INSTALLATION, OPERATION
& MAINTENANCE
HTV/HTD/HTH Series
Two-Stage
Geothermal Heat Pumps
2 to 6 Tons
Heat Controller, Inc. • 1900 Wellworth Ave. • Jackson, MI 49203 • (517)787-2100 • www.heatcontroller.com
Heat Controller GeoMax HTV/HTD/HTH
2 n Geothermal
Heat Pump Systems
SERIES
Heat Controller, Inc.
Model Breakdown
Model nomenclature – Two Stage geothermal heat Pump
P = Back
W = Straight
H = Horizontal
J = Cupro-Nickel
Table of Contents
Model Nomenclature..................................................... 1
Electrical-Low Voltage Wiring...................................... 25
Storage........................................................................... 3
Low Water Temperature Cutout Selection.................. 25
Pre-Installation............................................................... 3
Water Valve Wiring..................................................26-27
Physical Data.................................................................. 4
Thermostat Wiring........................................................ 28
Duct System Installation................................................ 5
ECM Blower Control............................................... 29-30
Vertical Unit Location.................................................. 5-7
Electrical Wiring Schematics....................................... 31
Horizontal Unit Location...........................................8-11
CXM Controls.......................................................... 32-35
Piping Installation.................................................. 12-13
Unit Start-Up and Operating Conditions................36-37
Ground Loop Applications......................................14-16
Unit and System Checkout Procedure...................37-38
Open Loop-Ground Water Systems........................17-18
Unit Start-Up Procedure......................................... 38-40
Hot Water Generator...............................................19-21
Coax Pressure Drop Table........................................... 40
Water Quality Standards.............................................. 22
Operating Pressures...............................................41-42
Electrical-Line Voltage.................................................. 23
Preventative Maintenance..................................... 43-44
Power Wiring................................................................. 24
Functional and Performance Troubleshooting..... 45-49
1
1
hazardous situation, which if not avoided
damage.
will result in death or serious injury.
DANGER labels on unit access panels
Heat Controller,
Inc.
HTV/HTD/HTH SERIES
must
be observed.
⌧ WARNING! ⌧
TNOTICE: Notification of installation,
SAFETY Indicates a potentially
WARNING:
hazardous situation, which if not avoided
Warnings,
noticesinjury.
appear
could
resultcautions
in death and
or serious
throughout this manual. Read these items
carefully before attempting any installation,
service or troubleshooting of the
equipment.
T
operation or maintenance information,
WARNING!
All refrigerant
but which is not
which is important,
discharged
from this unit must be
hazard-related.
recovered WITHOUT EXCEPTION.
Technicians
must follow
industry
CAUTION: Indicates
a potentially
accepted
guidelines
and
all local,
hazardous situation or an unsafe
practice,
state,
and
federal
statutes
for
which if not avoided could result inthe
minor or
recovery
and
disposal
of
refrigerants.
moderate injury or product or property
Ifdamage.
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
⌧ WARNING!
⌧ after
T
it is removed.
⌧ WARNING! ⌧
DANGER: Indicates an immediate
hazardous situation,
if not avoided
WARNING!
Verifywhich
refrigerant
type
will
result
in
death
or
serious
injury.
before proceeding. Units are
DANGERwith
labels
on unit refrigerant.
access panels
shipped
R-410A
must
be
observed.
The R-410A application and service
manual should be read and
WARNING: Indicates
a potentiallyto
understood
before attempting
hazardous
situation, circuits
which if not
avoided
service
refrigerant
with
could result in death or serious injury.
R-410A.
T
WARNING!
All refrigerant
⌧ CAUTION!
⌧
T
discharged from this unit must be
recovered WITHOUT EXCEPTION.
CAUTION! To avoid equipment
Technicians must follow industry
damage, DO NOT use these units as
accepted guidelines and all local,
a source of heating or cooling during
state, and federal statutes for the
the construction process. The
recovery and disposal of refrigerants.
mechanical components and filters
If a compressor is removed from this
will quickly become clogged with
unit, refrigerant circuit oil will remain
construction dirt and debris, which
in the compressor. To avoid leakage
may cause system damage.
of compressor oil, refrigerant lines of
the compressor must be sealed after
it is removed.
⌧ WARNING! ⌧
⌧ To
WARNING!
⌧ of
WARNING!
avoid the release
T
refrigerant into the atmosphere, the
refrigerant
circuit
of this
unit must
be
WARNING!
Verify
refrigerant
type
serviced
only by technicians
before proceeding.
Units arewho
meet
local,
state
and federal
shipped
with
R-410A
refrigerant.
proficiency
requirements.
The R-410A application and service
manual should be read and
understood before attempting to
service refrigerant circuits with
R-410A.
T
T
⌧ WARNING! ⌧
CAUTION! To avoid equipment
damage, DO NOT use these units as
a source of heating or cooling during
the construction process. The
mechanical components and filters
will quickly become clogged with
construction dirt and debris, which
may cause system damage.
3
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.
2
3
⌧ CAUTION! ⌧
HTV/HTD/HTH SERIES
Heat Controller, Inc.
General Information
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oil, is a$1'6281'$77(18$7,21
synthetic oil used in many refrigeration systems
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WARNING!
including those with R-410A refrigerant. POE oil, if it ever
comes in contact with PVC or CPVC piping, may cause
failure of the PVC/CPVC. PVC/CPVC piping should never
be used as supply or return water piping with water source
heat pump products containing R-410A as system failures
and property damage may result.
3
HTV/HTD/HTH SERIES
Heat Controller, Inc.
General Information
GENERAL INFORMATION
 CAUTION! 
T
 CAUTION! 
T
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.
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.
NOTICE! Failure to remove shipping brackets from spring-mounted compressors will
cause excessive noise, and could cause component failure due to added vibration.
UNIT PHYSICAL DATA
PHYSICAL
DATA (60Hz Only)
TWO STAGEUNIT
HTV/HTD/HTH
SERIES
Model
GeoMax2 TWO-STAGE HTV/HTD SERIES (60 Hz Only)
24
36
48
Compressor (1 Each)
Model
Factory Charge R410A (oz)
24
Compressor (1 Each)
ECM Fan Motor & Blower
Factory Charge R410A (oz)
Fan Motor (hp)
58
ECM Fan Motor & Blower
Blower Wheel Size (dia x w) - (in)
Fan Motor (hp)
Water Connection Size
Blower Wheel Size (dia x w) - (in)
Swivel (in)
½
1
Water Connection Size
HWG Connection Size
Swivel (in)
Swivel (in)
1
Swivel (in)
Volume (US Gallons)
1
Coax Volume
Vertical Upflow/Downflow
Volume (US Gallons)
Air Coil Dimensions (h x w) - (in)
Vertical Upflow
Standard Filter - 2” Pleated
Air Coil Dimensions (h x w) - (in)
HERV11,
- in x in
Standard
FilterQuantity
- 1”
28 x 20
1-24 x 28
/2
½
48
81
81
1
11 x 10
1
60
144
144
1
11 x 10
1
70
70
156
156
1
11 x 10
1
11 x 10
11 x 10
11 x 10
11 x 10
1
1
1
1
1
1
0.76
0.76
1
11 x 10
1
HWG Connection Size
Coax Volume
78
/2
1
78
Two-Stage Scroll
9x7
9x7
Two-Stage Scroll
36
58
60
1
0.92
0.92
28 x 25
1-28 x 30
1
1
1
1.24
1.24
32 x 25
1-30 x 32
1
1
1
1.56
1.56
36 x 25
1-30 x 36
1
1
1
1.56
1.56
36 x 25
1-30 x 36
28 x 20
28 x 25
32 x 25
36 x 25
36 x 25
1 - 28 x 24
1 - 28 x 30
2 - 16 x 30
1 - 16 x 20
1 - 16 x 20
Weight -qty
Operating,
(lbs)
Throwaway,
(in)
266
327
416
1 - 20 x443
30
1 - 20 x443
30
Weight
-Packaged,
Weight
- Operating,
(lbs)(lbs)
266 276
327337
416426
443453
443453
Horizontal
Weight
- Packaged, (lbs)
276
337
426
453
453
Air Coil Dimensions (H x W), in
18 x 31
20 x 35
20 x 40
20 x 45
2” Pleated mountings, TXV
2 - devices,
18 x 18 and 1all- units
12 x have
20 ½”1and
- 18¾”x electrical
20
2
- 20 x 24
All Standard
units have Filter
spring-compressor
knockouts.
MERV11, Quantity - in x in
Weight - Operating, lbs
266
Weight - Packaged, lbs
276
20 x 45
2 - 20 x 24
1 - 20 x 25
1 - 20 x 24
327
416
443
443
337
426
453
453
5
All units have TXV devices, 1/2” and 3/4” electrical knockouts.
4
HTV/HTD/HTH SERIES
DUCT SYSTEM INSTALLATION
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.
6
INSTALLATION
VERTICAL UNIT LOCATION
Units are not designed for outdoor
installation. Locate the unit in an
INDOOR area that allows enough space
for service personnel to perform typical
maintenance or repairs without removing
unit from the mechanical room/closet.
Vertical units are typically installed in a
mechanical room or closet. Never
install units in areas subject to freezing or
where humidity levels could cause
cabinet condensation (such as
unconditioned spaces subject to 100%
outside air). Consideration should be
given to access for easy removal of the
filter and access panels. Provide
sufficient room to make water, electrical,
and duct connection(s).
If the unit is located in a confined space,
such as a closet, provisions must be
made for return air to freely enter the
space by means of a louvered door, etc.
Any access panel screws that would be
difficult to remove after the unit is
installed should be removed prior to
setting the unit. Refer to Figures 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.
Heat Controller, Inc.
HTV/HTD/HTH
SERIES
INSTALLATION
Heat Controller, Inc.
2. Provide adequate clearance for filter
replacement and drain pan cleaning.
Do not block filter access with piping,
conduit or other materials. Refer to
or Engineering
Design
Guide for
unit
submittal data
or Engineering
3.
4.
5.
6.
Figure 1: Unit Mounting
dimensional
Design
Guidedata.
for dimensional data.
Provide access for fan and fan motor
maintenance and for servicing the
compressor and coils without removing
the unit.
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.
In limited side access installations,
pre-removal of the control box side
mounting screws will allow control box
removal for future servicing.
Provide access to water valves and
fittings and screwdriver access to the
unit side panels, discharge collar and
all electrical connections.
Figure 2: Typical Unit Installation
Using Ducted Return Air
Flexible canvas duct connector to
reduce noise and vibration
Internally insulate supply duct of first 15’
each way to reduce noise
Use turning vanes in supply transition
Rounded return transition
Internally insulate return transition
duct to reduce noise
7
6
INSTALLATION
HTV/HTD/HTH SERIES
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
baffle as illustrated to reduce line-of
sight sound transmitted through
return air grilles.
2. Mount the unit on a rubber or
neoprene isolation pad to minimize
vibration transmission to the building
structure.
Heat Controller, Inc.
CONDENSATE PIPING
These units utilize a 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 flush
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
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.
8
7
Heat Controller, Inc.
HTV/HTD/HTH SERIES
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 filter and access panels. Provide sufficient
room to make water, electrical, and duct connection(s).
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 soffit using field supplied, threaded rods
sized to support the weight of the unit.
Use four (4) field supplied threaded rods and factory
provided vibration isolators to suspend the unit. Hang the
unit clear of the floor slab above and support the unit by the
mounting bracket assemblies only. DO NOT attach the unit
flush with the floor slab above.
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 Figure 3 for an illustration of a typical installation. Refer to
unit specifications catalog for dimensional data.
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
3/8" [10mm] Threaded
Conform to the following guidelines when selecting
Rod (by others)
unit location:
Vibration Isolator
1. Provide a hinged access door in concealed-spline or
(factory supplied)
plaster ceilings. Provide removable ceiling tiles in T-bar
or lay-in ceilings. Refer to horizontal unit dimensions for
specific series and model in unit specifications catalog.
Washer
(by others)
Size the access opening to accommodate the service
Double Hex Nuts
technician during the removal or replacement of the
(by others)
compressor and the removal or installation of the unit
itself.
2. Provide access to hanger brackets, water valves and
fittings. Provide screwdriver clearance to access panels,
discharge collars and all electrical connections.
3. DO NOT obstruct the space beneath the unit with
Figure 2: Horizontal Unit Pitch
piping, electrical cables and other items that prohibit
Varilla Roscada de 3/8"
future removal of components or the unit itself.
(fabricada por terceros)
4. Use a manual portable jack/lift to lift and support theAislador de Vibraciones
weight of the unit during installation and servicing. (para codificación por color y
notas de instalación, consulte
las instrucciones de
del soport
The installation of water source heat pump units and allinstalación
e colgador)
associated components, parts and accessories which
Arandela
(fabricada por terceros)
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.
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
8
1/4" [6.4mm] pitch
for drainage
Drain
Connection
HTV/HTD/HTH SERIES
Heat Controller, Inc.
HORIZONTAL INSTALLATION
Figure
Figure 3:
3: Typical
TypicalHorizontal
HorizontalUnit
UnitInstallation
Installation
3/8" [10mm] threaded rods
(by others)
Return Air
Thermostat
Wiring
Power Wiring
Optional Balancing Valve
Supply Air
Optional Low Pressure Drop Water
Control Valve
(can be internally mounted
on some models)
Unit Power
Insulated supply duct with
at least one 90 deg elbow
to reduce air noise
Flexible Duct
Connector
Stainless steel braid hose
with integral "J" swivel
Building
Loop
Unit Power
Disconnect
(by others)
Water Out
Water In
Ball Valve with optional
integral P/T plug
Unit Hanger
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.
Varillas Roscadas de 3/8"
(fabricadas por terceros)
Retorno de
aire
Cableado
del termostato
Alimentación
de energía de
la unidad
Aire de alimentación
Manguera trenzada de
acero inoxidable con accesorio
giratorio en “J”
Válvula compensadora opcional
Válvula invertida opcional para
control de baja presión de agua
(puede montarse en forma interna)
Colgador
de la unidad
Conducto de alimentación
aislado con un codo (mínimo)
de 90 grados para reducir el
ruido del aire
Circuito
de edificación
Disyuntor de
energía de la unidad
(fabricado por terceros)
Entrada de agua
Salida de agua
Válvula a bola con tapón
P/T integrado opcional
Cableado de
alimentación
de energía
9
Heat Controller, Inc.
HTV/HTD/HTH SERIES
Overview
Horizontal units can be field converted between side
(straight) and back (end) discharge using the instructions
below.
Figure 4: Left Return Side to Back
Remove Screws
Water
Connection End
Return Air
Note: It is not possible to field convert return air
between left or right return models due to the necessity
of refrigeration copper piping changes.
Side Discharge
Preparation
It is best to field convert the unit on the ground before
hanging. If the unit is already hung it should be taken down
for the field 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.
Water
Connection End
Rotate
Return Air
Move to Side
Replace Screws
Water
Connection End
Return Air
Drain
Discharge Air
Back Discharge
Figure 5: Right Return Side to Back
Back to Side Discharge Conversion
If the discharge is changed from back to side, use above
instruction noting that illustrations will be reversed.
Water
Connection End
Return Air
Left vs. Right Return
It is not possible to field 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 configuration 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.
Supply Duct
Side Discharge
Water
Connection End
Return Air
Drain
Discharge Air
Back Discharge
Extremo de Con
10
Retorno de Aire
HTV/HTD/HTH SERIES
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.
Heat Controller, Inc.
Figure 6: Horizontal Condensate Connection
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 (waterseal) 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.
Vent
*3/4" IPT
Trap Depth
1.5" [38mm]
Min 1.5"
[38mm]
3/4" PVC or
Copper by others
* 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.
Each unit must be installed with its own individual trap and
connection to the condensate line (main) or riser. Provide
a means to flush or blow out the condensate line. DO NOT
install units with a common trap and/or vent.
1/4" per foot
(21mm per m)
drain slope
Rev.: 6/26/09S
CAUTION!
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.
CAUTION! Ensure condensate line is pitched toward
drain 1/4" per foot [21mm per m] of run.
DUCT SYSTEM INSTALLATION
Duct System Installation
The duct system should be sized to handle the design
airflow quietly. Refer to Figure 3 for horizontal duct system
details or figure 8 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 specifications catalog for the series and
model of 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.
11
Heat Controller, Inc.
Piping Installation
HTV/HTD/HTH SERIES
PIPING INSTALLATION
INSTALLATION OF SUPPLY AND RETURN
PIPING
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.
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.
Install hose assemblies properly and check
regularly to avoid system failure and
reduced service life.
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).
⌧ CAUTION! ⌧
T
CAUTION! Corrosive system water
requires corrosion resistant fittings and
hoses, and may require water treatment.
Table 1: Metal Hose Minimum Bend Radii
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.
Hose Diameter
Minimum Bend Radii
1/2”
2-1/2”
3/4”
4”
1”
5-1/2”
1-1/4”
6-3/4”
T
⌧ CAUTION! ⌧
CAUTION!
lines or hoses.
9
12
Do not bend or kink supply
PIPING INSTALLATION
HTV/HTD/HTH SERIES
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.
T
Heat Controller, Inc.
 CAUTION!

CAUTION! Piping must comply with all
applicable codes.
Figure 5: Water Connections
The female locking ring is threaded
onto the pipe
pipe threads
threads which holds the
the
male pipe end against the rubber
gasket, and seals the joint. HAND
TIGHTEN ONLY! DO NOT OVER
TIGHTEN!
WATER CONNECTIONS
Models utilize swivel piping fittings for
water connections tthat
hatare
are rated
rated for
450 psi operating pressure. The
connections have a rubber gasket seal
similar to a garden hose gasket, which
when mated to the flush end of most 1”
threaded male pipe fittings provides a
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.
10
13
HTV/HTD/HTH SERIES
Heat Controller, Inc.
GROUND-LOOP HEAT PUMP APPLICATIONS
Ground-Loop Heat Pump Applications
T
 CAUTION!
All plastic to metal threaded fittings should
be avoided due to their potential to leak in
earth coupled applications. A flanged
fitting should be substituted. P/T plugs
should be used so that flow can be
measured using the pressure drop of the
unit heat exchanger.

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.
T
 CAUTION!
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
backfilling. 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.

CAUTION! Ground loop applications
require extended range equipment with
refrigerant/water circuit insulation.
FLUSHING THE EARTH LOOP
Once piping is completed between the unit,
Flow Controller and the ground loop (Figure
6a), the loop is ready for final purging and
charging. A flush cart with at least a 1.5 hp
pump is required to achieve enough fluid
velocity in the loop piping system to purge
air and dirt particles. An antifreeze solution
is used in most areas to prevent freezing.
All air and debris must be removed from the
earth loop piping before operation. Flush
the loop with a high volume of water at a
minimum velocity of 2 fps in all piping. The
steps below must be followed for proper
flushing.
1. Fill loop with water from a garden hose
through the flush cart before using the
flush cart pump to insure an even fill.
2. Once full, the flushing process can
begin. Do not allow the water level in
the flush cart tank to drop below the
pump inlet line to avoid air being
pumped back out to the earth loop.
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
fittings should not be used at any time due
to their tendency to corrode.
11
14
GROUND-LOOPHTV/HTD/HTH
HEAT PUMP
APPLICATIONS
SERIES
3. Try to maintain a fluid level in the tank
above the return tee so that air cannot
be continuously mixed back into the
fluid. Surges of 50 psi can be used to
help purge air pockets by simply
shutting off the return valve going into
the flush cart reservoir. This “dead
heads” the pump to 50 psi 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 fluid level in the flush
cart tank when the return valve is shut
off. If air is adequately purged from the
system, the level will drop only 1-2
inches in a 10” diameter PVC flush tank
(about a half gallon), since liquids are
incompressible. If the level drops more
than this, flushing should continue since
air is still being compressed in the loop
fluid. Perform the “dead head”
procedure a number or times.
Note: This fluid level drop is your only
indication of air in the loop.
Heat Controller, Inc.
Run the unit in either heating or cooling for a
number of minutes to condition the loop to a
homogenous temperature. This is a good
time for tool cleanup, piping insulation, etc.
Then, perform final flush and pressurize the
loop to a static pressure of 50-75 psi (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 flooded.
This is not required for Taco circulators.
Insure that the Flow Controller provides
adequate flow through the unit by checking
pressure drop across the heat exchanger
and compare to the pressure drop tables at
the back of the manual.
ANTIFREEZE
In areas where minimum entering loop
temperatures drop below 40°F 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
Antifreeze may be added before, during or
after the flushing procedure. However,
depending upon which time is chosen,
antifreeze could be wasted when emptying
the flush cart tank. See antifreeze section
for more details.
Loop static pressure will fluctuate with the
seasons. Pressures will be higher in the
winter months than during the cooling
season. This fluctuation is normal and
should be considered when charging the
system initially.
12
15
GROUND-LOOPHTV/HTD/HTH
HEAT PUMPSERIES
APPLICATIONS
Heat Controller, Inc.
All alcohols should be premixed and
pumped from a reservoir outside of the
building when possible or introduced under
the water level to prevent fumes. Calculate
the total volume of fluid in the piping system.
Then use the percentage by volume shown
in Table 2 and 2a for the amount of
antifreeze needed. Antifreeze
concentration should be checked from a
well mixed sample using a hydrometer to
measure specific gravity.
LOW WATER TEMPERATURE CUTOUT
SETTING
CXM Control
When antifreeze is selected, the FP1 jumper
(JW3) should be clipped to select the low
temperature (antifreeze 13°F) set point and
avoid nuisance faults (see “Low Water
Temperature Cutout Selection” in this
manual).
Table 2: Antifreeze Percentages by Volume
Minimum Temperature for Low Temperature Protection
Type
10°F
15°F
20°F
25°F
Methanol
25%
21%
16%
10%
100% USP Food Grade Propylene Glycol
38%
25%
22%
15%
Ethanol*
29%
25%
20%
14%
* Must not be denatured with any petroleum based product
Table 2a: Approximate Fluid Volume (gal.)
per 100’ of Pipe
Fluid Volume (gal. 100’ Pipe)
Pipe
Copper
Rubber Hose
Polyethylene
Unit Heat
Size
Volume (gal)
1”
4.1
1.25”
6.4
2.5”
9.2
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
2” IPS SCH40
17.0
Typical
1.0
Exchanger
13
16
Figure 6a: Typical Ground Loop
Application
HTV/HTD/HTH SERIES
OPEN LOOP-GROUND WATER SYSTEMS
Typical open loop piping is shown in Figure
7. Shut off valves should be included for
ease of servicing. Boiler drains or other
valves should be “tee’d”into the lines to
allow acid flushing of the heat exchanger.
Shut off valves shouldEe positioned to allow
flow through the coax via the boiler drains
without allowing flow into the piping system.
P/T plugs should be used so that pressure
drop and temperature can be measured.
Supplymaterials
and return
waterbe
piping
should
be
Piping
should
limited
to copper
Heat Controller, Inc.
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, the5yznar 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
Other
water quality issues such as iron fouling,
corrosion prevention and erosion and
clogging should be referenced in Table 3.
limited to copper, HPDE, or other acceptable
or
PVC SCH80.1ote: Due to the
high temperature material. Note that PVC or
pressure
and temperature
extremes, as
PVCthey
CPVC material
is not recommended
are notiscompatible
with the polyolester oil
SCH40
not recommended.
used in R-410A products.
EXPANSION TANK AND PUMP
Use a closed, bladder-t\pe expansion tank
to minimize mineral formation due to air
exposure. The expDnsion 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 ofLn various ways,
depending on local building codes (e.g.
recharge well, storm sewer, drain field,
adjacent stream or pond, etc.). Most local
codes forbid the use of sanitary sewer for
disposal. Consult your local building and
zoning department to assure compliance in
your area.
Water 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.,n 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 qualified technician,
as acid and specialSumping equipment is
required. Desuperheater coils can likewise
become scaled and possibly plugged. In
areas with extremely hard water, the owner
should be informed that the heat exchanger
may require occasional acid flushing.
Additional maintenance may be required.
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 off-cycle. Pilot operated slow closing
valves are recommended to reduce water
hammer.
WATER QUALITY STANDARDS
Table 3 should be consulted for water quality
requirements. Scaling potential should be
assessed using the pH/Calcium hardness
method.
17
Heat Controller, Inc.
GROUND-WATER HEAT PUMP APPLICATIONS
HTV/HTD/HTH SERIES
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).
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.
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.
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
18
HTV/HTD/HTH SERIES
Hot Water Generator
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 Controller, Inc.
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 efficient system,
providing the maximum storage and temperate source
water to the HWG.
Heat pumps equipped with the HWG option include a builtin water to refrigerant heat exchanger that eliminates the
need to tie into the heat pump refrigerant circuit in the field.
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.
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.
The temperature set point of the HWG is field 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.
Figure 14: Typical HWG Installation
Cold Inlet
Domestic
Cold Supply Hot Outlet
to home
Shut-off Valve #2
Shut-off Valve #1
Upper
element to
120 - 130°F
[49 - 54°C]
Shut-off Valve #3
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).
Lower
element to
100 - 110°F
[38 - 43°C]
Powered
Water
Heater
Shut-off
Valve #4
Tee and drain
Insulated water lines 5/8Ó OD, 50 ft maximum (one way)
[16mm OD, 15 meters maximum]
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.
Figure 15: HWG Double Tank Installation
Hot Outlet to
house
Hot Outlet
This example ignored standby losses of the tank. When
those losses are considered the additional savings are
even greater.
Cold Inlet from
Domestic supply
Shut Off Valve #2
Cold Inlet
Shut-off
Valve #1
Upper element to 130°F [54°C]
(or owner preference)
Shut-off
Valve #4
Powered
WARNING!
Shut-off
Valve #3
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.
Unpowered
Water Heater
Lower element to 120°F [49°C]
Water Heater
Field Supplied 3/4” brass nipple and “T”
Insulated water lines - 5/8” OD, 50 ft maximum (one way)
[16mm OD, 15 meters maximum]
19
HTV/HTD/HTH SERIES
Heat Controller, Inc.
Installation
The HWG is controlled by two sensors and a microprocessor
control. One sensor is located on the compressor discharge
line to sense the discharge refrigerant temperature. The
other sensor is located on the HWG heat exchanger’s “Water
In” line to sense the potable water temperature.
ANTI-SCALD
VALVE PIPING
CONNECTIONS
ANTI-SCALD
VALVE
WARNING!
HOT WATER
TO HOUSE
SW10 HWG PUMP TEST. When this switch is in the “ON”
position, the HWG pump is forced to operate even if there
is no call for the HWG. This mode may be beneficial to
assist in purging the system of air during Initial start up.
When SW10 is in the “OFF” position, the HWG will operate
normally. This switch is shipped from the factory in the
“OFF” (normal) position. NOTE; If left in the “On” position for
5 minutes, the pump control will revert to normal operation.
SW11 HWG TEMP. The control setpoint of the HWG can be
set to either of two temperatures, 125°F or 150°F. When SW11
is in the “ON” position the HWG setpoint is 150°F. When SW11
is in the “OFF” position the HWG setpoint is 125°F. This switch
Is shipped from the factory in the “OFF” (125°F) position.
H
WATER HEATER
SW12 HWG STATUS. This switch controls operation of
the HWG. When SW12 is in the “ON” position the HWG is
disabled and will not operate. When SW12 is in the “OFF”
position the HWG is in the enabled mode and will operate
normally. This switch is shipped from the factory in the
“ON” (disabled) position. CAUTION: DO NOT PLACE THIS
SWITCH IN THE ENABLED POSITION UNITL THE HWG
PIPING IS CONNECTED, FILLED WITH WATER, AND
PURGED OR PUMP DAMAGE WILL OCCUR.
When the control is powered and the HWG pump output
is not active, the status LED (AN1) will be “On”. When the
HWG pump output is active for water temperature sampling
or HWG operation, the status LED will slowly flash (On 1
second, Off 1 second).
If the control has detected a fault, the status LED will flash
a numeric fault code as follows:
WARNING!
WARNING! USING A 150°F SETPOINT ON THE
HWG WILL RESULT IN WATER TEMPERATURES
SUFFICIENT TO CAUSE SEVERE PHYSICAL INJURY
IN THE FORM OF SCALDING OR BURNS, EVEN
WHEN THE HOT WATER TANK TEMPERATURE
SETTING IS VISIBLY SET BELOW 150°F. THE
150°F HWG SETPOINT MUST ONLY BE USED ON
SYSTEMS THAT EMPLOY AN APPROVED ANTISCALD VALVE (CLIMATEMASTER PART NUMBER
AVAS4) AT THE HOT WATER STORAGE TANK
WITH SUCH VALVE PROPERLY SET TO CONTROL
WATER TEMPERATURES DISTRIBUTED TO ALL HOT
WATER OUTLETS AT A TEMPERATURE LEVEL THAT
PREVENTS SCALDING OR BURNS!
C
M
8” MAX
WARNING! UNDER NO CIRCUMSTANCES SHOULD
THE SENSORS BE DISCONNECTED OR REMOVED
AS FULL LOAD CONDITIONS CAN DRIVE HOT
WATER TANK TEMPERATURES FAR ABOVE SAFE
TEMPERATURE LEVELS IF SENSORS HAVE BEEN
DISCONNECTED OR REMOVED.
The microprocessor control monitors the refrigerant and
water temperatures to determine when to operate the
HWG. The HWG will operate any time the refrigerant
temperature is sufficiently above the water temperature.
Once the HWG has satisfied the water heating demand
during a heat pump run cycle, the controller will cycle the
pump at regular Intervals to determine if an additional HWG
cycle can be utilized. The microprocessor control Includes
3 DIP switches, SW10 (HWG PUMP TEST), SW11 (HWG
TEMP), and SW12 (HWG STATUS).
CHECK VALVE
COLD WATER
SUPPLY
Hot Water Sensor Fault
Compressor Discharge sensor fault
High Water Temperature (>160ºF)
Control Logic Error
1 flash
2 flashes
3 flashes
4 flashes
Fault code flashes have a duration of 0.4 seconds with
a 3 second pause between fault codes. For example, a
“Compressor Discharge sensor fault” will be four flashes
0.4 seconds long, then a 3 second pause, then four flashes
again, etc.
20
HTV/HTD/HTH SERIES
Warning! The HWG pump Is fully wired from the
factory. Use extreme caution when working around
the microprocessor control as it contains line voltage
connections that presents a shock hazard that can
cause severe injury or death!
Heat Controller, Inc.
piping. This will purge air from the HWG piping.
2. Open a hot water faucet to vent air from the system
until water flows from faucet; turn off faucet. Open
valve #4.
3. Depress the hot water tank pressure relief valve
handle to ensure that there is no air remaining in
the tank.
4. Inspect all work for leaks.
5. Before restoring power or fuel supply to the water
heater, adjust the temperature setting on the tank
thermostat(s) to insure maximum utilization of the heat
available from the refrigeration system and conserve
the most energy. On tanks with both upper and lower
elements and thermostats, the lower element should
be turned down to 100°F [38°C] or the lowest setting;
the upper element should be adjusted to 120-130°F
[49-54°C]. Depending upon the specific needs of the
customer, you may want to adjust the upper element
differently. On tanks with a single thermostat, a preheat
tank should be used (Fig 15).
6. Replace access cover(s) and restore power or
fuel supply.
The heat pump, water piping, pump, and hot water tank
should be located where the ambient temperature does
not fall below 50°F [10°C]. Keep water piping lengths at a
minimum. DO NOT use a one way length greater than 50
ft. (one way) [15 m]. See Table 7 for recommended piping
sizes and maximum lengths.
All installations must be in accordance with local
codes. The installer is responsible for knowing the
local requirements, and for performing the installation
accordingly. DO NOT connect the pump wiring until “Initial
Start-Up” section, below. Powering the pump before all
installation steps are completed may damage the pump.
Water Tank Preparation
1. Turn off power or fuel supply to the hot water tank.
2. Connect a hose to the drain valve on the water
tank.
3. Shut off the cold water supply to the water tank.
4. Open the drain valve and open the pressure relief
valve or a hot water faucet to drain tank.
5. When using an existing tank, it should be flushed
with cold water after it is drained until the water
leaving the drain hose is clear and free of sediment.
6. Close all valves and remove the drain hose.
7. Install HWG water piping.
Initial Start-Up
1. Make sure all valves in the HWG water circuit are
fully open.
2. Turn on the heat pump and allow it to run for
10-15 minutes.
3. Set SW12 to the “OFF” position (enabled) to
engage the HWG.
4. The HWG pump should not run if the compressor is
not running.
5. The temperature difference between the water
entering and leaving the HWG coil should be
approximately 5-10°F [3-6°C].
6. Allow the unit to operate for 20 to 30 minutes to
insure that it is functioning properly.
HWG Water Piping
1. Using at least 5/8” [16mm] O.D. copper, route and
install the water piping, valves and air vent as
shown in Figures 14 or 15. Install an approved antiscald valve if the 150°F HWG setpoint is or will be
selected. An appropriate method must be employed
to purge air from the HWG piping. This may be
accomplished by flushing water through the HWG
(as In Figures 14 and 15) or by Installing an air vent
at the high point of the HWG piping system.
2. Insulate all HWG water piping with no less than 3/8”
[10mm] wall closed cell insulation.
3. Open both shut off valves and make sure the tank
drain valve is closed.
Table 7: HWG Water Piping Sizes and Length
Water Tank Refill
1. Close valve #4. Ensure that the HWG valves
(valves #2 and #3) are open. Open the cold water
supply (valve #1) to fill the tank through the HWG
Unit
Nominal
Tonnage
Nominal
HWG Flow
(gpm)
1/2" Copper (max
length*)
3/4" Copper
(max length*)
1.5
0.6
50
-
2.0
0.8
50
-
2.5
1.0
50
-
3.0
1.2
50
-
3.5
1.4
50
-
4.0
1.6
45
50
5.0
2.0
25
50
6.0
2.4
10
50
*Maximum length is equivalent length to one way of L copper.
21
Heat Controller, Inc.
HTV/HTD/HTH SERIES
Notes:
•
Closed Recirculating system is identified by a closed pressurized piping system.
•
Recirculating open wells should observe the open recirculating design
considerations.
WATER QUALITY STANDARDS
Water Quality Standards
Table 3: Water Quality Standards
Water Quality
Parameter
HX Material
Closed Recirculating
Open Loop and Recirculating Well
Scaling Potential - Primary Measurement
Above the given limits, scaling is likely to occur. Scaling indexes should be calculated using the limit
pH Calcium
Hardness Method
All
-
pH ‹7.5 and Ca Hardness ‹100ppm
Index Limits for Probable Scaling Situations (Operation outside these limits is not recommended)
Scaling indexes should be calculated at 150°F operation for direct use and HWG applications, and at 90°F for indirect HX use. A monitoring
plan should be implemented.
Ryznar Stability Index
Langelier Saturation
Index
All
-
All
-
6.0 - 7.5
If >7.5 minimize steel pipe use
-0.5 to +0.5
If <-0.5 minimize steel pipe use. Based upon 150°F
Direct well, 85°F Indirect Well
Iron Fouling
Iron Fe (Ferrous)
(Bacterial Iron Potential)
Iron Fouling
All
-
All
-
<0.2 ppm (Ferrous)
If Fe (ferrous) >0.2 ppm with pH 6 - 8, ppm check for
<0.5 ppm of Oxygen
Above this level deposition will occur
Corrosion Prevention
pH
All
6 - 8.5
6 - 8.5
Monitor/treat as needed
Minimize steel pipe below 7 and no open tanks with pH <
<0.5 ppm
Hydrogen Sulfide (H2S)
All
At H2S>0.2 ppm, avoid use of copper and copper nickel
-
Rotten egg smell appears at 0.5 ppm level
Copper alloy (bronze or brass) cast components are okay
Ammonia ion as
Hydroxide, Chloride,
Nitrate and Sulfate
All
-
<0.5 ppm
Compounds
Maximum Allowable at maximum water temperature
Maximum Chloride Levels
50°F
75°F
100°F
Copper
-
<20 ppm
NR
NR
Cupro Nickel
-
<150 ppm
NR
NR
304 SS
-
<400 ppm
<250 ppm
<150 ppm
316 SS
-
<1000 ppm
<550 ppm
<375 ppm
Titanium
-
<1000 ppm
<550 ppm
<375 ppm
Erosion and Clogging
<10 ppm of particles and a
maximum velocity of 6 fps filtered
Particulate Size & Erosion
All
for maximum 800 micron (800mm,
20 mesh) size
Notes:
•
Closed Recirculating system is identified by a closed pressurized piping system.
•
Recirculating open wells should observe the open recirculating design
19
22
Notes:
•
NR - Application not recommended
•
“-“ No design maximum
HTV/HTD/HTH SERIES
Heat Controller, Inc.
ELECTRICAL - LINE VOLTAGE
Electrical - Line Voltage
 WARNING!
T
ELECTRICAL - LINE VOLTAGE
All field installed wiring, including electrical
ground, must comply with the National
Electrical Code as well as all applicable
local codes. Refer to the unit electrical
data for fuse sizes. Consult wiring diagram
for field connections that must be made by
the installing (or electrical) contractor. All
final electrical connections must be made
with a length of flexible conduit to minimize
vibration and sound transmission to the
building.

WARNING! To avoid possible injury
or death due to electrical shock, open
the power supply disconnect switch
and secure it in an open position
during installation.
 CAUTION!
T

CAUTION! Use only copper
conductors for field installed electrical
wiring. Unit terminals are not
designed to accept other types of
conductors.
GENERAL LINE VOLTAGE WIRING
Be sure the available power is the same
voltage and phase shown on the unit serial
plate. Line and low voltage wiring must be
done in accordance with local codes or the
National Electric Code, whichever is
applicable.
Table 4: Electrical Data (Standard Units) HTV/HTD/HTH
Table 4: Electrical
Data (Standard Units) HTV/HTD
Compressor
Voltage
Min/Max
Fan Motor Total Unit
Model
Code
Voltage
Voltage
QTY
RLA
LRA
FLA
FLA
Min/Max
024 Model1
208/230-60/1
Voltage
197/254
036
208/230-60/1
197/254
1
Voltage
Compressor
QTY
HWG
Max/Fuse
Unit
Loop 3.9 Motor 18.6
21.2
Circuit
Fuse30
Total
Min
Max
1
10.3
RLA
LRA
16.7
FLA
82.0
FLA 3.9 FLA
FLA
25.0
Amp
29.2
Size45
*
1
52.0
Pump
MCA
Fan
Ext
048 024 1
208/230-60/1
208/230-60/1197/254
197/2541
110.7
56.0
21.2
0.4
96.0
4.0 6.9
4. 3
19.4
32.5
22.1
37.8
3050
060 036 1
208/230-60/1197/254
197/2541
208/230-60/1
117.0
25.6
87.0
118.0
0.4
4.0 6.9
4. 3
36.9
25.7
43.3
30.0
4560
1
27.2
150.0
38.5
45.3
070
048
1
208/230-60/1
208/230-60/1
197/254
197/254
1
Rated Voltage of 208-230/60/1
HACR circuit breaker in USA only
Wire length 060
based on one
way measurement with
2% voltage drop
208/230-60/1
197/254
1
070
208/230-60/1
197/254
1
21.5
100.0
0.4
4.0
0.4
4.0
6.9
7. 0
32.9
70
38.3
50
45.9
70
27.6
Min/Max Voltage of 197/254
All fuses Class RK-5
size based4.0
on 60°C copper
125.0 Wire0.4
7.0 conductor
37.4 and Minimum
43.9 Circuit
60Ampacity.
27.6
153.0
* HACR Circuit Breaker in USA Only
All Fuses Class RK-5
20
23
7.0
39.0
Heat Controller, Inc.
HTV/HTD/HTH SERIES
ELECTRICAL - POWER WIRING
Electrical - Power Wiring
T
⌧ WARNING! ⌧
Figure
Single
Figure9:9:HTV/HTD/HTH
HTV/HTD Single
Phase Line
Phase Line Voltage Field Wiring
Voltage Field Wiring
WARNING! Disconnect electrical
power source to prevent injury or
death from electrical shock.
T
Capacitor
Contactor CC
Unit Power Supply
⌧ CAUTION! ⌧
See Electrical Table
for Breaker Size
CAUTION! Use only copper
conductors for field installed electrical
wiring. Unit terminals are not
designed to accept other types of
conductors.
CXM Control
Transformer
Low Voltage
Connector
ELECTRICAL - LINE VOLTAGE
All field installed wiring, including electrical
ground, must comply with the National
Electrical Code as well as all applicable
local codes. Refer to the unit electrical
data for fuse sizes. Consult wiring diagram
for field connections that must be made by
the installing (or electrical) contractor. All
final electrical connections must be made
with a length of flexible conduit to minimize
vibration and sound transmission to the
building.
BLOWER SPEED SELECTION
ECM Motor speeds are set via low voltage
controls (see “ECM Blower Control”). Most
Heat
Controller
units Design
are shipped
Consult
Engineering
Guideonforthe
specific
unit
airflow
tables.
medium speed tap. Consult Engineering
Design Guide for specific unit airflow tables.
Typical unit design delivers rated airflow at
nominal static (0.15 in. w.g.) on medium
speed and rated airflow at a higher static
(0.4 to 0.5 in. w.g.) on high speed for
applications where higher static is required.
Low speed will deliver approximately 85% of
rated airflow at 0.10 in. w.g.
GENERAL LINE VOLTAGE WIRING
Be sure the available power is the same
voltage and phase shown on the unit serial
plate. Line and low voltage wiring must be
done in accordance with local codes or the
National Electric Code, whichever is
applicable.
POWER CONNECTION
Line voltage connection is made by
connecting the incoming line voltage wires
to the “L” side of the contactor as shown in
Figure 9. Consult Table 4 for correct fuse
size.
21
24
HTV/HTD/HTH SERIES
ELECTRICAL - POWER & LOW VOLTAGE WIRING
Electrical - Power & Low Voltage Wiring
Heat Controller, Inc.
ELECTRICAL - LOW VOLTAGE WIRING
THERMOSTAT CONNECTIONS
Units include factory wiring from the CXM
board to the ECM interface board.
Thermostat wiring should be connected to
the ECM interface board.
The factory setting for FP1 is for systems
using water (30°F refrigerant temperature).
In low water temperature (extended range)
applications with antifreeze (most ground
loops), jumper JW3 should be clipped as
shown in Figure 10 to change the setting to
10°F refrigerant temperature, a more
suitable temperature when using an
antifreeze solution. All Heat Controller
units operating with entering water
temperatures below 59°F include the
water/refrigerant circuit insulation package
to prevent internal condensation.
LOW WATER TEMPERATURE CUTOUT
SELECTION
The CXM control allows the field selection of
low water (or water-antifreeze solution)
temperature limit by clipping jumper JW3,
which changes the sensing temperature
associated with thermistor FP1. Note that
the FP1 thermistor is located on the
refrigerant line between the coaxial heat
exchanger and expansion device.
Therefore, FP1 is sensing refrigerant
temperature, not water temperature, which
is a better indication of how water flow
rate/temperature is affecting the
refrigeration circuit.
Figure 10: FP1 Limit Setting
JW3-FP1
Jumper should be clipped for low
temperature operation
.
CXM PCB
22
25
HTV/HTD/HTH SERIES
ELECTRICAL
- LOW VOLTAGE WIRING
Electrical - Low Voltage Wiring
Heat Controller, Inc.
valve wiring for Taco 500 Series and Taco
ESP Series valves. Slow closing valves
take approximately 60 seconds to open
(very little water will flow before 45
seconds). Once fully open, an end switch
allows the compressor to be energized.
Only relay or triac based electronic
thermostats should be used with slow
closing valves. When wired as shown, the
slow closing valve will operate properly with
the following notations:
ACCESSORY CONNECTIONS
A terminal paralleling the compressor
contactor coil has been provided on the
CXM control. Terminal “A” is designed to
control accessory devices, such as water
valves. Note: This terminal should be
used only with 24 Volt signals and not line
voltage. Terminal “A” is energized with the
compressor contactor. See Figure 11 or
the specific unit wiring diagram for details.
Low Voltage VA Ratings
COMPONENT
1. The valve will remain open during a unit
lockout.
2. The valve will draw approximately 25-35
VA through the “Y” signal of the
thermostat.
VA
Typical Blower Relay
6-7
Typical Reversing Valve Solenoid
4-6
30A Compressor Contactor
6-9
SubTotal
Note: This valve can overheat the
anticipator of an electromechanical
thermostat. Therefore, only relay or triac
based thermostats should be used.
16-22
+CXM Board (5-9 VA)*
21-31
Remaining VA for Accessories
19-29
* Standard transformer is 75VA.
TWO-STAGE UNITS
Two-stage units should be designed with
two parallel valves for ground water
applications to limit water use during first
stage operation. For example, at 1.5
gpm/ton, a HTV048 unit requires 6 gpm for
full load (2nd stage) operation, but only 4
gpm during 1st stage operation. Since the
unit will operate on first stage 80-90% of the
time, significant water savings can be
realized by using two parallel solenoid
valves with two flow regulators. In the
example above, stage one solenoid would
be installed with a 4 gpm flow regulator on
the outlet, while stage two would utilize a 2
gpm flow regulator. When stage one is
operating, the second solenoid valve will be
closed. When stage two is operating, both
valves will be open, allowing full load flow
rate.
Figure11:
11:Accessory
Acce ssory
Wiring
Figure
Wiring
WATER SOLENOID VALVES
An external solenoid valve(s) should be
used on ground water installations to shut
off flow to the unit when the compressor is
not operating. A slow closing valve may be
required to help reduce water hammer.
Figure 11 shows typical wiring for a 24VAC
external solenoid valve. Figures 12 and 13
illustrate typical slow closing water control
23
26
ELECTRICAL
- LOWSERIES
VOLTAGE
WIRING
HTV/HTD/HTH
Heat Controller, Inc.
Figure 14 illustrates piping for two-stage
solenoid valves. Review Figures 11 - 13
for wiring of stage one valve. Stage two
valve should be wired between terminal “Y2”
(ECM board) and terminal “C”. NOTE:
When EWT is below 50°F, 2 gpm per ton is
required.
Figure 12: AVM Valve Wiring
Figure
Figure 13:
13: Taco
Taco SBV
EBV Valve
Valve Wiring
Wiring
Figure 14: Two-Stage Piping
Note: Shut-off valves, strainers and
other required components not shown
Taco SBV Valve
24
27
HTV/HTD/HTH
SERIES
ELECTRICAL
- THERMOSTAT
WIRING
Electrical - Thermostat Wiring
Heat Controller, Inc.
THERMOSTAT INSTALLATION
The thermostat should be located on an
interior wall in a larger room, away from
supply duct drafts. DO NOT locate the
thermostat in areas subject to sunlight,
drafts or on external walls. The wire
access hole behind the thermostat may in
certain cases need to be sealed to prevent
erroneous temperature measurement.
Position the thermostat back plate against
the wall so that it appears level and so the
thermostat wires protrude through the
middle of the back plate
Mark the position of the back plate mounting
holes and drill holes with a 3/16” bit. Install
supplied anchors and secure plate to the
wall. Thermostat wire must be 18 AWG
wire. Wire the appropriate thermostat as
shown in Figure 15 to the low voltage
terminal strip on the ECM control board.
Practically any heat pump thermostat will
work with Heat Controller units, provided it
has the correct number of heating and
cooling stages.
Figure 15: Unit with ECM Fan
(A Two-Stage Thermostat is Required)
Connection to ECM Control
Thermostat
ECM Interface Board
Compressor
Y1
Y1
Heating Stage
Y2
Y2
Reversing Valve
0
0
Fan
G
G
24 VAC Hot
R
R
24 VAC Common
C
C
Fault LED
L
L
25
28
ECM Blower Control
ECMHTV/HTD/HTH
BLOWERSERIES
CONTROL
The ECM fan is controlled by an interface
board that converts thermostat inputs and
field selectable CFM settings to signals used
by the ECM motor controller. Fan speeds
are selected via a nine position DIP switch.
To take full advantage of the ECM motor
features, a multi-stage thermostat should be
used (2-stage heat/2-stage cool or 3-stage
heat/2-stage cool).
Heat Controller, Inc.
Auxiliary/Emergency Heat Settings: The
auxiliary/emergency heat setting determines
the CFM when the unit is in auxiliary heat or
emergency heat mode. This setting is
used for units with internal electric heat.
When auxiliary electric heat is energized
(i.e. compressor and electric heat), the
greater of the auxiliary/emergency or
heating setting will be used. A “G” (fan)
signal must be present from the thermostat
for electric heat to operate. Consult the
Engineering Design Guide for the specific
unit model to correlate speed tap setting to
airflow in CFM.
Note: Power must be off to the unit for at
least three seconds before the ECM motor
will recognize a speed change. The motor
will recognize a change in the CFM adjust or
dehumidification mode settings while the
unit is powered.
CFM Adjust Settings: The CFM adjust
setting allows four selections. The NORM
setting is the factory default position. The
+ or - settings adjust the airflow by +/- 15%.
The +/- settings are used to “fine tune”
airflow adjustments. The TEST setting
runs the ECM motor at 80% torque, which
causes the motor to operate like a standard
PSC motor, and disables the CFM counter.
There are four different airflow settings from
lowest airflow rate (speed tap 1) to the
highest airflow rate (speed tape 4). The
charts below indicate settings for the ECM
interface board, followed by detailed
information for each setting.
Cooling Settings: The cooling setting
determines the cooling (normal) CFM for the
ECM motor. Cooling (normal) setting is
used when the unit is not in dehumidification
mode. Tap 1 is the lowest CFM setting,
while tap 4 is the highest CFM setting. To
avoid air coil freeze-up, tap 1 may not be
used if the dehumidification mode is
selected. Consult Engineering Design
Guide for the specific unit model to correlate
speed tap setting to airflow in CFM.
Dehumidification Mode Settings: The
dehumidification mode setting provides field
selection of humidity control. When
operating in the normal mode, the cooling
airflow settings are determined by the
cooling tap setting above. When
dehumidification is enabled there is a
reduction in airflow in cooling to increase the
moisture removal of the heat pump.
Consult Engineering Design Guide for the
specific unit model to correlate speed tap to
airflow in CFM. The dehumidification
mode can be enabled in two ways.
Heating Settings: The heating setting
determines the heating CFM. Tap 1 is the
lowest CFM setting, while tap 4 is the
highest CFM setting. Consult Engineering
Design Guide for the specific unit model to
correlate speed tap setting to airflow in
CFM.
1. Constant Dehumidification Mode:
When the dehumidification mode is
selected (via DIP switch setting), the
ECM motor will operate with a multiplier
applied to the cooling CFM settings
(approx. 20-25% lower airflow).
26
29
ECMHTV/HTD/HTH
BLOWERSERIES
CONTROL
Heat Controller, Inc.
Any time the unit is running in the cooling mode,
it will operate at the lower airflow to improve
latent capacity. The “DEHUM” LED will be
illuminated at all times. Heating airflow is not
Figure 16: ECM Interface Layout
affected. NOTE: Do not select
dehumidification mode if cooling setting is tap 1.
2. Automatic (Humidistat-Controlled)
Dehumidification Mode: When the
dehumidification mode is selected (via DIP
switch setting) AND a humidistat is
connected to terminal DH, the cooling airflow
will only be reduced when the humidistat
senses that additional dehumidification is
required. The DH terminal is reverse logic.
Therefore, a humidistat (not dehumidistat) is
required. The “DEHUM” LED will be
illuminated only when the humidistat is
calling for dehumidification mode. Heating
airflow is not affected. NOTE: Do not
select dehumidification mode if cooling
setting is tap 1.
Table 5: ECM Board Tap Settings
Heating Settings
Cooling Settings
Tap
Setting
DIP Switch
SW1
SW2
1
ON
ON
2
ON
OFF
3
OFF
ON
4
OFF
OFF
Tap
Setting
DIP Switch
Setting
Tap
SW3
SW4
1
ON
ON
2
ON
3
4
DIP Switch
Setting
SW5
SW6
1
ON
ON
OFF
2
ON
OFF
OFF
ON
3
OFF
ON
OFF
OFF
4
OFF
OFF
CFM Adjust Settings
Tap
Aux / Emergency Heat Settings
Dehum Mode Settings
DIP Switch
Tap
Setting
DIP Switch
SW7
SW8
Test
ON
ON
Norm
ON
-
ON
OFF
Dehumid
OFF
+
OFF
ON
Norm
OFF
OFF
27
30
SW9
HTV/HTD/HTH SERIES
Typical Wiring Diagram
Heat Controller, Inc.
HTV/HTD/HTH Units with CXM Board and ECM Fan Motor (single phase)
31
Heat Controller, Inc.
CXM Controls
HTV/HTD/HTH SERIES
CXM CONTROLS
Air Coil Low Temperature Limit Setting:
Jumper 2 (JW2-FP2 Low Temp) provides
field selection of temperature limit setting for
FP2 of 30°F or 10°F (refrigerant
temperature). Note: This jumper should
only be clipped under extenuating
circumstances, as recommended by the
factory.
Not Clipped = 30°F, Clipped = 10°F
CXM CONTROL
For detailed control information, see CXM
Application, Operation and Maintenance
Manual.
FIELD SELECTABLE INPUTS
Test Mode: Test mode allows the service
technician to check the operation of the
control in a timely manner. By momentarily
shorting the test terminals, the CXM control
enters a 20 minute test mode period in
which all time delays are sped up 15 times.
Upon entering rest mode, the status LED will
flash a code representing the last fault. For
diagnostic ease at the thermostat, the alarm
relay will also cycle during test mode. The
alarm relay will cycle on and off similar to the
status LED to indicate a code representing
the last fault, at the thermostat. Test mode
can be exited by shorting the test terminals
for 3 seconds.
Retry Mode: If the control is attempting a
retry of a fault, the status LED will slow flash
(slow flash = one flash every 2 seconds) to
indicate the control is in the process of
retrying.
Alarm Relay Setting: Jumper 1 (JW1-AL2
Dry) provides field selection of the alarm
relay terminal AL2 to be jumpered to 24VAC
or to be a dry contact (no connection).
Not Clipped = AL2 connected to R.,
Clipped = AL2 dry contact (no
connection).
DIP SWITCHES
Note: In the following field configuration
options, DIP switches should only be
changed when power is removed from the
CXM control.
DIP Switch 1: Unit Performance Sentinel
Disable - provides field selection to disable
the UPS feature.
On = Enabled. Off = Disabled.
FIELD CONFIGURATION OPTIONS
Note: In the following field configuration
options, jumper wires should be clipped
ONLY when power is removed from the
CXM control.
DIP Switch 2: Stage 2 Selection - provides
selection of whether compressor has an “on”
delay. If set to stage 2, the compressor will
have a 3 second delay before energizing.
Also, if set for stage 2, the alarm relay will
NOT cycle during test mode.
On = Stage 1. Off = Stage 2.
Water Coil Low Temperature Limit
Setting: Jumper 3 (JW3-FP1 Low Temp)
provides field selection of temperature limit
setting for FP1 of 30°F or 10°F (refrigerant
temperature).
Not Clipped = 30°F, Clipped = 10°F
DIP Switch 3: Not Used.
29
32
CXM
CONTROLS
HTV/HTD/HTH
SERIES
DIP Switch 4: DDC Output at EH2 provides selection for DDC operation. If set
to “DDC Output at EH2,” the EH2 terminal will
continuously output the last fault code of the
controller. If set to “EH2 normal,” EH2 will
operate as standard electric heat output.
On = EH2 Normal. Off = DDC Output at
EH2
Note: Some CXM controls only have a 2
position DIP switch package. If this is the
case, this option can be selected by clipping
the jumper which is in position 4 of SW1.
Jumper not clipped = EH2 Normal, Jumper
clipped = DDC Output at EH2.
T
Heat Controller, Inc.
⌧ CAUTION! ⌧
CAUTION! Do not restart units
without inspection and remedy of
faulting condition. Equipment
damage may occur.
DIP Switch 5: Factory Setting - Normal
position is “On”. Do not change selection
unless instructed to do so by the factory.
Table 6: CXM and Alarm
Relay Operations
Description of Operation
LED
Alarm Relay
Normal Mode
ON
Open
Normal Mode with UPS Warning
ON
Cycle (closed 5 sec., open 25 sec.)
CXM is Non-Functional
OFF
Open
Fault Retry
Slow Flash
Open
Lockout
Fast Flash
Closed
Over/Under Voltage Shutdown
Slow Flash
Open (closed after 15 minutes)
Test Mode - No Fault in Memory
Flashing Code 1
Cycling Code 1
Test Mode - HP Fault in Memory
Flashing Code 2
Cycling Code 2
Test Mode - LP Fault in Memory
Flashing Code 3
Cycling Code 3
Test Mode - FP1 Fault in Memory
Flashing Code 4
Cycling Code 4
Test Mode - FP2 Fault in Memory
Flashing Code 4
Cycling Code 5
Test Mode - CO Fault in Memory
Flashing Code 6
Cycling Code 6
Test Mode - Over/Under Shutdown in Memory
Flashing Code 7
Cycling Code 7
Test Mode - UPS in Memory
Flashing Code 8
Cycling Code 8
Test Mode - Swapped Thermistors
Flashing Code 9
Cycling Code 9
- Slow Flash = 1 flash every 2 seconds
- Fast Flash = 2 flashes every 1 second
- Flash Code 2 = 2 quick flashes, 10 second pause, 2 quick flashes, 10 second pause, etc.
- On Pulse 1/3 second; Off Pulse 1/3 second
30
33
HTV/HTD/HTH
SERIESCONTROLS
SAFETY FEATURES
- CXM
Safety Features - CXM Controls
Heat Controller, Inc.
Safety Features:
The safety features below are provided to
protect the compressor, heat exchangers,
wiring and other components from damage
caused by operation outside of design
conditions.
Anti-Short cycle Protection: The control
features a 5 minute anti-short cycle
protection for the compressor. Note: The
5 minute anti-short cycle also occurs at
power up.
Random Start: The control features a
random start upon power up of 5-80 seconds.
Fault Retry: In Fault Retry Mode, the Status
LED begins slowly flashing to signal that the
control is trying to recover from a fault input.
The control will stage off the outputs and then
“try again” to satisfy the thermostat input call.
Once the thermostat input call is satisfied, the
control will continue on as if no fault occurred.
If 3 consecutive faults occur without satisfying
the thermostat input call, the control will go
into “lockout” mode. The last fault causing
the lockout will be stored in memory and can
be viewed at the “fault” LED by going into test
mode. Note: FP1/FP2 faults are factory
set at only one try.
Lockout: In Lockout Mode, the Status LED
will begin fast flashing. The compressor
relay is turned off immediately. Lockout
Mode can be “soft” reset by turning off the
thermostat (or satisfying the call). A “soft”
reset keeps the fault in memory but resets the
control. A “hard” reset (disconnecting power
to the control) resets the control and erases
fault memory.
Lockout with Emergency Heat: While in
lockout mode, if W becomes active (CXM),
Emergency Heat Mode will occur.
High Pressure Switch: When the high
pressure switch opens due to high refrigerant
pressures, the compressor relay is
de-energized immediately since the high
pressure switch is in series with the
compressor contactor coil. The high
pressure fault recognition is immediate (does
not delay for 30 continuous seconds before
de-energizing the compressor).
High pressure lockout code = 2
Example: 2 quick flashes, 10 sec pause, 2
quick flashes, 10 sec. pause, etc.
Low Pressure Switch: The low pressure
switch must be open and remain open for 30
continuous seconds during “on” cycle to be
recognized as a low pressure fault. If the
low pressure switch is open for 30 seconds
prior to compressor power up it will be
considered a low pressure (loss of charge)
fault. The low pressure switch input is
bypassed for the initial 60 seconds of a
compressor run cycle.
Low pressure lockout code = 3
Water Coil Low Temperature (FP1): The
FP1 thermistor temperature must be below
the selected low temperature limit setting for
30 continuous seconds during a compressor
run cycle to be recognized as a FP1 fault.
The FP1 input is bypassed for the initial 60
seconds of a compressor run cycle. FP1 is
set at the factory for one try. Therefore, the
control will go into lockout mode once the
FP1 fault has occurred.
FP1 lockout code = 4
Air Coil Low Temperature (FP2): The FP2
thermistor temperature must be below the
selected low temperature limit setting for 30
continuous seconds during a compressor run
cycle to be recognized as a FP2 fault. The
FP2 input is bypassed for the initial 60
seconds of a compressor run cycle. FP2 is
set at the factory for one try. Therefore, the
control will go into lockout mode once the
FP2 fault has occurred.
FP2 lockout code = 5
31
34
SAFETY FEATURES - CXM CONTROLS
HTV/HTD/HTH SERIES
Heat Controller, Inc.
Swapped FP1/FP2 thermistors: During test
mode, the control monitors to see if the FP1
and FP2 thermistors are in the appropriate
places. If the control is in test mode, the
control will lockout with code 9 after 30
seconds if:
a) The compressor is on in the cooling
mode and the FP1 sensor is colder than
the FP2 sensor,, or:
b) The compressor is on in the heating
mode and the FP2 sensor is colder than
the FP1 sensor.
Swapped FP1/FP2 thermistor code = 9
Condensate Overflow: The condensate
overflow sensor must sense overflow level for
30 continuous seconds to be recognized as a
CO fault. Condensate overflow will be
monitored at all times.
CO lockout code = 6
Over/Under Voltage Shutdown:: An
over/under voltage condition exists when the
control voltage is outside the range of 19VAC
to 30VAC. Over/under voltage shut down is
a self-resetting safety. If the voltage comes
back within range for at least 0.5 seconds,
normal operation is restored. This is not
considered a fault or lockout. If the CXM is
in over/under voltage shutdown for 15
minutes, the alarm relay will close.
Over/under voltage shut down code = 7
Unit Performance Sentinel-UPS: The
UPS feature indicates when the heat pump is
operating inefficiently. A UPS condition
exists when:
b) In heating mode with compressor
energized, FP2 is greater than 125°F for
30 continuous seconds, or:
b) In cooling mode with compressor
energized, FP1 is greater than 125°F for
30 continuous seconds, or:
c) In cooling mode with compressor
energized, FP2 is less than 40°F for 30
continuous seconds.
DIAGNOSTIC FEATURES
The LED on the CXM board advises the
technician of the current status of the CXM
control. The LED can display either the
current CXM mode or the last fault in memory
if in test mode. If there is no fault in
memory, the LED will flash Code 1 (when in
test mode).
CXM CONTROLS
CXM CONTROL START-UP OPERATION
The control will not operate until all inputs and
safety controls are checked for normal
conditions. The compressor will have a 5
minute anti-short cycle delay at power-up.
The first time after power-up that there is a
call for compressor, the compressor will
follow a 5 to 80 second random start delay.
After the random start delay and anti-short
cycle delay, the compressor relay will be
energized. On all subsequent compressor
calls, the random start delay is omitted.
If a UPS condition occurs, the control will
immediately go to UPS warning. The Status
LED will remain on as if the control is in
normal mode. Outputs of the control
excluding LED and alarm relay, will NOT be
affected by UPS. The UPS condition cannot
occur during a compressor off cycle. During
UPS warning, the alarm relay will cycle on
and off. The cycle rate will be “on” for 5
seconds, “off” for 25 seconds, “on” for 5
seconds, “off” for 25 seconds, etc.
UPS warning code = 8
32
35
HTV/HTD/HTH SERIES
Heat Controller, Inc.
Unit Commissioning And Operating Conditions
Operating Limits
Environment – Units are designed for indoor installation only. 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).
Power Supply – A voltage variation of +/– 10% of nameplate utilization voltage is acceptable.
Determination of operating limits is dependent primarily upon three factors: 1) return air temperature. 2) water
temperature, and 3) ambient temperature. When any one of these factors is at minimum or maximum levels, the other two
factors should be at normal levels to insure proper unit operation. Extreme variations in temperature and humidity and/
or corrosive water or air will adversely affect unit performance, reliability, and service life. Consult Table 8a for operating
limits.
Table 8a: Building Operating Limits
Operating Limits
Air Limits
Min. ambient air, DB
Rated ambient air, DB
Max. ambient air, DB
Min. entering air, DB/WB
Rated entering air, DB/WB
Max. entering air, DB/WB
Water Limits
Min. entering water
Normal entering water
Max. entering water
Normal Water Flow
Cooling
HTV/HTD/HTH
TT
45ºF [7ºC]
80.6ºF [27ºC]
110ºF [43ºC]
60/45ºF [16/7ºC]
80.6/66.2ºF [27/19ºC]
100/75ºF [38/24ºC]
Heating
Cooling
39ºF [4ºC]
68ºF [20ºC]
85ºF [29ºC]
40ºF [4.4ºC]
68ºF [20ºC]
80ºF [27ºC]
45ºF [7ºC]
80.6ºF [27ºC]
110ºF [43ºC]
60/50ºF [16/10ºC]
80.6/66.2ºF [27/19ºC]
95/75ºF [35/24ºC]
30ºF [-1ºC]
20ºF [-6.7ºC]
50-110ºF [10-43ºC]
30-70ºF [-1 to 21ºC]
120ºF [49ºC]
90ºF [32ºC]
1.5 to 3.0 gpm / ton
[1.6 to 3.2 l/m per kW]
TS
Heating
39ºF [4ºC
68ºF [20ºC
85ºF [29ºC]
45ºF [7ºC]
68ºF [20ºC
80ºF [27ºC]
30ºF [-1ºC]
20ºF [-6.7ºC]
50-110ºF [10-43ºC]
30-70ºF [-1 to 21ºC]
120ºF [49ºC]
90ºF [32ºC]
1.5 to 3.0 gpm / ton
[1.6 to 3.2 l/m per kW]
Rev.: 8 June, 2009P
Commissioning Conditions
Consult Table 8b for the particular model. Starting conditions vary depending upon model and are based upon the
following notes:
Notes:
1. Conditions in Table 8b are not normal or continuous operating conditions. Minimum/maximum limits are startup conditions to bring the building space up to occupancy temperatures. Units are not designed to operate
under these conditions on a regular basis.
2. Voltage utilization range complies with AHRI Standard 110.
Table 8b: Building Commissioning Limits
Commissioning Limits
Air Limits
Min. ambient air, DB
Rated ambient air, DB
Max. ambient air, DB
Min. entering air, DB/WB
Rated entering air, DB/WB
Max. entering air, DB/WB
Water Limits
Min. entering water
Normal entering water
Max. entering water
Cooling
HTV/HTD/HTH
TT/TS
45ºF [7ºC]
80.6ºF [27ºC]
110ºF [43ºC]
*50ºF [10ºC]
80.6/66.2ºF [27/19ºC]
110/83ºF [43/28ºC]
Heating
39ºF [4ºC]
68ºF [20ºC]
85ºF [29ºC]
40ºF [4.5ºC]
68ºF [20ºC]
80ºF [27ºC]
30ºF [-1ºC]
20ºF [-6.7ºC]
50-110ºF [10-43ºC]
30-70ºF [-1 to 21ºC]
120ºF [49ºC]
90ºF [32ºC]
1.5 to 3.0 gpm / ton
Normal Water Flow
[1.6 to 3.2 l/m per kW]
*If with active ClimaDry™ 70/61℉ (21/16℃)
Rev.: 8 June, 2009P
36
HTV/HTD/HTH SERIES
Heat Controller, Inc.
Unit StartingUNIT
AndSTARTING
OperatingAND
Conditions
OPERATING CONDITIONS
DO NOT use “Stop Leak” or similar
chemical agent in this system.
Addition of chemicals of this type to
the loop water will foul the heat
exchanger and inhibit unit operation.
T
DO NOT oil motors. Check unit fan speed
selection and compare to design
requirements.
⌧ Condensate line: Verify that condensate
line is open and properly pitched toward
drain.
⌧ Water flow balancing: Record inlet and
outlet water temperatures for each heat
pump upon startup. This check can
eliminate nuisance trip outs and high
velocity water flow that could erode heat
exchangers.
⌧ Unit air coil and filters: Insure that filter
is clean and accessible. Clean air coil of
all manufacturing oils.
⌧ Unit controls: Verify that CXM field
selection options are properly set.
⌧ CAUTION! ⌧
CAUTION! To avoid possible
damage to a plastic (PVC) piping
system, do not allow temperatures to
exceed 113°F.
UNIT AND SYSTEM CHECKOUT
Unit and System Checkout:
BEFORE POWERING SYSTEM, please
check the following:
UNIT CHECKOUT
⌧ Balancing/shutoff valves: Insure that all
isolation valves are open and water
control valves are wired.
⌧ Line voltage and wiring: Verify that
voltage is within an acceptable range for
the unit and wiring and fuses/breakers
are properly sized. Verify that low
voltage wiring is complete.
⌧ Unit control transformer: Insure that
transformer has the properly selected
voltage tap.
⌧ Entering water and air: Insure that
entering water and air temperatures are
within operating limits of Table 7.
⌧ Low water temperature cutout: Verify
that low water temperature cut-out on the
CXM control is properly set.
⌧ Unit fan: Manually rotate fan to verify
free rotation and insure that blower wheel
is secured to the motor shaft. Be sure to
remove any shipping supports if needed.
34
SYSTEM CHECKOUT
⌧ System water temperature: Check
water temperature for proper range and
also verify heating and cooling set points
for proper operation.
⌧ System pH: Check and adjust water pH
if necessary to maintain a level between
6 and 8.5. Proper pH promotes
longevity of hoses and fittings (see Table
3).
⌧ System flushing: Verify that all hoses
are connected end to end when flushing
to insure that debris bypasses the unit
heat exchanger, water valves and other
components. Water used in the system
must be potable quality initially and clean
of dirt, piping slag, and strong chemical
cleaning agents. Verify that all air is
purged from the system. Air in the
system can cause poor operation or
system corrosion.
37
Heat Controller, Inc. UNIT
T
SERIES
STARTINGHTV/HTD/HTH
AND OPERATING
CONDITIONS
5. Two factors determine the operating
limits of Heat Controller heat pumps, (a)
return air temperature, and (b) water
temperature. When any one of these
factors is at a minimum or maximum
level, the other factor must be at normal
level to insure proper unit operation.
a. Adjust the unit thermostat to the
warmest setting. Place the
thermostat mode switch in the
“COOL” position. Slowly reduce
thermostat setting until the
compressor activates.
b. Check for cool air delivery at the
unit grille within a few minutes after
the unit has begun to operate.
⌧ CAUTION! ⌧
CAUTION! Verify that ALL water
control valves are open and allow
water flow prior to engaging the
compressor. Freezing of the coax or
water lines can permanently damage
the heat pump.
T
⌧ CAUTION! ⌧
CAUTION! To avoid equipment
damage, DO NOT leave system filled
in a building without heat during the
winter unless antifreeze is added to
the water loop. Heat exchangers
never fully drain by themselves and
will freeze unless winterized with
antifreeze.
Note: Units have a five minute
time delay in the control circuit that
can be eliminated on the control
board as shown below in Figure 17
on Page 37. See controls
description for details.
c. Verify that the compressor is on
and that the water flow rate is
correct by measuring pressure drop
through the heat exchanger using
the P/T plugs and comparing to
Table 8.
d. Check the elevation and
cleanliness of the condensate lines.
Dripping may be a sign of a blocked
line. Check that the condensate
trap is filled to provide a water seal.
e. Refer to Table 7. Check the
temperature of both entering and
leaving water. If temperature is
within range, proceed with the test.
If temperature is outside of the
operating range, check refrigerant
pressures and compare to Table 9.
Verify correct water flow by
comparing unit pressure drop
across the heat exchanger versus
the data in Table 8.
NOTICE! Failure to remove shipping
brackets from spring-mounted
compressors will cause excessive
noise, and could cause component
failure due to added vibration.
UNIT START-UP PROCEDURE
Unit Start-Up Procedure
1. Turn the thermostat fan position to
“ON”. Blower should start.
2. Balance air flow at registers.
3. Adjust all valves to their full open
positions. Turn on the line power
heat pump
4. Room temperature should be
within the minimum-maximum
ranges of Table 9. During
start-up checks, loop water
temperature entering the heat
Pump should be between 60°F and
95°F.
35
38
HTV/HTD/HTH SERIES
Heat Controller, Inc.
UNIT START-UP PROCEDURE
Unit Start-Up Procedure
by comparing unit pressure drop
across the heat exchanger versus the
data in Table 8. Heat of extraction
(HE) can be calculated and compared
to submittal data capacity pages.
The formula for HE for systems with
water is as follows:
HE = TD x GPM x 500, where TD is
the temperature difference between
the entering and leaving water, and
GPM is the flow rate in U.S. GPM,
determined by comparing the
pressure drop across the heat
exchanger to Table 8.
e. Check air temperature rise across the
air coil when compressor is operating.
Air temperature rise should be
between 20°F and 30°F.
f. Check for vibration, noise, and water
leaks.
7. If unit fails to operate, perform
troubleshooting analysis (see
troubleshooting section). If the check
described fails to reveal the problem and
the unit still does not operate, contact a
trained service technician to insure
proper diagnosis and repair of the
equipment.
8. When testing is complete, set system to
maintain desired comfort level.
9. BE CERTAIN TO FILL OUT AND
FORWARD WARRANTY
REGISTRATION CARD TO HEAT
CONTROLLER.
Heat of rejection (HR) can be
calculated and compared to
submittal data capacity pages.
The formula for HR for systems
with water is as follows:
HR = TD x GPM x 500, where TD is
the temperature difference between
the entering and leaving water, and
GPM is the flow rate in U.S. GPM,
determined by comparing the
pressure drop across the heat
exchanger to Table 8.
f. Check air temperature drop across
the air coil when compressor is
operating. Air temperature drop
should be between 15°F and 25°F.
g. Turn thermostat to “OFF” position.
A hissing noise indicates proper
functioning of the reversing valve.
6. Allow five (5) minutes between tests for
pressure to equalize before beginning
heating test
a. Adjust the thermostat to the lowest
setting. Place the thermostat
mode switch in the “HEAT”
position.
b. Slowly raise the thermostat to a
higher temperature until the
compressor activates.
c. Check for warm air delivery within a
few minutes after the unit has
begun to operate.
d. Refer to Table 7. Check the
temperature of both entering
and leaving water. If
temperature is within range,
proceed with the test. If
temperature is outside of the
operating range, check
refrigerant pressures and
compare to Table 9. Verify
correct water flow
Note: If performance during any mode
appears abnormal, refer to the CXM section
or troubleshooting section of this manual.
To obtain maximum performance, the air coil
should be cleaned before start-up. A 10%
solution of dishwasher detergent and water is
recommended.
36
39
HTV/HTD/HTH SERIES
Heat Controller, Inc.
Unit Start-Up Procedure
UNIT START-UP PROCEDURE
UNIT START-UP PROCEDURE
 WARNING!

T
 WARNING! 
TWARNING! When the disconnect
WARNING!
When high
the disconnect
switch is closed,
voltage is
switch is closed, high voltage is
present in some areas of the electrical
present in some areas of the electrical
panel. Exercise extreme caution
panel. Exercise extreme caution
when working with energized
when working with energized
equipment.
equipment.
Figure 17: Test Mode Pins
Figure 17: Test Mode Pins
CAUTION!
CAUTION! 

CAUTION!Verify
Verify
that
water
CAUTION!
that
all all
water
control
valves
are
open
and
allow
control valves are open and allow
water
toto
engaging
thethe
waterflow
flowprior
prior
engaging
compressor.
of of
thethe
coax
or or
compressor.Freezing
Freezing
coax
water
lines
can
permanently
damage
water lines can permanently damage
the
theheat
heatpump.
pump.
Short
test pins
Short test pins
together
to together to
enter Test Mode
enterand
Test Mode and
speed-up timing
and timing and
speed-up
delays for 20delays
minutes
for 20 minutes
UNIT
OPERATING
CONDITIONS
Unit Operating Conditions
UNIT
OPERATING
CONDITIONS
Table8:
8: HTV/HTD/HTH
HTV/HTD CoaxWater
WaterPressure
Pressure Drop
Table
Drop
Table 8: HTV/HTD Coax Water Pressure Drop
Model
Model
GPM
4.0
4.0
024
024
036
036
048
048
6.0
6.0
1.3
1.5
2.6
3.1
1.3
2.6
1.1
2.3
1.1
2.3
1.0
2.1
1.0
2.1
3.8
3.0
3.4
2.7
4.08.0
1.2 5.1
1.0
4.3
0.8
3.8
0.6
3.4
6.04.0
2.6 1.2
2.5
1.0
2.3
0.8
2.1
0.6
8.06.0
4.5 2.6
4.2
2.5
4.0
2.3
3.7
2.1
9.08.0
5.7 4.5
5.2
4.2
4.8
4.0
4.4
3.7
5.59.0
1.1 5.7
0.9
5.2
0.8
4.8
0.7
4.4
8.35.5
2.2 1.1
2.1
0.9
2.0
0.8
1.8
0.7
11.0
3.9
3.6
12.0
4.5
7.0
0.5
10.5
1.9
14.0
3.9
15.0
4.8
7.0
10.5
15.0
11.3
7.5
1.7
3.9
3.9
0.3
4.5
1.8
0.5
3.5
1.9
4.3
3.9
1.5
4.8
3.4
1.7
15.0
6.9
11.3
17.0
8.9 3.9
15.0
6.9
17.0
4.2
8.9
6.0
7.7
37
2.1
3.6
4.2
0.3
1.8
3.5
4.3
1.5
3.4
3.2
3.8
0.2
1.7
3.2
3.9
1.3
3.0
5.4
6.9
2.0
3.2
3.8
0.2
1.7
3.2
3.9
1.3
3.0
2.7
90°F
3.4
2.2
3.0
90°F
70°F
4.3
8.3
3.4
70°F
50°F
5.1 4.1
14.0
070
3.1
30°F
Pressure Drop, psi
8.07.0
7.5
070
1.5
50°F
4.1
12.0
060
30°F
7.0
11.0
060
Pressure Drop, psi
GPM
3.1
3.5
0.1
1.6
2.9
3.5
1.3
2.8
5.0
6.5
1.8
3.1
3.5
0.1
1.6
2.9
3.5
1.3
2.8
6.0
5.4
5.0
40
7.7
6.9
6.5
UNIT OPERATING CONDITIONS
HTV/HTD/HTH SERIES
•
•
NOTE: Table 9 includes the following notes:
•
•
Airflow is at nominal (rated) conditions;
Entering air is based upon 70°F DB in
heating and 80/67° in cooling;
•
Subcooling is based upon head
pressure at compressor service port;
HTV/HTD/HTH
TXV expansion
device;
HTV/HTD
units units
havehave
TXV expansion
device;
Cooling air and water values can vary
greatly with changes in humidity level.
Table 9: HTV/HTD
HTV/HTD/HTH
Pressuresand
andTemperatures
Temperatures(60Hz)
(60 Hz)
SeriesTypical
Typical Unit Operating Pressures
38
41
Heat Controller, Inc.
Heat Controller, Inc.
HTV/HTD/HTH SERIES
Table 9: HTV/HTD/HTH Typical Unit Operating Pressures and Temperatures (60 Hz) - continued
42
HTV/HTD/HTH SERIES
PREVENTIVE MAINTENANCE
Preventive Maintenance
Heat Controller, Inc.
Hot Water Generator Coils
See water coil maintenance for ground water
units. If the potable water is hard or not
chemically softened, the high temperatures of
the desuperheater will tend to scale even
quicker than the water coil and may need
more frequent inspections. In areas with
extremely hard water, a HWG is not
recommended.
Water Coil Maintenance
(Direct ground water applications only)
If the system is installed in an area with a
known high mineral content (125 P.P.M. or
greater) in the water, it is best to establish a
periodic maintenance schedule with the
owner so the coil can be checked regularly.
Consult the well water applications section of
this manual for a more detailed water coil
material selection. Should periodic coil
cleaning be necessary, use standard coil
cleaning procedures, which are compatible
with the heat exchanger material and copper
water lines. Generally, the more water
flowing through the unit, the less chance for
scaling. Therefore, 1.5 gpm per ton is
recommended as a minimum flow.
Minimum flow rate for entering water
temperatures below 50°F is 2.0 gpm per ton.
Filters
Filters must be clean to obtain maximum
performance. Filters should be inspected
every month under normal operating
conditions and be replaced when necessary.
Units should never be operated without a
filter.
Washable, high efficiency, electrostatic filters,
when dirty, can exhibit a very high pressure
drop for the fan motor and reduce air flow,
resulting in poor performance. It is
especially important to provide consistent
washing of these filters (in the opposite
direction of the normal air flow) once per
month using a high pressure wash similar to
those found at self-serve car washes.
Water Coil Maintenance
(Water loop applications)
Generally, water coil maintenance is not
needed for closed loop systems. However,
if the piping is known to have high dirt or
debris content, it is best to establish a
periodic maintenance schedule with the
owner so the water coil can be checked
regularly. Dirty installations are typically the
result of deterioration of iron or galvanized
piping or components in the system.
Condensate Drain
In areas where airborne bacteria may
produce a “slimy” substance in the drain pan,
it may be necessary to treat the drain pan
chemically with an algaecide approximately
every three months to minimize the problem.
Water Flow
Generally, the more water flowing through the
unit, the less chance for scaling. However,
flow rates over 3 gpm per ton can produce
water (or debris) velocities that can erode the
heat exchanger wall and ultimately produce
leaks.
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Heat Controller, Inc.
PREVENTIVE MAINTENANCE
HTV/HTD/HTH SERIES
The condensate pan may also need to be
cleaned periodically to insure indoor air
quality. The condensate drain can pick up
lint and dirt, especially with dirty filters.
Inspect the drain twice a year to avoid the
possibility of plugging and eventual overflow.
Compressor
Conduct annual amperage checks to insure
that amp draw is no more than 10% greater
than indicated on the serial plate data.
Refrigerant System
To main tain sealed circuit integrity, do not
install service gauges unless unit operation
appears abnormal. Reference the operating
charts for pressures and temperatures.
Verify that air and water flow rates are at
proper levels before servicing the refrigerant
circuit.
Fan Motors
All units have lubricated fan motors. Fan
motors should never be lubricated unless
obvious, dry operation is suspected.
Periodic maintenance oiling is not
recommended, as it will result in dirt
accumulating in the excess oil and cause
eventual motor failure. Conduct annual dry
operation check and amperage check to
insure amp draw is no more than 10%
greater than indicated on serial plate data.
Air Coil
The air coil must be cleaned to obtain
maximum performance. Check once a year
under normal operating conditions and, if
dirty, brush or vacuum clean. Care must be
taken not to damage the aluminum fins while
cleaning.
CAUTION: Fin edges are sharp.
Cabinet
Do not allow water to stay in contact with the
cabinet for long periods of time to prevent
corrosion of the cabinet sheet metal.
Generally, vertical cabinets are set up from
the floor a few inches to prevent water from
entering the cabinet. The cabinet can be
cleaned using a mild detergent.
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HTV/HTD/HTH SERIES
Heat Controller, Inc.
FUNCTIONAL TROUBLESHOOTING
Functional Troubleshooting
Fault
Main Power Problems
Htg
Clg
X
X
Possible Cause
Solution
Green Status Led Off
Check line voltage circuit breaker and cisconnect
Check for line voltage between L1 and L2 on
Check for 24 VAC between R and C on CXM
Check primary/secondary voltage on transformer
X
HP Fault - Code 2
Reduced Or No Water Flow In Cooling
High Pressure
Check pump operation or valve operation/setting
Check water flow adjust to proper flow rate
X
Water Temperature Out Of Range In
Bring water temp within design parameters
Cooling
X
Reduced Or No Air Flow In Heating
Check for dirty air filter and clean or replace
Check fan motor operation and airflow restriction
Dirty Air coil - construction dust etc.
Too high of external static. Check static valve
X
X
X
Air Temperature Out Of Range In Heating
Bring return air temp within design parameters
Overcharged With Refrigerant
Check superheat/subcooling vs. typical operation
table
X
X
Bad Hp Switch
Check switch continuity and operation. Replace
LP/LOC Fault- Code 3
X
X
Insufficient Charge
Check for refrigerant leaks
Low Pressure/Loss of
X
Compressor Pump Down At Start-Up
Check charge and start-up water flow
X
Reduced Or No Water Flow In Heating
Check pump operation or water valve operation
Charge
FP1 Fault - Code 4
Water Coil -
Plugged strainer or filter. Clean or replace
Low Temperature Limit
Check water flow adjust to proper flow rate
X
Inadequate Anti-Freeze Level
Check antifreeze density with hydrometer
X
Improper Temperature Limit Setting (30°F
Clip JW3 jumper for antifreeze (10°F)
Vs. 10°F)
X
X
FP2 - Code 5
Water Temperature Out of Range
Bring water temp within design parameters
X
Bad Thermistor
Check temp and impedance correlation per chart
X
Reduced Or No Air Flow In Cooling
Check for dirty air filter and clean or replace
Air Coil
Check fan motor operation and airflow restriction
Low Temperature Limit
Too high of external static. Check static valve
X
Air Temperature Out Of Range
Too much cold vent air? Bring entering air to design
parameters
X
Improper Temperature Limit Setting (30°F
Normal airside applications will require 30°F
Vs. 10°F)
X
X
Bad Thermistor
Check temp and impedance correlation per chart
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HTV/HTD/HTH SERIES
Heat Controller, Inc.
FUNCTIONAL TROUBLESHOOTING
Functional Troubleshooting
Fault
Htg
Clg
Possible Cause
Solution
Condensate Fault -
X
X
Blocked Drain
Check for blockage and clean drain
Code 6
X
X
Improper Trap
Check trap dimensions and location
X
Poor Drainage
Check for piping slope away from unit
Poor venting. Check vent location
Over/Under Voltage -
X
X
Moisture on Sensor
Check for moisture shorting to air coil
X
Under Voltage
Check power supply and 24VAC voltage before
Code 7
operation
(Auto Resetting)
Check power supply wire size
Check compressor starting. Need hard start kit
Check 24 VAC and unit transformer tap for correct
supply voltage
X
X
Check power supply voltage and 24 VAC before
operation
Check 24 VAC and unit transformer tap for correct
supply voltage
Unit Performance
X
Sentinel - Code 8
No Fault Code Shown
Unit Short Cycles
X
Heating Mode FP2>125°F
Check for poor air flow or overcharged unit
X
Cooling Mode FP1>125°F or FP2<40°F
Check for poor water flow, or air flow
X
No Compressor Operation
See “only fan operates”
X
X
Compressor Overload
Check and replace if necessary
X
X
Control Board
Reset power and check operation
X
X
Dirty Air Filter
Check and clean air filter
X
X
Unit in “Test Mode”
Reset power or wait 20 minutes for auto exit
X
X
Unit Selection
Unit may be oversized for space. Check sizing load
of space
Only Fan Runs
X
X
Compressor Overload
Check and replace if necessary
X
X
Thermostat Position
Insure thermostat set for heating or cooling
X
X
Unit Locked Out
Check for lockout codes. Reset power
X
X
Compressor Overload
Check compressor overload. Replace if necessary
X
X
Thermostat Wiring
Check thermostat wiring at heat pump. Jumper for
compressor operation in test mode
Only Compressor Runs
X
X
Thermostat Wiring
Check G wiring at heat pump. Jumper G and R
operation
X
X
Fan Motor Relay
Jumper G and R for fan operation. Check for across
BR contacts
Check fan power enable relay operation (if possible)
X
X
Fan Motor
Check for line voltage at motor. Check capacity
X
X
Thermostat Wiring
Check thermostat wiring at heat pump. Jumper
compressor operation in test mode.
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FUNCTIONAL
TROUBLESHOOTING
HTV/HTD/HTH SERIES
FUNCTIONAL TROUBLESHOOTING
Functional
Fault Troubleshooting
Htg
Clg
Possible Cause
Solution
Unit Does Not Operate
Fault
in Cooling
Unit Does Not Operate
Htg
X
Clg
Reversing Valve
Possible Cause
X
Reversing Valve
X
Thermostat Set-up
X
X
Thermostat Wiring
Thermostat Set-up
X
X
Thermostat Wiring
Thermostat Wiring
X
Thermostat Wiring
Heat Controller, Inc.
Set for cooling demand and check 24 VAC on RV
Solution
CXM board
Set for cooling demand and check 24 VAC on RV
If RV is stuck, run high pressure up by reducing and
CXM board
while operating engage and disengage RV to push
If RV is stuck, run high pressure up by reducing and
valve
while operating engage and disengage RV to push
Check for ‘O’ RV set-up not ‘B’
valve
Check O wiring at heat pump. Jumper O and R
Check for ‘O’ RV set-up not ‘B’
‘Click’
Check O wiring at heat pump. Jumper O and R
Put thermostat in cooling mode. Check for 24 (check
‘Click’
between C and O); check for 24 VAC on W between W
Put thermostat in cooling mode. Check for 24 (check
and C). There should be voltage on W. If voltage is
between C and O); check for 24 VAC on W between W
present on W, thermostat or wired incorrectly
and C). There should be voltage on W. If voltage is
in Cooling
present on W, thermostat or wired incorrectly
PERFORMANCE TROUBLESHOOTING
Performance Troubleshooting
PERFORMANCE TROUBLESHOOTING
Performance
Troubleshooting
Performance
Insufficient Capacity/
Troubleshooting
Not Cooling or Heating
Insufficient Capacity/
Properly
Not Cooling or Heating
Htg
Clg
Htg
X
Clg
X
X
X
X
Possible Cause
Dirty Filter
Solution
Possible Cause
Replace or clean
X
Reduced or No Air Flow in Cooling
X
Reduced or No Air Flow in Cooling
X
X
Leaky Duct Work
X
X
Leaky Duct Work
X
X
Low Refrigerant Charge
X
X
X
X
X
X
X
X
X
X
X
X
Restricted metering device
Low Refrigerant Charge
Defective Reversing Valve
Restricted metering device
Thermostat Improperly Located
Defective Reversing Valve
Unit Undersized
Thermostat Improperly Located
X
X
X
X
Unit Undersized
Scaling in Water Heat Exchanger
X
X
X
X
Inlet Water Too Hot or Cold
Scaling in Water Heat Exchanger
Check for dirty air filter and clean or replace
Replace or clean
Check fan motor operation and airflow restriction
Check for dirty air filter and clean or replace
Too high of external static. Check static valve
Check fan motor operation and airflow restriction
Check for dirty air filter and clean or replace
Too high of external static. Check static valve
Check fan motor operation and airflow restriction
Check for dirty air filter and clean or replace
Too high of external static. Check static valve
Check fan motor operation and airflow restriction
Check supply and return air temperatures at two
Too high of external static. Check static valve
distant duct registers if significantly different ,
Check supply and return air temperatures at two
restrictions are present
distant duct registers if significantly different ,
Check superheat and subcooling per chart
restrictions are present
Check superheat and subcooling per chart
Check superheat and subcooling per chart
Perform RV touch test
Check superheat and subcooling per chart
Check location and for air drafts behind stat
Perform RV touch test
Recheck loads & sizing check sensible clg load vs.
Check location and for air drafts behind stat
heat pump capacity
Recheck loads & sizing check sensible clg load vs.
Perform scaling check and clean if necessary
heat pump capacity
Check load, loop sizing, loop backfill, ground
Perform scaling check and clean if necessary
X
X
Inlet Water Too Hot or Cold
Check load, loop sizing, loop backfill, ground
X
Properly
X
X
Reduced or No Air Flow in Heating
Dirty Filter
Solution
Reduced or No Air Flow in Heating
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HTV/HTD/HTH SERIES
Heat Controller, Inc.
PERFORMANCE TROUBLESHOOTING
Performance Troubleshooting
Performance
Htg
Clg
Possible Cause
Solution
Troubleshooting
High Head Pressure
X
Reduced or No Air Flow in Heating
Check for dirty air filter and clean or replace
Check fan motor operation and airflow restriction
Too high of external static. Check static valve
X
Reduced or No Water Flow in Cooling
Check pump operation or valve operation/setting
Check water flow adjust to proper flow rate
X
Inlet Water too Hot
Check load, loop sizing, loop backfill ground
Air Temperature Out of Range in Heating
Bring return air temp within design parameters
X
Scaling in water heat exchanger
Perform scaling check and clean if necessary
X
Unit Overcharged
Check superheat and subcooling. Reweight in
X
X
charge
Low Suction Pressure
X
X
Non-condensables in System
Vacuum system and reweigh in charge
X
X
Restricted Metering Device
Check superheat and subcooling per chart
Reduced Water Flow in Heating
Check pump operation or water valve operation
X
Plugged strainer or filter. Clean or replace
Check water flow adjust to proper flow rate
X
X
Water Temperature Out of Range
Bring water temp within design parameters
Reduced Air Flow in Cooling
Check for dirty air filter and clean or replace
Check fan motor operation and airflow restrictions
Too high of external static. Check static valve
X
Air Temperature Out of Range
Too much cold vent air? Bring entering air temp to
design parameters
X
X
Insufficient Charge
Check for refrigerant leaks
Low Discharge Air
X
Too High of Air Flow
Check fan motor speed selection and airflow
Temperature in Heating
X
Poor Performance
See ‘Insufficient Capacity’
X
Too High of Air Flow
Check fan motor speed selection and airflow
X
Unit Oversized
Recheck loads & sizing check sensible clg load
High Humidity
pump capacity
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HTV/HTD/HTH SERIES
TROUBLESHOOTING FORM
Troubleshooting Form
Heat of Extraction (Absorption) or Heat of Rejection =
Flow rate gpm 500* x °F (water temp. difference)
= BTUH (heat absorbed or rejected)
Superheat = Suction temp - Suction saturation temp = _____________°F Superheat
Subcooling = Discharge Saturation Temp - Liquid Line Temp. = ____________°F Subcooling
* Use 500 for Water, 485 for antifreeze solution
Note: Never connect refrigerant gauges during startup procedures. Conduct water-side
analysis using P/T ports to determine water flow and temperature difference. If water-side
analysis shows poor performance, refrigerant troubleshooting may be required. Connect
refrigerant gauges as a last resort.
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Heat Controller, Inc.
Design, material, performance data and components
subject to change without notice.
1900 Wellworth Ave., Jackson, Michigan 49203 t Ph. 517-787-2100 t Fax 517-787-9341
THE QUALITY LEADER CONDITIONING AIR
www.heatcontroller.com
08-2011
10-2014
*97B0016N07*
97B0016N07
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