Heat Controller HTS User Manual

Installation, Operation and

Maintenace Manual

GeoLogix®

HTS Series Split System,

Two Stage, 2-5 Tons

1900 Wellworth Ave., Jackson, Michigan 49203 • Ph. 517-0787-2100 • Fax [phone] • www.heatcontroller.com

THE QUALITY LEADER IN CONDITIONING AIR

HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS

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Table of Contents

	Model Nomenclature . . . . . . . . . . . . . . . . . . . .	3	Electrical - Line Voltage . . . . . . . . . . . . . .	. . . 23
	Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4	Electrical - Low Voltage Wiring . . . . . . . . .	. . . 24
	Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5	Low Water Temperature Cutout Selection	. . . 24
	Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . .	5	Thermostat Wiring . . . . . . . . . . . . . . . . . . .	. . . 25
	Equipment Selection . . . . . . . . . . . . . . . . . . . .	6	DXM2 Controls . . . . . . . . . . . . . . . . . . . . .	. . . 26-27
	Air Coil Match-ups . . . . . . . . . . . . . . . . . . . . . .	6	Wire Diagram. . . . . . . . . . . . . . . . . . . . . . .	. . . 28
	Air Handler Selection . . . . . . . . . . . . . . . . . . .	7	Unit Commissioning and
	Installation	8-9	Operating Conditions . . . . . . . . . . . . . . . . .	. . . 29
			Unit Start-Up and Operating Conditions	30
	Water Connections	9
			Unit Start-Up Procedure	30-31
	Ground Loop Applications	9-11
			Unit Operating Conditions	32-33
	Open Loop - Ground Water Systems	12-13
			Preventive Maintenance	34
	Water Quality Standards	14
			Troubleshooting	35-37
	Lineset Information	15
			DXM2 Process Flow Chart	38
	Refrigeration Installation	15-19
			Functional & Performance Troubleshooting	. . 39-42
	Hot Water Generator	20-22

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Model Nomenclature : for Indoor Split Series

1

2

3

4

5

6

7

8

9

10

11

12

13

14

HT S 0 2 4 B 1 D 0 1 N N N

SERIES

HT = Heat Controller Two Stage

SUPPLY AIR FLOW &

MOTOR CONFIGURATION

CONFIGURATION

N = NOT APPLICABLE

S = SPLIT

UNIT SIZE

RETURN AIR FLOW CONFIGURATION

024

N = NOT APPLICABLE

036

048

060

REVISION LEVEL

HEAT EXCHANGER OPTIONS

A = Obsolete 6-29-12

Copper

Cupro-Nickel

B = Current Revision DXM2 Effective 6-29-12

Standard

C

N

VOLTAGE

1 = 208-230/60/1

WATER CIRCUIT OPTIONS

0 = None

CONTROLS

1 = HWG w/Internal Pump

C = CXM (Revision A only)

D = DXM2 (Revision B only)

CABINET

0 = Residential

1

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Safety

Safety

Warnings, cautions and notices appear throughout this manual. Read these items carefully before attempting any installation, service or troubleshooting of the equipment.

DANGER: Indicates an immediate hazardous situation, which if not avoided will result in death or serious injury. DANGER labels on unit access panels must be observed.

WARNING: Indicates a potentially hazardous situation, which if not avoided could result in death or serious injury.

CAUTION: Indicates a potentially hazardous situation or an unsafe practice, which if not avoided could result in minor or moderate injury or product or property damage.

NOTICE: Notification of installation, operation or maintenance information, which is important, but which is not hazard-related.

WARNING!

WARNING! Verify refrigerant type before proceeding. Units are shipped with R-410A refrigerants. The unit label will indicate which refrigerant is provided. The EarthPure® Application and Service Manual should be read and understood before attempting to service refrigerant circuits with R-410A

WARNING!

WARNING! To avoid the release of refrigerant into the atmosphere, the refrigerant circuit of this unit must be serviced only by technicians who meet local, state, and federal proficiency requirements.

WARNING!

WARNING! All refrigerant discharged from this unit must be recovered WITHOUT EXCEPTION. Technicians must follow industry accepted guidelines and all local, state, and federal statutes for the recovery and disposal of refrigerants. If a compressor is removed from this unit, refrigerant circuit oil will remain in the compressor. To avoid leakage of compressor oil, refrigerant lines of the compressor must be sealed after it is removed.

CAUTION!

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.

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Inspection

Upon receipt of the equipment, carefully check the shipment against the bill of lading. Make sure all units have been received. Inspect the packaging of each unit, and inspect each unit for damage. Insure that the carrier makes proper notation of any shortages or damage on all copies of the freight bill and completes a common carrier inspection report. Concealed damage not discovered during unloading must be reported to the carrier within 15 days of receipt of shipment. If not filed within 15 days, the freight company can deny the claim without recourse. Note: It is the responsibility of the purchaser to file all necessary claims with the carrier. Notify your equipment supplier of all damage within fifteen (15) days of shipment.

Storage

Equipment should be stored in its original packaging in a clean, dry area. Store units in an upright position at all times. Stack units a maximum of 3 units high.

Unit Protection

Cover units on the job site with either the original packaging or an equivalent protective covering. Cap the open ends

of pipes stored on the job site. In areas where painting, plastering, and/or spraying has not been completed, all due precautions must be taken to avoid physical damage to the units and contamination by foreign material. Physical damage and contamination may prevent proper start-up and may result in costly equipment clean-up.

Examine all pipes, fittings, and valves before installing any of the system components. Remove any dirt or debris found in or on these components.

Pre-Installation

Installation, Operation, and Maintenance instructions are provided with each unit. Horizontal equipment is designed for installation above false ceiling or in a ceiling plenum. Other unit configurations are typically installed in a mechanical room. The installation site chosen should include adequate service clearance around the unit. Before unit start-up,

read all manuals and become familiar with the unit and its operation. Thoroughly check the system before operation.

Prepare units for installation as follows:

1.Compare the electrical data on the unit nameplate with ordering and shipping information to verify that the correct unit has been shipped.

2.Keep the cabinet covered with the original packaging until installation is complete and all plastering, painting, etc. is finished.

3.Verify refrigerant tubing is free of kinks or dents and that it does not touch other unit components.

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General Information

4.Inspect all electrical connections. Connections must be clean and tight at the terminals.

5.Loosen compressor bolts on units equipped with compressor spring vibration isolation until the compressor rides freely on the springs. Remove shipping restraints.

6.Locate and verify any hot water generator (HWG) or other accessory kit located in the compressor section.

CAUTION!

WARNING! All refrigerant discharged from this unit must be recovered WITHOUT EXCEPTION. Technicians must follow industry accepted guidelines and all local, state, and federal statutes for the recovery and disposal of refrigerants. If a compressor is removed from this unit, refrigerant circuit oil will remain in the compressor. To avoid leakage of compressor oil, refrigerant lines of the compressor must be sealed after it is removed.

CAUTION!

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.

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Equipment Selection

NOTICE! AHRI matched systems are required for warranty and applicable federal tax credits.

The installation of geothermal heat pump units and all associated components, parts, and accessories which make up the installation shall be in accordance with the regulations of ALL authorities having jurisdiction and MUST conform to all applicable codes. It is the responsibility of the installing contractor to determine and comply with ALL applicable codes and regulations.

General

Proper indoor coil selection is critical to system efficiency. Using an older-model coil can affect efficiency and may not provide the customer with rated or advertised EER and COP. Coil design and technology have dramatically improved operating efficiency and capacity in the past 20 years. Homeowners using an older coil are not reaping these cost savings and comfort benefits. NEVER MATCH AN R-22 INDOOR COIL WITH AN R-410A COMPRESSOR SECTION.

Newer indoor coils have a larger surface area, enhanced fin design, and grooved tubing. These features provide a larger area for heat transfer, improving efficiency and expanding capacity. Typical older coils may only have one-third to onehalf the face area of these redesigned coils.

Indoor Coil Selection - HTS GeoLogix®

HCI split system heat pumps are rated in the AHRI directory with a specific indoor coil match. GeoLogix® (HTS) models are rated with Heat Controller WDG Series air handlers and MWG Series coils as shown in Table 1a. Other brands of air handlers may attain the same AHRI ratings providing that the specifications meet or exceed those listed in Table 1a AND Table 1b. However, for warranty and federal tax

credits, an AHRI matched system is required. An ECM motor and TXV is required. Cap tubes and fixed orifices are not acceptable. PSC fans may be used if matched to Table 1b, but will not meet AHRI ratings. If using PSC fan, compressor section must be operated as a single stage unit (i.e. wired for either 1st stage or 2nd stage). Without the ability to vary the airflow, supply air temperatures may not be acceptable if the compressor is allowed to change stages when used with a PSC fan motor.

Table 1a: WDG/MWG Indoor Section Matches for AHRI Ratings

Compressor Section Model	024	036		048	060
Indoor Section Model	024	036		048	060
Refrigerant			HFC-410A
Metering Device		TXV (required)
Air Coil
Type	N	N		N	N
Rows	2	2		2	3
Dimensions	14 x 17	24 x 17		24 x 17	24 x 17
Cabinet Configuration		Upflow/Downflow/Horizontal (Multipoise)
WDG Series Fan Motor Type - HP	ECM - 1/2	ECM - 1/2		ECM - 1	ECM - 1

Table 1b: Tranquility® 27 Air Handler Characteristics for Brands other than Above Models

	Model*	Nominal Tons*	Evaporator	CFM	Capacity
			Temp (ºF)		(MBtuh)**
024	- Part Load	1.5	50	530	19.2 - 22.4
024	- Full Load	2.0	52	880	24.2 - 28.2
036	- Part Load	2.5	51	700	25.2 - 29.2
036	- Full Load	3.0	50	1200	34.5 - 40.1
048	- Part Load	3.5	47	1000	34.3 - 39.9
048	- Full Load	4.0	48	1650	46.3 - 53.8
060	- Full Load	5.0	48	1850	54.5 - 63.3

*Nominal tons are at AHRI/ISO 13256-1 GLHP conditions. Two-stage units may be operated in single-stage mode if desired, where smaller capacity is required. For example, a model 024 may be used as a 1-1/2 ton unit if “locked” into 1st stage operation only. If PSC fan is used, unit must be “locked” into either 1st or 2nd stage. An ECM fan is required for two-stage operation and for AHRI ratings. Size air handler for “Full Load” if operating in two-stage mode.

**When selecting an air handler based upon the above conditions, choose entering WB temperature of 67ºF. Use evaporator temperature, CFM and capacity requirements as listed above. The air handler capacity must be at least at the minimum capacity shown in the table in order for the AHRI rating condition to be valid. See Figure 1 for an example selection.

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Equipment Selection

Air Handler Selection Example

Figure 1 shows a typical performance table for a heat pump air handler. Suppose the evaporator temperature required is 50ºF, the capacity required is 35,000 Btuh and the airflow required is 1,200 CFM. Each evaporator temperature listed in the table shows three wet bulb temperatures. As recommended in the table notes above, select the 67ºF WB column. At 1,200 CFM, the model 003 capacity is 36 MBtuh, which is higher than the minimum capacity required of 35,000 Btuh. In this example, model 003 would be the appropriate match.

Figure 1: Selecting Air Handler

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Installation

NOTICE! Failure to remove shipping brackets from spring-mounted compressors will cause excessive noise, and could cause component failure due to added vibration.

The installation of water source heat pump units and all associated components, parts and accessories which make up the installation shall be in accordance with the regulations of ALL authorities having jurisdiction and MUST conform to all applicable codes. It is the responsibility of the installing contractor to determine and comply with ALL applicable codes and regulations.

Removing Existing Condensing Unit (Where Applicable)

1.Pump down condensing unit. Close the liquid line service valve of existing condensing unit and start compressor to pump refrigerant back into compressor section. Then, close suction service valve while compressor is still running to trap refrigerant in outdoor section. Immediately kill power to the condensing unit.

2.Disconnect power and low voltage and remove old condensing unit. Cut or unbraze line set from unit. Remove condensing unit.

3.If condensing unit is not operational or will not pump down, refrigerant should be recovered using appropriate equipment.

4.Replace line set, especially if upgrading system from R-22 to R-410A refrigerant. If line set cannot be replaced, it must be thoroughly flushed before installing new compressor section. R-410A compressors use POE

oil instead of mineral oil (R-22 systems). Mineral oil is not compatible with POE oil, and could cause system damage if not completely flushed from the line set.

Indoor Compressor Section Location

The HTS indoor compressor section is 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. 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 service access panels. Provide sufficient room to make water, electrical, and line set connections.

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 2 for an illustration of a typical installation. Refer to “Physical Dimensions” section for dimensional data. Conform to the following guidelines when selecting unit location:

1.Install the unit on a piece of rubber, neoprene or other mounting pad material for sound isolation. The pad should be at least 3/8” [10mm] to 1/2” [13mm] in

thickness. Extend the pad beyond all four edges of the unit.

2.Provide adequate clearance for maintenance and service. Do not block access panels with piping, conduit or other materials.

3.Provide access for servicing the compressor and coils without removing the unit.

4.Provide an unobstructed path to the unit within the closet or mechanical room. Space should be sufficient to allow removal of the unit, if necessary.

5.In limited side access installations, pre-removal of the control box side mounting screws will allow control box removal for future servicing (R22 units only).

6.Provide access to water valves and fittings and screwdriver access to the unit side panels and all electrical connections.

Air Handler and Coil Installation

This manual specifically addresses the compressor section of the system. Air handler and coil location and installation should be according to the instructions provided with the air handling/coil unit.

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Installation

Figure 2: HTS Installation

External Flow Controller Mounting

The Flow Controller can be mounted beside the unit as shown in Figure 4. Review the Flow Controller installation manual for more details.

Water Connections-Residential (Distributor) Models Residential models utilize swivel piping fittings for water connections that are rated for 450 psi (3101 kPa) operating pressure. The connections have a rubber gasket seal similar to a garden hose gasket, which when mated to the flush end of most 1” threaded male pipe fittings provides a leak-free seal without the need for thread sealing tape or joint compound. Insure that the rubber seal is in the swivel connector prior to attempting any connection (rubber seals are shipped attached to the swivel connector). DO NOT OVER TIGHTEN or leaks may occur.

The female locking ring is threaded onto the pipe threads which holds the male pipe end against the rubber gasket, and seals the joint. HAND TIGHTEN ONLY! DO NOT OVERTIGHTEN!

Figure 3: Water Connections (Indoor Compressor Section)

Swivel Nut

	Hand Tighten
	Only!
Stainless steel	Do Not
snap ring	Overtighten!
Gasket
	Brass Adaptor

GROUND-LOOP HEAT PUMP APPLICATIONS

CAUTION!

CAUTION! The following instructions represent industry accepted installation practices for closed loop earth coupled heat pump systems. Instructions are provided to assist the contractor in installing trouble free ground loops. These instructions are recommendations only. State/provincial and local codes MUST be followed and installation MUST conform to ALL applicable codes. It is the responsibility of the installing contractor to determine and comply with ALL applicable codes and regulations.

Pre-Installation

Prior to installation, locate and mark all existing underground utilities, piping, etc. Install loops for new construction before

sidewalks, patios, driveways, and other construction has begun. During construction, accurately mark all ground loop piping on the plot plan as an aid in avoiding potential future damage to the installation.

Piping Installation

The typical closed loop ground source system is shown in Figure 3. All earth loop piping materials should be limited to polyethylene fusion only for in-ground sections of the loop. Galvanized or steel fittings should not be used at any time due to their tendency to corrode. All plastic to metal threaded fittings should be avoided due to their potential to leak in earth coupled applications. A flanged fitting should

be substituted. P/T plugs should be used so that flow can be measured using the pressure drop of the unit heat exchanger.

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Ground-Loop Heat Pump Applications

Earth loop temperatures can range between 25 and 110°F [-4 to 43°C]. Flow rates between 2.25 and 3 gpm per ton [2.41 to 3.23 l/m per kW] of cooling capacity 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 [689 kPa] should be used when testing. Do not exceed the pipe pressure rating. Test entire system when all loops are assembled.

Flushing the Earth Loop

Once piping is completed between the unit, Flow Controller and the ground loop (Figure 4), the loop is ready for final purging and charging. A flush cart with at least a 1.5 hp [1.1 kW] pump is required to achieve enough fluid velocity in the loop piping system to purge air and dirt particles. An

antifreeze solution is used in most areas to prevent freezing. All air and debris must be removed from the earth loop piping before operation. Flush the loop with a high volume of water at a minimum velocity of 2 fps (0.6 m/s) in all piping. The steps below must be followed for proper flushing.

1.Fill loop with water from a garden hose through the flush cart before using the flush cart pump to insure an even fill.

2.Once full, the flushing process can begin. Do not allow the water level in the flush cart tank to drop below the pump inlet line to avoid air being pumped back out to the earth loop.

3.Try to maintain a fluid level in the tank above the return tee so that air cannot be continuously mixed back into the fluid. Surges of 50 psi (345 kPa) can be used to help purge air pockets by simply shutting off the return valve going into the flush cart reservoir. This “dead heads” the pump to 50 psi (345 kPa). To purge, dead head the pump until maximum pumping pressure is reached. Open the return valve and a pressure surge will be sent through the loop to help purge air pockets from the piping system.

4.Notice the drop in fluid level in the flush cart tank when the return valve is shut off. If air is adequately purged from the system, the level will drop only 1-2 inches (2.5 - 5 cm) in a 10” (25 cm) diameter PVC flush tank (about a half gallon [2.3 liters]), since liquids are incompressible. If the level drops more than this, flushing should continue since air is still being compressed in the loop fluid. Perform the “dead head” procedure a number of times.

Note: This fluid level drop is your only indication of air in the loop.

Antifreeze may be added before, during or after the flushing procedure. However, depending upon which time is chosen, antifreeze could be wasted when emptying the flush cart tank. See antifreeze section for more details.

Loop static pressure will fluctuate with the seasons.

Pressures will be higher in the winter months than during the cooling season. This fluctuation is normal and should be considered when charging the system initially. Run the unit in either heating or cooling for a number of minutes to condition the loop to a homogenous temperature. This is a good time for tool cleanup, piping insulation, etc. Then, perform final flush and pressurize the loop to a static pressure of 50-75 psi [345-517 kPa] (winter) or 35-40 psi [241-276 kPa] (summer). After pressurization, be sure to loosen the plug at the end

of the Grundfos loop pump motor(s) to allow trapped air to be discharged and to insure the motor housing has been flooded. This is not required for Taco circulators. Insure that the Flow Controller provides adequate flow through the unit by checking pressure drop across the heat exchanger and compare to the pressure drop tables at the back of the manual.

Antifreeze

In areas where minimum entering loop temperatures drop below 40°F [5°C] or where piping will be routed through areas subject to freezing, antifreeze is required. Alcohols and glycols are commonly used as antifreeze; however your local sales manager should be consulted for the antifreeze best suited to your area. Freeze protection should be maintained to 15°F [9°C] below the lowest expected entering loop temperature. For example, if 30°F [-1°C] is the minimum expected entering loop temperature, the leaving

loop temperature would be 25 to 22°F [-4 to -6°C] and freeze protection should be at 15°F [-10°C].

Calculation is as follows:

30°F - 15°F = 15°F [-1°C - 9°C = -10°C].

All alcohols should be premixed and pumped from a reservoir outside of the building when possible or introduced under the water level to prevent fumes. Calculate the total volume of fluid in the piping system. Then use the percentage by

volume shown in Table 2 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 - DXM2 Control

When antifreeze is selected, the LT1 jumper (JW3) should be clipped to select the low temperature (antifreeze 13°F [-10.6°C]) set point and avoid nuisance faults (see “Low Water Temperature Cutout Selection” in this manual). NOTE:

Low water temperature operation requires extended range equipment.

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Ground-Loop Heat Pump Applications

Table 2: Approximate Fluid Volume (U.S. gal. [L]) per 100’ of Pipe

Fluid Volume (gal [liters] per 100’ [30 meters] Pipe)

	Pipe	Size	Volume (gal) [liters]
		1”	4.1 [15.3]
	Copper	1.25”	6.4 [23.8]
		2.5”	9.2 [34.3]
	Rubber Hose	1”	3.9 [14.6]
		3/4” IPS SDR11	2.8 [10.4]
		1” IPS SDR11	4.5 [16.7]
		1.25” IPS SDR11	8.0 [29,8]
	Polyethylene	1.5” IPS SDR11	10.9	[40.7]
		2” IPS SDR11	18.0	[67.0]
		1.25” IPS SCH40	8.3 [30.9}
		1.5” IPS SCH40	10.9	[40.7]
		2” IPS SCH40	17.0	[63.4]
	Unit Heat	Typical	1.0	[3.8]
	Exchanger
	Flush Cart Tank	10” Dia x 3ft tall	10 [37.9]
		[254mm x 91.4cm tall]

Figure 4: Loop Connection (Indoor Compressor Section)

To Loop

Flow

Controller

Unit Power

Disconnect

Insulated

Hose Kit

AH & Thermostat Wiring

Air Pad or Extruded polystyrene insulation board

P/T Plugs

NOTICE! Cabinet opening around loop piping (outdoor compressor section) must be sealed to prevent entry of rodents that could potentially damage unit wiring by chewing on the insulation.

Table 3: Antifreeze Percentages by Volume

	Type	Minimum Temperature for Low Temperature Protection
		10°F [-12.2°C]	15°F [-9.4°C]	20°F [-6.7°C]	25°F [-3.9°C]
	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

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Ground-Water Heat Pump Applications -Compressor Section Only

Open Loop - Ground Water Systems

(“Indoor” Compressor Section Only)

The “outdoor” version of the compressor section may not be used with open loop systems due to potential freezing of water piping. Typical open loop piping is shown in Figure 9. Shut off valves should be included for ease of servicing. Boiler drains or other valves should be “tee’d” into the lines to allow acid flushing of the heat exchanger. Shut off valves should be positioned to allow flow through the coax via the

boiler drains without allowing flow into the piping system. P/T plugs should be used so that pressure drop and temperature can be measured. Piping materials should be limited to copper or PVC SCH80. Note: Due to the pressure and temperature extremes, PVC SCH40 is not recommended.

Water quantity should be plentiful and of good quality. Consult Table 4 for water quality guidelines. The unit can be ordered with either a copper or cupro-nickel water heat exchanger. Consult Table 4 for recommendations.

Copper is recommended for closed loop systems and open loop ground water systems that are not high in mineral content or corrosiveness. In conditions anticipating heavy scale formation or in brackish water, a cupro-nickel heat exchanger is recommended. In ground water situations where scaling could be heavy or where biological growth such as iron bacteria will be present, an open loop system is not recommended. Heat exchanger coils may over time lose heat exchange capabilities due to build up of mineral deposits. Heat exchangers must only be serviced by a qualified technician, as acid and special pumping equipment is required. Desuperheater coils can likewise become scaled and possibly plugged. In areas with extremely hard water, the owner should be informed that the heat exchanger

may require occasional acid flushing. In some cases, the desuperheater option should not be recommended due to hard water conditions and additional maintenance required.

Water Quality Standards

Table 4 should be consulted for water quality requirements. Scaling potential should be assessed using the pH/Calcium hardness method. If the pH <7.5 and the Calcium hardness is less than 100 ppm, scaling potential is low. If this method yields numbers out of range of those listed, the Ryznar Stability and Langelier Saturation indecies should be calculated. Use the appropriate scaling surface temperature for the application, 150°F [66°C] for direct use (well water/ open loop) and DHW (desuperheater); 90°F [32°F] for indirect use. A monitoring plan should be implemented in these probable scaling situations. Other water quality issues such as iron fouling, corrosion prevention and erosion and clogging should be referenced in Table 4.

Expansion Tank and Pump

Use a closed, bladder-type expansion tank to minimize mineral formation due to air exposure. The expansion tank should be sized to provide at least one minute continuous run time of the pump using its drawdown capacity rating to prevent pump short cycling. Discharge water from the unit is not contaminated in any manner and can be disposed of in various ways, depending on local building codes (e.g. recharge well, storm sewer, drain field, adjacent stream or pond, etc.). Most local codes forbid the use of sanitary sewer for disposal. Consult your local building and zoning department to assure compliance in your area.

The pump should be sized to handle the home’s domestic water load (typically 5-9 gpm [23-41 l/m]) plus the flow rate required for the heat pump. Pump sizing and expansion tank must be chosen as complimentary items. For example, an expansion tank that is too small can causing premature pump failure due to short cycling. Variable speed pumping applications should be considered for the inherent energy savings and smaller expansion tank requirements.

Motorized Modulating Water Control Valve

Note the placement of the water control valve in figure 9. Always maintain water pressure in the heat exchanger by placing the water control valve(s) on the discharge line to prevent mineral precipitation during the off-cycle. Pilot

operated slow closing valves are recommended to reduce water hammer. If water hammer persists, a mini-expansion tank can be mounted on the piping to help absorb the excess hammer shock. This valve regulates the flow using entering and leaving water delta-T of the system. Entering and leaving water temperature is read on the communicating thermostat or configuration/diagnostic service tool. Further details on valve operation are described later in this manual.

12	Heat Controller, Inc. Water-Source Heating and Cooling Systems

T h e Q u a l i t y L e a d e r i n C o n d i t i o n i n g A i r

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Ground-Water Heat Pump Applications

Water Coil Low Temperature Limit Setting

For all open loop systems the 30°F [-1.1°C] FP1 setting (factory setting-water) should be used to avoid freeze damage to the unit. See “Low Water Temperature Cutout Selection” in this manual for details on the low limit setting.

CAUTION!

CAUTION! Refrigerant pressure activated water regulating valves should never be used with HCI equipment.

To manually open the internal modulating motorized water valve in HTS024 - 048 push down on the handle to unlock it. Then rotate the handle to the open position as shown in Figure 9a. This fully opens the valve for flushing. Once

flushing is complete, return the valve handle to its normally closed position.

To manually open the internal modulating motorized water valve in HTS060, push down on the lock release button while turning the handle to the open position as shown in Figure 9a. This fully opens the valve for flushing. Once flushing is complete, press the lock release again and return the valve handle to its normally closed position.

	Figure 9: Water Well Connections			Figure 9a: Optional Modulating Motorized Valve Positions
				Sizes024 - 048	Sizes 060
		Flow		026-049	Sizes 06472
	Water			Closed	Closed
		Regulator	Pressure
	Control
	Valve		Tank
			Water Out	Water In
					/RFN 5HOHDVH
			Shut-Off	Open	Open
			Valve
			Optional
			Filter
		Boiler
	P/T Plugs	Drains

Optional Modulating Motorized Valve - For Open Loop Applications

A low Cv modulating motorized valve is used for this application to provide more precise control against the higher system pressure differential of open loop applications.

The Motorized Modulating Valve is regulated by the Communicating DXM2 board based on entering and leaving water temperature ( T). The DXM2 board gives a 0-10v signal to determine flow rate. The motorized modulating valve defaults to closed position if it loses signal but still has 24V power running to it. If the motorized modulating valve loses both signal from the DXM2 board AND 24V power, it will remain in the same position it was in when it lost 24V power. DO NOT USE open loop units in closed loop applications due to significant pressure drop through the open loop motorized modulating valve.

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13

HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS

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Water Quality Standards

Table 4: Water Quality Standards

	Water Quality	HX	Closed	Open Loop and Recirculating Well
	Parameter	Material	Recirculating

Scaling Potential - Primary Measurement

Above the given limits, scaling is likely to occur. Scaling indexes should be calculated using the limits below

	pH/Calcium Hardness	All	-	pH < 7.5 and Ca Hardness <100ppm
	Method

Index Limits for Probable Scaling Situations - (Operation outside these limits is not recommended)

Scaling indexes should be calculated at 66°C for direct use and HWG applications, and at 32°C for indirect HX use.

A monitoring plan should be implemented.

	Ryznar	All		-	6.0 - 7.5
	Stability Index				If >7.5 minimize steel pipe use.
	Langelier	All		-	-0.5 to +0.5
	Saturation Index				If <-0.5 minimize steel pipe use. Based upon 66°C HWG and
					Direct well, 29°C Indirect Well HX
	Iron Fouling
	Iron Fe 2+ (Ferrous)	All		-	<0.2 ppm (Ferrous)
	(Bacterial Iron potential)				If Fe2+ (ferrous)>0.2 ppm with pH 6 - 8, O2<5 ppm check for iron bacteria.
	Iron Fouling	All		-	<0.5 ppm of Oxygen
					Above this level deposition will occur .

Corrosion Prevention

pH

Hydrogen Sulfide (H2S)

Ammonia ion as hydroxide, chloride, nitrate and sulfate compounds

Maximum

Chloride Levels

		6 - 8.5
All		Monitor/treat as
		needed
		-
All
All	-
Copper		-
Cupronickel	-
304 SS	-
316 SS	-
Titanium	-

6 - 8.5

Minimize steel pipe below 7 and no open tanks with pH <8

<0.5 ppm

At H2S>0.2 ppm, avoid use of copper and copper nickel piping or HX's. Rotten egg smell appears at 0.5 ppm level.

Copper alloy (bronze or brass) cast components are OK to <0.5 ppm.

<0.5 ppm

Maximum Allowable at maximum water temperature.

10 C	24 C	38 C
<20ppm	NR	NR
<150 ppm	NR	NR
<400 ppm	<250 ppm	<150 ppm
<1000 ppm	<550 ppm	< 375 ppm
>1000 ppm	>550 ppm	>375 ppm

Erosion and Clogging

		<10 ppm of particles
		and a maximum
Particulate Size and	All	velocity of 1.8 m/s
Erosion		Filtered for maximum
		841 micron [0.84 mm,
		20 mesh] size.

<10 ppm (<1 ppm "sandfree” for reinjection) of particles and a maximum velocity of 1.8 m/s. Filtered for maximum 841 micron 0.84 mm,

20 mesh] size. Any particulate that is not removed can potentially clog components.

Rev.: 3/22/2012

The Water Quality Table provides water quality requirements for coaxial heat exchangers. When water properties are outside of those requirements, an external secondary heat exchanger must be used to isolate the heat pump heat exchanger from the unsuitable water. Failure to do so will void the warranty for the coaxial heat exchanger.

Notes:

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14	Heat Controller, Inc. Water-Source Heating and Cooling Systems