belt B X 48 B X 46 B X 48 B X 50 B X 51

A B C D E

Drive Package

Heat Controller, Inc. HBH SERIES IOM Manual

HBH072 Blower Performance

SCFM ESP 0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10 1.20 1.30 1.40 1.50

BHP 0.28 0.32 0.35 0.39 0.42 0.45 0.48 0.52 0.56 0.60 0.64 0.69 0.72 0.76

Sheave/Mtr B B B A A A A A A C C C C C

1800

1900

2000

2100

2200

2300

2400

2500

2600

2700

2800

2900

3000

A = Standard Static/Standard Motor, B = Low Static/Standard Motor, C = High Static/Standard Motor, D = Standard Static/Large Motor, E = High Static/Large Motor Unit factory shipped with standard static sheave and drive at 2.5 turns open. Other speed require eld selection. For applications requiring higher static pressures, contact your local representative. Performance data does not include drive losses and is based on sea level conditions. Do not operate in black regions. All airow is rated at lowest Voltage if unit is dual Voltage rated, i.e. 208V for 208-230V units.

RPM 599 645 690 735 775 815 850 885 910 940 965 995 1015 1040

Turns Open 3 2 1 4 3.5 2.5 2 1.5 1 5 4.5 4 3.5 3

BHP 0.31 0.36 0.40 0.44 0.49 0.53 2.50 0.62 0.65 0.69 0.73 0.76 0.80 0.84

Sheave/Mtr B B A A A A A A C C C C C C

RPM 604 655 695 740 780 820 855 890 920 950 980 1005 1030 1055

Turns Open 3 2 5 4 3 2.5 2 1.5 5.5 4.5 4 3.5 3 3

BHP 0.31 0.34 0.39 0.45 0.50 0.54 0.59 0.63 0.67 0.72 0.75 0.79 0.82 0.86 0.90

Sheave/Mtr B B B A A A A A A C C C C C C

RPM 568 615 660 705 750 785 825 860 895 930 960 990 1015 1040 1065

Turns Open 4.5 2.5 1.5 4.5 3.5 3 2.5 1.5 1 5 4.5 4 3.5 3 2.5

BHP 0.33 0.38 0.42 0.46 0.50 0.54 0.59 0.65 0.70 0.74 0.78 0.81 0.85 0.89 0.94 0.98

Sheave/Mtr B B B A A A A A A A C C C C C C

RPM 531 583 630 670 715 755 795 835 875 905 940 970 1000 1025 1055 1080

Turns Open 4.5 3.5 2 5 4.5 3.5 2.5 2 1.5 1 5 4 4 3 2.5 2.5

BHP 0.37 0.40 0.45 0.49 0.55 0.60 0.65 0.70 0.75 0.79 0.83 0.87 0.92 0.96 1.00 1.04

Sheave/Mtr B B B A A A A A A C C C C C E E

RPM 552 599 645 685 730 770 810 850 885 915 950 980 1010 1040 1065 1090

Turns Open 4 3 2 5 4 3 2.5 2 1.5 5.5 4.5 4 3.5 3 2.5 2

BHP 0.42 0.47 0.51 0.56 0.60 0.65 0.70 0.75 0.80 0.84 0.89 0.94 1.00 1.05 1.10 1.16

Sheave/Mtr B B B A A A A A A C C C E E E E

RPM 573 620 660 705 745 785 820 860 895 925 960 990 1020 1050 1075 1105

Turns Open 3.5 2.5 1.5 4.5 4 3 2.5 1.5 1 5 4.5 4 3.5 3 2.5 2

BHP 0.48 0.52 0.57 0.61 0.66 0.72 0.78 0.83 0.87 0.92 0.97 1.02 1.07 1.13 1.19 1.25

Sheave/Mtr B B A A A A A A A C C E E E E E

RPM 604 645 690 730 765 805 845 880 910 945 975 1010 1035 1065 1095 1125

Turns Open 3 2 5 4 3.5 2.5 2 1.5 1 5 4 3.5 3 2.5 2 1.5

BHP 0.52 0.57 0.61 0.66 0.72 0.78 0.83 0.89 0.94 1.00 1.03 1.08 1.14 1.20 1.25 1.31

Sheave/Mtr B B A A A A A A C E E E E E E E

RPM 620 660 700 740 780 815 850 885 920 950 985 1015 1045 1075 1100 1130

Turns Open 2.5 1.5 4.5 4 3 2.5 2 1.5 5.5 4.5 4 3.5 3 2.5 2 1.5

BHP 0.56 0.61 0.66 0.70 0.76 0.82 0.88 0.93 0.98 1.04 1.08 1.14 1.20 1.26 1.32 1.37

Sheave/Mtr B A A A A A A A C E E E E E E E

RPM 635 675 715 750 790 825 860 895 925 960 990 1020 1050 1080 1110 1135

Turns Open 2.5 5 4.5 3.5 3 2 1.5 1 5 4.5 4 3.5 3 2.5 1.5 1.5

BHP 0.61 0.66 0.71 0.76 0.82 0.87 0.93 0.98 1.04 1.10 1.15 1.21 1.27 1.33 1.39 1.45

Sheave/Mtr B A A A A A A A E E E E E E E E

RPM 655 695 730 770 805 840 875 905 940 970 1000 1030 1060 1090 1120 1145

Turns Open 2 4.5 4 3.5 2.5 2 1.5 1 5 4.5 3.5 3 2.5 2 1.5 1

BHP 0.66 0.72 0.77 0.83 0.88 0.93 0.99 1.05 1.11 1.16 1.22 1.30 1.37 1.44 1.51 1.57

Sheave/Mtr B A A A A A A D E E E E E E E E

RPM 670 710 750 785 815 850 885 915 950 980 1010 1040 1070 1100 1130 1155

Turns Open 1.5 4.5 3.5 3 2.5 1.5 1.5 1 4.5 4 3.5 3 2.5 2 1.5 1

BHP 0.71 0.77 0.82 0.87 0.93 0.98 1.04 1.10 1.16 1.22 1.30 1.36 1.43 1.50 1.57 1.63

Sheave/Mtr A A A A A A D E E E E E E E E E

RPM 685 725 765 795 830 860 895 925 955 985 1020 1045 1075 1105 1135 1160

Turns Open 5 4 3.5 3 2 1.5 1 5 4.5 4 3.5 3 2.5 1.5 1 1

BHP 0.79 0.84 0.90 0.95 1.01 1.07 1.13 1.19 1.25 1.31 1.38 1.46 1.52 1.59 1.66

Sheave/Mtr A A A A A D D E E E E E E E E

RPM 710 745 780 815 850 885 915 945 975 1005 1035 1065 1090 1120 1150

Turns Open 4.5 4 3 2.5 2 1 1 5 4 3.5 3 2.5 2 1.5 1

IOM Manual HBH SERIES Heat Controller, Inc.

HBH096 Blower Performance

SCFM ESP 0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10 1.20 1.30 1.40 1.50

BHP 0.45 0.50 0.54 0.59 0.63 0.69 0.74 0.80 0.85 0.90 0.94 0.99 1.04 1.10 1.16 1.22

Sheave/Mtr B B B B B A A A A A A A A A C C

2400

2500

2600

2700

2800

2900

3000

3100

3200

A = Standard Static/Standard Motor, B = Low Static/Standard Motor, C = High Static/Standard Motor, D = Standard Static/Large Motor, E = High Static/Large Motor

Unit factory shipped with standard static sheave and drive at 2.5 turns open. Other speed require 󰘰eld selection.

For applications requiring higher static pressures, contact your local representative. Performance data does not include drive losses and is based on sea level conditions.

Do not operate in black regions. All air󰘱ow in rated at lowest Voltage if unit is dual Voltage rated, i.e. 208V for 208-230V units.

RPM 578 625 665 705 745 785 820 860 895 925 960 990 1020 1050 1080 1110

Turns

Open

BHP 0.50 0.55 0.59 0.64 0.69 0.75 0.81 0.88 0.92 0.97 1.01 1.06 1.12 1.17 1.23 1.29

Sheave/Mtr B B B B A A A A A A A A A C C C

RPM 599 645 685 725 765 800 835 875 905 940 970 1005 1035 1060 1090 1120

Turns

Open

BHP 0.55 0.60 0.65 0.69 0.75 0.80 0.86 0.92 0.97 1.02 1.08 1.13 1.19 1.25 1.30 1.36

Sheave/Mtr B B B B A A A A A A A A A C C C

RPM 625 665 705 740 780 815 850 885 920 950 985 1015 1045 1075 1100 1130

Turns

Open

BHP 0.60 0.65 0.70 0.75 0.80 0.86 0.91 0.97 1.02 1.08 1.14 1.20 1.26 1.32 1.38 1.44

Sheave/Mtr B B B A A A A A A A A A C C C C

RPM 645 685 725 760 795 830 865 900 930 960 995 1025 1055 1085 1115 1140

Turns

Open

BHP 0.65 0.71 0.76 0.82 0.87 0.93 0.98 1.04 1.10 1.16 1.21 1.28 1.36 1.43 1.50 1.56

Sheave/Mtr B B B A A A A A A A A A C C C C

RPM 665 705 745 780 810 845 880 910 945 975 1005 1035 1065 1095 1125 1150

Turns

Open

BHP 0.71 0.76 0.82 0.87 0.92 0.98 1.03 1.09 1.16 1.22 1.29 1.36 1.43 1.50 1.57 1.63

Sheave/Mtr B B A A A A A A A A A A C C C C

RPM 685 720 760 795 825 860 890 920 955 985 1015 1045 1075 1105 1135 1160

Turns

Open

BHP 0.78 0.84 0.89 0.95 1.00 1.06 1.12 1.18 1.24 1.30 1.37 1.43 1.50 1.58 1.64 1.71

Sheave/Mtr B B A A A A A A A A A C C C C C

RPM 700 740 775 810 845 880 910 940 970 1000 1030 1055 1085 1115 1140 1170

Turns

Open

BHP 0.85 0.91 0.96 1.02 1.08 1.14 1.22 1.29 1.36 1.44 1.50 1.57 1.63 1.70 1.76 1.82

Sheave/Mtr B B A A A A A A A A A C C C C C

RPM 720 755 790 825 860 890 925 955 985 1015 1040 1070 1095 1125 1150 1175

Turns

Open

BHP 0.93 1.00 1.07 1.14 1.20 1.26 1.32 1.38 1.44 1.51 1.57 1.64 1.70 1.78 1.85 1.92

Sheave/Mtr B A A A A A A A A A C C C C C C

RPM 740 775 810 845 875 905 935 965 995 1025 1050 1080 1105 1135 1160 1185

Turns

Open

5 4 3 2.5 1.5 5.5 5 4 3.5 3 2.5 2 1.5 1 4 3.5

4.5 3.5 2.5 2 6 5 4.5 4 3.5 3 2.5 2 1 4.5 3.5 3

4 3 2.5 1.5 5.5 5 4.5 3.5 3 2.5 2 1.5 1 4 3.5 3

3.5 2.5 2 6 5.5 4.5 4 3.5 3 2.5 2 1.5 4.5 4 3.5 3

3 2.5 1.5 5.5 5 4.5 4 3 2.5 2 1.5 1 4 3.5 3 2.5

2.5 2 6 5.5 5 4 3.5 3 2.5 2 1.5 1 4 3.5 3 2.5

2.5 1.5 5.5 5 4.5 4 3.5 2.5 2 1.5 1 4.5 3.5 3.5 3 2.5

2 1 5.5 4.5 4 3.5 3 2.5 2 1.5 1 4 3.5 3 2.5 2

1.5 5.5 5 4.5 4 3.5 3 2 1.5 1 4.5 4 3.5 3 2.5 2

Table Continued on Next Page

Heat Controller, Inc. HBH SERIES IOM Manual

HBH096 Blower Performance

Table Continued from Previous Page

All Data is Wet Coil

SCFM ESP 0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10 1.20 1.30 1.40 1.50

BHP 1.01 1.08 1.14 1.21 1.28 1.33 1.39 1.45 1.51 1.58 1.64 1.72 1.78 1.84 1.93 2.00

Sheave/Mtr B A A A A A A A A A C C C C C E

3300

3400

3500

3600

3700

3800

3900

4000

RPM 755 790 820 855 890 915 945 975 1005 1035 1060 1090 1115 1140 1170 1195

Turns

Open

BHP 1.08 1.15 1.22 1.29 1.35 1.41 1.47 1.53 1.59 1.68 1.75 1.83 1.90 1.96 2.02 2.08

Sheave/Mtr A A A A A A A A A A C C C C E E

RPM 765 800 835 870 900 930 960 990 1015 1045 1070 1100 1125 1150 1175 1200

Turns

Open

BHP 1.16 1.23 1.29 1.36 1.42 1.48 1.54 1.60 1.66 1.73 1.79 1.85 1.92 2.01 2.09 2.17

Sheave/Mtr A A A A A A A A A C C C C E E E

RPM 780 815 845 880 910 940 970 1000 1025 1055 1080 1105 1130 1160 1185 1210

Turns

Open

BHP 1.24 1.30 1.37 1.44 1.51 1.58 1.65 1.72 1.78 1.86 1.92 1.98 2.06 2.13 2.21 2.29

Sheave/Mtr A A A A A A A A A C C C E E E E

RPM 795 825 860 890 920 950 980 1010 1035 1065 1090 1115 1145 1165 1190 1215

Turns

Open

BHP 1.34 1.40 1.46 1.53 1.61 1.68 1.75 1.82 1.90 1.97 2.06 2.13 2.21 2.28 2.36 2.44

Sheave/Mtr A A A A A A A A C C E E E E E E

RPM 820 850 880 910 940 970 1000 1025 1055 1080 1110 1135 1160 1180 1205 1230

Turns

Open

BHP 1.43 1.49 1.56 1.63 1.70 1.78 1.86 1.94 2.02 2.12 2.20 2.28 2.34 2.42 2.50 2.58

Sheave/Mtr A A A A A A A A E E E E E E E E

RPM 840 870 900 930 960 990 1020 1045 1070 1100 1125 1150 1170 1195 1220 1245

Turns

Open

BHP 1.58 1.64 1.71 1.78 1.85 1.93 2.01 2.09 2.19 2.27 2.35 2.41 2.49 2.57 2.65

Sheave/Mtr A A A A A A D D E E E E E E E

RPM 865 890 920 950 980 1010 1035 1060 1090 1115 1140 1160 1185 1210 1235

Turns

Open

BHP 1.68 1.75 1.83 1.92 2.00 2.08 2.16 2.26 2.34 2.42 2.50 2.56 2.64 2.72 2.80

Sheave/Mtr A A A A D D D E E E E E E E E

RPM 885 910 940 970 1000 1025 1050 1080 1105 1130 1155 1175 1200 1225 1250

Turns

Open

1 5.5 5 4 3.5 3 2.5 2 1.5 1 4 3.5 3 3 2.5 2

6 5 4.5 4 3.5 3 2.5 2 1.5 1 4 3.5 3 2.5 2 2

5.5 5 4.5 3.5 3 2.5 2 1.5 1 4.5 4 3.5 3 2.5 2 1.5

5.5 4.5 4 3.5 3 2.5 2 1.5 1 4 3.5 3 2.5 2.5 2 1.5

5 4.5 3.5 3 2.5 2 1.5 1 4.5 4 3.5 3 2.5 2 1.5 1.5

4.5 4 3.5 3 2.5 2 1.5 1 4 3.5 3 2.5 2.5 2 1.5 1

4 4 3 2.5 2 1.5 1 1 4 3.5 3 2.5 2 1.5 1.5

4 3.5 2.5 2.5 2 1 1 4 3.5 3 2.5 2 2 1.5 1

IOM Manual HBH SERIES Heat Controller, Inc.

HBH120 Blower Performance

SCFM ESP 0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10 1.20 1.30 1.40 1.50

BHP 0.75 0.81 0.86 0.91 0.97 1.03 1.09 1.15 1.21 1.27 1.34 1.41 1.47 1.54 1.61 1.67

Sheave/Mtr B B B B B B A A A A A A A A A A

3000

3100

3200

3300

3400

3500

3600

3700

3800

3900

4000

4100

4200

A = Standard Static/Standard Motor, B = Low Static/Standard Motor, C = High Static/Standard Motor, D = Standard Static/Large Motor, E = High Static/Large Motor

Unit factory shipped with standard static sheave and drive at 2.5 turns open. Other speed require 󰘰eld selection.

For applications requiring higher static pressures, contact your local representative. Performance data does not include drive losses and is based on sea level conditions.

Do not operate in black regions. All air󰘱ow in rated at lowest Voltage if unit is dual Voltage rated, i.e. 208V for 208-230V units.

RPM 680 720 755 790 825 860 895 925 955 985 1015 1045 1070 1100 1130 1155

Turns Open 5 4 3.5 3 2.5 1.5 5.5 5 4.5 4 3.5 3 2.5 2 1.5 1

BHP 0.82 0.88 0.94 0.99 1.04 1.10 1.17 1.26 1.33 1.40 1.46 1.53 1.59 1.66 1.72 1.80

Sheave/Mtr B B B B B A A A A A A A A A A C

RPM 700 735 775 805 840 875 905 940 970 1000 1025 1055 1080 1110 1135 1165

Turns Open 4.5 4 3 2.5 2 6 5.5 4.5 4.5 3.5 3 3 2.5 2 1.5 4

BHP 0.90 0.96 1.03 1.10 1.17 1.23 1.29 1.35 1.41 1.47 1.55 1.61 1.68 1.74 1.81 1.89

Sheave/Mtr B B B B B A A A A A A A A A A C

RPM 720 755 790 825 860 890 920 950 980 1010 1040 1065 1095 1120 1145 1175

Turns Open 4 3.5 3 2 1.5 5.5 5 4.5 4 3.5 3 2.5 2 1.5 1 3.5

BHP 0.98 1.04 1.11 1.18 1.25 1.31 1.37 1.43 1.49 1.55 1.62 1.68 1.75 1.81 1.88 1.95

Sheave/Mtr B B B B A A A A A A A A A A A C

RPM 740 770 805 840 875 905 935 965 995 1020 1050 1075 1105 1130 1155 1180

Turns Open 4 3 2.5 2 6 5.5 5 4 4 3 2.5 2.5 2 1.5 1 3.5

BHP 1.06 1.13 1.19 1.26 1.33 1.38 1.44 1.50 1.56 1.65 1.72 1.80 1.87 1.94 2.00 2.06

Sheave/Mtr B B B B A A A A A A A A A A C C

RPM 755 790 820 855 890 915 945 975 1005 1035 1060 1090 1115 1140 1165 1190

Turns Open 3.5 3 2.5 1.5 6 5 4.5 4 3.5 3 2.5 2 1.5 1 4 3

BHP 1.14 1.21 1.27 1.34 1.40 1.46 1.52 1.58 1.65 1.71 1.77 1.84 1.90 1.98 2.06 2.14

Sheave/Mtr B B B A A A A A A A A A A A C C

RPM 770 805 835 870 900 930 960 990 1020 1045 1070 1100 1125 1150 1175 1200

Turns Open 3 2.5 2 6 5.5 5 4.5 3.5 3.5 3 2.5 2 1.5 1 3.5 3

BHP 1.23 1.29 1.36 1.42 1.50 1.57 1.64 1.71 1.77 1.84 1.90 1.96 2.05 2.13 2.21 2.27

Sheave/Mtr B B B A A A A A A A A A A C C C

RPM 790 820 855 885 915 945 975 1005 1030 1060 1085 1110 1140 1165 1190 1210

Turns Open 3 2.5 1.5 6 5.5 4.5 4 3.5 3 2.5 2 1.5 1.5 4 3.5 3

BHP 1.32 1.38 1.44 1.51 1.58 1.65 1.73 1.81 1.88 1.96 2.03 2.10 2.18 2.26 2.34 2.42

Sheave/Mtr B B A A A A A A A A A A A C C C

RPM 810 840 870 900 930 960 990 1020 1045 1075 1100 1125 1150 1175 1200 1225

Turns Open 2.5 2 6 5.5 5 4.5 4 3 3 2.5 2 1.5 1 3.5 3 2.5

BHP 1.41 1.47 1.54 1.61 1.68 1.75 1.82 1.91 1.99 2.07 2.17 2.25 2.31 2.39 2.47 2.55

Sheave/Mtr B B A A A A A A A A A A A C C C

RPM 830 860 890 920 950 980 1005 1035 1060 1085 1115 1140 1160 1185 1210 1235

Turns Open 2 1.5 5.5 5 4.5 4 3.5 3 2.5 2 1.5 1 1 3.5 3 2.5

BHP 1.54 1.60 1.67 1.74 1.82 1.89 1.96 2.04 2.14 2.22 2.30 2.38 2.46 2.52 2.60 2.68

Sheave/Mtr B A A A A A A A A A A A C C C C

RPM 850 875 905 935 965 995 1020 1045 1075 1100 1125 1150 1175 1195 1220 1245

Turns Open 2 6 5.5 5 4.5 3.5 3 2.5 2.5 2 1.5 1 3.5 3 2.5 2

BHP 1.63 1.71 1.78 1.86 1.94 2.03 2.11 2.19 2.27 2.37 2.45 2.51 2.59 2.67 2.75 2.85

Sheave/Mtr A A A A A A A A A A A A C C C C

RPM 865 895 920 950 980 1010 1035 1060 1085 1115 1140 1160 1185 1210 1235 1260

Turns Open 6 5.5 5 4.5 4 3.5 3 2.5 2 1.5 1 1 3.5 3 2.5 2

BHP 1.73 1.81 1.90 1.97 2.05 2.12 2.20 2.27 2.34 2.42 2.52 2.62 2.70 2.80 2.90

Sheave/Mtr A A A A A A A A A A A C C C C

RPM 885 915 945 970 1000 1025 1055 1080 1105 1130 1155 1180 1200 1225 1250

Turns Open 6 5.5 4.5 4 4 3 2.5 2 2 1.5 1 3.5 3 2.5 2

BHP 1.87 1.94 2.02 2.08 2.16 2.24 2.32 2.40 2.48 2.58 2.68 2.76 2.86 2.96

Sheave/Mtr A A A A A A A A A A C C C C

RPM 905 935 965 990 1020 1045 1070 1095 1120 1145 1170 1190 1215 1240

Turns Open 5.5 5 4.5 4 3.5 3 2.5 2 1.5 1 3.5 3.5 3 2.5

Heat Controller, Inc. HBH SERIES IOM Manual

HBH120 Blower Performance

Table Continued from Previous Page

All Data is Wet Coil

SCFM ESP 0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10 1.20 1.30 1.40 1.50

BHP 2.00 2.07 2.16 2.23 2.31 2.41 2.49 2.57 2.66 2.74 2.84 2.94 3.02 3.15

Sheave/Mtr A A A A A A A A A C C C E E

4300

4400

4500

4600

4700

4800

4900

5000

RPM 930 955 985 1010 1035 1065 1090 1115 1140 1160 1185 1210 1230 1255

Turns Open 5 4.5 4 3.5 3 2.5 2 1.5 1.5 4 3.5 3 2.5 2

BHP 2.14 2.22 2.32 2.40 2.48 2.56 2.65 2.74 2.82 2.92 3.00 3.10 3.18

Sheave/Mtr A A A A A A A A A C E E E

RPM 950 975 1005 1030 1055 1080 1110 1135 1155 1180 1200 1225 1245

Turns Open 4.5 4 3.5 3 3 2.5 2 1.5 1 4 3 3 2.5

BHP 2.30 2.38 2.46 2.54 2.62 2.72 2.80 2.88 3.00 3.08 3.16 3.26

Sheave/Mtr A A A A A A A A D E E E

RPM 970 995 1020 1045 1070 1100 1125 1145 1170 1195 1215 1240

Turns Open 4.5 4 3.5 3 2.5 2 1.5 1.5 1 3.5 3 2.5

BHP 2.39 2.45 2.54 2.63 2.72 2.83 2.92 3.00 3.10 3.18 3.28 3.38

Sheave/Mtr A A A A A A A D D E E E

RPM 980 1000 1025 1050 1075 1105 1130 1150 1175 1195 1220 1245

Turns Open 4 3.5 3.5 3 2.5 2 1.5 1 1 3.5 3 2.5

BHP 2.46 2.52 2.62 2.72 2.82 2.92 3.02 3.12 3.22 3.32 3.40 3.50

Sheave/Mtr A A A A A A D D E E E E

RPM 985 1005 1030 1055 1080 1105 1130 1155 1180 1205 1225 1250

Turns Open 4 3.5 3 2.5 2 1.5 1.5 1 4 3.5 2.5 2.5

BHP 2.57 2.64 2.74 2.84 2.94 3.04 3.14 3.24 3.32 3.42 3.52 3.60

Sheave/Mtr A A A A A D D D E E E E

RPM 990 1010 1035 1060 1085 1110 1135 1160 1180 1205 1230 1250

Turns Open 4 3.5 3 2.5 2 1.5 1 1 3.5 3 2.5 2

BHP 2.68 2.78 2.88 3.00 3.06 3.16 3.26 3.36 3.44 3.54 3.64 3.75

Sheave/Mtr A A A D D D D E E E E E

RPM 995 1020 1045 1070 1090 1115 1140 1165 1185 1210 1235 1255

Turns Open 3.5 3 3 2.5 1.5 1.5 1 4 3.5 3 2.5 2

BHP 2.82 2.92 3.00 3.10 3.20 3.28 3.38 3.48 3.56 3.66 3.74

Sheave/Mtr A A D D D D D E E E E

RPM 1005 1030 1050 1075 1100 1120 1145 1170 1190 1215 1235

Turns Open 3.5 3 2.5 2 1.5 1 1 3.5 3 2.5 2

IOM Manual HBH SERIES Heat Controller, Inc.

Unit Starting 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 – A voltage variation of +/– 10% of nameplate utilization voltage is acceptable.

Determination of operating limits is dependent primarily upon three factors: 1) return air temperature. 2) water temperature, and 3) ambient temperature. When any one of these factors is at minimum or maximum levels, the other two factors should be at normal levels to ensure proper unit operation. Extreme variations in temperature and humidity and/or corrosive water or air will adversely affect unit performance, reliability, and service life. Consult Table 9a for operating limits.

Starting Conditions - Starting conditions are based

upon the following notes:

Notes:

1. Conditions in Table 9b are not normal or continuous operating conditions. Minimum/maximum limits are start-up conditions to bring the building space up to occupancy temperatures. Units are not designed to operate under these conditions on a regular basis.

2. Voltage utilization range complies with AHRI Standard 110.

Table 9a: Operating Limits

TCH

Starting Limits

Air Limits

Min. ambient air, DB 45ºF [7ºC] 39ºF [4ºC] Rated ambient air, DB 80.6ºF [27ºC] 68ºF [20ºC] Max. ambient air, DB 110ºF [43ºC] 85ºF [29ºC] Min. entering air, DB/WB 60/50ºF [16/10ºC] 50ºF [10ºC] Rated entering air, DB/WB 80.6/66.2ºF [27/19ºC] 68ºF [20ºC] Max. entering air, DB/WB

Water Limits

Min. entering water 30ºF [-1ºC] Normal entering water 50-110ºF [10-43ºC] 30-70ºF [-1 to 21ºC] Max. entering water

Normal Water Flow

Cooling Heating

95/75ºF [35/24ºC]

120ºF [49ºC]

HBH

80ºF [27ºC]

20ºF [-6.7ºC]

90ºF [32ºC]

1.5 to 3.0 gpm / ton

[1.6 to 3.2 l/m per kW]

Table 9b: Commissioning Limits

TCH

Commissioning Limits

Air Limits

Min. ambient air, DB 45ºF [7ºC] 39ºF [4ºC] Rated ambient air, DB 80.6ºF [27ºC] 68ºF [20ºC] Max. ambient air, DB 110ºF [43ºC] 85ºF [29ºC] Min. entering air, DB/WB 50/45ºF [10/7ºC] 40ºF [4.5ºC] Rated entering air, DB/WB 80.6/66.2ºF [27/19ºC] 68ºF [20ºC] Max. entering air, DB/WB 110/83ºF [43/28ºC] 80ºF [27ºC]

Water Limits

Min. entering water 30ºF [-1ºC] 20ºF [-6.7ºC] Normal entering water 50-110ºF [10-43ºC] 30-70ºF [-1 to 21ºC] Max. entering water 120ºF [49ºC] 90ºF [32ºC]

Normal Water Flow

Cooling Heating

HBH

1.5 to 3.0 gpm / ton

[1.6 to 3.2 l/m per kW]

Heat Controller, Inc. HBH SERIES IOM Manual

Piping System Cleaning and Flushing

Piping System Cleaning and Flushing - Cleaning

and ushing the WLHP piping system is the single most

important step to ensure proper start-up and continued

efcient operation of the system.

Follow the instructions below to properly clean and ush the

system:

1. Ensure that electrical power to the unit is disconnected.

2. Install the system with the supply hose connected directly to the return riser valve. Use a single length of

exible hose.

3. Open all air vents. Fill the system with water. DO NOT

allow system to overow. Bleed all air from the system.

Pressurize and check the system for leaks and repair as appropriate.

4. Verify that all strainers are in place (Heat Controller recommends a strainer with a #20 stainless steel wire mesh). Start the pumps, and systematically check each vent to ensure that all air is bled from the system.

5. Verify that make-up water is available. Adjust make-up water as required to replace the air which was bled from the system. Check and adjust the water/air level in the expansion tank.

6. Set the boiler to raise the loop temperature to approximately 86°F [30°C]. Open a drain at the lowest point in the system. Adjust the make-up water replacement rate to equal the rate of bleed.

7. Rell the system and add trisodium phosphate in a

proportion of approximately one pound per 150 gallons [1/2 kg per 750 l] of water (or other equivalent approved cleaning agent). Reset the boiler to raise the loop

temperature to 100°F [38°C]. Circulate the solution for a minimum of 8 to 24 hours. At the end of this period, shut off the circulating pump and drain the solution. Repeat system cleaning if desired.

8. When the cleaning process is complete, remove the short-circuited hoses. Reconnect the hoses to the proper supply, and return the connections to each of

the units. Rell the system and bleed off all air.

9. Test the system pH with litmus paper. The system water should be in the range of pH 6.0 - 8.5 (see table 3). Add chemicals, as appropriate to maintain neutral pH levels.

10. When the system is successfully cleaned, ushed, relled and bled, check the main system panels,

safety cutouts and alarms. Set the controls to properly maintain loop temperatures.

DO NOT use “Stop Leak” or similar chemical agent in this system. Addition of chemicals of this type to the loop water will foul the heat exchanger and inhibit unit operation.

Note: The manufacturer strongly recommends all piping connections, both internal and external to the unit, be pressure tested by an appropriate method prior to any

nishing of the interior space or before access to all

connections is limited. Test pressure may not exceed

the maximum allowable pressure for the unit and all components within the water system. The manufacturer will not be responsible or liable for damages from water

leaks due to inadequate or lack of a pressurized leak test, or damages caused by exceeding the maximum pressure rating during installation.

IOM Manual HBH SERIES Heat Controller, Inc.

Unit Starting and Operating Conditions

SYSTEM CHECKOUT

CAUTION!

� CAUTION! �

CAUTION! Do not use PVC piping. Temperatures will

exceed 113°F (45°C).

Unit and System Checkout

BEFORE POWERING SYSTEM, please check the following:

UNIT CHECKOUT

q Balancing/shutoff valves: Insure that all isolation valves

are open and water control valves are wired.

q 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.

q Unit control transformer: Insure that transformer has

the properly selected voltage tap. Commercial 208230V units are factory wired for 208V operation unless

specied otherwise.

q Entering water and air: Insure that entering water and

air temperatures are within operating limits of Table 9.

q Low water temperature cutout: Verify that low water

temperature cut-out on the CXM control is properly set.

q Unit fan: Manually rotate fan to verify free rotation and

insure that blower wheel is secured to the motor shaft. Be sure to remove any shipping supports if needed. DO NOT oil motors upon start-up. Fan motors are preoiled at the factory. Check unit fan speed selection and compare to design requirements.

q Condensate line: Verify that condensate line is open

and properly pitched toward drain.

q Water ow balancing: Record inlet and outlet water

temperatures for each heat pump upon startup. This check can eliminate nuisance trip outs and high velocity

water ow that could erode heat exchangers.

q Unit air coil and lters: Insure that lter is clean and

accessible. Clean air coil of all manufacturing oils.

q Unit controls: Verify that CXM eld selection options are

properly set.

q System water temperature: Check water temperature

for proper range and also verify heating and cooling set points for proper operation.

q System pH: Check and adjust water pH if necessary

to maintain a level between 6 and 8.5. Proper pH promotes longevity of hoses and ttings (see table 3).

q System ushing: Verify that all hoses are connected

end to end when ushing to insure that debris bypasses

the unit heat exchanger, water valves and other components. Water used in the system must be potable quality initially and clean of dirt, piping slag, and strong chemical cleaning agents. Verify that all air is purged from the system. Air in the system can cause poor operation or system corrosion.

q Cooling tower/boiler: Check equipment for proper set

points and operation.

q Standby pumps: Verify that the standby pump is

properly installed and in operating condition.

q System controls: Verify that system controls function

and operate in the proper sequence.

q Low water temperature cutout: Verify that low water

temperature cut-out controls are provided for the outdoor portion of the loop. Otherwise, operating problems may occur.

q System control center: Verify that the control center

and alarm panel have appropriate set points and are operating as designed.

q Miscellaneous: Note any questionable aspects of

the installation.

CAUTION!

� CAUTION! �

CAUTION! Verify that ALL water control valves are open and

allow water ow prior to engaging the compressor. Freezing

of the coax or water lines can permanently damage the heat pump.

CAUTION!

� CAUTION! �

CAUTION! To avoid equipment damage, DO NOT

leave system lled in a building without heat during the

winter unless antifreeze is added to the water loop. Heat exchangers never fully drain by themselves and will freeze unless winterized with antifreeze.

Heat Controller, Inc. HBH SERIES IOM Manual

Unit Start-Up Procedure

Unit Start-up Procedure

1. Turn the thermostat fan position to “ON”. Blower should start.

2. Balance air ow at registers.

3. Adjust all valves to their full open positions. Turn on the line power to all heat pumps.

4. Room temperature should be within the minimum-maximum ranges of table 9. During start-up checks, loop water temperature entering the heat pump should be between 60°F [16°C] and 95°F [35°C].

5. Two factors determine the operating limits of Heat Controller heat pumps, (a) return air temperature, and (b) water temperature. When any one of these factors is at a minimum or maximum level, the other factor must be at normal level to insure proper unit operation. a. Adjust the unit thermostat to the warmest setting.

Place the thermostat mode switch in the “COOL” position. Slowly reduce thermostat setting until the compressor activates.

b. Check for cool air delivery at the unit grille within a

few minutes after the unit has begun to operate.

Note: Units have a ve minute time delay in the

control circuit that can be eliminated on the CXM control board as shown below in Figure 28. See controls description for details.

c. Verify that the compressor is on and that the water

ow rate is correct by measuring pressure drop

through the heat exchanger using the P/T plugs and comparing to tables 10a through 10e.

d. Check the elevation and cleanliness of the

condensate lines. Dripping may be a sign of a blocked line. Check that the condensate trap is

lled to provide a water seal.

e. Check the temperature of both entering and

leaving water. If temperature is within range table, proceed with the test. If temperature is outside of the operating range, check refrigerant pressures and compare to tables 12 through 15. Verify correct

water ow by comparing unit pressure drop across

the heat exchanger versus the data in tables 10a through 10e. Heat of rejection (HR) can be calculated and compared to submittal data capacity pages. The formula for HR for systems with water is as follows: HR (Btuh) = TD x GPM x 500, where TD is the temperature difference between the entering and

leaving water, and GPM is the ow rate in U.S.

GPM, determined by comparing the pressure drop across the heat exchanger to tables 8a through 8e. In S.I. units, the formula is as follows: HR (kW) = TD x l/s x 4.18.

f. Check air temperature drop across the air coil when

compressor is operating. Air temperature drop should be between 15°F and 25°F [8°C and 14°C].

g. Turn thermostat to “OFF” position. A hissing noise

indicates proper functioning of the reversing valve.

6. Allow ve (5) minutes between tests for pressure to

equalize before beginning heating test.

a. Adjust the thermostat to the lowest setting. Place the

thermostat mode switch in the “HEAT” position.

b. Slowly raise the thermostat to a higher temperature

until the compressor activates.

c. Check for warm air delivery within a few minutes

after the unit has begun to operate.

d. Refer to table 17. Check the temperature of both

entering and leaving water. If temperature is within range, proceed with the test. If temperature is outside of the operating range, check refrigerant pressures and compare to tables 11 through 16.

Verify correct water ow by comparing unit pressure

drop across the heat exchanger versus the data in tables 10a through 10e. Heat of extraction (HE) can be calculated and compared to submittal data capacity pages. The formula for HE for systems with water is as follows:

HE (Btuh) = TD x GPM x 500, where TD is the

temperature difference between the entering and

leaving water, and GPM is the ow rate in U.S. GPM,

determined by comparing the pressure drop across the heat exchanger to tables 10a through 10e. In S.I. units, the formula is as follows: HE (kW) = TD x l/s x

4.18.

e. Check air temperature rise across the air coil when

compressor is operating. Air temperature rise should be between 20°F and 30°F [11°C and 17°C].

f. Check for vibration, noise, and water leaks.

7. If unit fails to operate, perform troubleshooting analysis (see troubleshooting section). If the check described fails to reveal the problem and the unit still does not operate, contact a trained service technician to insure proper diagnosis and repair of the equipment.

8. When testing is complete, set system to maintain desired comfort level.

9. BE CERTAIN TO FILL OUT AND FORWARD ALL WARRANTY REGISTRATION PAPERS TO HEAT CONTROLLER.

Note: If performance during any mode appears abnormal, refer to the CXM section or troubleshooting section of this manual. To obtain maximum performance, the air

coil should be cleaned before start-up. A 10% solution of dishwasher detergent and water is recommended.

IOM Manual HBH SERIES Heat Controller, Inc.

Unit Start-Up Procedure

Figure 28: Test Mode Pins

Short test pins together to enter Test Mode and speed-up timing and delays for 20 minutes.

UNIT OPERATING CONDITIONS

Table 10a: HB Coax Water Pressure Drop

Model

072

096

120

U.S.

GPM

10 0.631 37.85 1.2 [8.3] 0.9 [6.2] 0.5 [3.4] 0.3 [2.1]

15 0.946 56.781 3.3 [22.8] 2.8 [19.08] 2.1 [14.5] 1.8 [12.4]

20 1.262 75.708 6.2 [42.7] 5.3 [36.5] 4.2 [29.0] 3.8 [26.2]

12 0.757 45.425 2.1 [14.5] 1.7 [11.7] 1.3 [9.0] 1.1 [7.6]

18 1.136 68.137 5.3 [36.5] 4.5 [31.0] 3.6 [24.8] 3.3 [22.8]

24 1.514 90.85 9.3 [64/1] 7.9 [54.5] 6.6 [45.5] 6.1 [42.1]

15 0.946 56.781 4 [27.6] 3.2 [22.1] 2.2 [15.2] 2 [13.8]

22.5 1.42 85.172 8.6 [59.3] 7.2 [49.6] 5.5 [37.9] 5.1 [35.2]

30 1.893 113.562 14.5 [100] 12.2 [83.4] 9.8 [67.6] 9.2 [63.4]

l/s l/m

30°F [-1°C] 50°F [10°C] 70°F [21°C] 90°F [32°C]

WARNING!

� WARNING! �

WARNING! When the disconnect switch is closed, high

voltage is present in some areas of the electrical panel. Exercise caution when working with energized equipment.

CAUTION!

� CAUTION! �

CAUTION! Verify that ALL water control valves are open and

allow water ow prior to engaging the compressor. Freezing

of the coax or water lines can permanently damage the heat pump.

Pressure Drop, psi [kPa]*

*Note: To convert kPa to millibars, multiply by 10.

Heat Controller, Inc. HBH SERIES IOM Manual

Unit Operating Conditions

Operating Pressure/Temperature tables include the

following notes:

• Airow is at nominal (rated) conditions;

• Entering air is based upon 70°F [21°C] DB in heating

and 80/67°F [27/19°C] in cooling;

Table 11: HB Series Typical Unit Operating Pressures and Temperatures (60Hz - I.P. Units)

Cooling Heating

Entering

Water

Temp °F

30*

100

120

*Based on 15% Methanol antifreeze solution

Water

Flow

GPM/ton

2.25

1.5

Suction

Pressure

PSIG

122 - 125 116 - 119

112 - 115

128 - 134 122 - 131

119 - 129

132 - 139 131 - 137

131 - 136

137 - 144 135 - 142

135 - 141

139 - 147 138 - 146

138 - 146

144 - 153 143 - 153

143 - 152

Discharge

Pressure

PSIG

197 - 204 177 - 184 168 - 173

240 - 252 219 - 233 209 - 224

311 - 329 287 - 306 275 - 294

400 - 420 373 - 395 359 - 383

448 - 471 420 - 445 405 - 432

549 - 583 525 - 557 511 - 543

Superheat Subcooling

13 - 16 17 - 19 19 - 21

11 - 14 12 - 17 13 - 18

9 - 12 10 - 13 10 - 13

8 - 10

9 - 11

9 - 12

8 - 9 8 - 10 8 - 10

7 - 8

8 - 9

15 - 20 15 - 18 14 - 18

13 - 16 12 - 16 11 - 15

12 - 15 10 - 12

9 - 11

13 - 16 10 - 12

9 - 11

13 - 16 11 - 13 10 - 11

15 - 17 12 - 14 11 - 13

Water

Temp Rise

°F

20 - 24 13 - 16 10 - 12

20 - 22 13 - 15 10 - 11

19 - 21 13 - 14

9 -11

19 - 20 12 - 14

9 - 10

18 - 20 12 - 13

9 - 10

17 - 19 11 - 13

9 - 10

• Subcooling is based upon head pressure at compressor

service port;

• Cooling air and water values can vary greatly with

changes in humidity level.

Air Temp

Drop °F

22 - 23 21 - 22 21 - 22

21 - 22 21 - 22 21 - 22

20 - 21 20 - 21 20 - 21

19 - 20 19 - 20 19 - 20

18 - 19 18 - 19 18 - 19

17 - 18 17 - 18 17 - 18

Suction

Pressure

PSIG

60 - 63 289 - 306 9 - 12 8 - 17 3 - 4 20 - 22

67 - 71 71 - 75 74 - 76

97 - 102 104 - 108 107 - 122

130 - 135 139 - 144 145 - 149

164 - 169 175 - 178 179 - 187

Discharge

Pressure

PSIG

297 - 315 301 - 321 303 - 323

333 - 355 339 - 361 342 - 369

367 - 392 375 - 402 380 - 407

401 - 430 411 - 442 415 - 455

Superheat Subcooling

10 - 12 10 - 12 11 - 13

9 - 11 9 - 11 9 - 11

9 - 11 10 - 11 10 - 11

10 - 13 12 - 16 13 - 18

9 - 18 10 - 19 10 - 19

13 - 21 13 - 21 13 - 20

13 - 21 13 - 20 13 - 19

13 - 17 14 - 17 14 - 16

Water

Temp Drop

°F

8 - 9 6 - 7 4 - 5

11 - 12

8 - 9 6 - 7

14 - 16 10 - 12

8 - 9

18 - 20 12 - 14

9 - 11

Air Temp

Rise °F DB

22 - 23 23 - 24 23 - 25

29 - 30 30 - 31 31 - 32

35 - 37 37 - 38 38 - 39

41 - 43 43 - 45 44 - 46

NOTE: The tables include the following notes:

• Airow is at nominal (rated) conditions;

• Entering air is based upon 70°F [21°C] DB in heating and 80/67°F [27/19°C] in cooling;

• Subcooling is based upon head pressure at compressor service port;

• Cooling air and water values can vary greatly with

changes in humidity level.

Table 12: Water Temperature Change Through Heat Exchanger

Water Flow, gpm [l/m]

For Closed Loop: Ground Source or

Closed Loop Systems at 3 gpm per

ton [3.2 l/m per kW]

For Open Loop: Ground Water

Systems at 1.5 gpm per ton

[1.6 l/m per kW]

Rise, Cooling

°F, [°C]

9 - 12

[5 - 6.7]

20 - 26

[11.1 - 14.4]

Drop, Heating

°F, [°C]

4 - 8

[2.2 - 4.4]

10 - 17

[5.6 - 9.4]

IOM Manual HBH 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. Should periodic coil cleaning be necessary, use standard coil cleaning procedures, which are compatible with the heat exchanger material and copper

water lines. Generally, the more water owing through the

unit, the less chance for scaling. Therefore, 1.5 gpm per

ton [1.6 l/m per kW] is recommended as a minimum ow. Minimum ow rate for entering water temperatures below

50°F [10°C] is 2.0 gpm per ton [2.2 l/m per kW].

Water Coil Maintenance -

(All other water loop applications) Generally water coil maintenance is not needed for closed loop systems. However, if the piping is known to have high dirt or debris content, it is best to establish a periodic maintenance schedule with the owner so the water coil can be checked regularly. Dirty installations are typically the result of deterioration of iron or galvanized piping or components in the system. Open cooling towers requiring heavy chemical treatment and mineral buildup through water use can also contribute to higher maintenance. Should periodic coil cleaning be necessary, use standard coil cleaning procedures, which are compatible with both the heat exchanger material and copper water lines. Generally,

the more water owing through the unit, the less chance for scaling. However, ow rates over 3 gpm per ton (3.9 l/m per

kW) can produce water (or debris) velocities that can erode the heat exchanger wall and ultimately produce leaks.

Filters - Filters must be clean to obtain maximum performance. Filters should be inspected every month under normal operating conditions and be replaced when

necessary. Units should never be operated without a lter.

Washable, high efciency, electrostatic lters, when dirty,

can exhibit a very high pressure drop for the fan motor and

reduce air ow, resulting in poor performance. It is especially

important to provide consistent washing of these lters (in the opposite direction of the normal air ow) once per month

using a high pressure wash similar to those found at selfserve car washes.

Condensate Drain - In areas where airborne bacteria may produce a “slimy” substance in the drain pan, it may be necessary to treat the drain pan chemically with an algaecide approximately every three months to minimize the problem. The condensate pan may also need to be cleaned periodically to insure indoor air quality. The condensate drain

can pick up lint and dirt, especially with dirty lters. Inspect

the drain twice a year to avoid the possibility of plugging and

eventual overow.

Compressor - Conduct annual amperage checks to insure that amp draw is no more than 10% greater than indicated on the serial plate data.

Fan Motors - All units have lubricated fan motors. Fan motors should never be lubricated unless obvious, dry operation is suspected. Periodic maintenance oiling is not recommended, as it will result in dirt accumulating in the excess oil and cause eventual motor failure. Conduct annual dry operation check and amperage check to insure amp draw is no more than 10% greater than indicated on serial plate data.

Belt - Check that the belt is tight. Retighten if needed. Replace if it is split or cracked.

Air Coil - The air coil must be cleaned to obtain maximum performance. Check once a year under normal operating conditions and, if dirty, brush or vacuum clean. Care must

be taken not to damage the aluminum ns while cleaning.

CAUTION: Fin edges are sharp.

Refrigerant System - To maintain sealed circuit integrity, do not install service gauges unless unit operation appears abnormal. Reference the operating charts for pressures

and temperatures. Verify that air and water ow rates are at

proper levels before servicing the refrigerant circuit.

Heat Controller, Inc. HBH SERIES IOM Manual

Fault Htg Clg Possible Cause Solution

Main power Problems X X Green Status LED Off Check Line Voltage circuit breaker and disconnect

Check for line voltage between L1 and L2 on the contactor Check for 24VAC between R and C on CXM/DXM

Check primary/secondary voltage on transformer HP Fault-Code 2 X Reduced or no water flow Check pump operation or valve operation/setting High pressure in cooling

Check water flow adjust to proper flow rate

Water Temperature out of range in cooling

Bring water temp within design parameters

X Reduced or no Air flow Check for dirty air filter and clean or replace

in heating Check fan motor operation and airflow restrictions

Dirty Air Coil- construction dust etc.

Too high of external static. Check static vs blower table

Air Temperature out of range in heating

Bring return air temp within design parameters

X X

Overcharged with refrigerant

Check superheat/subcooling vs typical operating condition

table

X X

Bad HP Switch Check switch continuity and operation. Replace

LP/LOC Fault-Code 3 X X Insufficient charge Check for refrigerant leaks

Low Pressure/Loss of Charge X

Compressor pump down at startup

Check charge and start-up water flow

FP1 Fault - Code 4 X Reduced or no water flow Check pump operation or water valve operation/setting

Water Coil low temperature limit

in heating Plugged strainer or filter. Clean or replace.

Check water flow adjust to proper flow rate

X Inadequate anti-freeze level Check antifreeze density with hydrometer

Improper temperature limit setting (30°F vs 10°F [-1°C vs -12°C])

Clip JW3 jumper for antifreeze (10°F [-12°C]) use

X Water Temperature out of range Bring water temp within design parameters

X X Bad thermistor Check temp and impedance correlation per chart

FP2 fault - Code 5 X Reduced or no Air flow Check for dirty air filter and clean or replace

Air Coil low temperature limit

in cooling Check fan motor operation and airflow restrictions

Too high of external static. Check static vs blower table

X Air Temperature out of range

Too much cold vent air? Bring entering air temp within

design parameters

Improper temperature limit setting (30°F vs 10°F [-1°C vs -12°C])

Normal airside applications will require 30°F [-1°C] only

X X Bad thermistor Check temp and impedance correlation per chart

Condensate Fault-Code

X X Blocked Drain Check for blockage and clean drain X X Improper trap Check trap dimensions and location ahead of vent

X Poor Drainage Check for piping slope away from unit

Check slope of unit toward outlet

Poor venting. Check vent location

X Moisture on sensor Check for moisture shorting to air coil

Over/Under VoltageCode 7

X X Under Voltage

Check power supply and 24VAC voltage before and during

operation. (Auto resetting) Check power supply wire size

Check compressor starting. Need hard start kit?

Check 24VAC and unit transformer tap for correct power

supply voltage

X X

Over Voltage

Check power supply voltage and 24VAC before and during

operation.

Check 24VAC and unit transformer tap for correct power

supply voltage

Unit Performance Sentinel-Code 8

X Heating mode FP2>125°F [52°C] Check for poor air flow or overcharged unit.

Cooling Mode FP1>125°F [52°C]

OR FP2< 40ϒF [4ϒC]

Check for poor water flow, or air flow

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 board Reset power and check operation

Unit Short Cycles X X Dirty Air Filter Check and Clean air filter

X X Unit in "Test Mode" Reset power or wait 20 minutes for auto exit.

X X Unit selection

Unit may be oversized for space. Check sizing for actual

load of space.

X X Compressor Overload Check and Replace if necessary

Only Fan Runs

X X Thermostat position

Insure thermostat set for heating or cooling operation

X X Unit locked out Check for lockout codes. Reset power.

X X Compressor Overload Check compressor overload. Replace if necessary.

X X Thermostat wiring

Check thermostat wiring at heat pump. Jumper Y and R for compressor operation in test mode.

Plugged Air Filter

Restricted Return Air Flow

X X

Replace Air Filter

Find & eliminate restriction. Increase return duct and/or grille size.

Functional Troubleshooting

IOM Manual HBH SERIES Heat Controller, Inc.

Functional Troubleshooting

Only Compressor Runs X X Thermostat wiring

X X Fan motor relay

X X Fan motor Check for line voltage at motor. Check capacitor

X X Thermostat wiring

Unit Doesn't Operate in Cooling

X Reversing Valve

X Thermostat setup Check for 'O' RV setup not 'B'

X Thermostat wiring

Thermostat wiring

Check G wiring at heat pump. Jumper G and R for fan operation.

Jumper G and R for fan operation. Check for Line voltage across BR contacts.

Check fan power enable relay operation (if present)

Check thermostat wiring at heat pump. Jumper Y and R for compressor operation in test mode.

Set for cooling demand and check 24VAC on RV coil and at CXM/DXM board.

If RV is stuck, run high pressure up by reducing water flow and while operating engage and disengage RV coil voltage to push valve.

Check O wiring at heat pump. Jumper O and R for RV coil 'Click'. Put thermostat in cooling mode. Check for 24VAC on O

(check between C and O); check for 24VAC on W (check between W and C). There should be voltage on O, but not on W. If voltage is present on W, thermostat may be bad or wired incorrectly.

Performance Troubleshooting

Insufficient capacity/ X X Dirty Filter Replace or clean

Not cooling or heating X Reduced or no Air flow Check for dirty air filter and clean or replace

properly in heating Check fan motor operation and airflow restrictions

Htg Clg Possible Cause Solution

X Reduced or no Air flow Check for dirty air filter and clean or replace

in cooling Check fan motor operation and airflow restrictions

X X Leaky duct work

X X Low refrigerant charge Check superheat and subcooling per chart X X Restricted metering device Check superheat and subcooling per chart. Replace.

X Defective Reversing Valve Perform RV touch test

X X Thermostat improperly located Check location and for air drafts behind stat

X X Unit undersized

X X Scaling in water heat exchanger Perform Scaling check and clean if necessary

Too high of external static. Check static vs blower table

Too high of external static. Check static vs blower table Check supply and return air temperatures at the unit and at distant duct registers if significantly different, duct leaks are present

Recheck loads & sizing check sensible clg load and heat pump capacity

X X Inlet Water too Hot or Cold Check load, loop sizing, loop backfill, ground moisture.

High Head Pressure X Reduced or no Air flow Check for dirty air filter and clean or replace

Low Suction Pressure X Reduced water flow Check pump operation or water valve operation/setting

Low discharge air temperature in heating

High humidity X Too high of air flow Check fan motor speed selection and airflow chart

in heating Check fan motor operation and airflow restrictions

Too high of external static. Check static vs blower table

X Reduced or no water flow Check pump operation or valve operation/setting

in cooling Check water flow adjust to proper flow rate

X Inlet Water too Hot Check load, loop sizing, loop backfill, ground moisture.

Air Temperature out of range in heating

X Scaling in water heat exchanger Perform Scaling check and clean if necessary X X Unit Overcharged Check superheat and subcooling. Reweigh in charge X X Non-condensables insystem Vacuum system and reweigh in charge X X Restricted metering device Check superheat and subcooling per chart. Replace.

in heating Plugged strainer or filter. Clean or replace.

X Water Temperature out of range Bring water temp within design parameters

X Reduced Air flow Check for dirty air filter and clean or replace

in cooling Check fan motor operation and airflow restrictions

X Air Temperature out of range

X X Insufficient charge Check for refrigerant leaks

X Too high of air flow Check fan motor speed selection and airflow chart

X Poor Performance See 'Insufficient Capacity'

X Unit oversized

Bring return air temp within design parameters

Check water flow adjust to proper flow rate

Too high of external static. Check static vs blower table Too much cold vent air? Bring entering air temp within design parameters

Recheck loads & sizing check sensible clg load and heat pump capacity

Heat Controller, Inc. HBH SERIES IOM Manual

Packaged Unit Refrigeration Schematic

Customer: _____________________________________

Antifreeze: ________________________

Model#: ________________________ Serial#: ________________ Loop type: _______________

Complaint: ________________________________________________________________________

Date: ________________________

Location: ________________________

Model Number: ________________________

Serial Number: ________________________

Refrigerant Circuit Diagrams

Functional Troubleshooting - I.P. Units

HEATING CYCLE ANALYSIS -

PSI

AIR

COIL

°F °F

EXPANSION

VALVE

FILTER DRIER*

COAX

HWG

FLASH

GAS LINE

°F

FP1

SENSOR

°F

°F °F

PSI PSI

WATER IN WATER OUT

Look up pressure drop in

°F

FP2: HEATING LIQUID LINE

I.O.M. or spec. catalog to determine flow rate.

COOLING CYCLE ANALYSIS -

Refrigerant Type:

HFC-410A

AIR

COIL

°F °F

PSI

°F

SUCTION

COMPRESSOR

DISCHARGE

°F

PSI

SUCTION

COMPRESSOR

SAT

°F

FILTER DRIER*

FP1: CLG

LIQ LINE

COAX

°F

°F °F

PSI PSI

WATER IN WATER OUT

DISCHARGE

HWG

°F

PSI

SAT

Look up pressure drop in

Voltage: ________

Comp Amps: _______

Total Amps: ________

FP2: FLASH GAS LINE

EXPANSION

VALVE

°F

OTHER SIDE OF FILTR DR

I.O.M. or spec. catalog to determine flow rate.

Heat of Extraction (Absorption) or Heat of Rejection =

________ flow rate ( diff. ( factor = _____________

Superheat

Subcooling



Use 500 for water, 485 for antifreeze.

gpm) x ________ temp. deg. F) x ________ fluid

Suction temperature - suction saturation temp.

Discharge saturation temp. - liquid line temp.

Note: Never connect refrigerant gauges during startup procedures. Conduct water-side analysis using P/T ports to determine water ow and temperature dierence. If water-side analysis shows poor performance, refrigerant troubleshooting may be required. Connect refrigerant gauges as a last resort.



(Btu/hr)

(deg F)

Rev. 12/08

11/2010

Heatcontroller HBH 6-10 T User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual