Heat Controller HEV-H User 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
DXM2 Controls ..............................................................................................30-31
Unit Start-Up and Operating Conditions ........................................................32-38
Preventive Maintenance .....................................................................................39
Troubleshooting .............................................................................................40-44
2
Heat Controller, Inc. HEV/H SERIES Installation, Operation & Maintenance
MOTOR, AND TWO STAGE SCROLL COMPRESSORS.
HEV
HEH
HeatController
H E H B0 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
B = Current Revision
for Sizes 024, 036, 060
VOLTAGE
CONTROLS
CABINET INSULATION
WA TER CIRCUIT OPTIONS
A = Copper Water Coil w/Tin Plated Air Coil
HEAT EXCHANGER OPTIONS
J = Cupro-Nickel Water Coil w/Tin Plated 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 ONL Y
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 51 48 54 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” [25.4 mm]
Pleated MERV 8 Throwaway, in [mm]
Weight - Operating, lbs [kg] 208 [94.3] 208 [94.3] 233 [105.6] 244 [110.7] 299 [135.6] 314 [142.4]
Weight - Packaged, lbs [kg] 213 [96.6] 213 [96.6] 239 [108.4] 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]
2 - 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]
2 - 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]
1 - 20 x 24
[508 x 610]
1 - 14 x 20
[356 x 508]
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]
1 - 20 x 24
[508 x 610]
1 - 14 x 20
[356 x 508]
6
Heat Controller, Inc. HEV/H SERIES Installation, Operation & Maintenance
HE - VERTICAL UPFLOW 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
2.5
1
2.5
1
2.5
HWG
FPT
1
2.5
1
2.5
1
2.5
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 UPFLOW DIMENSIONAL DATA
Vertical
Upfl ow
Model
Duct Flange Installed (+/- 0.10 in, +/- 2.5mm)
M
Left
N
Return
Discharge Connection
024 - 030
036 - 042
048 - 060
in
cm
in
cm
in
cm
7.4
18.8
7.4
18.8
7.4
18.8
4.2
10.7
6.0
15.2
6.0
15.2
Auxiliary Electric Heaters mounted externally.
P
N
O
Supply
Width
13.9
35.3
13.9
35.3
13.9
35.3
Return Connection
Standard Deluxe Filter Frame
(+/- 0.10 in, +/- 2.5mm)
P
Supply
Depth
14.0
35.6
14.0
35.6
14.0
35.6
N
P
B
Q
Right
Return
6.7
17.0
7.4
18.8
8.4
21.3
R
2.2
5.6
1.4
3.5
2.8
7.1
S
Return
Depth
18.0
45.7
22.5
57.1
25.8
65.5
Standard Filter Bracket
Air Coil
Return
Height
18.0
45.7
22.0
55.9
26.2
66.4
T
Field Installed
Discharge Flange
BSP
U
1.0
2.5
1.0
2.5
1.0
2.5
Access Panels
ASP
U
ront
Front
O
Q
Top View-Right Return
R
T
C
Right Return Right View
- Air Coil Opening
Air Coil Side
S
Residential
Filter Rack
Shown
Air Coil
Back
Top View-Left Return
U
T
C
Left Return Left View
Air Coil Side
S
CSPCSP
- Air Coil Opening
O
Front
M
R
A
Air Coil
FrontBack
CSP
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
2' [61cm]
Service
L
K
Opptional
2' [61cm]
Service
Access
CAP
Isometric
View
Left Rtn
(Right Rtn
Opposite
Side)
EE
5
4
2
3
J
1
D
U
FF
DD
F
H
E
A
See Aff---- for accessory air filter frame with duct collar
Filter Rails Removed
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
ರ
ರ
ರ
* Some units include a painted drain connection.
Using a threaded pipe or similar device to clear
any excess paint accumulated inside this fitting
may ease final drain line installation.
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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 (waterseal) 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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10
Heat Controller, Inc. HEV/H SERIES Installation, Operation & Maintenance
VERTICAL INSTALLATION
Horizontal Unit Location
Packaged 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 or any other method. 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 catalog specifi cations for dimensional data.
Conform to the following guidelines when selecting a
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 catalog specifi cations.
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 GHP system 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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IDFWRU\VXSSOLHG
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Figure 6: Horizontal Unit Pitch
11
1/4” (6.4mm) pi
per foot for drai
Drain
Connection
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.
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
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
Place unit in well lit area. Remove the screws as shown
1.
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.
Figure 8: Left Return Side to Back
Water
Connection End
Water
Connection End
Water
Connection End
Side Discharge
Remove Screws
Move to Side
Replace Screws
Return Air
Rotate
Return Air
Return Air
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.
Back Discharge
Figure 9: Right Return Side to Back
Return Air
Supply Duct
Side Discharge
Return Air
Drain
Drain
Discharge Air
Connection End
Water
Connection End
Water
13
Discharge Air
Back Discharge
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
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