Heat Controller HPV Quick Start Manual
INSTALLATION, OPERATION
& MAINTENANCE MANUAL
Residential Packaged
Geothermal Heat Pump
HP Series
1
/2 to 5 Tons
1
Heat Controller, Inc. • 1900 Wellworth Ave. • Jackson, MI 49203 • (517)787-2100 • www.heatcontroller.com
Installation, Operation & Maintenance HP SerieS Heat Controller, Inc.
Table of Contents
Model Nomenclature ............................................................................................2
Safety Instructions ................................................................................................3
Pre-Installation......................................................................................................4
Physical Data........................................................................................................5
Vertical Unit Dimensions....................................................................................6-7
Vertical Installation.............................................................................................8-9
Water Connection Installation .............................................................................10
Ground-Loop Heat Pump Applications ..........................................................10-12
Ground-Water Heat Pump Applications ..............................................................13
Water Quality Standards ....................................................................................14
Hot Water Generator .....................................................................................15-17
Electrical Data ...............................................................................................18-22
Blower Performance Data ..................................................................................23
Wiring Diagrams ............................................................................................24-25
CXM Controls ................................................................................................26-28
Unit Start-Up and Operating Conditions ........................................................29-36
Preventive Maintenance .....................................................................................37
Troubleshooting .............................................................................................38-42
1
Heat Controller, Inc. HP SerieS Installation, Operation & Maintenance
DRAWINGNO:
Decoder HP
S = STRAIGHT DISCHARGE, HORIZONTAL ONLY
Unit Nomenclature
HEAT CONTROLLER SERIES
TRH/TRV HPH/HPV
MODEL TYPE
HP = HEAT CONTROLLER RESIDENTIAL 410A
1 2 3 4 5 6 7
H P H A0 3 6 C1 5 0 A L B
CONFIGURATION
V=VERTICAL
H = HORIZONTAL
V = VERTICAL
V
UNIT SIZE
018
024
030
036
042
048
060
REVISION LEVEL
A = CURRENT REVISION
C = CXM (CSA/NRTL for USA & CANADA)
VOLTAGE
1 = 208-230/60/1
CONTROLS
9 10 11 12 13 14
8
WATER CIRCUIT OPTIONS
0 = NONE
1 = HWG w/ INTERNAL PUMP
CABINET INSULATION
0 = RESIDENTIAL
5 = RESIDENTIAL w/ULTRA QUIET
T
SUPPLY AIR OPTIONS
T=TOP DISCHARGE
B = BACK DISCHARGE, HORIZONTAL ONLY
T = TOP DISCHARGE, VERTICAL ONLY
RETURN AIR OPTIONS
L = LEFT RETURN
R = RIGHT RETURN
HEAT EXCHANGER OPTIONS
A = Copper Water Coil w/E-Coated Air Coil
J = Cupro-Nickel Water Coil w/E-Coated Air Coil
NOTE: Above model nomenclature is a general reference. Consult individual specication catalogs for detailed information.
2
Installation, Operation & Maintenance HP 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.
� WARNING! �
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.
� WARNING! �
WARNING! All refrigerant discharged
from this unit must be recovered WITHOUT
EXCEPTION. Technicians must follow industry
accepted guidelines and all local, state, and
federal statutes for the recovery and disposal of
refrigerants. If a compressor is removed from
this unit, refrigerant circuit oil will remain in the
compressor. To avoid leakage of compressor
oil, refrigerant lines of the compressor must be
sealed after it is removed.
� CAUTION! �
� WARNING! �
WARNING! To avoid the release of
refrigerant into the atmosphere, the
refrigerant circuit of this unit must be
serviced only by technicians who meet local,
state, and federal 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.
3
Heat Controller, Inc. HP SerieS Installation, Operation & Maintenance
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”
SHIPPING BOLTS (2 on each side) TO MAXIMIZE
VIBRATION AND SOUND ATTENUATION.
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
congurations 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.
REMOVE COMPRESSOR SUPPORT PLATE 1/4”
7.
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.
� CAUTION! �
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.
� CAUTION! �
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.
� CAUTION! �
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.
� CAUTION! �
4
Installation, Operation & Maintenance HP SerieS Heat Controller, Inc.
Physical Data
HP Series
Compressor (1 Each) Rotary Scroll
Factory Charge R410A (oz) 43 43 48 50 70 74 82
PSC Fan Motor & Blower
Fan Motor Type/Speeds PSC/3 PSC/3 PSC/3 PSC/3 PSC/3 PSC/3 PSC/3
Fan Motor (hp) 1/6 1/4 3/4 1/2 3/4 3/4 1
Blower Wheel Size (Dia x w) 8x7 9x7 9x7 9x8 9x8 10x10 11x10
Water Connection Size 1” Swivel
Hx Water Volume (gal.) .45 .286 .323 .323 .890 .738 .939
Vertical
Air Coil Dimensions (H x W) 20x17.25 20x17.25 20x17.25 24x21.75 24x21.76 28x25 28x25
Filter Standard - 1" Throwaway 20x20 20x20 20x20 24x24 24x24 28x28 28x28
Weight - Operating (lbs.) 168 184 192 213 228 283 298
Weight - Packaged (lbs.) 173 194 197 219 234 290
018 024 030 036 042 048 060
305
Maximum Working Water Pressure
Pressure PSIG (kPa)
Unit Source Circuit 500 (3,447)
HWG Circuit 125 (862)
5
Heat Controller, Inc. HP SerieS Installation, Operation & Maintenance
HP - Vertical Upow Dimensional Data
Vertical
uplow
Model
018 - 030
036 - 042
048 - 060
Vertical
Upow
Model
018
024 -
030
036 -
042
048 -
060
in
cm
in
cm
in
cm
in
cm
in
cm
in
cm
in
cm
Overall Cabinet
A
WidthBDepthCHeight
22.4
56.9
22.4
56.9
25.4
64.5
Loop
In
D
3.7
9.4
3.7
9.4
3.7
9.4
3.7
9.4
22.4
56.9
25.4
64.5
29.1
73.9
1 2 3 4 5
Loop
In
E
1.9
4.8
1.9
4.8
1.8
4.6
1.8
4.6
40.5
102.9
46.5
118.1
50.5
128.3
Water Connections - Standard Units
Loop
Out
F
9.7
24.6
9.7
24.6
12.7
32.3
12.7
32.3
Loop
Out
E
1.9
4.8
1.9
4.8
1.8
4.6
1.8
4.6
Cond. 3/4” HWG In HWG Out
H I DD EE FF EE
7.0
17.8
7.0
17.8
8.0
20.3
8.0
20.3
1.9
4.8
1.9
4.8
1.8
4.6
1.8
4.6
11.7
29.7
12.4
31.5
15.2
38.6
15.2
38.6
1.6
4.1
1.6
4.1
1.6
4.1
1.6
4.1
14.9
37.8
15.7
39.9
18.4
46.7
18.4
46.7
1.6
4.1
1.6
4.1
1.6
4.1
1.6
4.1
Electrical Knockouts
Vertical
018 - 060
Model
in
cm
J
1/2”
Low
Voltage
4.0
10.2
K
1/2”
Low
Voltage
7.0
17.8
L
3/4”
Power
Supply
10.0
25.4
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 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 ange is eld installed.
4. Condensate is 3/4” socket.
5. Source water and optional HWG connections are 1” swivel.
6
Installation, Operation & Maintenance HP SerieS Heat Controller, Inc.
HP - Vertical Upow Dimensional Data
Vertical
Model
018 - 030
036 - 042
048 - 060
in
cm
in
cm
in
cm
Duct Flange Installed (+/- 0.10 in, +/- 2.5mm)
M N
7.2
18.3
7.2
18.3
8.2
20.8
Legend:
CAP = Control Access Panel
BSP = Blower Service Panel
CSP = Compressor Access Panel
ASP = Alternative Service Panel
P
Discharge Connection
Supply
Width
4.2
10.7
6.0
15.2
5.7
14.5
14.0
35.6
14.0
35.6
16.0
40.6
N
Return Connection
Using Return Air Opening
O
N
P
Supply
Depth
14.0
35.6
14.0
35.6
18.0
45.7
B
P
Q R
5.4
13.7
5.2
13.2
5.2
13.2
2.2
5.6
2.1
5.3
2.1
5.3
S
Return
Depth
Return
Height
18.4
46.7
22.9
58.2
26.2
66.5
Standard Filter Bracket
Air Coil
T
20.3
51.6
24.3
61.7
28.3
71.9
Field Installed
Discharge Flange
U
1.1
2.8
1.1
2.8
1.1
2.8
Access Panels
BSP
ASP
Front
O
Q
Top View-Right Return
R
U
T
C
Right Return Right View
- Air Coil Opening
Air Coil Side
S
Opptional
2' [61cm]
Service
Access
Left Rtn
(Right Rtn
Opposite
Side)
Air Coil Side
Top View-Left Return
S
O
Front
M
R
A
CSP
2' [61cm]
Service
CAP
Isometric
View
U
Air Coil
Air Coil
T
C
Power Supply
3/4" [19.1 mm] HV
Knockout
Low Voltage
1/2" [12.7 mm] LV
Knockout
CSPCSP
BackFront
Left Return Left View
- Air Coil Opening
FrontBack
Low Voltage
1/2" [12.7 mm] LV
Knockout
CSP
L
K
J
U
A
EE
5
4
3
2
2
3
1
D
FF
DD
F
H
E
7
Heat Controller, Inc. HP 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
8
Rev 3/27/00
Installation, Operation & Maintenance HP SerieS Heat Controller, Inc.
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.
2.
Mount the unit on a rubber or neoprene isolation pad to
minimize vibration transmission to the building structure.
Figure 9: Vertical Sound Attenuation
Condensate Piping – Vertical Units
Vertical units utilize a condensate hose inside the
cabinet as a trapping loop; therefore an external trap
is not necessary. Figure 10a shows typical condensate
connections. Figure 10b illustrates the internal trap for
a typical vertical heat pump. Each unit must be installed
with its own individual vent and a means to flush or blow
out the condensate drain line. Do not install units with a
common trap and/or vent.
Figure 10a: Vertical Condensate Drain
1/4” per foot (21mm per m)
slope to drain
Figure 10b: Vertical Internal Condensate Trap
9
Heat Controller, Inc. HP SerieS Installation, Operation & Maintenance
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
HP
GROUND-LOOP HEAT PUMP APPLICATIONS
� CAUTION! �
CAUTION! The following instructions
represent industry accepted installation
practices for closed loop earth coupled heat
pump systems. Instructions are provided
to assist the contractor in installing trouble
free ground loops. These instructions are
recommendations only. State/provincial
and local codes MUST be followed and
installation MUST conform to ALL applicable
codes. It is the responsibility of the installing
contractor to determine and comply with ALL
applicable codes and regulations.
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
Hand Tighten
Only!
Swivel Nut
Stainless steel
snap ring
Gasket
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
Do Not
Overtighten!
Brass Adaptor
10
Installation, Operation & Maintenance HP SerieS Heat Controller, Inc.
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
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]
11
Heat Controller, Inc. HP SerieS Installation, Operation & Maintenance
GROUND-LOOP HEAT PUMP APPLICATIONS
Figure 12: Typical Ground-Loop Application
Flow
Controller
Unit Power
Disconnect
Insulated
Hose Kit
Thermostat
Wiring
Air Pad or Extruded
polystyrene insulation
board
GROUND-WATER HEAT PUMP APPLICATIONS
Open Loop - Ground Water Systems
Typical open loop piping is shown in Figure 14. Shut off
valves should be included for ease of servicing. Boiler
drains or other valves should be “tee’d” into the lines to
allow acid flushing of the heat exchanger. Shut off valves
should be positioned to allow flow through the coax via
the boiler drains without allowing flow into the piping
system. P/T plugs should be used so that pressure drop
and temperature can be measured. Piping materials
should be limited to copper or PVC SCH80. Note: Due to
the pressure and temperature extremes, PVC SCH40
is not recommended.
Water quantity should be plentiful and of good quality.
Consult table 3 for water quality guidelines. The unit can
be ordered with either a copper or cupro-nickel water
heat exchanger. Consult Table 3 for recommendations.
Copper is recommended for closed loop systems and
open loop ground water systems that are not high
in mineral content or corrosiveness. In conditions
anticipating heavy scale formation or in brackish water, a
cupro-nickel heat exchanger is recommended. In ground
water situations where scaling could be heavy or where
biological growth such as iron bacteria will be present, an
open loop system is not recommended. Heat exchanger
coils may over time lose heat exchange capabilities due
to build up of mineral deposits. Heat exchangers must
13.
P/T Plugs
only be serviced by a qualified technician, as acid and
special pumping equipment is required. Desuperheater
coils can likewise become scaled and possibly plugged.
In areas with extremely hard water, the owner should be
informed that the heat exchanger may require occasional
acid flushing. In some cases, the desuperheater option
should not be recommended due to hard water conditions
and additional maintenance required.
Water Quality Standards
Table 3 should be consulted for water quality
requirements. Scaling potential should be assessed using
the pH/Calcium hardness method. If the pH <7.5 and the
calcium hardness is less than 100 ppm, scaling potential
is low. If this method yields numbers out of range of those
listed, the Ryznar Stability and Langelier Saturation
indecies should be calculated. Use the appropriate
scaling surface temperature for the application, 150°F
[66°C] for direct use (well water/open loop) and
desuperheater; 90°F [32°F] for indirect use. A monitoring
plan should be implemented in these probable scaling
situations. Other water quality issues such as iron fouling,
corrosion prevention and erosion and clogging should be
referenced in Table 3.
12
Installation, Operation & Maintenance HP SerieS Heat Controller, Inc.
GROUND-WATER HEAT PUMP APPLICATIONS
Expansion Tank and Pump
Use a closed, bladder-type expansion tank to minimize
mineral formation due to air exposure. The expansion
tank should be sized to provide at least one minute
continuous run time of the pump using its drawdown
capacity rating to prevent pump short cycling. Discharge
water from the unit is not contaminated in any manner
and can be disposed of in various ways, depending on
local building codes (e.g. recharge well, storm sewer,
drain field, adjacent stream or pond, etc.). Most local
codes forbid the use of sanitary sewer for disposal.
Consult your local building and zoning department to
assure compliance in your area.
Water Control Valve
Note the placement of the water control valve in
13.
Figure 14. Always maintain water pressure in the heat
exchanger by placing the water control valve(s) on the
discharge line to prevent mineral precipitation during
the off-cycle. Pilot operated slow closing valves are
recommended to reduce water hammer. If water hammer
persists, a mini-expansion tank can be mounted on the
piping to help absorb the excess hammer shock. Insure
that the total ‘VA’ draw of the valve can be supplied by
the unit transformer. For instance, a slow closing valve
can draw up to 35VA. This can overload smaller 40 or
50 VA transformers depending on the other controls in
the circuit. A typical pilot operated solenoid valve draws
approximately 15VA.
Flow Regulation
Flow regulation can be accomplished by two methods.
One method of flow regulation involves simply adjusting
the ball valve or water control valve on the discharge
line. Measure the pressure drop through the unit heat
exchanger, and determine flow rate from Tables 8. Since
Table 10C. Since
the pressure is constantly varying, two pressure gauges
may be needed. Adjust the valve until the desired flow of
1.5 to 2 gpm per ton [2.0 to 2.6 l/m per kW] is achieved.
A second method of flow control requires a flow control
device mounted on the outlet of the water control valve.
The device is typically a brass fitting with an orifice of
rubber or plastic material that is designed to allow a
specified flow rate. On occasion, flow control devices may
produce velocity noise that can be reduced by applying
some back pressure from the ball valve located on the
discharge line. Slightly closing the valve will spread the
pressure drop over both devices, lessening the velocity
noise. NOTE: When EWT is below 50°F [10°C], 2 gpm
per ton (2.6 l/m per kW) is required.
Water Coil Low Temperature Limit Setting
For all open loop systems the 30°F [-1.1°C] FP1 setting
(factory setting-water) should be used to avoid freeze
damage to the unit. See “Low Water Temperature Cutout
Selection” in this manual for details on the low limit setting.
Figure 13: Typical Open Loop/Well Application
Unit Power
Disconnect
Air Pad or
Extruded
polystyrene
insulation board
Thermostat
Wiring
Water
Control
Valve
P/T Plugs
Flow
Regulator
Boiler
Drains
Pressure
Tank
Water Out
Optional
Filter
Water In
Shut-Off
Valve
13
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