Heat Controller HEV024, HEV030, HEV036, HEV042, HEV048 Installation, Operation & Maintenance Manual
...
INSTALLATION, OPERATION
& MAINTENANCE MANUAL
Residential Packaged
Geothermal Heat Pump
HEV/H Series
2 to 5 Tons
Heat Controller, Inc. • 1900 Wellworth Ave. • Jackson, MI 49203 • (517)787-2100 • www.heatcontroller.com
Installation, Operation & Maintenance HEV/H SERIES Heat Controller, Inc.
Table of Contents
Model Nomenclature ............................................................................................3
Safety Instructions ................................................................................................4
Pre-Installation......................................................................................................5
Physical Data........................................................................................................6
Vertical Unit Dimensions....................................................................................7-8
Vertical Installation................................................................................................9
Water Connection Installation .............................................................................14
Ground-Loop Heat Pump Applications ..........................................................15-16
Ground-Water Heat Pump Applications ..............................................................17
Water Quality Standards ....................................................................................18
Hot Water Generator .....................................................................................19-21
Electrical Data ...............................................................................................22-26
Blower Performance Data .............................................................................27-28
Wiring Diagrams .................................................................................................29
DXM 2 Controls .............................................................................................30-33
Unit Start-Up and Operating Conditions ........................................................34-40
Preventive Maintenance .....................................................................................41
Troubleshooting .............................................................................................42-46
2
Heat Controller, Inc. HEV/H SERIES Installation, Operation & Maintenance
MOTOR, AND TWO STAGE SCROLL COMPRESSORS.
HEV
HEH
HeatController
H E H A0 3 6 D1 0 0 A L B
1 2 3 4 5 6 7
8
91011121314
HE = HEAT CONTROLLER RESIDENTIAL 410A
MODEL TYPE
H = HORIZONTAL
CONFIGURATION
V = VERTICAL
UNIT SIZE
024
030
036
042
048
060
REVISION LEVEL
A = Current Revision
VO LTAG E
CONTROLS
CABINET INSULATION
WATER CIRCUIT OPTIONS
A = Copper Water Coil w/E-Coated Air Coil
HEAT EXCHANGER OPTIONS
J = Cupro-Nickel Water Coil w/E-Coated Air Coil
L = LEFT RETURN w/ 1” Merv 8 Pleated Filter and Frame
RETURN AIR OPTIONS
R = RIGHT RETURN w/ 1” Merv 8 Pleated Filter and Frame
B = BACK DISCHARGE, HORIZONTAL ONLY
SUPPLY AIR OPTIONS
T = TOP DISCHARGE, VERTICAL ONLY
S = STRAIGHT DISCHARGE, HORIZONTAL ONLY
0 = NONE
1 = HWG w/ INTERNAL PUMP
0 = RESIDENTIAL
1 = 208-230/60/1
D = DXM 2
Unit Nomenclature
3
Installation, Operation & Maintenance HEV/H SERIES Heat Controller, Inc.
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.
ѥ WARNING! ѥ
WARNING! Verify refrigerant type before
proceeding. Units are shipped with R-22
refrigerant.
R-410A
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.
ѥ WARNING! ѥ
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.
ѥ CAUTION! ѥ
ѥ WARNING! ѥ
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.
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.
4
Heat Controller, Inc. HEV/H SERIES Installation, Operation & Maintenance
GENERAL INFORMATION
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 Heat Controller 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
Installation, Operation and Maintenance
are provided with each unit. Horizontal equipment is
instructions are provided with each unit. Vertical unit
designed for installation above false ceiling or in a ceiling
confi gurations are typically installed in a mechanical
plenum. Other unit configurations are typically installed
room. The installation site chosen should include
in a mechanical room. The installation site chosen
adequate ervice clearance around the unit. Before
should include adequate service clearance around the
unit start-up, read all manuals and become familiar
unit. Before unit start-up, read all manuals and become
with the unit and its operation. Thoroughly check the
familiar with the unit and its operation. Thoroughly check
system before operation.
the system before operation.
Prepare units for installation as follows:
1. Compare the electrical data on the unit nameplate
with ordering and shipping information to verify that
the correct unit has been shipped.
2. Keep the cabinet covered with the original packaging
until installation is complete and all plastering,
painting, etc. is finished.
3. Verify refrigerant tubing is free of kinks or dents and
that it does not touch other unit components.
4. Inspect all electrical connections. Connections must
be clean and tight at the terminals.
5. Remove any blower support packaging.
6. Loosen compressor bolts on units equipped with
compressor spring vibration isolation until the
compressor rides freely on the springs. Remove
shipping restraints.
7. REMOVE COMPRESSOR SUPPORT PLATE 1/4”
7.
8. Some airflow patterns are field convertible (horizontal
SHIPPING BOLTS (2 on each side) TO MAXIMIZE
units only). Locate the airflow conversion section of
VIBRATION AND SOUND ATTENUATION.
this IOM.
8. Some airflow patterns are field convertible (horizontal
9. Locate and verify any hangers, or other accessory
8.
units only). Locate the airflow conversion section of
kits located in the compressor section or blower
this IOM.
section.
9. Locate and verify any hangers, or other accessory
kits located in the compressor section or blower
section.
ѥ CAUTION! ѥ
CAUTION! DO NOT store or install units
in corrosive environments or in locations
subject to temperature or humidity extremes
CAUTION! DO NOT store or install units
(e.g., attics, garages, rooftops, etc.).
in corrosive environments or in locations
Corrosive conditions and high temperature
subject to temperature or humidity extremes
or humidity can significantly reduce
(e.g., attics, garages, rooftops, etc.).
performance, reliability, and service life.
Corrosive conditions and high temperature
Always move units in an upright position.
or humidity can significantly reduce
Tilting units on their sides may cause
performance, reliability, and service life.
equipment damage.
Always move units in an upright position.
ѥ CAUTION! ѥ
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
NOTICE! Failure to remove shipping brackets
failure due to added vibration.
from spring-mounted compressors will cause
excessive noise, and could cause component
failure due to added vibration.
ѥ CAUTION! ѥ
CAUTION! CUT HAZARD - Failure to follow
this caution may result in personal injury.
Sheet metal parts may have sharp edges
CAUTION! CUT HAZARD - Failure to follow
or burrs. Use care and wear appropriate
this caution may result in personal injury.
protective clothing, safety glasses and
Sheet metal parts may have sharp edges
gloves when handling parts and servicing
or burrs. Use care and wear appropriate
heat pumps.
protective clothing, safety glasses and
gloves when handling parts and servicing
heat pumps.
ѥ CAUTION! ѥ
5
Installation, Operation & Maintenance HEV/H SERIES Heat Controller, Inc.
Physical Data
Model 024 030 036 042 048 060
Compressor (1 Each) Copeland UltraTech Two-Stage Scroll
Factory Charge HFC-410a, oz [kg] 49 48 48 70 80 84
ECM Fan Motor & Blower
Fan Motor, hp [W] 1/2 [373] 1/2 [373] 1/2 [373] 3/4 [559] 3/4 [559] 1 [746]
Blower Wheel Size (Dia x W), in [mm]
Water Connection Size
Swivel - Residential Class 1” 1” 1” 1” 1” 1”
HWG Water Connection Size
Swivel - Residential Class 1” 1” 1” 1” 1” 1”
Vertical Upfl ow
Air Coil Dimensions (H x W), in [mm]
Standard Filter - 1” [25.4mm] Throwaway, qty (in) [mm]
Weight - Operating, lbs [kg] 216 [98.0] 224 [101.6] 245 [111.1] 260 [117.9] 315 [142.9] 330 [149.7]
Weight - Packaged, lbs [kg] 221 [100.2] 229 [103.9] 251 [113.8] 266 [120.6] 322 [146.0] 337 [152.9]
Horizontal
Air Coil Dimensions (H x W), in [mm]
Standard Filter - 1” [25mm] Pleated
MERV 8 Throwaway, in [mm]
Weight - Operating, lbs [kg] 200 [90.7] 208 [94.3] 229 [103.9] 244 [110.7] 299 [135.6] 314 [142.4]
Weight - Packaged, lbs [kg] 205 [93.0] 213 [96.6] 235 [106.6] 250 [113.4] 306 [138.8] 321 [145.6]
All units have grommet compressor mountings, TXV expansion devices, and 1/2” [12.7mm] & 3/4” [19.1mm] electrical knockouts.
9 x 7
[229 x 178]
20 x 17.25
[508 x 438]
20 x 20
[508 x 508}
16 x 22
[406 x 559]
18 x 24
[457 x 610]
9 x 7
[229 x 178]
20 x 17.25
[508 x 438]
20 x 20
[508 x 508}
16 x 22
[406 x 559]
18 x 24
[457 x 610]
9 x 8
[229 x 203]
24 x 21.75
[610 x 552]
24 x 24
[610 x 610]
20 x 25
[508 x 635]
14 x 20
[356 x 508]
9 x 8
[229 x 203]
24 x 21.75
[610 x 552]
24 x 24
[610 x 610]
20 x 25
[508 x 635]
14 x 20
[356 x 508]
10 x 10
[254 x 254]
28.75 x 24
[730 x 610]
28 x 28
[711 x 711]
20 x 35
[508 x 889]
20 x 38
[508 x 965]
11 x 10
[279 x 254]
28.75 x 24
[730 x 610]
28 x 28
[711 x 711]
20 x 35
[508 x 889]
20 x 38
[508 x 965]
6
Heat Controller, Inc. HEV/H SERIES Installation, Operation & Maintenance
HE - Vertical Upfl ow Dimensional Data
Vertical
Upfl ow
Model
024-030
036-042
048 -060
Vertical
Upfl ow
Model
024 - 030
036 - 042
048 - 060
Vertical
Model
024 - 060
Overall Cabinet
A
WidthBDepthCHeight
in
22.4
cm
56.9
in
22.4
cm
56.9
in
25.4
cm
64.5
12 3 4 5
Loop
incm3.8
incm3.8
incm4.0
10.2
Voltage
in
cm
D
In
9.6
9.6
1/2”
Low
11.7
E
Loop
Out
8.8
22.3
8.8
22.3
9.5
24.1
Electrical Knockouts
J
4.6
22.4
56.9
26.0
66.0
29.3
74.4
K
1/2”
Ext
Pump
6.1
15.5
40.5
102.9
46.5
118.1
50.5
128.3
Water Connections - Standard Units
Cond. HWG In HWG Out
FGH
19.5
49.5
22.1
56.1
22.1
56.1
13.4
34.0
15.2
38.6
15.2
38.6
L
3/4”
Power
Supply
7.6
19.3
15.7
39.9
18.5
47.0
18.5
47.0
Loop
Water
FPT
1” 1”
1” 1”
1” 1”
HWG
FPT
Notes:
1. While clear access to all removable panels is not required, installer should take care to comply with all building codes and allow
adequate clearance for future fi eld service.
2. Front & Side access is preferred for service access. However, all components may be serviced from the front access panel if side
access is not available.
3. Discharge fl ange is fi eld installed.
4. Condensate is 3/4” socket.
5. Source water and optional HWG connections are 1” swivel.
7
Installation, Operation & Maintenance HEV/H SERIES Heat Controller, Inc.
HE - Vertical Upfl ow Dimensional Data
Vertical
Upfl ow
Model
Duct Flange Installed (+/- 0.10 in, +/- 2.5mm)
M
Left
Return
024 - 030
036 - 042
048 - 060
Auxiliary Electric Heaters mounted externally.
O
in
cm
in
cm
in
cm
Front
Q
Top View-Right Return
R
P
Air Coil Side
S
7.4
18.8
7.4
18.8
7.4
18.8
N
Discharge Connection
O
N
Supply
Width
4.2
10.7
6.0
15.2
6.0
15.2
13.9
35.3
13.9
35.3
13.9
35.3
N
3
3
P
Supply
Depth
14.0
35.6
14.0
35.6
14.0
35.6
Q
Right
Return
6.7
17.0
7.4
18.8
8.4
21.3
B
P
Air Coil Side
Top View-Left Return
S
Return Connection
Standard Deluxe Filter Frame
(+/- 0.10 in, +/- 2.5mm)
S
R
Return
Depth
2.2
5.6
1.4
3.5
2.8
7.1
18.0
45.7
22.5
57.1
22.5
57.1
Standard Filter Frame
Air Coil
O
Front
A
M
R
CSP
Return
Height
18.0
45.7
22.0
55.9
22.0
55.9
2' [61cm]
Service
T
Field Installed
Discharge Flange
BSP
CAP
U
1.0
2.5
1.0
2.5
1.0
2.5
Isometric
View
Access Panels
ASP
Opptional
2' [61cm]
Service
Access
Left Rtn
(Right Rtn
Opposite
Side)
U
T
C
Residential
Filter Rack
Right Return Right View
- Air Coil Opening
Shown
U
Air Coil
Air Coil
T
C
1.6 [4.1 mm]
3
BackFront
3
Left Return Left View
- Air Coil Opening
CSPCSP
FrontBack
Power Supply
3/4" [19.1 mm] HV
Knockout
Low Voltage
1/2" [12.7 mm] LV
Knockout
Low Voltage
1/2" [12.7 mm] LV
Knockout
CSP
3
F
L
K
J
5
4
2
1
D
2
A
3
H
G
E
8
Heat Controller, Inc. HEV/H SERIES Installation, Operation & Maintenance
VERTICAL 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 7 and 8 for typical installation
illustrations. Refer to unit specifications catalog 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” [10mm] to 1/2” [13mm] in
thickness. Extend the pad beyond all four edges of the
unit.
2. Provide adequate clearance for filter replacement
and drain pan cleaning. Do not block filter access
with piping, conduit or other materials. Refer to unit
specifications for dimensional data.
3. Provide access for fan and fan motor maintenance
and for servicing the compressor and coils without
removing the unit.
4. Provide an unobstructed path to the unit within the
closet or mechanical room. Space should be sufficient
to allow removal of the unit, if necessary.
5. Provide access to water valves and fittings and
screwdriver access to the unit side panels, discharge
collar and all electrical connections.
Figure 7: Vertical Unit Mounting
Air Pad or Extruded
polystyrene insulation board
Figure 8: Typical Vertical Unit Installation
Using Ducted Return Air
Internally insulate supply
duct for first 4’ [1.2m] each
way to reduce noise
Use turning vanes in
supply transition
Flexible canvas duct
connector to reduce
noise and vibration
Rounded return
transition
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.
Internally insulate return
transition duct to reduce
noise
9
Rev 3/27/00
Installation, Operation & Maintenance HEV/H SERIES Heat Controller, Inc.
N
*3/4" FPT
Trap Depth
1.5" [38mm]
Min 1.5"
[38mm]
1/4" per foot
(21mm per m)
drain slope
3/4" PVC or
Copper by others
Vent
* Some units include a painted drain
connection. Using a threaded pipe or
similar device to clear any excess paint
accumulated inside this fitting may
ease final drain line installation.
VERTICAL I
VERTICAL INSTALLATION
Sound Attenuation for Vertical Units
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 9. Install a sound
baffle as illustrated to reduce line-of sight sound
transmitted through return air grilles.
Mount the unit on a rubber or neoprene isolation pad to
2.
minimize vibration transmission to the building structure.
Figure 9: Vertical Sound Attenuation
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Condensate Piping for Vertical Units -
Install condensate
trap at each unit with the top of the trap positioned below
the unit condensate drain connection as shown in Figure
4. Design the depth of the trap (water-seal) based upon the
amount of External Static Pressure (ESP) capability of the
blower (where 2 inches [51mm] of ESP capability requires 2
inches [51mm] of trap depth). As a general rule, 1-1/2 inch
[38mm] trap depth is the minimum.
Each unit must be installed with its own individual trap and
connection to the condensate line (main) or riser. Provide
a means to fl ush or blow out the condensate line. DO NOT
install units with a common trap and/or vent.
Always vent the condensate line when dirt or air can collect
in the line or a long horizontal drain line is required. Also vent
when large units are working against higher external static
pressure than other units connected to the same condensate
main since this may cause poor drainage for all units on
the line. WHEN A VENT IS INSTALLED IN THE DRAIN
LINE, IT MUST BE LOCATED AFTER THE TRAP IN THE
DIRECTION OF THE CONDENSATE FLOW.
Figure 4: Vertical Condensate Drain
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10
Heat Controller, Inc. HEV/H SERIES Installation, Operation & Maintenance
VERTICAL INSTALLATION
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 fi lter and access panels. Provide suffi cient room to make
water, electrical, and duct connection(s).
If the unit is located in a confi ned space, such as a closet,
provisions must be made for return air to freely enter the space
by means of a louvered door, etc. Any access panel screws
that would be diffi cult to remove after the unit is installed
should be removed prior to setting the unit. Refer to Figures 7a
and 7b for an illustration of a typical installation. Refer to unit
specifi cations catalog for dimensional data.
Conform to the following guidelines when selecting
unit location:
1.
Provide a hinged access door in concealed-spline or
plaster ceilings. Provide removable ceiling tiles in T-bar
or lay-in ceilings. Refer to horizontal unit dimensions for
specifi c series and model in unit specifi cations catalog.
Size the access opening to accommodate the service
technician during the removal or replacement of the
compressor and the removal or installation of the unit
itself.
2.
Provide access to hanger brackets, water valves and
fi ttings. Provide screwdriver clearance to access panels,
discharge collars and all electrical connections.
3. DO NOT obstruct the space beneath the unit with piping,
electrical cables and other items that prohibit future
removal of components or the unit itself.
4. Use a manual portable jack/lift to lift and support the
weight of the unit during installation and servicing.
The installation of 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.
Mounting Horizontal Units
Horizontal units have hanger kits pre-installed from the
factory as shown in Figure 5. Figures 7a and 7b shows a
typical horizontal unit installation.
Horizontal heat pumps are typically suspended above a
ceiling or within a soffi t using fi eld supplied, threaded rods
sized to support the weight of the unit.
Use four (4) fi eld supplied threaded rods and factory provided
vibration isolators to suspend the unit. Hang the unit clear
of the fl oor slab above and support the unit by the mounting
bracket assemblies only. DO NOT attach the unit fl ush with
the fl oor slab above.
Pitch the unit toward the drain as shown in Figure 6 to
improve the condensate drainage. On small units (less
than 2.5 Tons/8.8 kW) ensure that unit pitch does not cause
condensate leaks inside the cabinet.
NOTE: The top panel of a horizontal unit is a structural
component. The top panel of a horizontal unit must never
be removed from an installed unit unless the unit is properly
supported from the bottom. Otherwise, damage to the unit
cabinet may occur.
Figure 5: Hanger Bracket
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IDFWRU\VXSSOLHG
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Figure 6: Horizontal Unit Pitch
1/4” (6.4mm)
for drainage
Drain
Connection
11
Installation, Operation & Maintenance HEV/H SERIES Heat Controller, Inc.
HORIZONTAL INSTALLATION
Figure 7a: Typical Closed Loop Horizontal Unit Installation
3/8" [10mm] threaded rods
(by others)
Return Air
Power Wiring
Supply Air
Unit Power
Flexible Duct
Connector
Unit Power
Disconnect
(by others)
Unit Hanger
Air Coil -
Insulated supply duct with
at least one 90 deg elbow
to reduce air noise
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.
Figure 7b: Typical Ground Water Horizontal Unit Installation
Thermostat
Wiring
Flush
Ports
Water
Pressure Ports
Ball Valves
Water Out
Water In
Supply Air
Insulated supply duct with
at least one 90 deg elbow
to reduce air noise
Flexible Duct
Connector
3/8" [10mm] threaded rods
(by others)
Return Air
Power Wiring
Unit Power
Unit Power
Disconnect
(by others)
Unit Hanger
12
Thermostat
Wiring
Ball Valves
Water Out
Water In
Building
Loop
Heat Controller, Inc. HEV/H SERIES Installation, Operation & Maintenance
FIELD CONVERSION OF AIR DISCHARGE
Overview -
Horizontal units can be fi eld converted
between side (straight) and back (end) discharge using the
instructions below.
Note: It is not possible to fi eld convert return air between left
or right return models due to the necessity of refrigeration
copper piping changes.
Preparation - It is best to fi eld convert the unit on the ground
before hanging. If the unit is already hung it should be taken
down for the fi eld conversion.
Side to Back Discharge Conversion
1.
Place unit in well lit area. Remove the screws as shown
in Figure 8 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 ensure that the wheel is
not rubbing or obstructed.
7. Replace access panels.
Back to Side Discharge Conversion - If the discharge is
changed from back to side, use above instruction noting that
illustrations will be reversed.
Left vs. Right Return - It is not possible to fi eld convert
return air between left or right return models due to the necessity of refrigeration copper piping changes. However, the
conversion process of side to back or back to side discharge
for either right or left return confi guration is the same. In
some cases, it may be possible to rotate the entire unit 180
degrees if the return air connection needs to be on the opposite side. Note that rotating the unit will move the piping to
the other end of the unit.
Figure 8: Left Return Side to Back
Water
Connection End
Water
Connection End
Water
Connection End
Side Discharge
Back Discharge
Remove Screws
Move to Side
Replace Screws
Figure 9: Right Return Side to Back
Return Air
Return Air
Rotate
Return Air
Return Air
Drain
Discharge Air
Connection End
Water
13
Return Air
Drain
Discharge Air
Supply Duct
Side Discharge
Back Discharge
Water
Connection End
Installation, Operation & Maintenance HEV/H SERIES Heat Controller, Inc.
Gasket
Swivel Nut
Stainless steel
snap ring
Brass Adaptor
Hand Tighten
Only!
Do Not
Overtighten!
WATER CONNECTION INSTALLATION
External Flow Controller Mounting
The Flow Controller can be mounted beside the unit
as shown in Figure 12. Review the Flow Controller
installation manual for more details.
Water Connections-Residential HR Models
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 leakfree 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
HE
GROUND-LOOP HEAT PUMP APPLICATIONS
ѥ CAUTION! ѥ
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 12. 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.
which holds the male pipe end against the rubber
gasket, and seals the joint. HAND TIGHTEN ONLY! DO
NOT OVERTIGHTEN!
Figure 11: Water Connections
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
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 Loop
Once piping is completed between the unit, Flow
Controller and the ground loop (Figure 12), 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
14
Heat Controller, Inc. HEV/H SERIES Installation, Operation & Maintenance
GROUND-LOOP HEAT PUMP APPLICATIONS
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
1 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
CXM Control
When antifreeze is selected, the FP1 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.
Table 1: Approximate Fluid Volume (gal.)
per 100' of Pipe
Fluid Volume (gal [L]/100’ Pipe)
Pipe Size Volume (gal) [L]
1” 4.1 [15.5]
Copper
Rubber Hose 1” 3.9 [14.8]
Polyethylene
Unit Heat Exchanger Typical 1.0 [3.8]
Flush Cart Tank
1.25” 6.4 [24.2]
2.5” 9.2 [34.8]
3/4” IPS SDR11 2.8 [10.6]
1” IPS SDR11
1.25” IPS SDR11 8.0 [30.3]
1.5” IPS SDR11 10.9 [41.3]
2” IPS SDR11 18.0 [68.1]
1.25” IPS SCH40 8.3 [31.4]
1.5” IPS SCH40 10.9 [41.3]
2” IPS SCH40 17.0 [64.4]
10” Dia x 3ft
[254mm x 0.9m]
4.5 [17.0]
10 [37.9]
Table 2: Antifreeze Percentages by Volume
Table 3. Antifreeze Percentages by Volume
Type Minimum Temperature for Freeze Protection
10°F [-12.2
Methanol 25% 21% 16% 10%
100% USP food grade Propylene Glycol 38% 30% 22% 15%
°C] 15°F [-9.4°C] 20°F [-6.7°C] 25°F [-3.9°C]
15
Installation, Operation & Maintenance HEV/H SERIES Heat Controller, Inc.
Unit Power
Disconnect
Flow
Controller
Insulated
Hose Kit
P/T Plugs
Thermostat
Wiring
Air Pad or Extruded
polystyrene insulation
board
GROUND-LOOP HEAT PUMP APPLICATIONS
Figure 12: Typical Ground-Loop Application
GROUND-WATER HEAT PUMP APPLICATIONS
Open Loop - Ground Water Systems
Typical open loop piping is shown in Figure 14. 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 3 for water quality guidelines. The unit can
be ordered with either a copper or cupro-nickel water
heat exchanger. Consult Table 3 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
13.
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 3 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
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 3.
16
Heat Controller, Inc. HEV/H SERIES Installation, Operation & Maintenance
Air Pad or
Extruded
polystyrene
insulation board
Unit Power
Disconnect
Thermostat
Wiring
Pressure
Tank
Shut-Off
Valve
Boiler
Drains
Flow
Regulator
Water In
Water Out
Water
Control
Valve
Optional
Filter
P/T Plugs
GROUND-WATER HEAT PUMP APPLICATIONS
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.
Water Control Valve
Note the placement of the water control valve in
13.
Figure 14. 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. 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.
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 Tables 8. Since
Table 10C. Since
the pressure is constantly varying, two pressure gauges
may be needed. Adjust the valve until the desired flow of
1.5 to 2 gpm per ton [2.0 to 2.6 l/m per kW] is achieved.
A second method of flow control requires a flow control
device mounted on the outlet of the water control valve.
The device is typically a brass fitting with an orifice of
rubber or plastic material that is designed to allow a
specified flow rate. On occasion, flow control devices may
produce velocity noise that can be reduced by applying
some back pressure from the ball valve located on the
discharge line. Slightly closing the valve will spread the
pressure drop over both devices, lessening the velocity
noise. NOTE: When EWT is below 50°F [10°C], 2 gpm
per ton (2.6 l/m per kW) is required.
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.
Figure 13: Typical Open Loop/Well Application
17
Installation, Operation & Maintenance HEV/H SERIES Heat Controller, Inc.
WATER QUALITY STANDARDS
Table 3: Water Quality Standards
Water Quality
Parameter
Heat
Exchanger
Closed Loop
Recirculating
Open Loop and Recirculating Well
Material
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 -
Scaling indexes should be calculated at 150°F for direct use and Hot water generator applications,
and at 90°F 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
(Operation outside these limits is not recommended)
If <-0.5 minimize steel pipe use. Based upon 150 °F HWG and Direct
well, 85°F Indirect Well HX
Iron Fouling
Iron Fe2+(Ferrous)
(Bacterial Iron potential)
Iron Fouling All - <0.5 ppm of Oxygen
All - <0.2 ppm (Ferrous)
2+
If Fe
(ferrous)>0.2 ppm with pH 6 - 8, O2<5 ppm check for iron bacteria
Above this level deposition will occur.
Corrosion Prevention
pH All 6 - 8.5 6 - 8.5
Monitor/treat as
needed
Hydrogen Sulfide (H2S) All - <0.5 ppm
Ammonia ion All - <0.5 ppm
as hydroxide, chloride,
nitrate and sulfate
compounds
Maximum Maximum Allowable at maximum water temperature.
Chloride Levels
Copper - <20ppm NR NR
CuproNickel - <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
Minimize steel pipe below 7 and no open tanks with pH <8
At H2S>0.2 ppm, avoid use of copper and copper nickel piping or HX's.
Copper alloy (bronze or brass) cast components are OK to <0.5 ppm.
50°F (10°C) 75°F (24°C) 100°F (38°C)
Rotten egg smell appears at 0.5 ppm level.
Erosion and Clogging
<10 ppm of particles
Particulate Size and
Erosion
Notes:
• Closed Recirculating system is identified by a
• NR - Application not recommended.
• "-" No design Maximum.
All
and a maximum
velocity of 6 fps.
Filtered for maximum
800 micron size.
closed pressurized piping system. Recirculating open wells should observe the open recirculating design considerations.
<10 ppm (<1 ppm "sandfree" for reinjection) of particlesand a maximum
velocity of 6 fps. Filtered for maximum 800 micron size. Any particulate
that is not removed can potentially clog components.
Rev.: 04/04/04
18
Heat Controller, Inc. HEV/H SERIES Installation, Operation & Maintenance
Dual element electric water heaters are recommended.
If a gas, propane, oil or electric water heater with a
single element is used, a second preheat storage tank
is recommended to insure a usuable entering water
temperature for the HWG.
19
Installation, Operation & Maintenance HEV/H SERIES Heat Controller, Inc.
SCALD VALVE 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.
20
Heat Controller, Inc. HEV/H SERIES Installation, Operation & Maintenance
!
WARNING!
The HWG pump is fully wired from the factory. Use extreme
caution when working around the mircoprocessor control as it
contains line voltage connections that presents a shock hazard
that can cause severe injury or death!
!
21
Installation, Operation & Maintenance HEV/H SERIES Heat Controller, Inc.
ELECTRICAL - LINE VOLTAGE
ѥ WARNING! ѥ
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.
ѥ CAUTION! ѥ
CAUTION!
Use only copper conductors for field
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.
installed electrical wiring. Unit terminals are not
Electrical - Line Voltage
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.
Electrical Data -
HE
Volt
Model
HACR circuit break in U.S. only Wire length based on one way measurement with 2% voltage drop
All fuses Class RK-5 Wire sizes based on 140°F (60°C) copper conductor
Code
024 1 208-230/60/1 197/254 024 11.7 58.3 1 0.4 1.7 3.9 17.7 20.6 32.3 30
030 1 208-230/60/1 197/254 030 14.7 73.0 1 0.4 1.7 3.9 20.7 24.3 39.0 35
036 1 208-230/60/1 197/254 036 18.0 83.0 1 0.4 1.7 3.9 23.9 28.4 46.3 45
042 1 208-230/60/1 197/254 042 21.8 96.0 1 0.4 1.7 5.2 29.1 34.5 56.3 50
048 1 208-230/60/1 197/254 048 25.0 104.0 1 0.4 1.7 5.2 32.2 38.5 63.5 60
060 1 208-230/60/1 197/254 060 28.9 152.9 1 0.4 1.7 6.9 37.9 45.1 74.0 70
Rated Voltage
Voltage
Min/Max
Model
Compressor
RLA LRA Qty
HWG
Pump
FLA
Int
Loop
Pump
FLA
Fan
Motor
FLA
Total
Unit
FLA
Min
Circuit
Amps
Max
Fuse/
HACR
Max
Fuse/
HACR
22
Heat Controller, Inc. HEV/H SERIES Installation, Operation & Maintenance
Transformer
CXM
Control
Contactor -CC
BR
Low
Voltage
Connector
CB
L2
L1
Unit Power Supply
See electrical table for
breaker size
Grnd
Capacitor
ELECTRICAL - POWER WIRING
ELECTRICAL - POWER WIRING
Blower Speed Selection
Power Connection
Line voltage connection is made by connecting the
incoming line voltage wires to the “L” side of the contactor
as shown in Figures 18. Consult Table 4 for correct fuse
size.
PSC (Permanent Split Capacitor) blower fan speed can
be changed by moving the blue wire on the fan motor
terminal block to the desired speed as shown in Figure
19. Units are shipped on the medium speed tap. Consult
engineering design guide for specific unit airflow tables.
Typical unit design delivers rated airflow at nominal
208 Volt Operation
All residential 208-230 Volt units are factory wired for
230 Volt operation. The transformer may be switched
to the 208V tap as illustrated on the wiring diagram by
switching the red (208V) and the orange (230V) wires at
static (0.15 in. w.g. [37Pa]) on medium speed and rated
airflow at a higher static (0.4 to 0.5 in. w.g. [100 to 125
Pa]) 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. [25 Pa].
Figure 18: HR Single Phase Line Voltage
Figure 18: HE Single Phase Line Voltage
Field Wiring
Field Wiring
Special Note for ARI Testing: To achieve rated
airflow for ARI testing purposes on all PSC products,
AHRI
AHRI
it is necessary to change the fan speed to “HI” speed.
When the heat pump has experienced less than 100
operational hours and the coil has not had sufficient time
to be “seasoned”, it is necessary to clean the coil with a
mild surfactant such as Calgon to remove the oils left by
manufacturing processes and enable the condensate to
properly “sheet” off of the coil.
Figure 19: PSC Motor Speed Selection
Connect the blue wire to:
H for High speed fan
M for Medium speed fan
L for Low speed fan
Medium is factory setting
Fan Motor
HWG Wiring
The hot water generator pump power wiring is disabled
at the factory to prevent operating the HWG pump “dry.”
After all HWG piping is completed and air purged from
the water piping, the pump power wires should be applied
to terminals on the HWG power block PB2 as shown in
the unit wiring diagram. This connection can also serve
as a HWG disable when servicing the unit.
23
Installation, Operation & Maintenance HEV/H SERIES Heat Controller, Inc.
O
Rev.: 3/24/00
BR
Contactor - CC
Capacitator
Loop PB1 HWG PB2
CXM Control
Low Voltage
Connector
Transformer
CB
Circ Brkr
Grnd
HP
ELECTRICAL - L
ELECTRICAL - LOW VOLTAGE WIRING
Thermostat Connections
The thermostat should be wired directly to the CXM
DXM2
board. See “Electrical – Thermostat” for specific terminal
connections.
Figure 21: Low Voltage Field Wiring
DXM 2
Low Water Temperature Cutout Selection
The DXM2 control allows the fi eld selection of low water (or
water-antifreeze solution) temperature limit by clipping jumper
JW3, which changes the sensing temperature associated
with thermistor LT1. Note that the LT1 thermistor is located on
the refrigerant line between the coaxial heat exchanger and
expansion device (TXV). Therefore, LT1 is sensing refrigerant
temperature, not water temperature, which is a better
indication of how water fl ow rate/temperature is affecting the
refrigeration circuit.
The factory setting for LT1 is for systems using water (30°F
[-1.1°C] refrigerant temperature). In low water temperature
(extended range) applications with antifreeze (most ground
loops), jumper JW3 should be clipped as shown in Figure
19 to change the setting to 10°F [-12.2°C] refrigerant
temperature, a more suitable temperature when using
an antifreeze solution. All residential units include water/
refrigerant circuit insulation to prevent internal condensation,
which is required when operating with entering water
temperatures below 59°F [15°C].
Figure 22: LT1 Limit Setting
T6 T6
12
1
4
LP
LP
LT1
LT1
LT2
LT2
RV
RV
CO
CO
P7
24Vdc
EH1
EH2
P6
CCG
CC
Fault
Status
Off On
Off On
S3
Off On
1
y
S2
A0-1 A0-2
S1
2
y
P11
T1
AO2
Gnd
T2 T2 T3 T3 T4 T4
P10
JW3
CCH
Relay
T5
RV
Relay
Comp
Relay
P9
T5
DXM2 PCB
JW3-LT1 jumper should be clipped
for low temperature operation
24
Heat Controller, Inc. HEV/H SERIES Installation, Operation & Maintenance
ELECTRICAL - LOW VOLTAGE WIRING
Accessory Connections
A terminal paralleling the compressor contactor coil
has been provided on the CXM control. Terminal “A” is
DXM2
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 23 or the
specific unit wiring diagram for details.
Figure 23: Accessory Wiring
Ufsnjobm!Tusjq
D
Uzqjdbm
35WBD
B
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 23
shows typical wiring for a 24VAC external solenoid valve.
Figures 24 and 25 illustrate typical slow closing water
control 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:
Xbufs
Wbmwf
SBV
Figure 24: Taco Series 500 Valve Wiring
2
Y1
SBV
SBV
Y1
3
Taco Valve
AVM
C
1
Heater Switch
C
Thermostat
Figure 25: Taco ESP Valve Wiring
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.
Note: This valve can overheat the anticipator of an
electromechanical thermostat. Therefore, only relay or
triac based thermostats should be used.
25
Installation, Operation & Maintenance HEV/H SERIES Heat Controller, Inc.
ELECTRICAL - THERMOSTAT WIRING
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” (5mm) bit. Install supplied
anchors and secure plate to the wall. Thermostat wire must
be 18 AWG wire. Wire the appropriate thermostat as shown
in Figures 25a and 25b to the low voltage terminal strip
on the DXM2 control board. Practically any heat pump
thermostat will work with these units, provided it has the
correct number of heating and cooling stages.
CAUTION!
CAUTION! Refrigerant pressure activated water regulating
valves should never be used with ClimateMaster
equipment.
Figure 23a: Communicating Thermostat Connection to
DXM2 Control
Figure 24: Typical Thermostat 2 Heat/1 Cool
Connection to DXM2 Control
ATM21U01 Thermostat
Fan
Y
Y2/W
O
G
R
C
L
Compressor
Heating Stage 2
Reversing Valve
24Vac Hot
24Vac Common
Fault LED
(Using 2 Heat / 1 Cool thermostat is not
recommended if maximum efficiency is desired)
DXM2
Y1
W
O
G
R
C
AL1
ATC32U01 Thermostat
24Vac Hot
Comm +
Comm -
24Vac Common
Figure 23b: Conventional 3 Heat / 2 Cool Thermostat
Figure 24b: Conventional 3 Heat / 2 Cool Thermostat
Connection to DXM2 Control
Connection to DXM2 Control
R
A+
B-
C
Thermostat
DXM2
24V
A+
B-
Gnd
DXM2
Board
Fan
Y1
Y2
W
DH
O
G
R
C
Y1
Y2
W
H
O
G
R
C
L
AL1
Compressor
Compressor Stage 2
Auxiliary Heat
Dehumidification
Reversing Valve
24Vac Hot
24Vac Common
Fault LED
Notes:
1) ECM automatic dehumidification mode operates with dehumidification airflows
in the cooling mode when the dehumidification output from thermostat is active.
Normal heating and cooling airflows are not affected.
2) DXM2 board DIP switch S2-7 must be in the auto dehumidification mode for
automatic dehumidification
26
Heat Controller, Inc. HEV/H SERIES Installation, Operation & Maintenance
ECM BLOWER CONTROL
The ECM fan is controlled directly by the DXM2 control board
that converts thermostat inputs and CFM settings to signals
used by the ECM motor controller. To take full advantage of
the ECM motor features, a communicating or conventional
multi-stage thermostat should be used (2-stage heat/2-stage
cool or 3-stage heat/2-stage cool).
The DXM2 control maintains a selectable operating airfl ow
[CFM] for each heat pump operating mode. For each
operating mode there are maximum and minimum airfl ow
limits. See the ECM Blower Performance tables for the
maximum, minimum, and default operating airfl ows.
Airfl ow levels are selected using the confi guration menus
of a communicating thermostat or diagnostic tool. The
confi guration menus allow the installer to independently
select and adjust the operating airfl ow for each of the
operating modes. Air fl ow can be selected in 25 CFM
increments within the upper and lower limits shown on Table
6.The blower operating modes include:
• First Stage Cooling (Y1 & O)
• Second Stage Cooling (Y1, Y2, & O)
• First Stage Cooling with Dehumidifi cation
(Y1, O, & Dehumid)
• Second Stage Cooling with Dehumidifi cation
(Y1, Y2, O, & Dehumid)
• First Stage Heating (Y1)
• Second Stage Heating (Y1 & Y2)
• Third Stage (Auxiliary) Heating (Y1, Y2, & W
• Emergency Heating (W with no Y1 or Y2)
• Fan (G with no Y1, Y2, or W)
rpm at blower start up. This creates a much quieter blower
start cycle.
The ramp down feature allows the blower to slowly decrease
rpm to a full stop at the end of each blower cycle. This
creates a much quieter end to each blower cycle and adds
overall unit effi ciency.
The ramp down feature is eliminated during an ESD
(Emergency Shut Down) situation. When the DXM2 ESD
input is activated, the blower and all other control outputs are
immediately de-activated.
Dehumidifi cation Mode Settings: The dehumidifi cation mode
settings provide fi eld selection of humidity control. When
operating in the normal mode, the cooling airfl ow settings are
determined by the cooling settings. When dehumidifi cation
is enabled the appropriate dehumidifi cation airfl ow is used in
cooling to increase the moisture removal of the heat pump.
The dehumidifi cation mode can be enabled in two ways.
1. Constant Dehumidifi cation Mode: When the constant
dehumidifi cation mode is selected (S1–5 on the
DXM2 control), the ECM motor will operate using the
dehumidifi cation airfl ow slections while operating in
cooling to improve latent capacity. Heating airfl ow is
not affected.
2. Automatic (Humidistat-controlled) Dehumidifi cation
Mode: When the automatic dehumidifi cation mode
is selected (S2–7 on the DXM2 control) AND a
dehumidistat is connected to the H terminal, the
dehumidifi cation airfl ows will be used in cooling
only when the dehumidistat senses that additional
dehumidifi cation is required. Heating airfl ow is not
affected.
The ECM motor includes “soft start” and “ramp down”
features. The soft start feature is a gentle increase of motor
27
Installation, Operation & Maintenance HEV/H SERIES Heat Controller, Inc.
BLOWER PERFORMANCE DATA
Table 6: ECM Blower Performance Data Table
Airfl ow in CFM with wet coil and clean air fi lter
Max
Model
ESP
(in. wg)
024 0.75 1/2
030 0.5 1/2
036 0.6 1/2
042 0.6 3/4
048 0.75 3/4
060 0.75 1
Airfl ow is controlled within 5% up to the Max ESP shown with wet coil
Factory shipped on default CFM
Fan
Motor
(hp)
Range
Default 750 575 650 500 750 575 350 750
Maximum 850 650 800 600 850 850 850 850
Minimum 600 450 600 450 600 450 300 650
Default 950 650 800 575 950 650 450 950
Maximum 1100 750 1000 700 1100 1100 1100 1100
Minimum 750 525 750 525 750 525 375 750
Default 1125 750 975 650 1125 750 525 1125
Maximum 1250 950 1200 800 1250 1250 1250 1250
Minimum 900 600 900 600 900 600 450 900
Default 1300 925 1125 825 1300 925 600 1300
Maximum 1475 1100 1400 1000 1475 1475 1475 1475
Minimum 1050 750 1050 750 1050 750 525 1050
Default 1500 1125 1300 975 1500 1125 700 1500
Maximum 1700 1300 1600 1200 1700 1700 1700 1700
Minimum 1200 900 1200 900 1200 900 600 1350
Default 1875 1500 1625 1300 1875 1500 875 1875
Maximum 2100 1700 2000 1600 2100 2100 2100 2100
Minimum 1500 1200 1500 1200 1500 1200 750 1500
Cooling Mode Dehumid Mode Heating Mode
Stg 2 Stg 1 Stg 2 Stg 1 Stg 2 Stg 1
Residential
Units Only
Fan
Only
Mode
Aux/
Emerg
Mode
28
Heat Controller, Inc. HEV/H SERIES Installation, Operation & Maintenance
Wiring Diagram
HG
t-stat and 2Heat/1 Cool T-stat
Communicating T-stat, 3Heat/2 cool
29
Installation, Operation & Maintenance HEV/H SERIES Heat Controller, Inc.
DXM2 CONTROLS
DXM2 Control - For detailed control information, see DXM2
Application, Operation and Maintenance (AOM) 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 pressing the TEST
pushbutton, the DXM2 control enters a 20 minute test mode
period in which all time delays are sped up 15 times. Upon
entering test mode, the status LED display will change,
either fl ashing rapidly to indicate the control is in the test
mode, or displaying a numeric fl ash code representing the
current airfl ow if an ECM blower is connected and operating.
For diagnostic ease at conventional thermostats, the alarm
relay will also cycle during test mode. The alarm relay will
cycle on and off similar to the fault LED to indicate a code
representing the last fault, at the thermostat. Test mode can
be exited by pressing the TEST pushbutton for 3 seconds.
Retry Mode: If the control is attempting a retry of a fault,
the fault LED will slow fl ash (slow fl ash = one fl ash every 2
seconds) to indicate the control is in the process of retrying.
Field Confi guration Options - Note: In the following fi eld
confi guration options, jumper wires should be clipped ONLY
when power is removed from the DXM2 control.
Water coil low temperature limit setting: Jumper 3 (JW3LT1 Low Temp) provides fi eld selection of temperature limit
setting for LT1 of 30°F or 10°F [-1°F or -12°C] (refrigerant
temperature).
Not Clipped = 30°F [-1°C]. Clipped = 10°F [-12°C].
Alarm relay setting: Jumper 1 (JW1-AL2 Dry) provides fi eld
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 fi eld confi guration
options, DIP switches should only be changed when power
is removed from the DXM2 control.
DIP Package #1 (S1) - DIP Package #1 has 8 switches and
provides the following setup selections:
1.1 - Unit Performance Sentinel (UPS) disable: DIP Switch
1.1 provides fi eld selection to disable the UPS feature.
On = Enabled. Off = Disabled.
1.2 - Compressor relay staging operation: DIP 1.2 provides
selection of compressor relay staging operation. The
compressor relay can be selected to turn on with a stage 1
or stage 2 call from the thermostat. This is used with dual
stage units (2 compressors where 2 DXM2 controls are being
used) or with master/slave applications. In master/slave
applications, each compressor and fan will stage according
to its appropriate DIP 1.2 setting. If set to stage 2, the
compressor will have a 3 second on-delay before energizing
during a Stage 2 demand. Also, if set for stage 2, the alarm
relay will NOT cycle during test mode.
On = Stage 1. Off = Stage 2.
1.3 - Thermostat type (heat pump or heat/cool): DIP 1.3
provides selection of thermostat type. Heat pump or heat/
cool thermostats can be selected. When in heat/cool mode,
Y1 is the input call for cooling stage 1; Y2 is the input call
for cooling stage 2; W1 is the input call for heating stage 1;
and O/W2 is the input call for heating stage 2. In heat pump
mode, Y1 is the input call for compressor stage 1; Y2 is the
input call for compressor stage 2; W1 is the input call for
heating stage 3 or emergency heat; and O/W2 is the input
call for reversing valve (heating or cooling, depending upon
DIP 1.4).
On = Heat Pump. Off = Heat/Cool.
1.4 - Thermostat type (O/B): DIP 1.4 provides selection of
thermostat type for reversing valve activation. Heat pump
thermostats with “O” output (reversing valve energized for
cooling) or “B” output (reversing valve energized for heating)
can be selected with DIP 1.4.
On = HP stat with “O” output for cooling. Off = HP stat with
“B” output for heating.
1.5 - Dehumidifi cation mode: DIP 1.5 provides selection of
normal or dehumidifi cation fan mode. In dehumidifi cation
mode, the fan speed relay will remain off during cooling
stage 2. In normal mode, the fan speed relay will turn on
during cooling stage 2.
On = Normal fan mode. Off = Dehumidifi cation mode.
1.6 - DDC output at EH2: DIP 1.6 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.
1.7 - Boilerless operation: DIP 1.7 provides selection of
boilerless operation. In boilerless mode, the compressor is
only used for heating when LT1 is above the temperature
specifi ed by the setting of DIP 1.8. Below DIP 1.8 setting, the
compressor is not used and the control goes into emergency
heat mode, staging on EH1 and EH2 to provide heating.
On = normal. Off = Boilerless operation.
1.8 - Boilerless changeover temperature: DIP 1.8 provides
selection of boilerless changeover temperature setpoint.
Note that the LT1 thermistor is sensing refrigerant
temperature between the coaxial heat exchanger and the
expansion device (TXV). Therefore, the 50°F [10°C] setting is
not 50°F [10°C] water, but approximately 60°F [16°C] EWT.
On = 50°F [10°C]. Off = 40°F [16°C].
DIP Package #2 (S2) - DIP Package #2 has 8 switches and
provides the following setup selections:
2.1 - Accessory1 relay personality: DIP 2.1 provides
selection of ACC1 relay personality (relay operation/
characteristics). See Table 7a for description of functionality.
2.2 - Accessory1 relay personality: DIP 2.2 provides
selection of ACC 1 relay personality (relay operation/
characteristics). See Table 7a for description of functionality.
2.3 - Accessory1 relay personality: DIP 2.3 provides
selection of ACC 1 relay options. See Table 7a for
description of functionality.
30
Heat Controller, Inc. HEV/H SERIES Installation, Operation & Maintenance
(
DXM2 CONTROLS
2.4 - Accessory2 relay personality: DIP 2.4 provides
selection of ACC 2 relay personality (relay operation/
characteristics). See Table 7a for description of functionality.
2.5 - Accessory2 relay personality: DIP 2.5 provides
selection of ACC 2 relay personality (relay operation/
characteristics). See Table 7a for description of functionality.
2.6 - Accessory2 relay personality: DIP 2.6 provides
selection of ACC 2 relay options. See Table 7a for
description of functionality.
2.7 - Auto dehumidifi cation fan mode or high fan mode: DIP
2.7 provides selection of auto dehumidifi cation fan mode or
high fan mode. In auto dehumidifi cation mode, the fan speed
relay will remain off during cooling stage 2 IF the H input is
active. In high fan mode, the fan enable and fan speed relays
will turn on when the H input is active.
On = Auto dehumidifi cation mode. Off = High fan mode.
2.8 - Special factory selection: DIP 2.8 provides special
factory selection. Normal position is “On”. Do not change
selection unless instructed to do so by the factory.
Table 7a: Accessory DIP Switch Settings
DIP 2.1 DIP 2.2 DIP 2.3 ACC1 Relay Option
On On On Cycle with fan
Off On On Digital NSB
On Off On Water Valve - slow opening
On On Off OAD
Off Off Off Reheat Option - Humidistat
Off On Off Reheat Option - Dehumidistat
DIP 2.4 DIP 2.5 DIP 2.6 ACC2 Relay Option
On On On Cycle with compressor
Off On On Digital NSB
On Off On Water Valve - slow opening
On On Off OAD
SSV[OLY+07JVTIPUH[PVUZHYLPU]HSPK
DIP Package #3 (S3) - DIP Package #3 has 4 switches and
provides the following setup and operating selections:
3.1 – Communications confi guration: DIP 3.1 provides
selection of the DXM2 operation in a communicating system.
The DXM2 may operate as the Master of certain network
confi gurations. In most confi gurations the DXM2 will operate
as a master device.
On = Communicating Master device. Off = communicating
Slave device.
3.2 – HWG Test Mode: DIP 3.2 provides forced operation of
the HWG pump output, activating the HWG pump output for
up to fi ve minutes.
On = HWG test mode. Off = Normal HWG mode.
3.3 – HWG Temperature: DIP 3.3 provides the selection of
the HWG operating setpoint.
On = 150°F [66°C]. Off = 125°F [52°C].
CAUTION!
CAUTION! Do not restart units without inspection and
remedy of faulting condition. Equipment damage may occur.
3.4 – HWG Status: DIP 3.4 provides HWG operation control.
On = HWG mode enabled. Off = HWG mode disabled.
Table 7b: DXM2 LED and Alarm Relay Operations
Description
of Operation
DXM2 is
non-functional
Normal Mode On On Open
Normal Mode -
Communicating
Normal Mode with
UPS Warning
Normal Mode -
HWG pump active
Fault Retry - Slow Flash Open
Lockout - Fast Flash Closed
Active Over/Under
Voltage Condition
Night Setback Flashing Code 2 - -
ESD Flashing Code 3 - -
Invalid T-stat Inputs Flashing Code 4 - -
High Temperature
HWG Lockout
HWG Temperature
Sensor Fault
Test Mode Fast Flash - -
Test Mode -
ECM blower active
Test Mode -
No fault in memory
Test Mode - HP/HPWS
fault in memory
Test Mode -
LP fault in memory
Test Mode -
LT1 fault in memory
Test Mode -
LT2 fault in memory
Test Mode -
CO fault in memory
Test Mode - Over/Un-
der voltage in memory
Test Mode - UPS warn-
ing in memory
Test Mode - Swapped
thermistor in memory
Test Mode - Airfl ow
fault in memory
Test Mode - IFC Fault
in Memory
-Fast Flash = 2 fl ashes every 1 second
-Slow Flash = 1 fl ash every 2 seconds
-Very Slow Flash = 1 fl ash every 5 seconds
-Flash code 2 = 2 on pulses, 10 second pause, 2 on pulses, 10
second pause, etc.
-On pulse 1/3 second; off pulse 1/3 second
Status LED
(Red)
Off Off Open
On
On On
Slow Flash - Open
- Slow Flash
Flashing Code 5 - -
Flashing Code 6 - -
Flashing Code
per 100 CFM
-
-
-
-
-
-
-
-
-
-
-
Status LED
(Green)
Very Slow
Flash
- -
Flashing
Code 1
Flashing
Code 2
Flashing
Code 3
Flashing
Code 4
Flashing
Code 5
Flashing
Code 6
Flashing
Code 7
Flashing
Code 8
Flashing
Code 9
Flashing
Code 10
Flashing
Code 13
Alarm Relay
Open
Cycle (closed 5
sec., Open 25 sec.)
Open (Closed after
15 minutes)
Cycling Code 1
Cycling Code 2
Cycling Code 3
Cycling Code 4
Cycling Code 5
Cycling Code 6
Cycling Code 7
Cycling Code 8
Cycling Code 9
Cycling Code 10
Cycling Code 13
31
Installation, Operation & Maintenance HEV/H SERIES Heat Controller, Inc.
DXM2 CONTROLS
DXM2 Control Start-up Operation
Figure 25: Test Mode Button
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 fi rst
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.
Push test button to
enter Test Mode and
Table 7c: Unit Operation
speed-up timing and
delays for 20 minutes.
T-stat signal
Unit
ECM fan
G Fan only
G, Y1 Stage 1 heating
G, Y1, Y2 Stage 2 heating
G, Y1, Y2, W Stage 3 heating
1
1
1
G, W Emergency heat
G, Y1, O Stage 1 cooling
G, Y1, Y2, O Stage 2 cooling
1 Stage 1 = 1st stage compressor, 1st stage fan operation
Stage 2 = 2nd stage compressor, 2nd stage fan operation
Stage 3 = 2nd stage compressor, auxiliary electric heat, 3rd stage fan operation
2 Stage 1 = 1st stage compressor, 1st stage fan operation, reversing valve
Stage 2 = 2nd stage compressor, 2nd stage fan operation, reversing valve
2
2
Gnd
B-
A+ 24V
P5
P4
(240Vac)
Com
Fan Enable
Test
N.O.
(240Vac)
Fan Speed
P12
N.C.
N.O.
P8
12V
IN
OUT
Gnd
NC
32
Heat Controller, Inc. HEV/H SERIES Installation, Operation & Maintenance
DXM2 CONTROLS
Table 8: Nominal resistance at various temperatures
Temp
(°C)
Temp
(°F)
Resistance
(kOhm)
Temp
(°C)
Temp
(°F)
Resistance
(kOhm)
DXM2 Thermostat Details
Thermostat Compatibility – Most heat pump and heat/cool
thermostats can be used with the DXM2, as well as Heat
Controller communicating thermostats.
Anticipation Leakage Current – Maximum leakage current for “Y1” is 50 mA and for “W” is 20mA. Triacs can be
used if leakage current is less than above. Thermostats with
anticipators can be used if anticipation current is less than
that specifi ed above.
Thermostat Signals -
• “Y1, Y2, W1, O” and “G” have a 1 second recognition time
when being activated or being removed.
• “R” and “C” are from the transformer.
• “AL1” and “AL2” originate from the Alarm Relay.
• “A+” and “B-” are for a communicating thermostat.
• “A” is paralleled with the compressor output for use with
well water solenoid valves.
33
Installation, Operation & Maintenance HEV/H 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 – Voltage utilization shall comply with AHRI standard 110, voltage range A.
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 9a for operating limits.
Table 9a: Building Operating Limits
Operating Limits
Air Limits
Min. ambient air, DB 45ºF [7ºC] 39ºF [4ºC]
Rated ambient air, DB 80.6ºF [27ºC] 68ºF [20ºC]
Max. ambient air, DB 130ºF [43ºC] 85ºF [29ºC]
Min. entering air, DB/WB 65/45ºF [16/7ºC] 50ºF [4.4ºC]
Rated entering air, DB/WB 80.6/66.2ºF [27/19ºC] 68ºF [20ºC]
Max. entering air, DB/WB 100/75ºF [38/24ºC] 80ºF [27ºC]
Water Limits
Min. entering water 30ºF [-1ºC] 20ºF [-6.7ºC]
Normal entering water 50-110ºF [10-43ºC] 30-70ºF [-1 to 21ºC]
Max. entering water 120ºF [49ºC] 90ºF [32ºC]
Normal Water Flow
Cooling Heating
70/50ºF Reheat
Commissioning Conditions
Consult Table 9b for commissioning conditions. Starting conditions vary depending upon model and are based upon the
following notes:
Unit
1.5 to 3.0 gpm / ton
[1.6 to 3.2 l/m per kW]
Rev.: 16 Nov., 2011
Notes:
1. Conditions in Table 9b are not normal or continuous operating conditions. Minimum/maximum limits are start-up 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 complies with AHRI Standard 110, voltage range B.
Table 9b: Building Commissioning Limits
Commissioning Limits
Air Limits
Min. ambient air, DB 45ºF [7ºC] 39ºF [4ºC]
Rated ambient air, DB 80.6ºF [27ºC] 68ºF [20ºC]
Max. ambient air, DB 130ºF [43ºC] 85ºF [29ºC]
Min. entering air, DB/WB 60ºF [10ºC] 40ºF [4.5ºC]
Rated entering air, DB/WB 80.6/66.2ºF [27/19ºC] 68ºF [20ºC]
Max. entering air, DB/WB 110/83ºF [43/28ºC] 80ºF [27ºC]
Water Limits
Min. entering water 30ºF [-1ºC] 20ºF [-6.7ºC]
Normal entering water 50-110ºF [10-43ºC] 30-70ºF [-1 to 21ºC]
Max. entering water 120ºF [49ºC] 90ºF [32ºC]
Normal Water Flow
Cooling Heating
Unit
1.5 to 3.0 gpm / ton
[1.6 to 3.2 l/m per kW]
Rev.: 16 Nov., 2011
34
Heat Controller, Inc. HEV/H SERIES Installation, Operation & Maintenance
Starting/Commissioning Conditions
Table 9b: 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
Normal Water Flow
Cooling Heating
45°F [7°C]
80.6° [27°C]
110° [43°C]
50/45°F [10/7°C]
80.6/66.2°F [27/19°C]
110/83°F [43/28°C]
30°F [-1°C]
50-110°F [10-43°C]
120°F [49°C]
HE Series
39°F [4°C]
68° [20°C]
85° [29°C]
40°F [4.5°C]
68°F [20°C]
80°F [27°C]
20°F [-6.7°C]
30-70°F [-1 to 21°C]
90°F [32°C]
1.5 to 3.0 gpm/ton
[1.6 to 3.2 l/m per KWI
35
Installation, Operation & Maintenance HEV/H SERIES Heat Controller, Inc.
UNIT START-UP AND OPERATING CONDITIONS
Unit and System Checkout
BEFORE POWERING SYSTEM, please check the following:
UNIT CHECKOUT
Shutoff valves: Insure that all isolation valves are open.
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. Residential 208-230V units
are factory wired for 230V operation unless specifi ed
otherwise.
Loop/water piping is complete and purged of air. Water/
piping is clean.
Antifreeze has been added if necessary.
Entering water and air: Insure that entering water and air
temperatures are within operating limits of Tables 9a and
9b.
Low water temperature cutout: Verify that low water
temperature cut-out on the DXM2 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.
DO NOT oil motors upon start-up. Fan motors are preoiled at the factory. Check unit fan speed selection and
compare to design requirements.
Condensate line: Verify that condensate trap is installed
and pitched.
HWG pump is disconnected unless piping is completed
and air has been purged from the system.
Water fl ow balancing: Record inlet and outlet water
temperatures for each heat pump upon startup. This
check can eliminate nuisance trip outs and high velocity
water fl ow that could erode heat exchangers.
Unit air coil and fi lters: Insure that fi lter is clean and
accessible. Clean air coil of all manufacturing oils.
Unit controls: Verify that DXM2 fi eld selection options are
properly set. Low voltage wiring is complete.
Blower CFM and Water ∆T is set on communicating
thermostats or diagnostic tool.
Service/access panels are in place.
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 fi ttings (see Table 3).
System fl ushing: Verify that all air is purged from the
system. Air in the system can cause poor operation or
system corrosion. Water used in the system must be
potable quality initially and clean of dirt, piping slag,
and strong chemical cleaning agents. Some antifreeze
solutions may require distilled water.
Internal Flow Controller: Verify that it is purged of air and
in operating condition.
System controls: Verify that system controls function and
36
operate in the proper sequence.
Low water temperature cutout: Verify that low water
temperature cut-out controls are set properly
(LT1 - JW3).
Miscellaneous: Note any questionable aspects of
the installation.
CAUTION!
CAUTION! Verify that ALL water valves are open and
allow water fl ow prior to engaging the compressor.
Freezing of the coax or water lines can permanently
damage the heat pump.
CAUTION!
CAUTION! To avoid equipment damage, DO NOT
leave system fi lled 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.
Unit Start-up Procedure
1. Turn the thermostat fan position to “ON.” Blower
should start.
2. Balance air fl ow at registers.
3. Adjust all valves to their full open position. Turn on the
line power to all heat pump units.
4. Room temperature should be within the minimummaximum ranges of Table 9b. During start-up checks,
loop water temperature entering the heat pump should
be between 30°F [-1°C] and 95°F [35°C].
5. It is recommended that water-to-air units be fi rst started
in the cooling mode, when possible. This will allow liquid
refrigerant to fl ow through the fi
the TXV, allowing the fi lter-drier to catch any debris that
might be in the system before it reaches the TXV.
6.
Two factors determine the operating limits of geothermal
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.
Note: Units have a fi ve minute time delay in the
control circuit that can be bypassed on the DXM2
control board as shown below in Figure 25. See
controls description for details.
c. Verify that the compressor is on and that the water
fl ow rate is correct by measuring pressure drop
through the heat exchanger using the pressure ports
and comparing to Table 10.
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 fi lled
lter-drier before entering
Heat Controller, Inc. HEV/H SERIES Installation, Operation & Maintenance
UNIT START-UP PROCEDURE
Note: Units have a five minute time delay in the
control circuit that can be eliminated on the CXM
control board as shown below in Figure 30. 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 9. 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 Tables 10 through
12. Verify correct water flow by comparing unit
pressure drop across the heat exchanger versus
the data in Table 8. Heat of rejection (HR) can be
calculated and compared to catalog 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 [8°C and 14°C].
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 9. 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 Tables 10 through
12. Verify correct water flow by comparing unit
correct water fl ow 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
10C. Heat of rejection (HR) can be
Table 10C. Heat of extraction (HE) can
10C.
10C.
Table 13. Verify
compressor is operating. Air temperature rise should
be between 20°F and 30°F [11°C and 17°C].
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 ALL
WARRANTY REGISTRATION PAPERS TO HEAT
CONTROLLER.
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.
ѥ WARNING! ѥ
WARNING! When the disconnect switch is
closed, high voltage is present in some areas
of the electrical panel. Exercise caution when
working with energized equipment.
ѥ CAUTION! ѥ
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.
Figure 30: Test Mode Pins
Short test pins
together to enter Test
Mode and speed-up
timing and delays for
20 minutes.
37
Installation, Operation & Maintenance HEV/H SERIES Heat Controller, Inc.
UNIT OPERATING CONDITIONS
Table 10: HE Coax Water Pressure Drop
Model GPM
024
030
036
042
048
060
3.0
4.5
6.0
3.8
5.6
7.5
4.5
6.8
9.0
5.3
7.9
10.5
6.0
9.0
12.0
7.5
11.3
15.0
30°F 50°F 70°F 90°F
12.8
16.2
Pressure Drop (psi)
3.7
6.1
1.5
3.1
4.7
2.6
4.1
7.6
2.5
4.9
7.3
2.4
4.7
7.4
5.4
9.5
2.4
4.3
10.0
1.1
2.3
3.5
1.2
2.5
5.7
1.7
3.7
5.8
1.7
3.5
5.6
3.8
7.2
12.8
Table 12: Antifreeze Correction
Antifreeze Type
Water
Propylene Glycol
Methanol
Ethanol
Ethylene Glycol
Antifreeze
%
Total Cap Sens Cap Power Htg Cap Power
0 1.000 1.000 1.000 1.000 1.000 1.000
5 0.995 0.995 1.003 0.989 0.997 1.070
15 0.986 0.986 1.009 0.968 0.990 1.210
25 0.978 0.978 1.014 0.947 0.983 1.360
5 0.997 0.997 1.002 0.989 0.997 1.070
15 0.990 0.990 1.007 0.968 0.990 1.160
25 0.982 0.982 1.012 0.949 0.984 1.220
5 0.998 0.998 1.002 0.981 0.994 1.140
15 0.994 0.994 1.005 0.944 0.983 1.300
25 0.986 0.986 1.009 0.917 0.974 1.360
5 0.998 0.998 1.002 0.993 0.998 1.040
15 0.994 0.994 1.004 0.980 0.994 1.120
25 0.988 0.988 1.008 0.966 0.990 1.200
Table 11: Water Temperature Change Through Heat
Exchanger
1.9
3.4
8.6
1.0
2.0
3.0
0.8
2.0
4.8
1.5
3.1
5.1
1.3
3.0
4.9
3.3
6.3
11.1
EWT 90°F EWT 30°F
1.8
3.2
8.0
0.9
1.9
2.8
0.8
1.9
4.3
1.4
2.9
4.8
1.2
2.8
4.7
3.3
6.0
10.1
Cooling Heating
WPD
Corr. Fct.
EWT 30°F
9 - 12
(5 - 6.7)
20 - 26
(11.1 - 14.4)
4 - 8
(2.2 - 4.4)
10 - 17
(5.6 - 9.4)
38
Heat Controller, Inc. HEV/H SERIES Installation, Operation & Maintenance
UNIT OPERATING CONDITIONS
Table 13: HE Series Typical Unit Operating Pressures and Temperatures
024 Full Load Cooling - without HWG active Full Load Heating - without HWG active
Entering
Water
Temp °F
*Based on 15% Methanol antifreeze solution
Entering
Water
Temp °F
30*
110
*Based on 15% Methanol antifreeze solution
30*
50
70
90
110
Water
Flow
GPM/ton
2.25
2.25
2.25
2.25
2.25
1.5
1.5
1.5
1.5
1.5
Suction
Pressure
3
127-137
125-135
3
124-134
132-142
131-141
3
130-140
140-150
139-149
3
138-148
144-154
143-153
3
143-153
PSIG
Discharge
Pressure
PSIG
244-264
205-225
166-186
327-347
301-321
276-296
457-477
433-453
409-429
530-550
510-530
490-510
Superheat Subcooling
8-12
8-12
10-15
8-12
8-12
8-12
6-11
6-11
6-11
4-10
4-10
4-10
9-14
7-12
5-10
11-16
9-14
7-12
13-18
11-16
9-14
13-18
13-18
11-16
Water
Temp Drop
°F
20.6-22.6
14.5-16.5
8.41-10.41
19.9-21.9
14.0-16.0
8.0-10.0
19.9-21.9
13.2-15.2
7.5-9.5
18.9-20.9
13.0-15.0
7.11-9.11
Air Temp
Drop °F
DB
19-25
19-25
19-25
18-24
18-24
18-24
17-23
17-23
17-23
16-22
16-22
16-22
Suction
Pressure
PSIG
67-77
72-82
77-87
98-108
104-114
111-121
129-139
137-147
145-155
162-172
170-180
178-188
Discharge
Pressure
PSIG
297-317
303-323
309-329
340-360
343-363
346-366
373-393
390-410
401-421
406-426
415-435
423-443
Superheat Subcooling
1-6
3-8
3-8
6-11
6-11
8-12
10-15
11-16
11-16
14-19
14-19
14-19
2-7
5-10
5-10
5-10
5-10
5-10
5-10
5-10
5-10
3-8
3-8
3-8
Temp Drop
8.0-10.0
5.9-7.9
3.8-5.8
11.1-13.1
8.1-10.1
5.2-7.2
14.4-16.4
10.5-12.5
6.5-8.5
17.5-19.5
12.7-14.7
7.9-9.9
030 Full Load Cooling - without HWG active Full Load Heating - without HWG active
Water
Flow
GPM/ton
2.25
50
70
90
2.25
2.25
2.25
2.25
1.5
1.5
1.5
1.5
1.5
Suction
Pressure
3
122-132
121-131
3
121-131
122-132
121-131
3
121-131
133-143
133-143
3
132-142
137-147
136-146
3
135-145
PSIG
Discharge
Pressure
PSIG
240-260
213-233
186-206
316-336
298-318
280-300
438-458
420-440
401-421
507-527
490-510
473-493
Superheat Subcooling
10-15
11-16
11-16
9-14
9-14
9-14
8-13
8-13
8-13
6-11
7-12
7-12
11-16
9-14
7-12
12-17
11-16
9-14
14-19
13-18
11-16
16-21
14-19
13-18
Water
Temp Rise
°F
19.5-21.5
15.0-17.0
10.3-12.3
18.8-20.8
14.3-16.3
9.8-11.8
17.8-19.8
13.5-15.5
9.2-11.2
17.2-19.2
13.0-15.0
8.8-10.8
Air Temp
Drop °F
DB
18-23
19-24
19-24
17-22
17-22
17-22
15-20
15-20
15-20
15-20
15-20
15-20
Suction
Pressure
PSIG
65-75
67-77
72-82
95-105
100-110
105-115
124-134
130-140
137-147
156-166
163-173
170-180
Discharge
Pressure
PSIG
311-331
315-335
319-339
353-373
358-378
362-382
390-410
398-418
405-425
430-450
459-479
448-468
Superheat Subcooling
9-14
9-14
9-14
11-16
11-16
12-17
13-18
14-19
15-20
16-21
17-22
18-23
9-14
9-14
9-14
10-15
10-15
10-15
10-15
9-14
9-14
8-13
8-13
8-13
Temp Drop
8.0-10.0
10.5-12.5
8.2-10.2
13.5-15.5
10.5-12.5
16.5-18.5
12.8-14.8
9.0-11.0
Water
°F
Water
°F
6.2-8.2
4.3-6.3
5.8-7.8
7.5-9.5
Air Temp
Rise °F
DB
18-23
20-25
21-27
24-27
26-31
27-32
30-35
33-40
33-36
36-41
37-41
38-43
Air Temp
Rise °F
DB
19-24
20-25
21-26
26-31
26-31
27-32
33-38
33-38
34-39
37-42
39-44
40-45
036 Full Load Cooling - without HWG active Full Load Heating - without HWG active
Entering
Water
Temp °F
30*
50
70
90
110
Water
Flow
GPM/ton
1.5
2.25
3
1.5
2.25
3
1.5
2.25
3
1.5
2.25
3
1.5
2.25
3
Suction
Pressure
PSIG
123-133
122-132
121-131
128-138
124-134
119-129
135-145
134-144
132-142
139-149
138-148
137-147
Discharge
Pressure
PSIG
244-264
240-260
235-255
328-348
300-320
273-293
453-473
428-448
402-422
525-545
503-523
480-500
Superheat Subcooling
10-15
10-15
11-16
8-13
9-14
9-14
7-12
7-12
8-13
6-11
6-11
6-11
*Based on 15% Methanol antifreeze solution
12-17
9-14
7-12
12-17
10-15
9-14
13-18
11-16
9-14
14-19
12-17
10-15
Water
Temp Drop
°F
20.9-22.9
14.3-16.3
7.8-9.8
20.2-22.2
13.8-15.8
7.5-9.5
19.2-21.2
13.1-15.1
7.1-9.1
18.5-20.5
12.7-14.7
6.9-8.9
Air Temp
Drop °F
DB
17-22
17-22
17-22
16-21
16-21
16-21
16-21
15-20
14-19
13-18
13-18
14-19
39
Suction
Pressure
PSIG
60-70
65-75
70-80
88-98
96-106
105-115
116-126
128-138
139-149
148-158
160-170
173-183
Discharge
Pressure
PSIG
315-335
321-341
327-347
353-373
361-381
370-390
390-410
400-420
411-431
424-444
439-459
453-473
Superheat Subcooling
4-9
5-10
6-11
6-11
8-13
9-14
9-14
11-16
13-18
12-17
14-19
16-21
11-16
11-16
11-16
12-17
12-17
12-17
12-17
10-15
10-15
9-14
9-14
8-13
Water
Temp Drop
°F
10.0-12.0
6.7-8.7
3.4-5.4
13.2-15.2
9.0-11.0
4.8-6.8
17.0-19.0
11.6-13.6
6.1-8.1
20.9-22.9
14.2-16.2
7.4-9.4
Air Temp
Rise °F
DB
18-23
19-24
20-25
24-29
25-30
26-31
29-34
31-36
32-37
35-40
37-42
39-44
Installation, Operation & Maintenance HEV/H SERIES Heat Controller, Inc.
UNIT OPERATING CONDITIONS
Table 13: HE Series Typical Unit Operating Pressures and Temperatures: Continued
042 Full Load Cooling - without HWG active Full Load Heating - without HWG active
Entering
Water
Temp °F
110
*Based on 15% Methanol antifreeze solution
Entering
Water
Temp °F
30*
110
*Based on 15% Methanol antifreeze solution
30*
50
70
90
Water
Flow
GPM/ton
2.25
2.25
2.25
2.25
2.25
1.5
1.5
1.5
1.5
1.5
Suction
Pressure
3
121-131
120-130
3
120-130
127-137
125-135
3
125-135
133-143
132-142
3
132-142
137-147
136-146
3
136-146
PSIG
Discharge
Pressure
PSIG
230-250
200-240
164-184
305-325
290-310
263-283
426-446
406-426
390-410
494-514
477-497
460-480
Superheat Subcooling
10-15
11-16
11-16
8-13
9-13
10-15
7-12
7-12
7-12
5-10
6-11
6-11
10-15
8-13
6-11
10-15
9-14
7-12
11-16
9-14
8-13
11-16
10-15
8-13
Water
Temp Rise
°F
20.5-22.5
15.2-17.2
9.8-11.8
19.8-21.8
14.7-16.7
9.5-11.5
19-21
14-16
9-11
18-20
14-16
9-11
Air Temp
Drop °F
DB
22-27
22-27
22-27
20-25
21-26
21-26
19-24
19-24
19-24
18-23
18-23
18-23
Suction
Pressure
PSIG
64-74
67-77
71-81
95-105
100-110
104-114
124-134
131-141
138-148
157-167
164-174
172-182
Discharge
Pressure
PSIG
314-334
317-337
321-341
351-371
356-376
361-381
386-406
390-410
400-420
423-443
432-452
441-461
Superheat Subcooling
6-11
6-11
7-12
8-13
9-14
10-15
11-16
12-17
13-18
13-18
15-20
16-21
9-14
9-14
9-14
9-14
9-14
9-14
8-13
8-13
7-12
5-10
5-10
5-10
Temp Drop
10.7-12.7
13.8-15.8
10.4-12.4
16.8-18.8
12.7-14.7
048 Full Load Cooling - without HWG active Full Load Heating - without HWG active
Water
Flow
GPM/ton
2.25
50
2.25
70
2.25
90
2.25
2.25
1.5
1.5
1.5
1.5
1.5
Suction
Pressure
3
124-134
123-133
3
121-131
129-139
128-138
3
127-137
135-145
134-144
3
132-142
138-148
138-148
3
137-147
PSIG
Discharge
Pressure
PSIG
250-270
212-232
173-193
334-354
309-329
284-304
470-490
446-466
422-442
548-568
526-546
505-525
Superheat Subcooling
11-16
12-17
13-18
9-14
10-15
10-15
7-12
7-12
8-13
6-11
6-11
6-11
13-18
10-15
7-12
16-21
13-18
10-15
20-25
17-22
15-20
22-27
19-24
17-22
Water
Temp Drop
°F
20.1-22.1
14.8-16.8
9.5-11.5
19.6-21.6
14.4-16.4
9.3-11.3
18.9-20.9
13.8-15.8
8.8-10.8
18.6-20.6
13.6-15.6
8.6-10.6
Air Temp
Drop °F
DB
19-24
19-24
19-24
18-23
18-23
18-23
16-21
16-21
16-21
15-20
15-20
15-20
Suction
Pressure
PSIG
61-71
64-74
68-78
88-98
94-104
100-110
117-127
125-135
133-143
150-160
158-168
166-176
Discharge
Pressure
PSIG
290-310
293-313
296-316
319-339
324-344
330-350
349-369
357-377
365-385
384-404
391-411
399-419
Superheat Subcooling
9-14
9-14
10-15
11-16
11-16
12-17
13-18
14-19
15-20
15-20
16-21
17-22
5-10
5-10
5-10
6-11
6-11
6-11
5-10
5-10
4-11
3-8
2-7
2-7
Temp Drop
10.3-12.3
13.4-15.4
10.2-12.2
16.6-18.6
12.6-14.6
Water
°F
8.0-10.0
6.0-8.0
4.0-6.0
8.1-10.1
5.4-7.4
7.0-9.0
8.5-10.5
Water
°F
7.7-9.7
5.7-7.7
3.7-5.7
7.8-9.8
5.3-7.3
6.9-8.9
8.5-10.5
Air Temp
Rise °F
DB
20-25
20-25
21-26
26-31
27-32
27-32
32-37
33-37
34-39
38-43
40-45
41-46
Air Temp
Rise °F
DB
18-23
18-23
18-23
24-29
25-30
25-30
29-34
30-35
31-36
35-40
36-41
37-42
060 Full Load Cooling - without HWG active Full Load Heating - without HWG active
Entering
Water
Temp °F
110
30*
50
70
90
Water
Flow
GPM/ton
1.5
2.25
3
1.5
2.25
3
1.5
2.25
3
1.5
2.25
3
1.5
2.25
3
Suction
Pressure
PSIG
120-130
120-130
118-128
124-134
124-134
123-133
130-140
129-139
129-139
133-143
132-142
132-142
Discharge
Pressure
PSIG
225-245
222-242
220-240
300-320
278-298
256-276
420-440
400-420
390-410
495-515
475-495
454-474
Superheat Subcooling
9-14
9-14
9-14
8-13
8-13
8-13
7-12
7-12
7-12
6-11
6-11
6-11
*Based on 15% Methanol antifreeze solution
13-18
10-15
9-14
14-19
11-16
9-14
16-21
12-17
9-14
16-21
13-18
9-14
Water
Temp Drop
°F
21.8-23.8
14.7-16.7
8.7-10.7
19.9-21.9
14.1-16.1
8.3-10.3
19.0-21.0
13.4-15.4
7.9-9.9
18.5-20.5
13.1-15.1
7.6-9.6
Air Temp
Drop °F
DB
20-25
20-25
20-25
19-24
19-24
19-24
17-22
17-22
17-22
16-21
16-21
16-21
40
Suction
Pressure
PSIG
64-74
68-78
71-81
94-104
100-110
105-115
122-132
130-140
137-147
155-165
165-175
175-185
Discharge
Pressure
PSIG
309-329
313-333
317-337
343-363
350-270
356-376
377-397
386-406
394-414
412-432
423-443
423-443
Superheat Subcooling
7-12
7-12
8-13
9-14
10-15
10-15
11-16
12-17
13-18
14-19
15-20
16-21
10-15
10-15
10-15
12-18
11-16
10-15
9-14
8-13
7-12
6-11
5-10
4-9
Water
Temp Drop
°F
8.4-10.4
6.0-8.0
3.6-5.6
11.3-13.3
8.2-10.2
5.0-8.0
14.2-16.2
10.3-12.3
6.5-8.5
17.2-19.2
12.6-14.6
7.9-9.9
Air Temp
Rise °F
DB
19-24
20-25
20-25
25-30
26-31
26-31
31-36
31-36
33-38
36-41
37-42
39-44
Heat Controller, Inc. HEV/H SERIES Installation, Operation & Maintenance
PREVENTIVE MAINTENANCE
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 [2.0 l/m per kW]
is recommended as a minimum flow. Minimum flow rate
for entering water temperatures below 50°F [10°C] is 2.0
gpm per ton [2.6 l/m per kW].
Water Coil Maintenance
(All other 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. Open cooling
towers requiring heavy chemical treatment and mineral
buildup through water use can also contribute to higher
maintenance. Should periodic coil cleaning be necessary,
use standard coil cleaning procedures, which are
compatible with both the heat exchanger material and
copper water lines. Generally, the more water flowing
through the unit, the less chance for scaling. However,
flow rates over 3 gpm per ton (3.9 l/m per kW) can
produce water (or debris) velocities that can erode the
heat exchanger wall and ultimately produce leaks.
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.
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.
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. 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.
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 [7 - 8 cm] to prevent water from
entering the cabinet. The cabinet can be cleaned using a
mild detergent.
Refrigerant System
To maintain 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.
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.
41
Installation, Operation & Maintenance HEV/H SERIES Heat Controller, Inc.
TROUBLESHOOTING
General
If operational diffi culties are encountered, perform
the preliminary checks below before referring to the
troubleshooting charts.
• Verify that the unit is receiving electrical supply power.
• Make sure the fuses in the fused disconnect switches are
intact.
After completing the preliminary checks described above,
inspect for other obvious problems such as leaking
connections, broken or disconnected wires, etc. If everything
appears to be in order, but the unit still fails to operate
properly, refer to the “DXM2 Troubleshooting Process
Flowchart” or “Functional Troubleshooting Chart.”
DXM2 Board
DXM2 board troubleshooting in general is best summarized
as verifying inputs and outputs. After inputs and outputs
have been verifi ed, board operation is confi rmed and the
problem must be elsewhere. Below are some general
guidelines for troubleshooting the DXM2 control.
Field Inputs
Conventional thermostat inputs are 24VAC from the
thermostat and can be verifi ed using a voltmeter between C
and Y1, Y2, W, O, G. 24VAC will be present at the terminal
(for example, between “Y1” and “C”) if the thermostat is
sending an input to the DXM2 board.
Proper communications with a thermostat can be verifi ed
using the Fault LED on the DXM2. If the control is NOT
in the Test mode and is NOT currently locked out or in
a retry delay, the Fault LED on the DXM2 will fl ash very
slowly (1 second on, 5 seconds off), if the DXM2 is properly
communicating with the thermostat.
Sensor Inputs
All sensor inputs are ‘paired wires’ connecting each
component to the board. Therefore, continuity on pressure
switches, for example can be checked at the board
connector. The thermistor resistance should be measured
with the connector removed so that only the impedance of
the thermistor is measured. If desired, this reading can be
compared to the thermistor resistance chart shown in the
DXM2 AOM manual. An ice bath can be used to check the
calibration of the thermistor.
Outputs
The compressor and reversing valve relays are 24VAC
and can be verifi ed using a voltmeter. For units with PSC
blower motors, the fan relay provides a contact closure to
directly power the blower motor, or provide 24VAC to an
external fan relay. For units with ECM blower motors, the
DXM2 controls the motor using serial communications,
and troubleshooting should be done with a communicating
thermostat or diagnostic tool. The alarm relay can either
be 24VAC as shipped or dry contacts for use with DDC
controls by clipping the JW1 jumper. Electric heat outputs
are 24VDC “ground sinking” and require a voltmeter set for
DC to verify operation. The terminal marked “24VDC” is the
24VDC supply to the electric heat board; terminal “EH1” is
stage 1 electric heat; terminal “EH2” is stage 2 electric heat.
When electric heat is energized (thermostat is sending a “W”
input to the DXM2 controller), there will be 24VDC between
terminal “24VDC” and “EH1” (stage 1 electric heat) and/or
“EH2” (stage 2 electric heat). A reading of 0VDC between
“24VDC” and “EH1” or “EH2” will indicate that the DXM2
board is NOT sending an output signal to the electric heat
board.
Test Mode
Test mode can be entered for 20 minutes by pressing the
Test pushbutton. The DXM2 board will automatically exit test
mode after 20 minutes.
Advanced Diagnostics
If a communicating thermostat or diagnostic tool is
connected to the DXM2, additional diagnostic information
and troubleshooting capabilities are available. The current
status of all DXM2 inputs can be verifi ed, including the
current temperature readings of all temperature inputs.
With a communicating thermostat the current status of the
inputs can be accessed from the Service Information menu.
In the manual operating mode, most DXM2 outputs can
be directly controlled for system troubleshooting. With a
communicating thermostat the manual operating mode can
be accessed from the Installer menu. For more detailed
information on the advanced diagnostics of the DXM2, see
the DXM2 Application, Operation and Maintenance (AOM)
manual (part #97B0003N15).
DXM2 Troubleshooting Process Flowchart/Functional
Troubleshooting Chart
The “DXM2 Functional Troubleshooting Process Flowchart”
is a quick overview of how to start diagnosing a suspected
problem, using the fault recognition features of the DXM2
board. The “Functional Troubleshooting Chart” on the
following page is a more comprehensive method for
identifying a number of malfunctions that may occur, and is
not limited to just the DXM2 controls. Within the chart are
fi ve columns:
• The “Fault” column describes the symptoms.
• Columns 2 and 3 identify in which mode the fault is likely
to occur, heating or cooling.
• The “Possible Cause column” identifi es the most likely
sources of the problem.
• The “Solution” column describes what should be done to
correct the problem.
WARNING!
WARNING! HAZARDOUS VOLTAGE! DISCONNECT
ALL ELECTRIC POWER INCLUDING REMOTE
DISCONNECTS BEFORE SERVICING.
Failure to disconnect power before servicing can cause
severe personal injury or death.
42
Heat Controller, Inc. HEV/H SERIES Installation, Operation & Maintenance
DXM2 PROCESS FLOW CHART
WARNING!
WARNING! HAZARDOUS VOLTAGE! DISCONNECT
ALL ELECTRIC POWER INCLUDING REMOTE
DISCONNECTS BEFORE SERVICING.
Failure to disconnect power before servicing can cause
severe personal injury or death.
See “Unit
short
cycles”
See “Only
Fan Runs”
See “Only
Comp
Runs”
See “Does
not Operate
in Clg”
Attempt to
Lockout at
Yes
Yes
Yes
No
Unit Short
Compressor
Did unit lockout
after a period of
operation?
Does unit
operate in
Start
Did Unit
Start?
Yes
Did Unit
Start-up?
No
Cycles?
No
Only Fan
Runs?
No
Only
Runs?
No
No
cooling?
Yes
DXM2 Functional
Troubleshooting Flow Chart
No
Yes
Yes
Check Main
power (see power
problems)
See HP/
HPWS
Fault
See LT2
Fault
Check fault LED code
on control board
See
LP/LOC
Fault
Condensate
See LT1
Fault
See
Fault
See Over/
Under
Voltage
No fault
shown
Replace
DXM2
Unit is OK!
‘See Performance
Troubleshooting’ for
further help
43
Installation, Operation & Maintenance HEV/H SERIES Heat Controller, Inc.
Fault Htg Clg Possible Cause Solution
Main Power Problems
X X Green status LED off
Check Line Voltage circuit breaker and disconnect
Check for line voltage between L1 and L2 on the contactor
Check for 24VAC between R and C on DXM
Check primary/secondary voltage on transformer
HPWS
X Reduced or no water flow Check pump operation or valve operation/setting
in cooling
Check water flow adjust to proper flow rate
X
Water temperature out of range in
cooling
Bring water temp within design parameters
X
Reduced or no air flow
Check for dirty air filter and clean or replace
in heating
Check fan motor operation and airflow restrictions
Dirty air coil- construction dust etc.
Too high of external static. Check static vs blower table
X
Air t emperature out of range in
heating
Bring return air temp within design parameters
XX
Overcharged with refrigerant
Check superheat/subcooling vs typical operating condition
table
XX
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 Charge X
Compressor pump down at startup
Check charge and start-up water flow
LT1 Fault - Code 4
X
Reduced or no water flow
Check pump operation or water valve operation/setting
Water Low Temperature
in heating
Plugged strainer or filter - clean or replace
Check water flow adjust to proper flow rate
X Inadequate anti-freeze level Check antifreeze density with hydrometer
X
Improper low temperature setting
(30°F vs 10°F)
Clip LT1 jumper for antifreeze (10°F) use
X Water temperature out of range
Bring water temp within design parameters
X X Bad thermistor Check temp and impedance correlation per chart
LT2 Fault - Code 5
X
Reduced or no air flow
Check for dirty air filter and clean or replace
in cooling
Check fan motor operation and airflow restrictions
Too high of external static - check static vs blower table
X Air temperature out of range
Too much cold vent air - bring entering air temp within
design parameters
X
Improper low temperature setting
(30°F vs 10°F)
Normal airside applications will require 30°F only
X X Bad thermistor Check temp and impedance correlation per chart
Condensate Fault-Code
6
X X Blocked drain Check for blockage and clean drain
X X Improper trap Check trap dimensions and location ahead of vent
X Poor drainage
Check for piping slope away from unit
Check slope of unit toward outlet
Poor venting - check vent location
X Moisture on sensor Check for moisture shorting to air coil
Over/Under Voltage-Code 7
X X Under voltage
Check power supply and 24VAC voltage before and during
operation
(Auto Resetting)
Check power supply wire size
Check compressor starting. Need hard start kit?
Check 24VAC and unit transformer tap for correct power
supply voltage
X X Over voltage
Check power supply voltage and 24VAC before and during
operation.
Check 24VAC and unit transformer tap for correct power
supply voltage
Unit Performance
Sentinel-Code 8
X Heating Mode LT2>125°F Check for poor air flow or overcharged unit
X
Cooling Mode LT1>125°F OR
LT2< 40°F
Check for poor water flow, or air flow
Swapped Thermistor
Code 9
X X LT1 and LT2 swapped Reverse position of thermistors
XX
Plugged air filter
X X Restricted return air flow
Replace air filter
Find and eliminate rectriction - increase return duct
and/or grille size
ECM Fault - Code 10
X X Blower does not operate
Check blower line voltage
Check blower low voltage wiring
Blower operating with incorrect
airflow
Wrong unit size selection
Wrong unit family selection
Wrong motor size
Incorrect blower selection
Low Air Coil Pressure Fault
(ClimaDry) Code 11
X Reduced or no air flow in cooling
or ClimaDry
Low Air Coil Temperature
Fault - (ClimaDry) Code 12
X Reduced airflow in cooling,
ClimaDry, or constant fan
Air temperature out of range
Check switch continuity and operation - replaceBad pressure switch
Air temperature out of range
Bad thermistor Check temp and impedance correlation per chart
Check for dirty air filter and clean or replace
Check fan motor operation and airflow restrictions
Too high of external static - check static vs blower table
Too much cold vent air - bring entering air temp within
design parameters
Check for dirty air filter and clean or replace
Check fan motor operation and airflow restrictions
Too high of external static - check static vs blower table
Too much cold vent air - bring entering air temp within
design parameters
FUNCTIONAL TROUBLESHOOTING
44
Heat Controller, Inc. HEV/H SERIES Installation, Operation & Maintenance
No Fault Code Shown
X 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
Unit Short Cycles
X X Dirty air filter Check and clean air filte r
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 for actual
load of space
X X Compressor overload Check and replace if necessary
Only Fan Runs
X X Thermostat position Insure thermostat set for heating or cooling operation
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 DXM2 - put in Test Mode and
ESD - ERV Fault (DXM Only)
Green Status LED Code 3
XX
ERV unit has fault
(Rooftop units only)
Troubleshoot ERV unit fault
jumper Y1 and R to give call for compressor
IFC Fault Code 13 X Improper output setting Verify the AO-2 jumper is in the PWM positionX
No pump output signal Check DC voltage between A02 and GND - should be
between 0.5 and 10 VDC with pump active
Low pump voltage
Check line voltage to the pump
No pump feedback signal Check DC voltage between T1 and GND. Voltage should
be between 3 and 4 VDC with pump OFF, and between
0 and 2 VDC with the pump ON
Bad pump RPM sensor Replace pump if the line voltage and control signals are
present at the pump, and the pump does not operate
Fault Htg ClgPossible Cause Solution
FUNCTIONAL TROUBLESHOOTING (CONT.)
45
Installation, Operation & Maintenance HEV/H SERIES Heat Controller, Inc.
TROUBLESHOOTING FORM
HEATING CYCLE ANAL YSIS -
°F °F
Refrigerant Type :
R-410A
R22
FP2: HEATING
LIQUID LINE
COOLING CYCLE ANALYSIS -
°F °F
AIR
COIL
°F
AIR
COIL
EXPANSION
VALV E
°F
FLASH
GAS LINE
FP1
SENSOR
COAX
°F
°F °F
PSI PSI
WATER IN WATER OUT
PSI
°F
HWG
°F
PSI
SAT
SUCTION
COMPRESSOR
DISCHARGE
Look up pressure drop in
I.O.M. or spec. catalog to
determine flow rate.
PSI
°F
SAT
SUCTION
COMPRESSOR
SAT
FP2: FLASH
GAS LINE
EXPANSION
°F
OTHER SIDE
OF FILTR DR
VALV E
°F
°F
FP1: CLG
LIQ LINE
COAX
°F °F
PSI PSI
WATER IN WATER OUT
DISCHARGE
HWG
°F
PSI
Look up pressure drop in
SAT
I.O.M. or spec. catalog to
determine flow rate.
Heat of Extraction (Absorption) or Heat of Rejection =
________ flow rate ( diff. ( factor = _____________
Superheat
Subcooling
=
=
gpm) x ________ temp. deg. F) x ________ fluid
Suction temperature - suction saturation temp.
Discharge saturation temp. -liquid line temp.
=
=
†
Use 500 for water, 485 for antifreeze.
†
(Btu/hr)
(deg F)
(deg F)
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.
46
Heat Controller, Inc. HEV/H SERIES Installation, Operation & Maintenance
47
1/5/12
*97B0016N11*
97B0016N11
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