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 • (517)787-2100 • 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
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
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.
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
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]
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.
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
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
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
Jotvmbufe!Tpvoe!Cbggmf )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 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]
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