Heat Controller HBH/V Compact Instruction manual

Heat Controller, Inc. • 1900 Wellworth Ave. • Jackson, MI 49203 • [phone] • www.heatcontroller.com
Installation, Operation
& Mainenance Manual
Commercial Horizontal & Vertical
Packaged Water-Source Heat Pumps:
HBH/V Compact

IOM Instructions HBH/V CompaCt Heat Controller, Inc.
Model Nomenclature ..................................................2
General Information.................................................3-4
Physical Data..............................................................5
Horizontal Installation...........................................6-7,9
Field Conversion of Air Discharge..............................8
Vertical Installation...............................................10-11
Piping Installation .....................................................12
Water Loop Applications...........................................13
Open Loop - Ground Water Systems ..................14-17
Water Quality Standards ..........................................18
Electrical - Line Voltage............................................19
Electrical Data .....................................................20-21
Electrical - Power & Low Voltage Wiring .............22-24
Electrical - Thermostat Wiring ..................................25
CXM Controls...........................................................26
CXM Control - Safety Features ...........................27-28
Unit Starting & Operating Conditions........................29
Piping System Cleaning & Flushing .........................30
Unit & System Checkout...........................................31
Unit Start-Up Procedure......................................32-33
Unit Operating Procedures & Temperatures........34-37
Preventive Maintenance...........................................38
Functional Troubleshooting .................................39-42
TABLE OF CONTENTS

Heat Controller, Inc. HBH/V CompaCt IOM Instructions
7 May, 2009
Page 10
HEAT CONTROLLER OEM PRICE LIST
HBH & HBV Model Structure
HBH & HBV COMPACT Horizontal & Vertical HFC-410a Units
The basic unit price includes sealed heat pump refrigerant circuit and
air handler within cabinetry, lter, and a factory installed hanger kit on
horizontal units.
• Cabinetry - Compact design - galvanized steel construction -
powder coat nish on front access panels - controls access panel
- compressor access panels - FPT water connections - high and low
voltage knockouts - 1” (25mm), air lter and lter rack. All vertical
units have a left or right return air option, sizes 015 - 030 have a front
return option. All horizontal units have eld convertible discharge air
patterns with no extra parts required.
• Standard Controls - CXM Controller, loss of charge switch, high
pressure switch, water coil low temperature cutout, lockout safety
circuit resetable at thermostat or disconnect, LED fault indication,
ve minute anti-short cycle protection, random start, high and low
voltage protection, condensate overow protection, dry contact for
alarm.
• Compressor - High efciency hermetic scroll or rotary, overload
protected - internally sprung & externally isolated using dual vibration
dampening system for extra quiet operation. Mounting system
incorporates rubber grommet isolation under the compressor and
rubber grommet isolation between the compressor mounting tray and
unit base.
• Reversing Valve - 4-way, pilot operated, solenoid activated in the
cool mode.
• Refrigerant Circuit - Utilizes expansion valve metering device -
copper tubing interconnecting all components - sealed & tested
non-ozone depleting, HFC-410A refrigerant circuit with high & low
side schraeder ports.
• Water to Refrigerant Coil - Tube-in-tube, convoluted copper inner
water tube.
• Refrigerant to Air Coil - Lanced aluminum ns on ried copper
tubes.
• Blower Motor - Three-speed PSC direct drive, permanently
lubricated (Two-speed on 575 volt applications).
• UltraQuiet Option - Compressor incorporates spring mounting
system, 015-060 include compressor discharge mufer, blower
housing is covered with high density noise suppression material.
• Application - Units can be applied in WLHP, GWHP, or GLHP
applications.
Basic Unit Description:
HB H A036 C3 3 0 A L B
1 2 3 4 5 6 7
8
9 10 11 12 13 14
HB= HEATCONTROLLERCOMPACT410A
MODELTYPE
H= HORIZONTAL(NONPAINTED)
CONFIGURATION
V= VERTICAL(PAINTEDPOLARICE)
UNITSIZE
018- 1,8
024- 1,3,4,8
030- 1,3,4,8
036- 1,3,4,8
042- 1,3,4,5
048- 1,3,4,5
060- 1,3,4,5
REVISION LEVEL
A= CURRENTREVISIONFORSIZES006 -060
VOLTAGE
C= CXM
CONTROLS
3= STANDARDRANGE
CABINETINSULATION
0= NONE
FUTUREUSE
A= CopperWaterCoilw/E-CoatedAirCoil
HEATEXCHANGEROPTIONS
C= CopperWaterCoilw/Non-CoatedAirCoil
L=LEFTRETURN
RETURNAIROPTIONS
R= RIGHTRETURN
F= FRONTRETURN,VERTICAL 009-030
B= BACKDISCHARGE,HORIZONTALONLY
SUPPLYAIROPTIONS
Y=BACKDISCHARGE,HIGHSTATIC
HORIZONTAL018- 060
T=TOPDISCHARGE,VERTICALONLY
V=TOPDISCHARGE,HIGHSTATIC
VERTICAL018-060
S= STRAIGHTDISCHARGE,HORIZONTALONLY
Z= STRAIGHTDISCHARGE,HIGHSTATIC
HORIZONTAL018- 060
J= Cupro-NickelWaterCoilw/E-CoatedAirCoil
N= Cupro-NickelWaterCoilw/Non-CoatedAirCoil
4= STANDARDRANGE,WITH ULTRAQUIET
015- 1,8
1= 208-230/60/1
8= 265/60/1
3= 208-230/60/3
4= 460/60/3
5= 575/60/3
C= STANDARDRANGE,COOLINGONLY,VERTICALUNITS
3= DISCHARGEPRESSUREWATERREGULATINGVALVE(COOLINGONLY)
NOTAVAILABLEONUNITSIZES006,009AND012
V= LEFTRETURN,S.SDRAINPAN
W= RIGHTRETURN,S.SDRAINPAN
Z= FRONTRETURN,S.S.DRAIN PAN009-030
}VoltageCode
Entering Water Temperature Range: 20 - 120°F (-6.7 - 48.9°C)
Vertical Water Source Heat Pump
Sizes 015-060
Horizontal Water Source Heat Pump
Sizes 015-060
006-060 006-060
006
R-410A refrigerant circuit with high & low
• Cabinetry – Compact design - galvanized steel construction - controls
access panel - compressor access panels - FPT water connections -
high and low voltage knockouts - 1” (25mm), air lter and lter rack. All
vertical units have a left or right return air option, sizes 006-030 have a
front return option. All horizontal units have eld convertible discharge air
patterns with extra parts required.

General Information
WARNING! To avoid the release of refrigerant into the
atmosphere, the refrigerant circuit of this unit must be
serviced only by technicians who meet local, state, and
federal prociency requirements.
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! To avoid equipment damage, DO NOT use
these units as a source of heating or cooling during the
construction process. The mechanical components and
lters will quickly become clogged with construction dirt and
debris, which may cause system damage.
WARNING!
WARNING!
WARNING!
CAUTION!
Safety
Warnings, cautions and notices appear throughout this manual.
Read these items carefully before attempting any installation,
service or troubleshooting of the equipment.
DANGER: Indicates an immediate hazardous situation, which
if not avoided will result in death or serious injury. DANGER
labels on unit access panels must be observed.
WARNING: Indicates a potentially hazardous situation, which if
not avoided could result in death or serious injury.
CAUTION: Indicates a potentially hazardous situation or an
unsafe practice, which if not avoided could result in minor or
moderate injury or product or property damage.
NOTICE: Notication of installation, operation or maintenance
information, which is important, but which is not hazard-related.
WARNING! The Refrigerant Application and Service Manual
should be read and understood before attempting to service
refrigerant circuits with HFC-410A.
Inspection
Upon receipt of the equipment, carefully check the shipment
against the bill of lading. Make sure all units have been received.
Inspect the packaging of each unit, and inspect each unit for
damage. Insure that the carrier makes proper notation of any
shortages or damage on all copies of the freight bill and completes
a common carrier inspection report. Concealed damage not
discovered during unloading must be reported to the carrier within
15 days of receipt of shipment. If not led within 15 days, the
freight company can deny the claim without recourse. Note: It is
the responsibility of the purchaser to le all necessary claims with
the carrier. Notify your equipment supplier of all damage within
fteen (15) days of shipment.
Storage
Equipment should be stored in its original packaging in a clean,
dry area. Store units in an upright position at all times. 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, ttings, 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 are
provided with each unit. Horizontal equipment is designed for
installation above false ceiling or in a ceiling plenum. Other
unit congurations are typically installed in a mechanical room.
The installation site chosen should include adequate service
clearance around the unit. Before unit start-up, read all manuals
and become familiar with the unit and its operation. Thoroughly
check the system before operation.
IOM Instructions HBH/V CompaCt Heat Controller, Inc.
R-410A.

CAUTION! All three phase scroll compressors must have
direction of rotation veried at start-up. Verication is achieved by
checking compressor Amp draw. Amp draw will be substantially
lower compared to nameplate values. Additionally, reverse rotation
results in an elevated sound level compared to correct rotation.
Reverse rotation will result in compressor internal overload trip
within several minutes. Verify compressor type before proceeding.
CAUTION! DO NOT store or install units in corrosive
environments or in locations subject to temperature or
humidity extremes (e.g., attics, garages, rooftops, etc.).
Corrosive conditions and high temperature or humidity can
signicantly reduce performance, reliability, and service life.
Always move and store units in an upright position. Tilting
units on their sides may cause equipment damage.
NOTICE! Failure to remove shipping brackets from spring-
mounted compressors will cause excessive noise, and
could cause component failure due to added vibration.
CAUTION!
CAUTION!
CAUTION!
CAUTION! CUT HAZARD - Failure to follow this caution
may result in personal injury. Sheet metal parts may have
sharp edges or burrs. Use care and wear appropriate
protective clothing, safety glasses and gloves when
handling parts and servicing heat pumps.
General Information
Prepare units for installation as follows:
1. Compare the electrical data on the unit nameplate with
ordering and shipping information to verify that the correct
unit has been shipped.
2. Keep the cabinet covered with the original packaging until
installation is complete and all plastering, painting, etc. is
nished.
3. Verify refrigerant tubing is free of kinks or dents and that it
does not touch other unit components.
4. Inspect all electrical connections. Connections must be
clean and tight at the terminals.
5. Remove any blower support packaging (water-to-air units
only).
6. Loosen compressor bolts on units equipped with
compressor spring vibration isolation until the compressor
rides freely on the springs. Remove shipping restraints.
7.
Some airow patterns are eld convertible (horizontal units
only). Locate the airow conversion section of this IOM.
8. Locate and verify any hot water generator (HWG), hanger,
or other accessory kit located in the compressor section or
blower section.
Heat Controller, Inc. HBH/V CompaCt IOM Instructions

Unit Physical Data
HBH/V Series
HB Series 006 009 012 015 018 024 030 036 042 048 060
Compressor (1 Each) Rotary Scroll
Factory Charge R410A (oz) 17 18.5 23 32 43 43 47 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 PSC/3 PSC/3 PSC/3 PSC/3
Fan Motor (hp) 1/25 1/10 1/10 1/6 1/6 1/4 3/4 1/2 3/4 3/4 1
Blower Wheel Size (Dia x w) 5x5 5x5 6x5 8x7 8x7 9x7 9x7 9x8 9x8 10x10 11x10
Water Connection Size
IPT 1/2” 1/2” 1/2” 1/2" 1/2" 3/4" 3/4" 3/4" 3/4" 1" 1"
Vertical
Air Coil Dimensions (H x W) 10x15 10x15 10x15 20x17.25 20x17.25 20x17.25 20x17.25 24x21.75 24x21.76 24x28.25 24x28.25
Filter Standard - 1" Throwaway 10x18 10x18 10x18 20x20 20x20 20x20 20x20 24x24 24x24 1-14x24, 1-18x24 1-14x24, 1-18x24
Weight - Operating (lbs.) 103 105 114 153 158 189 197 203 218 263 278
Weight - Packaged (lbs.) 113 115 124 158 163 194 202 209 224 270
285
Horizontal
Air Coil Dimensions (H x W) 10x15 10x15 10x15 16x22 16x22 16x22 16x22 20x25 20x25 20x35 20x35
Filter Standard - 1" Throwaway 10x18 10x18 10x18 16x25 16x25 18x25
18x25 20x28 or 2-20x14 20x28 or 2-20x14 1-20x24, 1-20x14 1-20x24, 1-20x14
Weight - Operating (lbs.) 103 105 114 153 158 174 182 203 218 263 278
Weight - Packaged (lbs.) 113 115 124 158 163 179 187 209 224 270 285
Notes:
Models 006-012 have spring compressor mounts, all others have grommets,TXV expansion device, and 1/2” & 3/4” electrical knockouts.
Unit Maximum Water Working Pressure
Options Max Pressure PSIG [kPa]
Base Unit 500 [3,445]
Discharge Pressure
Water Regulating Valve 140 [965]
Use the lowest maximum pressure rating when multiple options are combined.
IOM Instructions HBH/V CompaCt Heat Controller, Inc.

Heat Controller, Inc. HBH/V CompaCt IOM Instructions
Horizontal Installation
Mounting Horizontal Units
Horizontal units have hanger kits pre-installed from the factory
as shown in Figure 1. Figure 3 shows a typical horizontal unit
installation.
Horizontal heat pumps are typically suspended above a ceiling
or within a soft using eld supplied, threaded rods sized to
support the weight of the unit.
Use four (4) eld supplied threaded rods and factory provided
vibration isolators to suspend the unit. Hang the unit clear of the
oor slab above and support the unit by the mounting bracket
assemblies only. DO NOT attach the unit ush with the oor
slab above.
Pitch the unit toward the drain as shown in Figure 2 to improve
the condensate drainage. On small units (less than 2.5
tons/8.8kW) ensure that unit pitch does not cause condensate
leaks inside the cabinet.
Figure 1: Hanger Bracket
Figure 2: Horizontal Unit Pitch
3/8" [10mm] Threaded
Rod (by others)
Vibration Isolator
(factory supplied)
Washer
(by others)
Double Hex Nuts
(by others)
Varilla Roscada de 3/8"
(fabricada por terceros)
Arandela
(fabricada por terceros)
Tuercas Hexagonales
Dobles (por terceros)
Instale losTornillos como
se Indica en el Diagrama
La longitud de este tornillo
debe ser de solamente 1/2”para evitar daños
Aislador deVibraciones
(para codificación por color y
notas de instalación, consulte
las instrucciones de
instalación del soport
e colgador)
1/4" [6.4mm] pitch
for drainage
Drain
Connection
Horizontal Unit Location
Units are not designed for outdoor installation. Locate
the unit in an INDOOR area that allows enough space
for service personnel to perform typical maintenance or
repairs without removing unit from the ceiling. Horizontal
units are typically installed above a false ceiling or in a
ceiling plenum. Never install units in areas subject to
freezing or where humidity levels could cause cabinet
condensation (such as unconditioned spaces subject
to 100% outside air). Consideration should be given to
access for easy removal of the lter and access panels.
Provide sufcient room to make water, electrical, and
duct connection(s).
If the unit is located in a conned space, such as a closet,
provisions must be made for return air to freely enter the
space by means of a louvered door, etc. Any access panel
screws that would be difcult to remove after the unit is
installed should be removed prior to setting the unit. Refer
to Figure 3 for an illustration of a typical installation. Refer
to unit engineering design guide for dimensional data.
In limited side access installations, pre-removal of the
control box side mounting screws will allow control box
removal for future servicing (HB units only).
Conform to the following guidelines when selecting
unit location:
1. Provide a hinged access door in concealed-spline
or plaster ceilings. Provide removable ceiling
tiles in T-bar or lay-in ceilings. Refer to horizontal
unit dimensions for specic series and model in
unit submittal data. Size the access opening to
accommodate the service technician during the
removal or replacement of the compressor and the
removal or installation of the unit itself.
2. Provide access to hanger brackets, water valves
and ttings. Provide screwdriver clearance to access
panels, discharge collars and all electrical connections.
3. DO NOT obstruct the space beneath the unit with
piping, electrical cables and other items that prohibit
future removal of components or the unit itself.
4. Use a manual portable jack/lift to lift and support the
weight of the unit during installation and servicing.
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.

IOM Instructions HBH/V CompaCt Heat Controller, Inc.
Horizontal Installation
Figure 3: Typical Horizontal Unit Installation
Air Coil
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.
NOTICE! Installation Note - Ducted Return: Many horizontal
WSHPs are installed in a return air ceiling plenum application
(above ceiling). Vertical WSHPs are commonly installed in a
mechanical room with free return (e.g. louvered door). Therefore,
lter rails are the industry standard and are included on Heat
Controller, Inc., commercial heat pumps for the purposes of
holding the lter only. For ducted return applications, the lter rail
must be removed and replaced with a duct ange or lter rack.
Canvas or exible connectors should also be used to minimize
vibration between the unit and ductwork.
HORIZONTAL INSTALLATION
(by others)
(by others)
Cableado
del termostato
Válvula compensadora opcional
Salida de agua
Entrada de agua
Válvula invertida opcional para
control de baja presión de agua
(puede montarse en forma interna)
Válvula a bola con tapón
P/T integrado opcional
Manguera trenzada de
acero inoxidable con accesorio
giratorio en “J”
Circuito
de edificación
Disyuntor de
energía de la unidad
(fabricado por terceros)
Alimentación
de energía de
la unidad
Conducto de alimentación
aislado con un codo (mínimo)
de 90 grados para reducir el
ruido del aire
Retorno de
aire
Aire de alimentación
Cableado de
alimentación
de energía
Varillas Roscadas de 3/8"
(fabricadas por terceros)
Colgador
de la unidad
Thermostat
Wiring
Optional Balancing Valve
Water In
Water Out
Optional Low Pressure Drop Water
Control Valve
(can be internally mounted
on some models)
Ball Valve with optional
integral P/T plug
Stainless steel braid hose
with integral "J" swivel
Building
Loop
Unit Power
Disconnect
Power Wiring
Insulated supply duct with
at least one 90 deg elbow
to reduce air noise
Return Air
Supply Air
Unit Hanger
3/8" [10mm] threaded rods
Unit Power
Flexible Duct
Connector
Figure 3: Typical Horizontal Unit Installation
Stainless steel braided hoses with
threaded connections
and one swivel end

Heat Controller, Inc. HBH/V CompaCt IOM Instructions
Field Conversion of Air Discharge
Water
Connection End
Return Air
Remove Screws
Water
Connection End
Return Air
Rotate
Move to Side
Side Discharge
Return Air
Water
Connection End
Discharge Air
Drain
Back Discharge
Replace Screws
Extremo de Con
Conducto de Alimentación
Retorno de Aire
Extremo de Conexión deAgua
Drenaje
Retorno de Aire
Descarga de Aire
Descarga Lateral
Descarga Posterior
Water
Connection End
Supply Duct
Return Air
Water
Connection End
Drain
Return Air
Discharge Air
Side Discharge
Back Discharge
Overview
Horizontal units can be eld converted between side (straight)
and back (end) discharge using the instructions below.
Note: It is not possible to eld convert return air between
left or right return models due to the necessity of
refrigeration copper piping changes.
Preparation
It is best to eld convert the unit on the ground before hanging.
If the unit is already hung it should be taken down for the eld
conversion.
Side to Back Discharge Conversion
1. Place unit in well lit area. Remove the screws as shown in
Figure 4 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 insure 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 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
con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 5: Right Return Side to Back
Figure 4: Left Return Side to Back

IOM Instructions HBH/V CompaCt Heat Controller, Inc.
Horizontal Installation
*3/4" IPT
Trap Depth
1.5" [38mm]
Min 1.5"
[38mm]
1/4" per foot
(21mm per m)
drain slope
3/4" PVC or
Copper by others
Rev.: 6/26/09S
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.
Figure 6: Horizontal Condensate Connection
CAUTION! Ensure condensate line is pitched toward drain
1/4” per foot [21mm per m] of run.
Condensate Piping – Horizontal Units
CAUTION!
Pitch the unit toward the drain as shown in Figure 2 to
improve the condensate drainage. On small units (less
than 2.5 tons/8.8 kW), insure that unit pitch does not
cause condensate leaks inside the cabinet.
Install condensate trap at each unit with the top of the trap
positioned below the unit condensate drain connection as
shown in Figure 6.
Each unit must be installed with its own individual trap
and connection to the condensate line (main) or riser.
Provide a means to ush or blow out the condensate line.
DO NOT install units with a common trap and/or vent.
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.
Duct System Installation
Proper duct sizing and design is critical to the
performance of the unit. The duct system should be
designed to allow adequate and even airow through
the unit during operation. Air ow through the unit MUST
be at or above the minimum stated airow for the unit
to avoid equipment damage. Duct systems should
be designed for quiet operation. Refer to Figure 3 for
horizontal duct system details or gure 8 for vertical duct
system details. A exible connector is recommended
for both discharge and return air duct connections on
metal duct systems to eliminate the transfer of vibration
to the duct system. To maximize sound attenuation of
the unit blower, the supply and return plenums should
include internal berglass duct liner or be constructed
from ductboard for the rst few feet. Application of the
unit to uninsulated ductwork in an unconditioned space
is not recommended, as the unit’s performance will be
adversely affected.
At least one 90° elbow should be included in the supply
duct to reduce air noise. If air noise or excessive air ow
is a problem, the blower speed can be changed. For
airow charts, consult submittal data for the series and
model of the specic unit.
If the unit is connected to existing ductwork, a previous
check should have been made to insure that the
ductwork has the capacity to handle the airow required
for the unit. If ducting is too small, as in the replacement
of a heating only system, larger ductwork should be
installed. All existing ductwork should be checked for
leaks and repaired as necessary.
DUCT SYSTEM INSTALLATION