Heat Controller HTV Series Guide

Heat Controller, Inc. • 1900 Wellworth Ave. • Jackson, MI 49203 • [phone] • www.heatcontroller.com
INSTALLATION, OPERATION
& MAINTENANCE
HTV/HTD/HTH Series
Two-Stage
Geothermal Heat Pumps
2 to 6 Tons

HTV/HTD/HTH SERIES Heat Controller, Inc.
1
Model Breakdown
Model Nomenclature – Two Stage Geothermal Heat Pump
Heat Controller GeoMax 2 nGeothermal Heat Pump Systems
1
H = Horizontal
J = Cupro-Nickel
P = Back
W = Straight
Table of Contents
Model Nomenclature .................................................... 1
Storage........................................................................... 3
Pre-Installation .............................................................. 3
Physical Data................................................................. 4
Duct System Installation............................................... 5
Vertical Unit Location................................................. 5-7
Horizontal Unit Location ..........................................8-11
Piping Installation ................................................. 12-13
Ground Loop Applications .....................................14-16
Open Loop-Ground Water Systems .......................17-18
Hot Water Generator..............................................19-21
Water Quality Standards............................................. 22
Electrical-Line Voltage................................................. 23
Power Wiring................................................................ 24
Electrical-Low Voltage Wiring...................................... 25
Low Water Temperature Cutout Selection................. 25
Water Valve Wiring .................................................26-27
Thermostat Wiring....................................................... 28
ECM Blower Control .............................................. 29-30
Electrical Wiring Schematics...................................... 31
CXM Controls ......................................................... 32-35
Unit Start-Up and Operating Conditions ...............36-37
Unit and System Checkout Procedure ..................37-38
Unit Start-Up Procedure........................................ 38-40
Coax Pressure Drop Table .......................................... 40
Operating Pressures ..............................................41-42
Preventative Maintenance.................................... 43-44
Functional and Performance Troubleshooting .... 45-49

Heat Controller, Inc. HTV/HTD/HTH SERIES
2
3
T
WARNING! Verify refrigerant type
before proceeding. Units are
shipped with R-410A refrigerant.
The R-410A application and service
manual should be read and
understood before attempting to
service refrigerant circuits with
R-410A.
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! ⌧
T
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.
⌧ WARNING! ⌧
T
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.
⌧ WARNING! ⌧
T
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.
⌧ CAUTION! ⌧
NOTICE: Notification of installation,
operation or maintenance information,
which is important, but which is not
hazard-related.
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.
3
T
WARNING! Verify refrigerant type
before proceeding. Units are
shipped with R-410A refrigerant.
The R-410A application and service
manual should be read and
understood before attempting to
service refrigerant circuits with
R-410A.
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! ⌧
T
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.
⌧ WARNING! ⌧
T
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.
⌧ WARNING! ⌧
T
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.
⌧ CAUTION! ⌧
NOTICE: Notification of installation,
operation or maintenance information,
which is important, but which is not
hazard-related.
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.

HTV/HTD/HTH SERIES Heat Controller, Inc.
3
GENERAL INFORMATION
4
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 your equipment
supplier of all damage within 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
This Installation, Operation, and
Maintenance manual is provided with each
unit. Units 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.
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” SHIPPING BOLTS (2 on
each side) TO MAXIMIZE VIBRATION
AND SOUND ATTENUATION.
General Information

Heat Controller, Inc. HTV/HTD/HTH SERIES
4
General Information
All units have TXV devices, 1/2” and 3/4” electrical knockouts.
GENERAL INFORMATION
5
T
CAUTION! DO NOT store or install
units in corrosive environments or in
locations subject to temperature or
humidity extremes (e.g., attics, rooftops,
etc.). Corrosive conditions and high
temperature or humidity can significantly
reduce performance, reliability, and service
life. Always move and store units in an
upright position. Tilting units on their
sides may cause equipment damage.
T
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.
CAUTION! CAUTION!
NOTICE! Failure to remove shipping brackets from spring-mounted compressors will
cause excessive noise, and could cause component failure due to added vibration.
Model 24 36 48 60
Compressor (1 Each) Two-Stage Scroll
Factory Charge R410A (oz) 58 78 81 144
ECM Fan Motor & Blower
Fan Motor (hp) ½ ½ 1 1
Blower Wheel Size (dia x w) - (in) 9 x 7 11 x 10 11 x 10 11 x 10
Water Connection Size
Swivel (in) 1 1 1 1
HWG Connection Size
Swivel (in) 1 1 1 1
Coax Volume
Volume (US Gallons) 0.760.921.241.56
Vertical Upflow
Air Coil Dimensions (h x w) - (in) 28 x 20 28 x 25 32 x 25 36 x 25
Standard Filter - 1”
Throwaway, qty (in)
1 - 28 x 24 1 - 28 x 30 2 - 16 x 30 1 - 16 x 20
1 - 20 x 30
Weight - Operating, (lbs) 266327416443
Weight - Packaged, (lbs) 276337426453
All units have spring compressor mountings, TXV devices, and all units have ½” and ¾” electrical knockouts.
GeoMax2 TWO-STAGE HTV/HTD SERIES (60 Hz Only)
UNIT PHYSICAL DATA
70
156
1
11 x 10
1
1
36 x 25
443
453
1.56
1 - 16 x 20
1 - 20 x 30


UNIT PHYSICAL DATA
TWO STAGE HTV/HTD/HTH SERIES (60Hz Only)
Model 24 36 48 60 70
Compressor (1 Each) Two-Stage Scroll
Factory Charge R410A (oz) 58 78 81 144 156
ECM Fan Motor & Blower
Fan Motor (hp) 1/21/21 1 1
Blower Wheel Size (dia x w) - (in) 9 x 7 11 x 10 11 x 10 11 x 10 11 x 10
Water Connection Size
Swivel (in) 1 1 1 1 1
HWG Connection Size
Swivel (in) 1 1 1 1 1
Coax Volume
Volume (US Gallons) 0.76 0.92 1.24 1.56 1.56
Vertical Upow/Downow
Air Coil Dimensions (h x w) - (in) 28 x 20 28 x 25 32 x 25 36 x 25 36 x 25
Standard Filter - 2” Pleated
HERV11, Quantity - in x in
1-24 x 28 1-28 x 30 1-30 x 32 1-30 x 36 1-30 x 36
Weight - Operating, (lbs) 266 327 416 443 443
Weight -Packaged, (lbs) 276 337 426 453 453
Horizontal
Air Coil Dimensions (H x W), in 18 x 31 20 x 35 20 x 40 20 x 45 20 x 45
Standard Filter - 2” Pleated
MERV11, Quantity - in x in
2 - 18 x 18 1 - 12 x 20
1 - 20 x 25
1 - 18 x 20
1 - 20 x 24
2 - 20 x 24 2 - 20 x 24
Weight - Operating, lbs 266 327 416 443 443
Weight - Packaged, lbs 276 337 426 453 453

HTV/HTD/HTH SERIES Heat Controller, Inc.
Duct System Installation
6
DUCT SYSTEM INSTALLATION
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 airflow
through the unit during operation. Air flow
through the unit MUST be at or above the
minimum stated airflow for the unit to avoid
equipment damage. Duct systems should
be designed for quiet operation. Refer to
Figure 2 for vertical duct system details. A
flexible 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 fiberglass duct liner or be
constructed from ductboard for the first 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 flow is a problem, the
blower speed can be changed. For airflow
charts, consult Engineering Design Guide for
the specific 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 airflow 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.
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 1 and
2 for typical installation illustrations.
Refer to Engineering Design Guide 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” to 1/2” in
thickness. Extend the pad beyond
all four edges of the unit.
INSTALLATION

Heat Controller, Inc. HTV/HTD/HTH SERIES
6
INSTALLATION
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 submittal data or Engineering
Design Guide 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. In limited side access installations,
pre-removal of the control box side
mounting screws will allow control box
removal for future servicing.
6. Provide access to water valves and
fittings and screwdriver access to the
unit side panels, discharge collar and
all electrical connections.
Figure 1: Unit Mounting
Figure 2: Typical Unit Installation
Using Ducted Return Air
7
Internally insulate supply duct of first 15’
each way to reduce noise
Use turning vanes in supply transition
Flexible canvas duct connector to
reduce noise and vibration
Rounded return transition
Internally insulate return transition
duct to reduce noise
or Engineering Design Guide for
dimensional data.

HTV/HTD/HTH SERIES Heat Controller, Inc.
7
INSTALLATION
SOUND ATTENUATION
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 3. Install a sound
bae 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.
CONDENSATE PIPING
These units utilizea condensate hose
inside the cabinet as a trapping loop;
therefore an external trap is not
necessary. Figure 4A shows typical
condensate connections. Figure 4B
illustrates the internal trap for a typical
vertical heat pump. Each unit must be
installed with its own individual vent
(where necessary) and a means to ush
or blow out the condensate drain line.
Do not install units with a common trap
and/or vent.
Figure 4A: Condensate Drain Air
Figure 3: Vertical Sound Attenuation
8
Figure 4B: Internal Condensate Trap
NOTICE! Units with clear plastic drain
lines should have regular maintenance
(as required) to avoid buildup of debris,
especially in new construction.

Heat Controller, Inc. HTV/HTD/HTH SERIES
8
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 speci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
specic series and model in unit speci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 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.
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.
Drain
Connection
1/4" [6.4mm] pitch
for drainage
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 los Tornillos como
se Indica en el Diagrama
La longitud de este tornillo
debe ser de solamente 1/2” para evitar daños
Aislador de Vibraciones
(para codificación por color y
notas de instalación, consulte
las instrucciones de
instalación del soport
e colgador)

HTV/HTD/HTH SERIES Heat Controller, Inc.
9
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
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! Failure to remove shipping brackets from
spring-mounted compressors will cause excessive
noise, and could cause component failure due to
added vibration.