Heat Controller HEV024, HEV030, HEV036, HEV042, HEV048 Installation, Operation & Maintenance Manual

INSTALLATION, OPERATION

& MAINTENANCE MANUAL

Residential Packaged

Geothermal Heat Pump

HEV/H Series

2 to 5 Tons

Heat Controller, Inc. • 1900 Wellworth Ave. • Jackson, MI 49203 • [phone] • www.heatcontroller.com

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

Table of Contents

Model Nomenclature ............................................................................................3

Safety Instructions ................................................................................................4

Pre-Installation......................................................................................................5

Physical Data........................................................................................................6

Vertical Unit Dimensions....................................................................................7-8

Vertical Installation................................................................................................9

Water Connection Installation .............................................................................14

Ground-Loop Heat Pump Applications ..........................................................15-16

Ground-Water Heat Pump Applications ..............................................................17

Water Quality Standards ....................................................................................18

Hot Water Generator .....................................................................................19-21

Electrical Data ...............................................................................................22-26

Blower Performance Data .............................................................................27-28

Wiring Diagrams .................................................................................................29

DXM 2 Controls .............................................................................................30-33

Unit Start-Up and Operating Conditions ........................................................34-40

Preventive Maintenance .....................................................................................41

Troubleshooting .............................................................................................42-46

2

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

MOTOR, AND TWO STAGE SCROLL COMPRESSORS.

HEV

HEH

HeatController

H E H A0 3 6 D1 0 0 A L B

1 2 3 4 5 6 7

8

91011121314

HE = HEAT CONTROLLER RESIDENTIAL 410A

MODEL TYPE

H = HORIZONTAL

CONFIGURATION

V = VERTICAL

UNIT SIZE

024
030
036
042
048
060

REVISION LEVEL

A = Current Revision

VO LTAG E

CONTROLS

CABINET INSULATION

WATER CIRCUIT OPTIONS

A = Copper Water Coil w/E-Coated Air Coil

HEAT EXCHANGER OPTIONS

J = Cupro-Nickel Water Coil w/E-Coated Air Coil

L = LEFT RETURN w/ 1” Merv 8 Pleated Filter and Frame

RETURN AIR OPTIONS

R = RIGHT RETURN w/ 1” Merv 8 Pleated Filter and Frame

B = BACK DISCHARGE, HORIZONTAL ONLY

SUPPLY AIR OPTIONS

T = TOP DISCHARGE, VERTICAL ONLY
S = STRAIGHT DISCHARGE, HORIZONTAL ONLY

0 = NONE
1 = HWG w/ INTERNAL PUMP

0 = RESIDENTIAL

1 = 208-230/60/1

D = DXM 2

Unit Nomenclature

3

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

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.

ѥ WARNING! ѥ

WARNING! Verify refrigerant type before

proceeding. Units are shipped with R-22
refrigerant.

R-410A

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: Notification of installation, operation or
maintenance information, which is important, but which is
not hazard-related.

ѥ WARNING! ѥ

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.

ѥ CAUTION! ѥ

ѥ WARNING! ѥ

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 proficiency requirements.

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
filters will quickly become clogged with
construction dirt and debris, which may
cause system damage.

4

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

GENERAL INFORMATION

Inspection

Upon receipt of the equipment, carefully check the shipment
against the bill of lading. Make sure all units have been
received. Inspect the packaging of each unit, and inspect
each unit for damage. Insure that the carrier makes 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 filed within 15 days, the freight company
can deny the claim without recourse. Note: It is the
responsibility of the purchaser to file all necessary claims
with the carrier. Notify Heat Controller of all damage within
fifteen (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. Stack units a maximum of 3 units high.

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, fittings, and valves before installing
any of the system components. Remove any dirt or debris
found in or on these components.

Pre-Installation

Installation, Operation, and Maintenance instructions

Installation, Operation and Maintenance

are provided with each unit. Horizontal equipment is

instructions are provided with each unit. Vertical unit

designed for installation above false ceiling or in a ceiling

confi gurations are typically installed in a mechanical

plenum. Other unit configurations are typically installed

room. The installation site chosen should include

in a mechanical room. The installation site chosen

adequate ervice clearance around the unit. Before

should include adequate service clearance around the

unit start-up, read all manuals and become familiar

unit. Before unit start-up, read all manuals and become

with the unit and its operation. Thoroughly check the

familiar with the unit and its operation. Thoroughly check

system before operation.

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 finished.

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.

6. Loosen compressor bolts on units equipped with
compressor spring vibration isolation until the
compressor rides freely on the springs. Remove
shipping restraints.

7. REMOVE COMPRESSOR SUPPORT PLATE 1/4”

7.

8. Some airflow patterns are field convertible (horizontal
SHIPPING BOLTS (2 on each side) TO MAXIMIZE

units only). Locate the airflow conversion section of

VIBRATION AND SOUND ATTENUATION.

this IOM.

8. Some airflow patterns are field convertible (horizontal

9. Locate and verify any hangers, or other accessory

8.

units only). Locate the airflow conversion section of

kits located in the compressor section or blower

this IOM.

section.

9. Locate and verify any hangers, or other accessory
kits located in the compressor section or blower
section.

ѥ CAUTION! ѥ

CAUTION! DO NOT store or install units

in corrosive environments or in locations
subject to temperature or humidity extremes

CAUTION! DO NOT store or install units

(e.g., attics, garages, rooftops, etc.).

in corrosive environments or in locations

Corrosive conditions and high temperature

subject to temperature or humidity extremes

or humidity can significantly reduce

(e.g., attics, garages, rooftops, etc.).

performance, reliability, and service life.

Corrosive conditions and high temperature

Always move units in an upright position.

or humidity can significantly reduce

Tilting units on their sides may cause

performance, reliability, and service life.

equipment damage.

Always move units in an upright position.

ѥ CAUTION! ѥ

Tilting units on their sides may cause
equipment damage.

NOTICE! Failure to remove shipping brackets
from spring-mounted compressors will cause
excessive noise, and could cause component

NOTICE! Failure to remove shipping brackets

failure due to added vibration.

from spring-mounted compressors will cause
excessive noise, and could cause component
failure due to added vibration.

ѥ CAUTION! ѥ

CAUTION! CUT HAZARD - Failure to follow

this caution may result in personal injury.
Sheet metal parts may have sharp edges

CAUTION! CUT HAZARD - Failure to follow

or burrs. Use care and wear appropriate

this caution may result in personal injury.

protective clothing, safety glasses and

Sheet metal parts may have sharp edges

gloves when handling parts and servicing

or burrs. Use care and wear appropriate

heat pumps.

protective clothing, safety glasses and
gloves when handling parts and servicing
heat pumps.

ѥ CAUTION! ѥ

5

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

Physical Data

Model 024 030 036 042 048 060

Compressor (1 Each) Copeland UltraTech Two-Stage Scroll

Factory Charge HFC-410a, oz [kg] 49 48 48 70 80 84

ECM Fan Motor & Blower

Fan Motor, hp [W] 1/2 [373] 1/2 [373] 1/2 [373] 3/4 [559] 3/4 [559] 1 [746]

Blower Wheel Size (Dia x W), in [mm]

Water Connection Size

Swivel - Residential Class 1” 1” 1” 1” 1” 1”

HWG Water Connection Size

Swivel - Residential Class 1” 1” 1” 1” 1” 1”

Vertical Upfl ow

Air Coil Dimensions (H x W), in [mm]

Standard Filter - 1” [25.4mm] Throw­away, qty (in) [mm]

Weight - Operating, lbs [kg] 216 [98.0] 224 [101.6] 245 [111.1] 260 [117.9] 315 [142.9] 330 [149.7]

Weight - Packaged, lbs [kg] 221 [100.2] 229 [103.9] 251 [113.8] 266 [120.6] 322 [146.0] 337 [152.9]

Horizontal

Air Coil Dimensions (H x W), in [mm]

Standard Filter - 1” [25mm] Pleated
MERV 8 Throwaway, in [mm]

Weight - Operating, lbs [kg] 200 [90.7] 208 [94.3] 229 [103.9] 244 [110.7] 299 [135.6] 314 [142.4]

Weight - Packaged, lbs [kg] 205 [93.0] 213 [96.6] 235 [106.6] 250 [113.4] 306 [138.8] 321 [145.6]

All units have grommet compressor mountings, TXV expansion devices, and 1/2” [12.7mm] & 3/4” [19.1mm] electrical knockouts.

9 x 7

[229 x 178]

20 x 17.25

[508 x 438]

20 x 20

[508 x 508}

16 x 22

[406 x 559]

18 x 24

[457 x 610]

9 x 7

[229 x 178]

20 x 17.25

[508 x 438]

20 x 20

[508 x 508}

16 x 22

[406 x 559]

18 x 24

[457 x 610]

9 x 8

[229 x 203]

24 x 21.75

[610 x 552]

24 x 24

[610 x 610]

20 x 25

[508 x 635]

14 x 20

[356 x 508]

9 x 8

[229 x 203]

24 x 21.75

[610 x 552]

24 x 24

[610 x 610]

20 x 25

[508 x 635]

14 x 20

[356 x 508]

10 x 10

[254 x 254]

28.75 x 24

[730 x 610]

28 x 28

[711 x 711]

20 x 35

[508 x 889]

20 x 38

[508 x 965]

11 x 10

[279 x 254]

28.75 x 24

[730 x 610]

28 x 28

[711 x 711]

20 x 35

[508 x 889]

20 x 38

[508 x 965]

6

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

HE - Vertical Upfl ow Dimensional Data

Vertical

Upfl ow

Model

024-030

036-042

048 -060

Vertical

Upfl ow

Model

024 - 030

036 - 042

048 - 060

Vertical

Model

024 - 060

Overall Cabinet

A

WidthBDepthCHeight

in

22.4

cm

56.9

in

22.4

cm

56.9

in

25.4

cm

64.5

12 3 4 5

Loop

incm3.8

incm3.8

incm4.0

10.2

Voltage

in

cm

D

In

9.6

9.6

1/2”

Low

11.7

E

Loop

Out

8.8

22.3

8.8

22.3

9.5

24.1

Electrical Knockouts

J

4.6

22.4

56.9

26.0

66.0

29.3

74.4

K

1/2”

Ext

Pump

6.1

15.5

40.5

102.9

46.5

118.1

50.5

128.3

Water Connections - Standard Units

Cond. HWG In HWG Out

FGH

19.5

49.5

22.1

56.1

22.1

56.1

13.4

34.0

15.2

38.6

15.2

38.6

L

3/4”

Power

Supply

7.6

19.3

15.7

39.9

18.5

47.0

18.5

47.0

Loop

Water

FPT

1” 1”

1” 1”

1” 1”

HWG

FPT

Notes:

1. While clear access to all removable panels is not required, installer should take care to comply with all building codes and allow
adequate clearance for future fi eld service.

2. Front & Side access is preferred for service access. However, all components may be serviced from the front access panel if side
access is not available.

3. Discharge fl ange is fi eld installed.

4. Condensate is 3/4” socket.

5. Source water and optional HWG connections are 1” swivel.

7

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

HE - Vertical Upfl ow Dimensional Data

Vertical

Upfl ow

Model

Duct Flange Installed (+/- 0.10 in, +/- 2.5mm)

M

Left

Return

024 - 030

036 - 042

048 - 060

Auxiliary Electric Heaters mounted externally.

O

in

cm

in

cm

in

cm

Front

Q

Top View-Right Return

R

P

Air Coil Side

S

7.4

18.8

7.4

18.8

7.4

18.8

N

Discharge Connection

O

N

Supply

Width

4.2

10.7

6.0

15.2

6.0

15.2

13.9

35.3

13.9

35.3

13.9

35.3

N

3

3

P

Supply

Depth

14.0

35.6

14.0

35.6

14.0

35.6

Q

Right

Return

6.7

17.0

7.4

18.8

8.4

21.3

B

P

Air Coil Side

Top View-Left Return

S

Return Connection

Standard Deluxe Filter Frame

(+/- 0.10 in, +/- 2.5mm)

S

R

Return

Depth

2.2

5.6

1.4

3.5

2.8

7.1

18.0

45.7

22.5

57.1

22.5

57.1

Standard Filter Frame

Air Coil

O

Front

A

M

R

CSP

Return

Height

18.0

45.7

22.0

55.9

22.0

55.9

2' [61cm]

Service

T

Field Installed
Discharge Flange

BSP

CAP

U

1.0

2.5

1.0

2.5

1.0

2.5

Isometric

View

Access Panels

ASP

Opptional

2' [61cm]

Service
Access
Left Rtn

(Right Rtn

Opposite

Side)

U

T

C

Residential
Filter Rack

Right Return Right View

- Air Coil Opening

Shown

U

Air Coil

Air Coil

T

C

1.6 [4.1 mm]

3

BackFront

3

Left Return Left View

- Air Coil Opening

CSPCSP

FrontBack

Power Supply

3/4" [19.1 mm] HV

Knockout

Low Voltage

1/2" [12.7 mm] LV

Knockout

Low Voltage

1/2" [12.7 mm] LV

Knockout

CSP

3

F

L

K

J

5
4
2

1

D

2

A

3

H

G

E

8

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

VERTICAL INSTALLATION

Vertical Unit Location

Units are not designed for outdoor installation. Locate
the unit in an INDOOR area that allows enough space
for service personnel to perform typical maintenance or
repairs without removing unit from the mechanical room/
closet. Vertical units are typically installed in a mechanical
room or closet. 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 filter and access panels.
Provide sufficient room to make water, electrical, and
duct connection(s).

If the unit is located in a confined 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 difficult to remove after the
unit is installed should be removed prior to setting the
unit. Refer to Figures 7 and 8 for typical installation
illustrations. Refer to unit specifications catalog for
dimensional data.

1. Install the unit on a piece of rubber, neoprene or
other mounting pad material for sound isolation. The
pad should be at least 3/8” [10mm] to 1/2” [13mm] in
thickness. Extend the pad beyond all four edges of the
unit.

2. Provide adequate clearance for filter replacement
and drain pan cleaning. Do not block filter access
with piping, conduit or other materials. Refer to unit
specifications for dimensional data.

3. Provide access for fan and fan motor maintenance
and for servicing the compressor and coils without
removing the unit.

4. Provide an unobstructed path to the unit within the
closet or mechanical room. Space should be sufficient
to allow removal of the unit, if necessary.

5. Provide access to water valves and fittings and
screwdriver access to the unit side panels, discharge
collar and all electrical connections.

Figure 7: Vertical Unit Mounting

Air Pad or Extruded
polystyrene insulation board

Figure 8: Typical Vertical Unit Installation

Using Ducted Return Air

Internally insulate supply
duct for first 4’ [1.2m] each
way to reduce noise

Use turning vanes in
supply transition

Flexible canvas duct
connector to reduce
noise and vibration

Rounded return
transition

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.

Internally insulate return
transition duct to reduce
noise

9

Rev 3/27/00

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

N

*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

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.

VERTICAL I

VERTICAL INSTALLATION

Sound Attenuation for Vertical Units

Sound attenuation is achieved by enclosing the unit
within a small mechanical room or a closet. Additional
measures for sound control include the following:

1. Mount the unit so that the return air inlet is 90° to
the return air grille. Refer to Figure 9. Install a sound
baffle as illustrated to reduce line-of sight sound
transmitted through return air grilles.
Mount the unit on a rubber or neoprene isolation pad to

2.
minimize vibration transmission to the building structure.

Figure 9: Vertical Sound Attenuation

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Condensate Piping for Vertical Units -

Install condensate
trap at each unit with the top of the trap positioned below
the unit condensate drain connection as shown in Figure

4. Design the depth of the trap (water-seal) based upon the
amount of External Static Pressure (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 fl ush or blow out the condensate line. DO NOT
install units with a common trap and/or vent.

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 4: Vertical Condensate Drain

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)Pqfo!Cpui!Foet!boe!Cpuupn*

Sfuvso!Bjs!Mpvwfs!ps!Hsjmmf

10

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

VERTICAL 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 fi lter and access panels. Provide suffi cient room to make
water, electrical, and duct connection(s).

If the unit is located in a confi 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 diffi cult to remove after the unit is installed
should be removed prior to setting the unit. Refer to Figures 7a
and 7b for an illustration of a typical installation. Refer to unit
specifi cations catalog 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
specifi c series and model in unit specifi cations catalog.
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
fi 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.

The installation of geothermal 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.

Mounting Horizontal Units

Horizontal units have hanger kits pre-installed from the
factory as shown in Figure 5. Figures 7a and 7b shows a
typical horizontal unit installation.

Horizontal heat pumps are typically suspended above a
ceiling or within a soffi t using fi eld supplied, threaded rods
sized to support the weight of the unit.

Use four (4) fi eld supplied threaded rods and factory provided
vibration isolators to suspend the unit. Hang the unit clear
of the fl oor slab above and support the unit by the mounting
bracket assemblies only. DO NOT attach the unit fl ush with
the fl oor slab above.

Pitch the unit toward the drain as shown in Figure 6 to
improve the condensate drainage. On small units (less
than 2.5 Tons/8.8 kW) ensure that unit pitch does not cause
condensate leaks inside the cabinet.

NOTE: The top panel of a horizontal unit is a structural
component. The top panel of a horizontal unit must never
be removed from an installed unit unless the unit is properly
supported from the bottom. Otherwise, damage to the unit
cabinet may occur.

Figure 5: Hanger Bracket

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Figure 6: Horizontal Unit Pitch

1/4” (6.4mm)
for drainage

Drain

Connection

11

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

HORIZONTAL INSTALLATION

Figure 7a: Typical Closed Loop Horizontal Unit Installation

3/8" [10mm] threaded rods

(by others)

Return Air

Power Wiring

Supply Air

Unit Power

Flexible Duct

Connector

Unit Power
Disconnect

(by others)

Unit Hanger

Air Coil -

Insulated supply duct with
at least one 90 deg elbow
to reduce air noise

To obtain maximum performance, the air coil should
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 anti-bacterial
systems may damage e-coated air coils.

Figure 7b: Typical Ground Water Horizontal Unit Installation

Thermostat

Wiring

Flush
Ports

Water

Pressure Ports

Ball Valves

Water Out

Water In

Supply Air

Insulated supply duct with
at least one 90 deg elbow
to reduce air noise

Flexible Duct

Connector

3/8" [10mm] threaded rods

(by others)

Return Air

Power Wiring

Unit Power

Unit Power
Disconnect

(by others)

Unit Hanger

12

Thermostat

Wiring

Ball Valves

Water Out

Water In

Building

Loop

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

FIELD CONVERSION OF AIR DISCHARGE

Overview -

Horizontal units can be fi eld converted
between side (straight) and back (end) discharge using the
instructions below.

Note: It is not possible to fi eld convert return air between left
or right return models due to the necessity of refrigeration
copper piping changes.

Preparation - It is best to fi eld convert the unit on the ground
before hanging. If the unit is already hung it should be taken
down for the fi eld conversion.

Side to Back Discharge Conversion

1.

Place unit in well lit area. Remove the screws as shown
in Figure 8 to free top panel and discharge panel.

2. Lift out the access panel and set aside. Lift and rotate

the discharge panel to the other position as shown,
being careful with the blower wiring.

3.

Check blower wire routing and connections for tension or
contact with sheet metal edges. Reroute if necessary.

4. Check refrigerant tubing for contact with

other components.

5. Reinstall top panel and screws noting that the location

for some screws will have changed.

6. Manually spin the fan wheel to ensure that the wheel is

not rubbing or obstructed.

7. Replace access 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 fi 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 discharge
for either right or left return confi guration is the 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 8: Left Return Side to Back

Water

Connection End

Water

Connection End

Water

Connection End

Side Discharge

Back Discharge

Remove Screws

Move to Side

Replace Screws

Figure 9: Right Return Side to Back

Return Air

Return Air

Rotate

Return Air

Return Air

Drain

Discharge Air

Connection End

Water

13

Return Air

Drain

Discharge Air

Supply Duct

Side Discharge

Back Discharge

Water

Connection End

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

Gasket

Swivel Nut

Stainless steel

snap ring

Brass Adaptor

Hand Tighten

Only!

Do Not

Overtighten!

WATER CONNECTION INSTALLATION

External Flow Controller Mounting

The Flow Controller can be mounted beside the unit
as shown in Figure 12. Review the Flow Controller
installation manual for more details.

Water Connections-Residential HR Models

Models utilize swivel piping fittings for water connections
that are rated for 450 psi (3101 kPa) operating pressure.
The connections have a rubber gasket seal similar to a
garden hose gasket, which when mated to the flush end
of most 1” threaded male pipe fittings provides a leak­free seal without the need for thread sealing tape or joint
compound. Insure that the rubber seal is in the swivel
connector prior to attempting any connection (rubber
seals are shipped attached to the swivel connector). DO
NOT OVER TIGHTEN or leaks may occur.

The female locking ring is threaded onto the pipe threads

HE

GROUND-LOOP HEAT PUMP APPLICATIONS

ѥ CAUTION! ѥ

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.

Pre-Installation

Prior to installation, locate and mark 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 12. All earth loop piping materials should be
limited to polyethylene fusion only for in-ground sections
of the loop. Galvanized or steel fittings should not be
used at any time due to their tendency to corrode. All
plastic to metal threaded fittings should be avoided due
to their potential to leak in earth coupled applications. A
flanged fitting should be substituted. P/T plugs should be
used so that flow can be measured using the pressure
drop of the unit heat exchanger.

which holds the male pipe end against the rubber
gasket, and seals the joint. HAND TIGHTEN ONLY! DO
NOT OVERTIGHTEN!

Figure 11: Water Connections

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
recommended in these applications.

Test individual horizontal loop circuits before backfilling.
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 Loop

Once piping is completed between the unit, Flow
Controller and the ground loop (Figure 12), the loop is
ready for final purging and charging. A flush cart with
at least a 1.5 hp [1.1 kW] pump is required to achieve
enough fluid velocity in the loop piping system to purge
air and dirt particles. An antifreeze solution is used in
most areas to prevent freezing. All air and debris must
be removed from the earth loop piping before operation.
Flush the loop with a high volume of water at a minimum
velocity of 2 fps (0.6 m/s) in all piping. The steps below
must be followed for proper flushing.

1. Fill loop with water from a garden hose through the
flush cart before using the flush cart pump to insure
an even fill.

2. Once full, the flushing process can begin. Do not
allow the water level in the flush cart tank to drop
below the pump inlet line to avoid air being pumped
back out to the earth loop.

3. Try to maintain a fluid level in the tank above the
return tee so that air cannot be continuously mixed
back into the fluid. Surges of 50 psi (345 kPa) can
be used to help purge air pockets by simply shutting
off the return valve going into the flush cart reservoir.
This “dead heads” the pump to 50 psi (345 kPa). To
purge, dead head the pump until maximum pumping

14

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

GROUND-LOOP HEAT PUMP APPLICATIONS

pressure is reached. Open the return valve and a
pressure surge will be sent through the loop to help
purge air pockets from the piping system.

4. Notice the drop in fluid level in the flush cart tank
when the return valve is shut off. If air is adequately
purged from the system, the level will drop only 1-2
inches (2.5 - 5 cm) in a 10” (25 cm) diameter PVC
flush tank (about a half gallon [2.3 liters]), since
liquids are incompressible. If the level drops more
than this, flushing should continue since air is still
being compressed in the loop fluid. Perform the “dead
head” procedure a number of times.

Note: This fluid level drop is your only indication of air in
the loop.

Antifreeze may be added before, during or after the
flushing procedure. However, depending upon which time
is chosen, antifreeze could be wasted when emptying the
flush cart tank. See antifreeze section for more details.

Loop static pressure will fluctuate with the seasons.
Pressures will be higher in the winter months than during
the cooling season. This fluctuation is normal and should
be considered when charging the system initially. Run the
unit in either heating or cooling for a number of minutes to
condition the loop to a homogenous temperature. This is
a good time for tool cleanup, piping insulation, etc. Then,
perform final flush and pressurize the loop to a static
pressure of 50-75 psi [345-517 kPa] (winter) or 35-40 psi
[241-276 kPa] (summer). After pressurization, be sure
to loosen the plug at the end of the Grundfos loop pump
motor(s) to allow trapped air to be discharged and to insure
the motor housing has been flooded. This is not required
for Taco circulators. Insure that the Flow Controller provides
adequate flow through the unit by checking pressure drop
across the heat exchanger and compare to the pressure
drop tables at the back of the manual.

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. Freeze 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 freeze 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 fluid in the piping system.
Then use the percentage by volume shown in Table
1 for the amount of antifreeze needed. Antifreeze
concentration should be checked from a well mixed
sample using a hydrometer to measure specific gravity.

Low Water Temperature Cutout Setting

DXM2 Control

CXM Control

When antifreeze is selected, the FP1 jumper (JW3)
should be clipped to select the low temperature (an­tifreeze 13°F [-10.6°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 1: Approximate Fluid Volume (gal.)
per 100' of Pipe

Fluid Volume (gal [L]/100’ Pipe)

Pipe Size Volume (gal) [L]

1” 4.1 [15.5]

Copper

Rubber Hose 1” 3.9 [14.8]

Polyethylene

Unit Heat Exchanger Typical 1.0 [3.8]

Flush Cart Tank

1.25” 6.4 [24.2]

2.5” 9.2 [34.8]

3/4” IPS SDR11 2.8 [10.6]

1” IPS SDR11

1.25” IPS SDR11 8.0 [30.3]

1.5” IPS SDR11 10.9 [41.3]

2” IPS SDR11 18.0 [68.1]

1.25” IPS SCH40 8.3 [31.4]

1.5” IPS SCH40 10.9 [41.3]

2” IPS SCH40 17.0 [64.4]

10” Dia x 3ft

[254mm x 0.9m]

4.5 [17.0]

10 [37.9]

Table 2: Antifreeze Percentages by Volume

Table 3. Antifreeze Percentages by Volume

Type Minimum Temperature for Freeze Protection

10°F [-12.2

Methanol 25% 21% 16% 10%

100% USP food grade Propylene Glycol 38% 30% 22% 15%

°C] 15°F [-9.4°C] 20°F [-6.7°C] 25°F [-3.9°C]

15