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.

Heat Controller, Inc. HTV/HTD/HTH SERIES
10
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.
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 de Agua
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
Figure 5: Right Return Side to Back
Figure 4: Left Return Side to Back

HTV/HTD/HTH SERIES Heat Controller, Inc.
11
Condensate Piping – Horizontal Units
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. Design the depth of the trap (water-
seal) based upon the amount of 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 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.
*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!
Duct System Installation
The duct system should be sized to handle the design
airow quietly. 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 specications catalog 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
CAUTION! Ensure condensate line is pitched toward
drain 1/4" per foot [21mm per m] of run.

Heat Controller, Inc. HTV/HTD/HTH SERIES
12
Piping Installation
PIPING INSTALLATION
INSTALLATION OF SUPPLY AND RETURN
PIPING
Note: When anti-freeze is used in the
loop, insure that it is compatible with the
Teflon tape or pipe joint compound that is
applied.
Maximum allowable torque for brass fittings
is 30 ft-lbs. If a torque wrench is not
available, tighten finger-tight plus one
quarter turn. Tighten steel fittings as
necessary.
Optional pressure-rated hose assemblies
designed specifically for use with Heat
Controller units are available. Similar
hoses can be obtained from alternate
suppliers. Supply and return connections
are fitted with swivel-joint fittings. To
prevent kinking during installation, make all
connections before final attachment to the
unit.
Follow these piping guidelines
1. Install a drain valve at the base of each
supply and return riser to facilitate system
flushing.
2. Install shut-off / balancing valves and
unions at each unit to permit unit removal
for servicing.
3. Place strainers at the inlet of each
system circulating pump.
4. Select the proper hose length to allow
slack between connection points.
Hoses may vary in length by +2% to -4%
under pressure.
5. Refer to Table 1. Do not exceed the
minimum bend radius for the hose
selected. Exceeding the minimum bend
radius may cause the hose to collapse,
which reduces water flow rate. Install
an angle adapter to avoid sharp bends in
the hose when the radius falls below the
required minimum.
Insulation is not required on loop water piping
except where the piping runs through
unheated areas, outside the building or when
the loop water temperature is below the
minimum expected dew point of the pipe
ambient conditions. Insulation is required if
loop water temperature drops below the dew
point (insulation is required for ground loop
applications in most climates).
Pipe joint compound is not necessary when
Teflon® thread tape is pre-applied to hose
assemblies or when flared-end connections
are used. If pipe joint compound is
preferred, use compound only in small
amounts on the external pipe threads of the
fitting adapters. Prevent sealant from
reaching the flared surfaces of the joint.
Install hose assemblies properly and check
regularly to avoid system failure and
reduced service life.
9
T
CAUTION! Corrosive system water
requires corrosion resistant fittings and
hoses, and may require water treatment.
⌧ CAUTION! ⌧
Hose Diameter Minimum Bend Radii
1/2” 2-1/2”
3/4” 4”
1” 5-1/2”
1-1/4” 6-3/4”
Table 1: Metal Hose Minimum Bend Radii
T
CAUTION! Do not bend or kink supply
lines or hoses.
⌧ CAUTION! ⌧

HTV/HTD/HTH SERIES Heat Controller, Inc.
13
PIPING INSTALLATION
NOTICE! Do not allow hoses to rest
against structural building components.
Compressor vibration may be transmitted
through the hoses to t he structure, causing
unnecessary noise.
10
T
CAUTION! Piping must comply with all
applicable codes.
CAUTION! 
Figure 5: Water Connections
WATER CONNECTIONS
Models utilize swivel piping ttings for
water connections t hat are rated for
450 psi operating pressure. The
connections have a rubber gasket seal
similar to a garden hose gasket, which
when mated to the ush end of most 1”
threaded male pipe ttings provides a
leak-free 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 which holds the
male pipe end against the rubber
gasket, and seals the joint. HAND
TIGHTEN ONLY! DO NOT OVER
TIGHTEN!
that are rated for
onto the pipe threads which holds the

Heat Controller, Inc. HTV/HTD/HTH SERIES
14
Ground-Loop Heat Pump Applications
GROUND-LOOP HEAT PUMP APPLICATIONS
11
T
All plastic to metal threaded ttings should
be avoided due to their potential to leak in
earth coupled applications. A anged
tting should be substituted. P/T plugs
should be used so that ow can be
measured using the pressure drop of the
unit heat exchanger.
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.
Earth loop temperatures can range between
25 and 110°F. Flow rates between 2.25
and 3 gpm per ton of cooling capacity is
recommended in these applications.
Test individual horizontal loop circuits before
backlling. Test vertical U-bends and pond
loop assemblies prior to installation.
Pressures of at least 100 psi should be used
when testing. Do not exceed the pipe
pressure rating. Test entire system when
all loops are assembled.
T
CAUTION!
Ground loop applications
require extended range equipment with
refrigerant/water circuit insulation.
CAUTION! 
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 6. All earth loop
piping materials should be limited to
polyethylene fusion only for in-ground
sections of the loop. Galvanized or steel
ttings should not be used at any time due
to their tendency to corrode.
FLUSHING THE EARTH LOOP
Once piping is completed between the unit,
Flow Controller and the ground loop (Figure
6a), the loop is ready for nal purging and
charging. A ush cart with at least a 1.5 hp
pump is required to achieve enough uid
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 in all piping. The
steps below must be followed for proper
ushing.
1. Fill loop with water from a garden hose
through the ush cart before using the
ush cart pump to insure an even ll.
2. Once full, the ushing process can
begin. Do not allow the water level in
the ush cart tank to drop below the
pump inlet line to avoid air being
pumped back out to the earth loop.

HTV/HTD/HTH SERIES Heat Controller, Inc.
15
12
3. Try to maintain a uid level in the tank
above the return tee so that air cannot
be continuously mixed back into the
uid. Surges of 50 psi can be used to
help purge air pockets by simply
shutting o the return valve going into
the ush cart reservoir. This “dead
heads” the pump to 50 psi to purge,
dead head the pump until maximum
pumping 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 uid level in the ush
cart tank when the return valve is shut
o. If air is adequately purged from the
system, the level will drop only 1-2
inches in a 10” diameter PVC ush tank
(about a half gallon), since liquids are
incompressible. If the level drops more
than this, ushing should continue since
air is still being compressed in the loop
uid. Perform the “dead head”
procedure a number or times.
Note: This uid level drop is your only
indication of air in the loop.
Antifreeze may be added before, during or
after the ushing procedure. However,
depending upon which time is chosen,
antifreeze could be wasted when emptying
the ush cart tank. See antifreeze section
for more details.
Loop static pressure will uctuate with the
seasons. Pressures will be higher in the
winter months than during the cooling
season. This uctuation is normal and
should be considered when charging the
system initially.
GROUND-LOOP HEAT PUMP APPLICATIONS
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 nal ush and pressurize the
loop to a static pressure of 50-75 psi (winter)
or 35-40 psi (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 ooded.
This is not required for Taco circulators.
Insure that the Flow Controller provides
adequate ow 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 or where
piping will be routed through areas subject
to freezing, antifreeze is required. Alcohols
and glycols are commonly used as
antifreeze. Check with local authorities for
the antifreeze best suited to your area.
Freeze protection should be maintained to
15°F below the lowest expected entering
loop temperature. For example, if 30°F is
the minimum expected entering loop
temperature, the leaving loop temperature
would be 25 to 22°F and freeze protection
should be at 15°F. Calculation is as
follows:
30°F - 15°F = 15°F

Heat Controller, Inc. HTV/HTD/HTH SERIES
16
GROUND-LOOP HEAT PUMP APPLICATIONS
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 uid in the piping system.
Then use the percentage by volume shown
in Table 2 and 2a for the amount of
antifreeze needed. Antifreeze
concentration should be checked from a
well mixed sample using a hydrometer to
measure specic 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) set point and
avoid nuisance faults (see “Low Water
Temperature Cutout Selection” in this
manual).
13
Minimum Temperature for Low Temperature Protection
Type
Table 2: Antifreeze Percentages by Volume
10°F 15°F 20°F 25°F
Methanol
100% USP Food Grade Propylene Glycol
Ethanol*
25%
38%
29%
21%
25%
25%
16%
22%
20%
10%
15%
14%
* Must not be denatured with any petroleum based product
Fluid Volume (gal. 100’ Pipe)
Pipe Size Volume (gal)
1” 4.1
1.25” 6.4
Copper
2.5” 9.2
Rubber Hose 1” 3.9
¾” IPS SDR11 2.8
1” IPS SDR11 4.5
1.25” IPS SDR11 8.0
1.5” IPS SDR11 10.9
2” IPS SDR11 18.0
1.25” IPS SCH40 8.3
1.5” IPS SCH40 10.9
Polyethylene
2” IPS SCH40 17.0
Unit Heat
Exchanger
Typical 1.0
Table 2a: Approximate Fluid Volume (gal.)
per 100’ of Pipe
Figure 6a: Typical Ground Loop
Application

HTV/HTD/HTH SERIES Heat Controller, Inc.
17
GROUND-WATER HEAT PUMP APPLICATIONS
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 for direct use (well water/open loop)
and HWG; 90°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.
EXPANSION TANK AND PUMP
OPEN LOOP-GROUND WATER SYSTEMS
Typical open loop piping is shown in Figure
7. Shut o valves should be included for
ease of servicing. Boiler drains or other
valves should be “tee’d” into the lines to
allow acid ushing of the heat exchanger.
Shut o valves should be positioned to allow
ow through the coax via the boiler drains
without allowing ow 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 should be plentiful and of good
quality. Consult Table 3 for water quality
guidelines. The unit has a cupro-nickel
water heat exchanger. Consult Table 3 for
recommendations. 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
only be serviced by a qualied 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 ushing.
Additional maintenance may be required.
WATER QUALITY STANDARDS
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 variousways,
depending on local building codes (e.g.
recharge well, storm sewer, drain eld,
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 Figure 7. 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 o-cycle. Pilot operated slow closing
valves are recommended to reduce water
hammer.
Table 3 should be consulted for waterquality
requirements. Scaling potential should be
assessed using the pH/Calcium hardness
method.
14
Other

Heat Controller, Inc. HTV/HTD/HTH SERIES
18
GROUND-WATER HEAT PUMP APPLICATIONS
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. Note the special
wiring diagrams for slow closing valves
(Figures 12 and 13).
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 Table 8. 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 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, 2 gpm
per ton is required.
WATER COIL LOW TEMPERATURE LIMIT
SETTING
For all open loop systems the 30°F 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 6b: Typical Open Loop / Well Application
15

HTV/HTD/HTH SERIES Heat Controller, Inc.
19
The HWG (Hot Water Generator) or desuperheater option
provides considerable operating cost savings by utilizing
excess heat energy from the heat pump to help satisfy
domestic hot water requirements. The HWG is active
throughout the year, providing virtually free hot water when
the heat pump operates in the cooling mode or hot water at
the COP of the heat pump during operation in the heating
mode. Actual HWG water heating capacities are provided in
the appropriate heat pump performance data.
Heat pumps equipped with the HWG option include a built-
in water to refrigerant heat exchanger that eliminates the
need to tie into the heat pump refrigerant circuit in the eld.
The control circuit and pump are also built in for residential
equipment. Figure 14 shows a typical example of HWG
water piping connections on a unit with built-in circulating
pump. This piping layout reduces scaling potential.
The temperature set point of the HWG is eld selectable
to 125°F or 150°F . The 150°F set point allows more heat
storage from the HWG. For example, consider the amount
of heat that can be generated by the HWG when using
the 125°F set point, versus the amount of heat that can be
generated by the HWG when using the 150°F set point.
In a typical 50 gallon two-element electric water heater
the lower element should be turned down to 100°F, or the
lowest setting, to get the most from the HWG. The tank
will eventually stratify so that the lower 80% of the tank,
or 40 gallons, becomes 100°F (controlled by the lower
element). The upper 20% of the tank, or 10 gallons, will be
maintained at 125°F (controlled by the upper element).
Using a 125°F set point, the HWG can heat the lower 40
gallons of water from 100°F to 125°F, providing up to 8,330
btu’s of heat. Using the 150°F set point, the HWG can
heat the same 40 gallons of water from 100°F to 150°F
and the remaining 10 gallons of water from 125°F to 150°F,
providing a total of up to 18,743 btu’s of heat, or more than
twice as much heat as when using the 125°F set point.
This example ignored standby losses of the tank. When
those losses are considered the additional savings are
even greater.
Electric water heaters are recommended. If a gas,
propane, or oil water heater is used, a second preheat
tank must be installed (Figure 15). If the electric water
heater has only a single center element, the dual tank
system is recommended to insure a usable entering water
temperature for the HWG.
Typically a single tank of at least 52 gallons (235 liters) is
used to limit installation costs and space. However, a dual
tank, as shown in Figure 15, is the most efcient system,
providing the maximum storage and temperate source
water to the HWG.
It is always advisable to use water softening equipment on
domestic water systems to reduce the scaling potential and
lengthen equipment life. In extreme water conditions, it may
be necessary to avoid the use of the HWG option since the
potential cost of frequent maintenance may offset or exceed
any savings. Consult Table 3 for scaling potential tests.
Hot Water Generator
Shut-off Valve #2
Cold Inlet
Hot Outlet
to home
Insulated water lines -
5/8Ó OD, 50 ft maximum (one way)
Powered
Water
Heater
Upper
element to
120 - 130°F
[49 - 54°C]
Lower
element to
100 - 110°F
[38 - 43°C]
Domestic
Cold Supply
Tee and drain
Shut-off Valve #3
[16mm OD, 15 meters maximum]
Shut-off Valve #1
Shut-off
Valve #4
Figure 14: Typical HWG Installation
Shut Off Valve #2
Insulated water lines - 5/8” OD, 50 ft maximum (one way)
[16mm OD, 15 meters maximum]
Upper element to 130°F [54°C]
(or owner preference)
Cold Inlet
Hot Outlet to
house
Powered
Water Heater
Cold Inlet from
Domestic supply
Hot Outlet
Unpowered
Water Heater
Field Supplied 3/4” brass nipple and “T”
Lower element to 120°F [49°C]
Shut-off
Valve #1
Shut-off
Valve #4
Shut-off
Valve #3
Figure 15: HWG Double Tank Installation
WARNING!
WARNING! A 150°F SETPOINT MAY LEAD TO
SCALDING OR BURNS. THE 150°F SET POINT MUST
ONLY BE USED ON SYSTEMS THAT EMPLOY AN
APPROVED ANTI-SCALD VALVE.