Heat Controller HSS, HTS SPLIT SYSTEM User Manual

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Split Products

HSS Series Split System,

11/2 to 5 Tons

HTS Series Split System,

Two Stage, 2-5 Tons

Outdoor Split

Geothermal Heat Pumps

Installation, Operation &

Table of Contents

Model Nomenclature 3

Safety 4

Storage 5

Pre-Installation 5

Equipment Selection 6

Air Coil Match-ups 6-7

Air Handler Selection 8

Installation 9

Water Connections 10-11

Ground Loop Applications 11-13

Open Loop - Ground Water Systems 14-15

Water Quality Standards 16

Refrigeration Installation 17-22

Lineset Information 17

Internal Hot Water Generator 23-24

Hot Water Generator Module 25-26

Electrical - Line Voltage 27-28

Power Wiring 28

Electrical - Low Voltage Wiring 29-31

Low Water Temperature Cutout Selection 31

Water Valve Wiring 31

Thermostat Wiring 31

CXM Controls 32-34

CXM Safety Features 33

Unit Start-Up and Operating Conditions 36

Unit Start-Up and System Checkout Procedure 37-38

Unit Operating Conditions 39-41

Preventive Maintenance 42

Troubleshooting 43-44

Functional & Performance Troubleshooting 45-46

Refrigerant Circuit Diagram 47

Revision Log 48

Maintenance Instructions

Revision: 23 June, 2008

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Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

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The Quality Leader in Conditioning Air

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Model Nomenclature: for Indoor Split Series

4 5 6 7

Model Nomenclature: for Indoor Split Series

NOTE: Above model nomenclature is a general reference. Consult individual specication catalogs for detailed information.

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HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Safety

Warnings, cautions and notices appear throughout this manual. Read these items carefully before attempting any

installation, service or troubleshooting of the equipment.

DANGER: Indicates an immediate hazardous situation, which

if not avoided will result in death or serious injury. DANGER labels on unit access panels must be observed.

WARNING: Indicates a potentially hazardous situation, which

if not avoided could result in death or serious injury.

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

NOTICE: Notication of installation, operation or

maintenance information, which is important, but which is not hazard-related.

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

CAUTION!

these units as a source of heating or cooling during the construction process. The mechanical components and

lters will quickly become clogged with construction dirt and

debris, which may cause system damage.

x WARNING! x

x CAUTION! x

To avoid equipment damage, DO NOT use

x WARNING! x

WARNING! Verify refrigerant type before proceeding. Units are shipped with R-22 and R-410A refrigerants. The unit label will indicate which refrigerant is provided. The EarthPure® Application and Service Manual should be read and understood before attempting to service refrigerant circuits with R-410A.

x WARNING! x

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 prociency requirements.

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Inspection

Upon receipt of the equipment, carefully check the shipment

against the bill of lading. Make sure all units have been received. Inspect the packaging of each unit, and inspect each unit for damage. Insure that the carrier makes proper notation of any shortages or damage on all copies of the freight bill and completes a common carrier inspection report. Concealed damage not discovered during unloading must be reported

to the carrier within 15 days of receipt of shipment. If not led

within 15 days, the freight company can deny the claim without

recourse. Note: It is the responsibility of the purchaser to le all necessary claims with the carrier. Notify your equipment supplier of all damage within fteen (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, ttings, and valves before installing any of

the system components. Remove any dirt or debris found in or on these components.

Pre-Installation

Installation, Operation, and Maintenance instructions are

provided with each unit. Horizontal equipment is designed for

installation above false ceiling or in a ceiling plenum. Other

unit congurations are typically installed in a mechanical room. The installation site chosen should include adequate

service clearance around the unit. Before unit start-up, read all manuals and become familiar with the unit and its operation. Thoroughly check the system before operation.

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

General Information

rides freely on the springs. Remove shipping restraints.

6. REMOVE COMPRESSOR SUPPORT PLATE 1/4”

SHIPPING BOLTS (2 on each side) TO MAXIMIZE VIBRATION AND SOUND ATTENUATION (R22 indoor units only).

7. Locate and verify any hot water generator (HWG) or

other accessory kit located in the compressor section.

x CAUTION! x

CAUTION! DO NOT store or install units in corrosive

environments or in locations subject to temperature or

humidity extremes (e.g., attics, garages, rooftops, etc.).

Corrosive conditions and high temperature or humidity can

signicantly reduce performance, reliability, and service life.

Always move and store units in an upright position. Tilting

units on their sides may cause equipment damage.

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

x CAUTION! x

CAUTION! CUT HAZARD - Failure to follow this caution may result in personal injury. Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing, safety glasses and gloves when handling parts and servicing heat pumps.

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 nished.

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. Loosen compressor bolts on units equipped with

compressor spring vibration isolation until the compressor

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HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Equipment Selection

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

General

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

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

Table 1a: GeoMax 2 (HTS) Air Handler Matches for ARI Ratings

Indoor Coil Selection - HTS GeoMax 2

HCI split system heat pumps are rated in the ARI directory with a specific indoor coil match. GeoMax 2 (HTS) models are rated with Carrier/Bryant FV4 or FE4 series variable speed air handlers as shown in Table 1a. Other brands of air handlers may attain the same ARI ratings providing that the specifications meet or exceed those listed in Table 1a AND Table 1b. An ECM motor and TXV is required. Cap tubes and fixed orifices are not acceptable. PSC fans may be used if matched to Table 1b, but will not meet ARI ratings. If using PSC fan, compressor section must be operated as a single stage unit (i.e. wired for either 1st stage or 2nd stage). Without the ability to vary the airflow, supply air temperatures may not be acceptable if the compressor is allowed to change stages when used with a PSC fan motor.

Compressor Section 024 036 048 060

Air Handler Model FV4

003 005 006 006

Refrigerant R-410A

Metering Device TXV (required)

Air Coil Type Rows - Fins/in. Face Area (sq. ft.)

Cabinet Configuration

ECM Settings for ARI Ratings (FV4 Fan Coil)

Slope

3 - 14.5

3.46

Upflow/Downflow/Horizontal (Multipoise)

AC/HP size: 036

System Type:

Comfort AC/HP

CFM Adjust: Nom

3 - 14.5

5.93

AC/HP size: 036

System Type:

HP-Effic AC/HP

CFM Adjust: High

3 - 14.5

7.42

AC/HP size: 048

System Type:

Comfort AC/HP

CFM Adjust: High

3 - 14.5

7.42

AC/HP size: 060

System Type:

Comfort AC/HP

CFM Adjust: High

Fan Motor Type - HP ECM - 1/2 ECM - 1/2 ECM - 3/4 ECM - 3/4

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Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Equipment Selection

Table 1b: GeoMax 2 (HTS) Air Handler Characteristics for Brands other than Above Models

Model*

Nominal

Tons*

024 - Part Load 1.5 50 530 19.2 - 22.4

024 - Full Load 2.0 52 880 24.2 - 28.2

036 - Part Load 2.5 51 700 25.2 - 29.2

036 - Full Load 3.0 50 1200 34.5 - 40.1

048 - Part Load 3.5 47 1000 34.3 - 39.9

048 - Full Load 4.0 48 1650 46.3 - 53.8

060 - Full Load 5.0 48 1850 54.5 - 63.3

* Nominal tons are at ARI/ISO 13256-1 GLHP conditions. Two-stage units may be operated in single-stage mode if desired, where smaller

capacity is required. For example, a model 026 may be used as a 1-1/2 ton unit if “locked” into 1st stage operation only. If PSC fan is used, unit must be “locked” into either 1st or 2nd stage. An ECM fan is required for two-stage operation and for ARI ratings. Size air handler for “Full Load” if operating in two-stage mode.

**When selecting an air handler based upon the above conditions, choose entering WB temperature of 67ºF. Use evaporator temperature,

CFM and capacity requirements as listed above. The air handler capacity must be at least at the minimum capacity shown in the table in order for the ARI rating condition to be valid. See Figure 1 for an example selection.

Evaporator

Temp (ºF)

CFM

Capacity

(MBtuh)**

Indoor Coil Selection - For HSS R-22 Units

Geothermal split system heat pumps with R-22 refrigerant are rated in the ARI directory with a “generic” indoor coil match and PSC fan. Selection of air handlers that attain the published ARI ratings must meet or exceed the specifications listed in Table

2. A TXV is required. Cap tubes and fixed orifices are not

acceptable.

Table 2: R-22 Air Handler Characteristics

Model*

Nominal

Tons*

018 1.5 50 600 18.5 - 21.3

024 2.0 47 800 25.5 - 29.3

030 2.5 49 1000 31.5 - 36.2

036 3.0 48 1200 37.0 - 42.5

042 3.5 45 1400 42.2 - 48.5

048 4.0 46 1600 50.0 - 57.5

060 5.0 45 2000 58.0 - 66.7

* Nominal tons are at ARI/ISO 13256-1 GLHP conditions. **When selecting an air handler based upon the above conditions, choose entering WB temperature of 67ºF. Use evaporator temperature,

Evaporator

Temp (ºF)

CFM

Capacity

(MBtuh)**

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HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Equipment Selection

Air Handler Selection Example

Figure 1 shows a typical performance table for a heat pump air

handler. Suppose the evaporator temperature required is 50ºF, the capacity required is 35,000 Btuh and the airow required

is 1,200 CFM. Each evaporator temperature listed in the table shows three wet bulb temperatures. As recommended in the

table notes above, select the 67ºF WB column. At 1,200 CFM,

the model 003 capacity is 36 MBtuh, which is higher than the

minimum capacity required of 35,000 Btuh. In this example,

model 003 would be the appropriate match.

Figure 1: Selecting Air Handler

Utilizing the Existing Air Handler or Coil (R22 units only)

It is recommended that a new coil or air handler be installed with any geothermal split system compressor section due to the

low initial cost of the additional equipment versus the reliability and benet of new technology, increased reliability and warranty. However, if the existing air handler must be used (R22 systems only), the following conditions apply:

• If the existing coil currently uses an orice, the orice must be

removed and replaced with a TXV. If the coil utilizes capillary tubes, it will not operate properly with the geothermal split system and should be replaced.

• If life expectancy of indoor coil (and associated components

- fan, cabinet, etc.) is less than 7-10 years, indoor section

should be replaced.

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

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

Removing Existing Condensing Unit (Where Applicable)

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

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

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

4. Replace line set, especially if upgrading system from R-22 to R-410A refrigerant. If line set cannot be replaced, it must be thoroughly flushed before installing new compressor section. R-410A compressors use POE oil instead of mineral oil (R-22 systems). Mineral oil is not compatible with POE oil, and could cause system damage if not completely flushed from the line set.

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Installation

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

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

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

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

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

Air Handler Installation

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

“Indoor” Compressor Section Location

Both “indoor” and “outdoor” versions of the geothermal split system compressor section are available. “Indoor” version is not designed for outdoor installation. Locate the unit in an INDOOR area that allows enough space for service personnel to perform typical maintenance or repairs without removing unit. Units are typically installed in a mechanical room or closet. Never install units in areas subject to freezing or where humidity levels could cause cabinet condensation (such as unconditioned spaces subject to 100% outside air). Consideration should be given to access for easy removal of service access panels. Provide sufficient room to make water, electrical, and line set connections.

Any access panel screws that would be difficult to remove after the unit is installed should be removed prior to setting the unit. Refer to Figure 2 for an illustration of a typical installation. Refer to “Physical Dimensions” section for dimensional data. Conform to the following guidelines when selecting unit location:

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.

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Gas ke t

Sw ive l Nut

Sta in les s s tee l

sna p rin g

Brass Ada p tor

Hand Tighten

Only !

Do Not

Ov e rtighte n !

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Installation

Figure 2: HTS/HSS Installation

External Flow Controller Mounting The Flow Controller can be mounted beside the unit as shown in Figure 7. Review the Flow Controller installation manual for more details.

Water Connections-Residential (Distributor) Models

Residential models utilize swivel piping ttings 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 ush end of most 1” threaded male pipe ttings provides a leak-free seal without the need for

thread sealing tape or joint compound. Insure that the rubber seal is in the swivel connector prior to attempting any connection (rubber seals are shipped attached to the swivel connector). DO NOT OVER TIGHTEN or leaks may occur.

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

Figure 4: Water Connections (Indoor Compressor Section)

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GROUND-LOOP HEAT PUMP APPLICATIONS

x CAUTION! x

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.

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Installation

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 Figures 7 and 8. All earth loop piping materials should be limited to polyethylene fusion only for in-ground sections of

the loop. Galvanized or steel ttings should not be used at

any time due to their tendency to corrode. All plastic to metal

threaded ttings should be avoided due to their potential to leak in earth coupled applications. A anged tting should be substituted. P/T plugs should be used so that ow can be

measured using the pressure drop of the unit heat exchanger.

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Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Ground-Loop Heat Pump Applications

Earth loop temperatures can range between 25 and 110°F [-4 to 43°C]. Flow rates between 2.25 and 3 gpm per ton

[2.41 to 3.23 l/m per kW] of cooling capacity is recommended in these applications.

Test individual horizontal loop circuits before backfilling. Test vertical U-bends and pond loop assemblies prior to installation. Pressures of at least 100 psi [689 kPa] should be used when testing. Do not exceed the pipe pressure rating. Test entire system when all loops are assembled.

Flushing the Earth Loop

Once piping is completed between the unit, Flow Controller and the ground loop (Figures 7 and 8), the loop is ready for final purging and charging. A flush cart with at least a 1.5 hp [1.1 kW] pump is required to achieve enough fluid velocity in the loop piping system to purge air and dirt particles. An antifreeze solution is used in most areas to prevent freezing. All air and debris must be removed from the earth loop piping before operation. Flush the loop with a high volume of water at a minimum velocity of 2 fps (0.6 m/s) in all piping. The steps below must be followed for proper flushing.

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

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

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

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

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

the loop to a homogenous temperature. This is a good time for tool cleanup, piping insulation, etc. Then, perform final flush and pressurize the loop to a static pressure of 50-75 psi [345-517 kPa] (winter) or 35-40 psi [241-276 kPa] (summer). After pressurization, be sure to loosen the plug at the end of the Grundfos loop pump motor(s) to allow trapped air to be discharged and to insure the motor housing has been flooded. This is not required for Taco circulators. Insure that the Flow Controller provides adequate flow through the unit by checking pressure drop across the heat exchanger and compare to the pressure drop tables at the back of the manual.

Antifreeze

In areas where minimum entering loop temperatures drop

below 40°F [5°C] or where piping will be routed through

areas subject to freezing, antifreeze is required. Alcohols and glycols are commonly used as antifreeze; however your local sales manager should be consulted for the antifreeze best suited to your area. Freeze protection

should be maintained to 15°F [9°C] below the lowest expected entering loop temperature. For example, if 30°F [-1°C] is the minimum expected entering loop temperature, the leaving loop temperature would be 25 to 22°F [-4 to

-6°C] and freeze protection should be at 15°F [-10°C].

Calculation is as follows:

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

All alcohols should be premixed and pumped from a reservoir outside of the building when possible or introduced under the water level to prevent fumes. Calculate the total volume of fluid in the piping system. Then use the percentage by volume shown in Table 2 for the amount of antifreeze needed. Antifreeze concentration should be checked from a well mixed sample using a hydrometer to measure specific gravity.

Low Water Temperature Cutout Setting 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.

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

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Ground-Loop Heat Pump Applications

Table 1: Approximate Fluid Volume (U.S. gal. [L]) per 100' of Pipe

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

Pipe Size Volume (gal) [liters]

1” 4.1 [15.3]

Copper

Rubber Hose 1” 3.9 [14.6]

Polyethylene

Unit Heat Exchanger Typical 1.0 [3.8]

Flush Cart Tank

1.25” 6.4 [23.8]

2.5” 9.2 [34.3]

3/4” IPS SDR11 2.8 [10.4]

1” iPS SDR11 4.5 [16.7]

1.25” IPS SDR11 8.0 [29.8]

1.5” IPS SDR11 10.9 [40.7]

2” IPS SDR11 18.0 [67.0]

1.25” IPS SCH40 8.3 [30.9]

1.5” IPS SCH40 10.9 [40.7]

2” IPS SCH40 17.0 [63.4]

10” Dia x 3ft tall

[254mm x 91.4cm tall]

10 [37.9]

Residential Split - 60Hz R22 &R410A

Figure 7: Loop Connection (Indoor Compressor Section)

Rev.: 5 June, 2008

Table 2: Antifreeze Percentages by Volume

Type

Methanol 100% USP food grade Propylene Glycol Ethanol*

* Must not be denatured with any petroleum based product

10°F [-12.2°C] 15°F [-9.4°C] 20°F [-6.7°C] 25°F [-3.9°C]

25% 38% 29%

NOTICE! Cabinet opening around loop piping (outdoor compressor section) must be sealed to prevent entry of

rodents that could potentially damage unit wiring by chewing on the insulation.

NOTICE! Outdoor compressor section may not be tilted

more than 5 degrees from level. Damage to the compressor

or stress on the loop piping could result if unit is tilted. A concrete pad, anchor posts and/or soil compaction may be

required to avoid tilting as ground settles.

Minimum Temperature for Low Temperature Protection

21% 25% 25%

16% 22% 20%

10% 15% 14%

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Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Ground-Water Heat Pump Applications - “Indoor” Compressor Section Only

Open Loop - Ground Water Systems (“Indoor” Compressor Section Only)

The “outdoor” version of the compressor section may not be used with open loop systems due to potential freezing of water piping. Typical open loop piping is shown in Figure 9. Shut off valves should be included for ease of servicing. Boiler drains or other valves should be “tee’d” into the lines to allow acid flushing of the heat exchanger. Shut off valves should be positioned to allow flow through the coax via the boiler drains without allowing flow into the piping system. P/T plugs should be used so that pressure drop and temperature can be measured. Piping materials should be limited to copper or PVC SCH80. Note: Due to the pressure and temperature extremes, PVC SCH40 is not recommended.

Water quantity should be plentiful and of good quality. Consult Table 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 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 DHW (desuperheater); 90°F [32°F] for

indirect use. A monitoring plan should be implemented in these probable scaling situations. Other water quality issues such as iron fouling, corrosion prevention and erosion and clogging should be referenced in Table 3.

Expansion Tank and Pump

Use a closed, bladder-type expansion tank to minimize mineral formation due to air exposure. The expansion tank should be sized to provide at least one minute continuous run time of the pump using its drawdown capacity rating to

prevent pump short cycling. Discharge water from the unit is not contaminated in any manner and can be disposed of in various ways, depending on local building codes (e.g. recharge well, storm sewer, drain field, adjacent stream or pond, etc.). Most local codes forbid the use of sanitary sewer for disposal. Consult your local building and zoning department to assure compliance in your area.

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

Water Control Valve

Note the placement of the water control valve in figure 9. Always maintain water pressure in the heat exchanger by placing the water control valve(s) on the discharge line to prevent mineral precipitation during the off-cycle. Pilot operated slow closing valves are recommended to reduce water hammer. If water hammer persists, a mini-expansion tank can be mounted on the piping to help absorb the excess hammer shock. 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 (see Figure 24). Note the special wiring diagrams for slow closing valves (Figures 25 & 26).

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 11a through 11b. 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], a

minimum of 2 gpm per ton (2.6 l/m per kW) is required.

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

The Quality Leader in Conditioning Air

Ground-Water Heat Pump Applications

Water Coil Low Temperature Limit Setting

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

this manual for details on the low limit setting.

x CAUTION! x

CAUTION! Many units installed with a factory or field supplied

manual or electric shut-off valve. DAMAGE WILL OCCUR if shut-off valve is closed during unit operation. A high pressure switch must be installed on the heat pump side of any field provided shut-off valves and connected to the heat pump controls in series with the built-in refrigerant circuit high pressure switch to disable compressor operation if water pressure exceeds pressure switch setting. The field installed high pressure switch shall have a cut-out pressure of 235 psig and a cut-in pressure of 190 psig. This pressure switch can be ordered from HCI with a 1/4” internal flare connection as part number 39B0005N01.

Residential Split - 60Hz R22 &R410A

Figure 9: Water Well Connections

Rev.: 5 June, 2008

x CAUTION! x

CAUTION! Refrigerant pressure activated water regulating

valves should never be used with HCI equipment.

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Water Quality

Parameter

Material

Closed

Recirculating

Open Loop and Recirculating Well

Scaling Potential - Primary Measurement

pH/Calcium Hardness

All

pH < 7.5 and Ca Hardness <100ppm

Method

Index Limits for Probable Scaling Situations -

(Operation outside these limits is not recommended)

Ryznar

All

- 6.0 - 7.5

Stability Index If >7.5 minimize steel pipe use.

Langelier

All

-0.5 to +0.5

Saturation Index

If <-0.5 minimize steel pipe use. Based upon 150°F [66°C] HWG and

Direct well, 85°F [29°C] Indirect Well HX

Iron Fouling

Iron Fe2+(Ferrous)

All

<0.2 ppm (Ferrous)

(Bacterial Iron potential)

If Fe

(ferrous)>0.2 ppm with pH 6 - 8, O2<5 ppm check for iron bacteria

Iron Fouling

All

<0.5 ppm of Oxygen

Above this level deposition will occur.

Corrosion Prevention

All

6 - 8.5

Monitor/treat as

needed

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

Hydrogen Sulfide (H

All

- <0.5 ppm

At H

S>0.2 ppm, avoid use of copper and copper nickel piping or HX's.

Rotten egg smell appears at 0.5 ppm level.

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

Ammonia ion

All

<0.5 ppm

as hydroxide, chloride, nitrate and sulfate compounds

Maximum

Maximum Allowable at maximum water temperature.

Chloride Levels

50°F (10°C) 75°F (24°C) 100ϒF (38ϒC)

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

Erosion and Clogging

Particulate Size and Erosion

All

<10 ppm of particles and a maximum velocity of 6 fps [1.8 m/s]. Filtered for maximum 800 micron [800mm, 20 mesh] size.

<10 ppm (<1 ppm "sandfree" for reinjection) of particlesand a maximum velocity of 6 fps [1.8 m/s]. Filtered for maximum 800 micron [800mm, 20 mesh] size.Any particulate that is not removed can potentially clog components.

Notes:

Rev.: 03/28/08S

• NR - Application not recommended.

• "-" No design Maximum.

• Closed Recirculating system is identified by a

closed pressurized piping system.

• Recirculating open wells should observe the open recirculating design considerations.

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

Scaling indexes should be calculated at 150°F [66°C] for direct use and HWG applications, and at 90°F [32°C] for indirect HX use. A monitoring plan should be implemented.

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Water Quality Standards

Table 3: Water Quality Standards

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x CAUTION! x

CAUTION! R-410A systems operate at higher pressures

than R-22 systems. Be certain that service equipment (gauges, tools, etc.) is rated for R-410A. Some R-22 service equipment may not be acceptable.

x CAUTION! x

CAUTION! Installation of a factory supplied liquid line bi-directional lter drier is required. Never install a suction line lter in the liquid line.

Line Set Installation

Figures 12a through 13b illustrate typical installations with the “indoor” and “outdoor” versions of the compressor section matched to either an air handler (fan coil) or add-on furnace coil. Table 4 shows typical line-set diameters at various lengths. Lineset lengths should be kept to a minimum and should always be installed with care to avoid kinking. Line sets over 60 feet [18 meters] long are not recommended due to potential oil transport problems and excessive pressure drop. If the line set is kinked or distorted, and it cannot be formed back into its original shape, the damaged portion of the line should be replaced. A restricted line set will effect the performance of the system.

A reversible heat pump filter drier is installed on the liquid line inside the compressor section cabinet (R-22 units only).

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Refrigeration Installation

R-410A models are shipped with a filter drier (loose) inside the cabinet that must be installed in the liquid line at the line set.

All brazing should be performed using nitrogen circulating at 2-3 psi [13.8-20.7 kPa] to prevent oxidation inside the tubing. All linesets should be insulated with a minimum of 1/2” [13mm] thick closed cell insulation. All insulation tubing should be sealed using a UV resistant paint or covering to prevent deterioration from sunlight.

When passing refrigerant lines through a wall, seal opening with silicon-based caulk. Avoid direct contact

with water pipes, duct work, oor joists, wall studs, oors or other structural components that could transmit

compressor vibration. Do not suspend refrigerant tubing

from joists with rigid straps. Do not attach line set to the

wall. When necessary, use hanger straps with isolation sleeves to minimize tranmission of line set vibration to the structure.

Installing the Lineset at the Compressor Section

Braze the line set to the service valve stubs as shown in Figure

10. On installations with long line sets, copper adapters may be needed to connect the larger diameter tube to the stubs. Nitrogen should be circulated through the system at 2-3 psi [13.8-20.7 kPa] to prevent oxidation contamination. Use a low silver phos-copper braze alloy on all brazed connections.

Compressor section is shipped with a factory charge. Therefore, service valves should not be opened until the line set has been leak tested, purged and evacuated. See

“Charging the System.”

Installing the Indoor Coil and Lineset

Table 4: Lineset Diameters and Charge Information

Factory†

Model

018 70 [1.98] 55 [1.56] 3/8” 3/4” 3/8” 3/4” 3/8” 3/4”

024 74 [2.10] 59 [1.67] 3/8” 3/4” 3/8” 3/4” 3/8” 7/8”

030 108 [3.06] 93 [2.64] 3/8” 3/4” 3/8” 7/8” 3/8” 7/8”

036 117 [3.32] 102 [2.89] 3/8” 3/4” 3/8” 7/8” 3/8” 7/8”

042 122 [3.46] 107 [3.03] 3/8” 7/8” 3/8” 7/8” 3/8” 7/8”

048 130 [3.69] 115 [3.26] 3/8” 7/8” 3/8” 7/8” 1/2” 1-1/8”

060 136 [3.86] 121 [3.43] 3/8” 1-1/8” 1/2” 1-1/8” 1/2” 1-1/8”

024 90 [2.55] 75 [2.13] 3/8” 3/4” 3/8” 3/4” 3/8” 7/8”

036 104 [2.95] 89 [2.52] 3/8” 7/8” 3/8” 7/8” 3/8” 7/8”

048 126 [3.57] 111 [3.15] 3/8” 7/8” 3/8” 7/8” 1/2” 1-1/8”

060 168 [4.76] 138 [3.91] 1/2” 1-1/8” 1/2” 1-1/8” 1/2” 1-1/8”

• Basic charge includes only the amount required for the condensing unit and the evaporating coil. An additional amount should be added allowing 0.6oz per ft. for 3/8” [0.6g per cm] and 1.2oz per ft. for 1/2” [1.1g per cm] of lineset used. †Factory charge is preset for 25’ [7.6 meters] lineset.

Charge (oz)

[kg]

Basic*

Charge (oz)

[kg]

20 Feet [6 meters] 40 Feet [12 meters] 60 Feet [18 meters]

Liquid Suction Liquid Suction Liquid Suction

HSS Series

HTS Series

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HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Refrigeration Installation

Figure 10: Braze Instructions

Figure 11: Air Coil Connection

Add-On Heat Pump Applications

The indoor coil should be located in the supply side of the furnace to avoid condensation damage to the furnace heat exchanger for add-on heat pump applications. A high temperature limit switch should be installed as shown in Figures 12b and 13b just upstream of the coil to de-energize the compressor any time the furnace is energized to avoid blowing hot air directly into the coil, elevating refrigerant pressures during operation. The heat pump will trip out on high pressure lockout without some method of disengaging the compressor during furnace operation. Alternatively, some thermostats with “dual fuel” mode will automatically deenergize the compressor when second stage (backup) heat is required.

Table 5: Service Valve Positions

Position Description System

CCW - Full Out Operation Position Open Closed

CCW - Full Out 1/2 turn CW Service Position Open Open

CW - Full In Shipping Position Closed Open

Figure 11 shows the installation of the lineset and TXV to a typical indoor coil. An indoor coil or air handler (fan coil) with a TXV is required. Coils with cap tubes may not be used. If coil includes removable fixed orifice, the orifice must be removed and a TXV must be installed as shown in Figure 11. Fasten the copper line set to the coil. Nitrogen should be circulated through the system at 2-3 psi [13.8-20.7 kPa] to prevent oxidation inside the refrigerant tubing. Use a low silver phos-copper braze alloy on all brazed connections.

Service

Port

The TXV should be brazed into place as shown in Figure 11, keeping the “IN” side toward the compressor section. The TXV has an internal check valve and must be installed in the proper direction for operation. Always keep the valve body cool with a brazing shield and wet rags to prevent damage to the TXV. Attach the bulb to the suction line using the supplied hose clamp. Be careful not to overtighten the clamp and deform the bulb.

NOTICE! The air coil should be thoroughly washed with a filming agent, (dishwasher detergent like Cascade) to help condensate drainage. Apply a 20 to 1 solution of detergent and water. Spray both sides of coil, repeat and rinse thoroughly with water.

Evacuation and Charging the Unit LEAK TESTING -

The refrigeration line set must be pressurized and checked for leaks before evacuating and charging the unit. To pressurize the line set, attach refrigerant gauges to the service ports and add an inert gas (nitrogen or dry carbon dioxide) until pressure reaches 60-90 psig [413-620 kPa]. Never use oxygen or acetylene to pressure test. Use a halogen leak tester or a good quality bubble solution to detect leaks on all connections made in the field. Check the service valve ports and stem for leaks. If a leak is found, repair it and repeat the above steps. For safety reasons do not pressurize system above 150 psig [1034 kPa]. System is now ready for evacuation and charging.

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Residential Split - 60Hz R22 &R410A

Figure 12a: Typical Split/Air Handler Installation (Indoor Compressor Section)

Power

Disconnects

Insulated

Linesets

PVC Condensate

with vented trap

Compressor

Section

Rev.: 5 June, 2008

Refrigeration Installation

TXV 'IN' toward

Compressor

Section

Low Voltage

Air pad or Extruded

polystryene

Figure 12b: Typical Split/Add-on Coil Fossil Fuel Furnace Installation (Indoor Compressor Section)

Air Temperature

Limit Switch

PVC Condensate

with vented trap

Compressor

Section

TXV 'IN' toward

Compressor

Section

Air pad or Extruded

polystyrene

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Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Refrigeration Installation

Evacuation Of The Lineset And Coil The line set and coil must be evacuated to at least 500 microns to remove any moisture and noncondensables. Evacuate the system through both service ports in the shipping position (full CW in - see table 5) to prevent false readings on the gauge because of pressure drop through service ports. A vacuum gauge or thermistor capable of accurately meausuring the vacuum depth is crucial in determining if the system is ready for charging. If the system meets the requirements in Figure 14, it is ready for charging.

Figure 14: Evacuation Graph

Charging The System

There are two methods of charging a refrigerant system. One method is the total charge method, where the volume of the system is determined and the refrigerant is measured and added into the evacuated system. The other method is the partial charge method where a small initial charge is added to an evacuated system, and remaining refrigerant added during operation.

Total Charge Method - See Table 4 for the compressor section basic charge. For line sets with 3/8” liquid lines add 0.6 ounces of refrigerant to the basic charge for every installed foot of liquid line [0.6 grams per cm]. Add 1.2 oz. per foot [1.1 grams per cm] if using l/2” line. Once the total charge is determined, the factory pre-charge (Table 4) is subtracted and the remainder is the amount needed to be added to the system. This method should be used with the ARI matched air handler.

EXAMPLE: R22 model 048 with 40 feet [12 meters] of installed liquid line (3/8” O.D.). The basic charge of model 048 is 115 oz [3.26 kg]. The 40 ft. [12 meter] 3/8” line set

requires 24 oz. [0.72 kg] (40 ft. x 0.6 oz./ft = 24 oz. -- 1200cm x 0.6g/cm = 720g). Total charge = 115 + 24 = 139 oz [3.26 +

0.72 = 3.98 kg]. The compressor section is shipped from the

factory with 130 oz. [3.69 kg] of refrigerant (for 25 ft [7.6m] lineset), so the amount to be added is 9 oz. [0.29 kg] (total

charge - shipped charge = charge to be added).

Table 6a: R-22 Charging Values

x NOTICE! x

NOTICE: Use tables 14a to 15 for superheat/subcooling

values. These tables use discharge pressure (converted to saturation temperature) and liquid line temperature for subcooling calculations. If using liquid line pressure,

subtract 3°F from the table values.

Table 6b: R-410A Charging Values

x NOTICE! x

NOTICE: Use tables 14a to 15 for superheat/subcooling

values. These tables use discharge pressure (converted to saturation temperature) and liquid line temperature for subcooling calculations. If using liquid line pressure,

subtract 3°F from the table values.

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Refrigeration Installation

Turn service valves full out CCW (see Table 5) and then turn back in one-half turn to open service ports. Add the required refrigerant so that the total charge calculated for the unit and line set is now in the system. Open the service valve fully counter clockwise so that the stem will backseat and prevent leakage through the schrader port while it is not in use. Start unit in the heating mode and measure superheat and subcooling values after 5 minutes of run time. See tables 14a to 15 for superheat and sub-cooling values. Superheat is measured using suction temperature and pressure at the compressor suction line. Subcooling should be measured using the liquid line temperature immediately outside the compressor section cabinet and either the liquid line service valve pressure or the compressor discharge pressure. Note that different values from tables 14a to 15 will be obtained due to the pressure losses through the condenser heat exchanger. Adding refrigerant will increase sub-cooling while superheat should remain fairly constant allowing for a slight amount of hunting in TXV systems. This increase in subcooling will require 5 minutes or so of operation before it should be measured. After values are measured, compare to the chart and go to “FINAL EVALUATION.”

PARTIAL CHARGE METHOD - Open service valve fully counterclockwise and then turn back in one-half turn to open service port. Add vaporized (Gas) into the suction side of the compressor until the pressure in the system reaches approximately 60-70 psig (R-22 systems) or 100-120 psig (R-410A systems). Never add liquid refrigerant into the suction side of a compressor. Start the unit in heating and add gas to the suction port at a rate not to exceed five pounds [2.27 kg] per minute. Keep adding refrigerant until the complete charge has been entered. Superheat is measured using suction temperature and pressure at the compressor suction line. Subcooling should be measured using the liquid line temperature immediately outside the compressor section cabinet and either the liquid line service valve pressure or the compressor discharge pressure. Note that different values from tables 14a to 15 will be obtained due to the pressure losses through the condenser heat exchanger. Adding refrigerant will increase sub-cooling while superheat should remain fairly constant allowing for a slight amount of hunting in TXV systems. This increase in subcooling will require 5 minutes or so of operation before it should be measured. After values are measured, compare to the chart and go to “FINAL EVALUATION.”

FINAL EVALUATION -In a split system, cooling subcooling values can be misleading depending on the location of the measurement. Therefore, it is recommended that charging be monitored in the heating mode. Charge should be evaluated by monitoring the subcooling in the heating mode. After initial check of heating sub-cooling, shut off unit and allow to sit 3-5 minutes until pressures equalize. Restart unit in the cooling mode and check the cooling superheat against Tables 14a to 15. If unit runs satisfactorily, charging is complete. If unit

Residential Split - 60Hz R22 &R410A

does not perform to specifications the cooling TXV (air coil side) may need to be readjusted (if possible) until the cooling superheat values are met.

Checking Superheat and Subcooling

Determining Superheat:

1. Measure the temperature of the suction line at a point

near the expansion valve bulb.

2. Determine the suction pressure by attaching refrigeration

gauges to the suction schrader connection at the compressor.

3. Convert the pressure obtained in step 2 to saturation

temperature (boiling point) by using the pressure/ temperature conversion table on the gauge set.

4. Subtract the temperature obtained in step 3 from step

1. The difference will be the superheat of the unit or the total number of degrees above saturation temperature. Refer to Tables 14a to 15 for superheat ranges at specific entering water conditions.

Example (R-22 refrigerant):

The temperature of the suction line at the sensing bulb is

50°F. The suction pressure at the compressor is 65 psig which is equivalent to 38°F saturation temperature from the

R-22 press/temp conversion table on the gauge set.

38°F subtracted from 50°F = 12°F Superheat.

Determining Sub-Cooling:

1. Measure the temperature of the liquid line on the smaller

refrigerant line (liquid line) just outside of the cabinet. This location will be adequate for measurement in both modes unless a significant temperature drop in the liquid line is anticipated.

2. Determine the condensor pressure (high side) by

attaching refrigerant gauges to the schrader connection on the liquid line service valve. If the hot gas discharge line of the compressor is used, refer to the appropriate column in Tables 14a to 15.

3. Convert the pressure obtained in step 2 to the

saturation temperature by using the press/temp conversion table on the gauge set.

Subtract the temperature of Step 3 from the temperature of Step 1. The difference will be the sub-cooling value for that unit (total degrees below the saturation temperature). Refer to Tables 14a or 6b for sub-cooling values at specific entering water temperatures.

Example (R-22 refrigerant):

The condenser pressure at the service port is 225 psig,

which is equivalent to 110°F saturation temperature. Discharge pressure is 236 psig at the compressor (113°F

saturation temperature). Measured liquid line temperature

is 100°F. 100°F subtracted from 110°F = 10 degrees sub-

cooling (13 degrees if using the compressor discharge pressure).

Rev.: 5 June, 2008

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Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Hot Water Generator

The HWG (Hot Water Generator) or desuperheater option provides considerable operating cost savings by utilizing excess heat energy from the heat pump to help satisfy domestic hot water requirements. The HWG is active throughout the year, providing virtually free hot water when the heat pump operates in the cooling mode or hot water at the COP of the heat pump during operation in the heating mode. Actual HWG water heating capacities are provided in the appropriate heat pump performance data.

Heat pumps equipped with the HWG option include a built-in water to refrigerant heat exchanger that eliminates the need to tie into the heat pump refrigerant circuit in the field. The control circuit and pump are also built in for residential equipment. Figure 15 shows a typical example of HWG water piping connections on a unit with built-in pump. This piping layout minimizes scaling potential.

Electric water heaters are recommended. If a gas, propane, or oil water heater is used, a second preheat tank must be installed (Figure 16). If the electric water heater has only a single center element, the dual tank system is recommended to insure a usable entering water temperature for the HWG.

Typically a single tank of at least 52 gallons (235 liters) is used to limit installation costs and space. However, a dual tank, as shown in Figure 16, is the most efficient system, providing the maximum storage and temperate

source water to the HWG. Using a concentric or coaxial hot water tank connection fitting eliminates the need to tie into the hot water tank cold water piping, but is more susceptible to scaling. The optional concentric fitting (part # S69619804) is available from your equipment supplier and should be installed as shown in Figure 17 for applications with low scaling potential or where a water softener is used. Consult Table 3 for scaling potential tests.

It is always advisable to use water softening equipment on domestic water systems to reduce the scaling potential and lengthen equipment life. In extreme water conditions, it may be necessary to avoid the use of the HWG option since the potential cost of frequent maintenance may offset or exceed any savings.

R-410 systems inherently have a lower hot gas temperature than R-22 systems because the equipment is more efficient (i.e. less waste heat is available). It is possible that energy could be transferred from the water heater to the hot gas line instead of from the hot gas line to the water heater during certain times of the year. To prevent this from occuring, a temperature switch will deactivate the pump at those conditions that typically occur in the cooling mode with entering water temperatures of less

than 50°F [10°C].

Figure 15: Typical HWG Installation (Indoor Compressor Section)

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

Figure 16: HWG Double Tank Installation (Indoor Compressor Section)

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Hot Water Generator

Figure 17: Alternate HWG Piping with concentric/coaxial tting (part #S69619804 not included with unit)

(Indoor Compressor Section)

Residential Split - 60Hz R22 &R410A

Water Tank Rell

1. Open the cold water supply to the tank.

2. Open a hot water faucet to vent air from the system until

water ows from the faucet; turn off faucet.

Depress the hot water tank pressure relief valve handle to

ensure that there is no air remaining in the tank.

4. Inspect all work for leaks.

Before restoring power or fuel supply to the water heater,

adjust the temperature setting on the tank thermostat(s)

to insure maximum utilization of the heat available from the refrigeration system and conserve the most energy. On tanks with both upper and lower elements and thermostats, the lower element should be turned down

to 100°F [38°C] or the lowest setting; the upper element should be adjusted to 120-130°F [49-54°C]. Depending upon the specic needs of the customer, you may want

to adjust the upper element differently. On tanks with a

single thermostat, a preheat tank should be used (gure

16).

6. Replace access cover(s) and restore power or

fuel supply.

Rev.: 5 June, 2008

The heat pump, water piping, pump, and hot water tank should be located where the ambient temperature does

not fall below 50°F [10°C]. Keep water piping lengths at a minimum. DO NOT use a one way length greater than 50 ft. [15 m].

All installations must be in accordance with local codes. The

installer is responsible for knowing the local requirements, and for performing the installation accordingly. DO NOT connect the pump wiring until “Initial Start-Up” section, below.

Powering the pump before all installation steps are completed will damage the pump.

Water Tank Preparation

1. Turn off power or fuel supply to the hot water tank.

2. Connect a hose to the drain valve on the water tank.

3. Shut off the cold water supply to the water tank.

4. Open the drain valve and open the pressure relief valve or a hot water faucet to drain tank.

5. When using an existing tank, it should be ushed with

cold water after it is drained until the water leaving the drain hose is clear and free of sediment.

6. Close all valves and remove the drain hose.

7. Install HWG water piping.

HWG Water Piping

1. Using at least 5/8” [16mm] O.D. copper, route and install

the water piping, valves and air vent as shown in Figures 15 to 18. The air vent MUST be at the high point of the

HWG water piping.

2. Insulate all HWG water piping with no less than 3/8” [10mm] wall closed cell insulation.

3. Open both shut off valves and make sure the tank drain valve is closed.

Initial Start-Up

1. Make sure all valves in the HWG water circuit are fully open.

2. Turn on the heat pump and allow it to run for 10-15 minutes.

3. Turn the heat pump and heat pump power supply “OFF” and CONNECT POWER TO THE HWG PUMP as shown

in the unit wiring diagram. Connect the pump power lead as instructed on the tag attached to the pump wiring.

4. The HWG pump should not run if the compressor is not running.

5. The temperature difference between the water entering

and leaving the HWG coil should be approximately 5-10°F [3-6°C].

6. Allow the unit to operate for 20 to 30 minutes to insure that it is functioning properly.

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Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Hot Water Generator Module Refrigeration Installation

x CAUTION! x

CAUTION! The HWG module must be installed in an area

that is not subject to freezing temperatures.

NOTICE! Make sure the compressor discharge line

is connected to the “Hot Gas In” stub on the Heat

Recovery Unit.

x CAUTION! x

CAUTION! Locate Refrigerant lines to avoid accidental damage by lawnmowers or children.

x WARNING! x

WARNING! The HWG module is an appliance that operates

in conjunction with the heat pump system, the hot water system and the electrical system. Installation should only be performed by skilled technicians with appropriate training and experience. The installation must be in compliance with local codes and ordinances. Local plumbing and electrical building codes take precedence over instructions contained herein.

The Manufacturer accepts no liability for equipment damaged

and/or personal injury arising from improper installation of the

HWG module.

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x WARNING! x

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.

x CAUTION! x

CAUTION!

electrical wiring. Unit terminals are not designed to accept other types of conductors.

Electrical - Line Voltage

All eld 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 eld connections that must be made by the installing (or electrical) contractor.

Use only copper conductors for eld installed

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Electrical - Line Voltage

exible conduit to minimize vibration and sound transmission

to the building.

General Line Voltage Wiring

Be sure the available power is the same voltage and phase shown on the unit serial plate. Line and low voltage wiring must be done in accordance with local codes or the National Electric Code, whichever is applicable.

Power Connection

Line voltage connection is made by connecting the incoming

line voltage wires to the “L” side of the contactor as shown in

Figures 21a through 21c. Consult Tables 8a through 8c for correct fuse size.

208-230 Volt Operation

Verify transformer tap with air handler wiring diagram to insure that the transformer tap is set to the correct voltage, 208V or 230V.

All nal electrical connections must be made with a length of

Table 8a: GeoMax 2 (HTS) Series Electrical Data

Model

Compressor

RLA LRA Qty

024 10.3 52.0 1 0.4 4.0 14.7 17.3 25 10 107 (32.7)

036 16.7 82.0 1 0.4 4.0 21.1 25.3 40 10 73 (22.3)

048 21.2 96.0 1 0.4 4.0 25.6 30.9 50 8 95 (29.2)

060 25.6 118.0 1 0.4 4.0 30.0 36.4 60 8 81 (24.8)

Rated Voltage of 208/230/60/1 Min/Max Voltage of 197/254 HACR circuit breaker in USA only All fuses Class RK-5

Wire length based on one way measurement with 2% voltage drop Wire size based on 60°C copper conductor and Minimum Circuit Ampacity.

HWG

Pump

FLA

External

Pump

FLA

Total

Unit FLA

Min

Circuit

Amps

Max

Fuse/

HACR

Min

AWG

Max Wire

Ft.

(m)

Table 8b: HSS Series Electrical Data

Model

018

024

030

036

042

048

060

Compressor

HWG

Pump

RLA LRA Qty

7.7 40.3 1 0.40 4.0 12.1 14.0 20 12 76 (23.3)

10.3 56.0 1 0.40 4.0 14.7 17.3 25 10 107 (32.7)

12.2 67.0 1 0.40 4.0 16.6 19.7 30 10 94 (28.7)

13.5 73.0 1 0.40 4.0 17.9 21.3 35 10 87 (26.5)

16.5 95.0 1 0.40 4.0 20.9 25.0 40 10 74 (22.6)

18.3 109.0 1 0.40 4.0 22.7 27.3 45 10 67 (20.7)

25.0 148.0 1 0.40 4.0 29.4 35.7 60 8 82 (25.2)

FLA

External

Pump

FLA

Total

Unit FLA

Min

Circuit

Amps

Max

Fuse/

HACR

Min

AWG

Max Wire

(m)

Rated Voltage of 208/230/60/1 Min/Max Voltage of 197/254 HACR circuit breaker in USA only All fuses Class RK-5

Wire length based on one way measurement with 2% voltage drop Wire size based on 60°C copper conductor and Minimum Circuit Ampacity.

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HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Electrical - Line Voltage

ELECTRICAL - POWER WIRING

Electrical - Line Voltage

All eld 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 eld connections that must be made by the installing (or electrical) contractor.

All nal electrical connections must be made with a length of exible conduit to minimize vibration and sound transmission

to the building.

General Line Voltage Wiring

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 21a through 21c. Consult Tables 8a through 8c for correct fuse size.

Figure 21a: R-410A Compressor Section Line Voltage Field Wiring

Unit Power Supply

(see electrical table for wire

and breaker size)

Figure 21b: R-22 Indoor Compressor Section Line Voltage Field Wiring

208-230 Volt Operation

Verify transformer tap with air handler wiring diagram to insure that the transformer tap is set to the correct voltage, 208V or 230V.

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Capacitor

CXM C ontr o l

Circ Brkr

Contactor -CC

Low Voltage Connector

HWG PB2

Loop PB1

Grnd

HWG Wiring - “Indoor” Compressor Section

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.

ELECTRICAL - LOW VOLTAGE WIRING

Thermostat Connections

The thermostat should be wired directly to the CXM board. Figures 22a through 22c show low voltage wiring. Note that the air handler or furnace transformer will be used to power

the CXM board in the compressor section. See “Electrical – Thermostat” for specic terminal connections.

Figure 22a: HTS Low Voltage Field Wiring

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Electrical - HWG Wiring

Low Water Temperature Cutout Selection

The CXM control allows the eld selection of low water (or water-antifreeze solution) temperature limit by clipping jumper

JW3, which changes the sensing temperature associated with thermistor FP1. Note that the FP1 thermistor is located on the refrigerant line between the coaxial heat exchanger and

expansion device (TXV). Therefore, FP1 is sensing refrigerant

temperature, not water temperature, which is a better indication

of how water ow rate/temperature is affecting the refrigeration

circuit.

Low voltage field wiring

Figure 22b: HSS Low Voltage Field Wiring

The factory setting for FP1 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 23 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].

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Thermostat

AMV

Taco Valve

Heater Switch

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Electrical - Low Voltage Wiring

Figure 23: FP1 Limit Setting

JW3-FP1 jumper

should be clipped

for low temperature

CXM PCB

operation

Accessory Connections

A terminal paralleling the compressor contactor coil has been

provided on the CXM control. Terminal “A” is designed to

control accessory devices, such as water valves. Note: This terminal should be used only with 24 Volt signals and not

line voltage. Terminal “A” is energized with the compressor contactor. See Figure 24 or the specic unit wiring diagram

for details.

Figure 24: Accessory Wiring

electromechanical thermostat. Therefore, only relay or triac based thermostats should be used.

Two-stage HTS Units

Two-stage units should be designed with two parallel valves for ground water applications to limit water use during first stage operation. For example, at 1.5 gpm/ton [2.0 l/m per kW], a model 049 unit requires 6 gpm [23 l/m] for full load (2nd stage) operation, but only 4 gpm [15 l/m] during 1st stage operation. Since the unit will operate on first stage 80-90% of the time, significant water savings can be realized by using two parallel solenoid valves with two flow regulators. In the example above, stage one solenoid would be installed with a 4 gpm [15 l/m] flow regulator on the outlet, while stage two would utilize a 2 gpm [8 l/m] flow regulator. When stage one is operating, the second solenoid valve will be closed. When stage two is operating, both valves will be open, allowing full load flow rate.

Figure 27 illustrates piping for two-stage solenoid valves. Review figures 24-26 for wiring of stage one valve. Stage two valve should be wired between “Y2” (compressor solenoid

-- wire nut connection) and terminal “C.” NOTE: When EWT

is below 50°F [10°C], a minimum of 2 gpm per ton (2.6 l/m per kW) is required.

Water Solenoid Valves - “Indoor” Compressor Section Only

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 24 shows typical wiring for a 24VAC external solenoid valve. Figures 25 and 26 illustrate typical slow closing water control valve wiring for Taco 500 series (HCI P/N AVM…) 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:

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

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Figure 25: AMV Valve Wiring

Figure 26: Taco SBV Valve Wiring

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Figure 27: Two-Stage HTS Piping

x CAUTION! x

CAUTION! Many units installed with a factory or field supplied

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Electrical - Low Voltage Wiring

x CAUTION! x

CAUTION! Refrigerant pressure activated water regulating

valves should never be used with HCI equipment.

Figure 28b: Typical Thermostat Wiring, HSS Single-Stage Units (2 Heat/1 Cool)

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 28a and 28b to the low voltage terminal strip on the CXM control board. Practically any heat pump thermostat will work with these units, provided it has the correct number of heating and cooling stages.

Figure 28a: Typical Thermostat Wiring, Two-Stage HTS Units (3 Heat/2 Cool)

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Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

CXM Controls

CXM Control

For detailed control information, see CXM Application, Operation and Maintenance (IOM) manual.

Field Selectable Inputs

Test mode: Test mode allows the service technician to check the operation of the control in a timely manner. By momentarily shorting the test terminals, the CXM control enters a 20 minute test mode period in which all time delays are sped up 15 times. Upon entering test mode, the status LED will flash a code representing the last fault. For diagnostic ease at the thermostat, the alarm relay will also cycle during test mode. The alarm relay will cycle on and off similar to the status LED to indicate a code representing the last fault, at the thermostat. Test mode can be exited by shorting the test terminals for 3 seconds. Retry Mode: If the control is attempting a retry of a fault, the

status LED will slow flash (slow flash = one flash every 2

seconds) to indicate the control is in the process of retrying.

Field Conguration Options

Note: In the following field configuration options, jumper wires should be clipped ONLY when power is removed from the CXM control.

Water coil low temperature limit setting: Jumper 3 (JW3FP1 Low Temp) provides field selection of temperature limit

setting for FP1 of 30°F or 10°F [-1°F or -12°C] (refrigerant

temperature).

Not Clipped = 30°F [-1°C]. Clipped = 10°F [-12°C].

Air coil low temperature limit setting: Jumper 2 (JW2-FP2 Low Temp) provides field selection of temperature limit

setting for FP2 of 30°F or 10°F [-1°F or -12°C] (refrigerant

temperature). Note: This jumper should only be clipped under extenuating circumstances, as recommended by the factory.

Not Clipped = 30°F [-1°C]. Clipped = 10°F [-12°C].

Alarm relay setting: Jumper 1 (JW1-AL2 Dry) provides field selection of the alarm relay terminal AL2 to be jumpered to 24VAC or to be a dry contact (no connection).

Not Clipped = AL2 connected to R. Clipped = AL2 dry contact

(no connection).

terminal will continuously output the last fault code of the controller. If set to “EH2 normal,” EH2 will operate as standard electric heat output.

On = EH2 Normal. Off = DDC Output at EH2.

NOTE: Some CXM controls only have a 2 position DIP switch package. If this is the case, this option can be selected by clipping the jumper which is in position 4 of SW1.

Jumper not clipped = EH2 Normal. Jumper clipped = DDC

Output at EH2.

DIP switch 5: Factory Setting - Normal position is “On.” Do not change selection unless instructed to do so by the factory.

-Slow Flash = 1 flash every 2 seconds

-Fast Flash = 2 flashes every 1 second

-Flash code 2 = 2 quick flashes, 10 second pause, 2 quick

flashes, 10 second pause, etc.

-On pulse 1/3 second; off pulse 1/3 second

Table 9a: CXM LED And Alarm Relay Operations

DIP Switches

Note: In the following field configuration options, DIP switches should only be changed when power is removed from the CXM control. DIP switch 1: Unit Performance Sentinel Disable - provides field selection to disable the UPS feature.

On = Enabled. Off = Disabled.

DIP switch 2: Stage 2 Selection - provides selection of whether compressor has an “on” delay. If set to stage 2, the compressor will have a 3 second delay before energizing. Also, if set for stage 2, the alarm relay will NOT cycle during test mode.

On = Stage 1. Off = Stage 2

DIP switch 3: Not Used. DIP switch 4: DDC Output at EH2 - provides selection for DDC operation. If set to “DDC Output at EH2,” the EH2

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Safety Features – CXM Control

The safety features below are provided to protect the compressor, heat exchangers, wiring and other components from damage caused by operation outside of design conditions. Anti-short cycle protection: The control features a 5 minute anti-short cycle protection for the compressor. Note: The 5 minute anti-short cycle also occurs at power up. Random start: The control features a random start upon power up of 5-80 seconds. Fault Retry: In Fault Retry mode, the Status LED begins slowly flashing to signal that the control is trying to recover from a fault input. The control will stage off the outputs and then “try again” to satisfy the thermostat input call. Once the thermostat input call is satisfied, the control will continue on as if no fault occurred. If 3 consecutive faults occur without satisfying the thermostat input call, the control will go into “lockout” mode. The last fault causing the lockout will be stored in memory and can be viewed by going into test mode. Note: FP1/FP2 faults are factory set at only one try. Lockout: In lockout mode, the status LED will begin fast flashing. The compressor relay is turned off immediately. Lockout mode can be “soft” reset by turning off the thermostat (or satisfying the call). A “soft” reset keeps the fault in memory but resets the control. A “hard” reset (disconnecting power to the control) resets the control and erases fault memory. Lockout with emergency heat: While in lockout mode, if W becomes active (CXM), emergency heat mode will occur. High pressure switch: When the high pressure switch opens due to high refrigerant pressures, the compressor relay is de-energized immediately since the high pressure switch is in series with the compressor contactor coil. The high pressure fault recognition is immediate (does not delay for 30 continuous seconds before deenergizing the compressor).

High pressure lockout code = 2

Example: 2 quick flashes, 10 sec pause, 2 quick flashes, 10 sec. pause, etc. Low pressure switch: The low pressure switch must be open and remain open for 30 continuous seconds during “on” cycle to be recognized as a low pressure fault. If the low pressure switch is open for 30 seconds prior to compressor power up it will be considered a low pressure (loss of charge) fault. The low pressure switch input is bypassed for the initial 60 seconds of a compressor run cycle.

Low pressure lockout code = 3

Water coil low temperature (FP1): The FP1 thermistor temperature must be below the selected low temperature limit setting for 30 continuous seconds during a compressor run cycle to be recognized as a FP1 fault. The FP1 input is bypassed for the initial 60 seconds of a compressor run cycle. FP1 is set at the factory for one try. Therefore, the control will go into lockout mode once the FP1 fault has occurred.

FP1 lockout code = 4

Air coil low temperature (FP2): The FP2 thermistor temperature

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

CXM Controls

must be below the selected low temperature limit setting for 30 continuous seconds during a compressor run cycle to be recognized as a FP2 fault. The FP2 input is bypassed for the initial 60 seconds of a compressor run cycle. FP2 is set at the factory for one try. Therefore, the control will go into lockout mode once the FP2 fault has occurred.

FP2 lockout code = 5

Condensate overflow: The condensate overflow sensor must sense overflow level for 30 continuous seconds to be recognized as a CO fault. Condensate overflow will be monitored at all times.

CO lockout code = 6

Over/under voltage shutdown: An over/under voltage condition exists when the control voltage is outside the range of 19VAC to 30VAC. Over/under voltage shut down is a self-resetting safety. If the voltage comes back within range for at least 0.5 seconds, normal operation is restored. This is not considered a fault or lockout. If the CXM is in over/under voltage shutdown for 15 minutes, the alarm relay will close.

Over/under voltage shut down code = 7

Unit Performance Sentinel-UPS (patent pending): The UPS feature indicates when the heat pump is operating inefficiently. A UPS condition exists when: a) In heating mode with compressor energized, FP2 is

greater than 125°F [52°C] for 30 continuous seconds, or:

b) In cooling mode with compressor energized, FP1 is

greater than 125°F [52°C] for 30 continuous seconds, or:

In cooling mode with compressor energized, FP2 is less

than 40°F [4.5°C] for 30 continuous seconds. If a UPS

condition occurs, the control will immediately go to UPS warning. The status LED will remain on as if the control is in normal mode. Outputs of the control, excluding LED and alarm relay, will NOT be affected by UPS. The UPS condition cannot occur during a compressor off cycle. During UPS warning, the alarm relay will cycle on and off. The cycle rate will be “on” for 5 seconds, “off” for 25 seconds, “on” for 5 seconds, “off” for 25 seconds, etc.

UPS warning code = 8

Swapped FP1/FP2 thermistors: During test mode, the control monitors to see if the FP1 and FP2 thermistors are in the appropriate places. If the control is in test mode, the control will lockout, with code 9, after 30 seconds if: a) The compressor is on in the cooling mode and the FP1

sensor is colder than the FP2 sensor, or:

b) The compressor is on in the heating mode and the FP2

sensor is colder than the FP1 sensor.

Swapped FP1/FP2 thermistor code = 9.

Diagnostic Features

The LED on the CXM board advises the technician of the current status of the CXM control. The LED can display either the current CXM mode or the last fault in memory if in test mode. If there is no fault in memory, the LED will flash Code 1 (when in test mode).

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Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

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CXM Controls

CXM Control Start-up Operation

The control will not operate until all inputs and safety controls are checked for normal conditions. The compressor will have a

5 minute anti-short cycle delay at power-up. The 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.

Table 9b: Unit Operation

HTS HSS HSS

T-stat signal

G Fan only Fan only Fan only

G, Y or Y1 Stage 1 heating

G, Y1, Y2 Stage 2 heating

G, Y1, Y2, W Stage 3 heating

G, W Emergency heat Emergency heat Emergency heat

G, Y or Y1, O Stage 1 cooling

G, Y1, Y2, O Stage 2 cooling

Variable Speed

Air Handler

Residential Split - 60Hz R22 &R410A

Variable Speed

PSC Air Handler

Rev.: 5 June, 2008

Air Handler

Stage 1 heating

Stage 2 heating

Stage 3 heating

Stage 1 cooling

Stage 2 cooling

Stage 1 heating

Stage 2 heating

N/A

Cooling

N/A

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, 2nd

or 3rd stage fan operation (depending on fan settings)

2 Stage 1 = 1st stage compressor, 1st stage fan operation, reversing valve Stage 2 = 2nd stage compressor, 2nd stage fan operation, reversing valve 3 Stage 1 = compressor, 1st stage fan operation Stage 2 = compressor, 2nd stage fan operation Stage 3 = compressor, auxiliary electric heat, 2nd or 3rd stage fan operation (depending on fan settings) 4 Stage 1 = compressor, 1st stage fan operation, reversing valve Stage 2 = compressor, 2nd stage fan operation, reversing valve 5 Stage 1 = compressor, fan Stage 2 = compressor, auxiliary electric heat, fan 6 Cooling = compressor, fan, reversing valve

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ϒ ϒ ϒ ϒ

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

CXM Controls

Table 10: Nominal resistance at various temperatures

CXM Thermostat Details Thermostat Compatibility - Most all heat pump thermostats can be used with the CXM control. However Heat/Cool stats are NOT compatible with the CXM.

Anticipation Leakage Current - Maximum leakage current

for "Y" 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 specified above.

Thermostat Signals -

• "Y" and "W" have a 1 second recognition time when

being activated or being removed.

• "O" and "G" are direct pass through signals but are

monitored by the micro processor.

• "R" and "C" are from the transformer.

• "AL1" and "AL2" originate from the alarm relay.

• "A" is paralleled with the compressor output for use

with well water solenoid valves.

• The "Y" 1/4" quick connect is a connection point to the "Y" input terminal P1 for factory use. This "Y" terminal can be used to drive panel mounted relays such as the loop pump relay.

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Unit Starting and Operating Conditions

Operating Limits

Environment – “Indoor” compressor section is designed for

indoor installation only. Never install “indoor” compressor section in areas subject to freezing or where humidity levels could cause cabinet condensation (such as unconditioned spaces subject to 100% outside air). “Outdoor” unit is designed for conditions where ambient air is below freezing (see Table

11).

Power Supply – A voltage variation of +/– 10% of nameplate

utilization voltage is acceptable.

Starting Conditions

Consult Table 11 for the particular model. Starting conditions vary depending upon model and are based upon the following notes:

Notes:

1. Conditions in Table 11 are not normal or continuous operating conditions. Minimum/maximum limits are startup conditions to bring the building space up to occupancy temperatures. Units are not designed to operate under these conditions on a regular basis.

2. Voltage utilization range complies with ARI Standard 110.

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.

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Table 11: Unit Operation

Operating Limits

Air Limits

Min. ambient air, DB 45°F [7°C] 39°F [4°C] -10°F [-23°C] -10°F [-23°C]

Rated ambient air, DB 80.6°F [27°C] 68°F [20°C] 80.6°F [27°C] 68°F [20°C]

Max. ambient air, DB 110°F [43°C] 85°F [29°C] 110°F [43°C] 85°F [29°C]

Min. entering air, DB/WB 50°F [10°C] 40°F [4.5°C] 50°F [10°C] 50°F [10°C]

Rated entering air, DB/WB 80.6/66.2°F [27/19°C] 68°F [20°C] 80.6/66.2°F [27/19°C] 68°F [20°C]

Max. entering air, DB/WB 110/83°F [43/28°C] 80°F [27°C] 110/83°F [43/28°C] 80°F [27°C]

Water Limits

Min. entering water 30°F [-1°C] 20°F [-6.7°C] 30°F [-1°C] 20°F [-6.7°C]

Normal entering water 50-110°F [10-43°C] 30-70°F [-1 to 21°C] 50-110°F [10-43°C] 30-70°F [-1 to 21°C]

Max. entering water 120°F [49°C] 90°F [32°C] 120°F [49°C] 90°F [32°C]

Normal water flow

Cooling Heating Cooling Heating

HTS/HSS PDW

1.5 to 3.0 gpm/ton 1.5 to 3.0 gpm/ton

2.0 to 3.9 l/m per kW 2.0 to 3.9 l/m per kW

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Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Unit Starting and Operating Conditions

Unit and System Checkout

BEFORE POWERING SYSTEM, please check the following:

UNIT CHECKOUT

� Balancing/shutoff valves: Insure that all isolation valves

are open and water control valves are wired.

� Line voltage and wiring: Verify that voltage is within

an acceptable range for the unit and wiring and fuses/ breakers are properly sized. Verify that low voltage wiring is complete.

� Unit control transformer: Insure that transformer has the

properly selected voltage tap. Residential 208-230V units are factory wired for 230V operation unless specified 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 Table 7.

� Low water temperature cutout: Verify that low water

temperature cut-out on the CXM control is properly set.

� Unit fan: Manually rotate fan to verify free rotation and

insure that blower wheel is secured to the motor shaft. Be sure to remove any shipping supports if needed. 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 line is open and

properly pitched toward drain.

� HWG pump is disconnected unless piping is completed

and air has been purged from the system.

� Water flow balancing: Record inlet and outlet water

temperatures for each heat pump upon startup. This check can eliminate nuisance trip outs and high velocity water flow that could erode heat exchangers.

� Unit air coil and filters: Insure that filter is clean and

accessible. Clean air coil of all manufacturing oils.

� Unit controls: Verify that CXM field selection options are

properly set. Low voltage wiring is complete.

� Blower speed is set. � 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 fittings (see Table 3).

� System flushing: 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.

� Flow Controller pump(s): Verify that the pump(s) is wired

and in operating condition.

� System controls: Verify that system controls function and

operate in the proper sequence.

� Low water temperature cutout: Verify that low water

temperature cut-out controls are set properly (FP1 - JW3).

� Miscellaneous: Note any questionable aspects of

the installation.

x CAUTION! x

CAUTION! Verify that ALL water control valves are open

and allow water ow prior to engaging the compressor.

Freezing of the coax or water lines can permanently damage the heat pump.

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

x CAUTION! x

CAUTION! To avoid equipment damage, DO NOT leave system 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 flow 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 11. During start-up checks, loop water temperature entering the heat pump should

be between 30°F [-1°C] and 95°F [35°C].

Two factors determine the operating limits of water source 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 five minute time delay in the

control circuit that can be eliminated on the CXM control board as shown below in Figure 29. See controls description for details.

c. Verify that the compressor is on and that the water

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

The Quality Leader in Conditioning Air

Unit Start-Up Procedure

flow rate is correct by measuring pressure drop through the heat exchanger using the P/T plugs and comparing to Tables 12a through 12b.

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 13. 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 14 and 15. Verify correct water flow by comparing unit pressure drop across the heat exchanger versus the data in Tables 12a through 12b. 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 Tables 12a through 12b.

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 13. 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 14 and 15 Verify correct water flow by comparing unit pressure drop across the heat exchanger versus the data in Tables 12a through 12b. 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 Tables 12a through 12b.

Check air temperature rise across the air coil when

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

Residential Split - 60Hz R22 &R410A

(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 RETURN ALL WARRANTY REGISTRATION PAPERWORK.

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.

Rev.: 5 June, 2008

x WARNING! x

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.

x CAUTION! x

CAUTION! Verify that ALL water control valves are open

and allow water ow prior to engaging the compressor.

Freezing of the coax or water lines can permanently damage the heat pump.

Figure 29: Test Mode Pins

Short test pins together to enter Test Mode and speed-up timing and delays for 20 minutes.

www.heatcontoller.com

HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS

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

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Unit Operating Conditions

Table 12a: Two-Stage HTS R-410A Compressor Section Coax Water Pressure Drop

Model GPM

4.0

024

6.0

7.0

8.0

4.0

036

6.0

8.0

9.0

5.5

048

8.3

11.0

12.0

7.0

060

10.5

14.0

15.0

Table 12b: R-22 HSS Compressor Section Coax Water Pressure Drop

Model GPM

018

4 5 6

024

5 6 8

030

6 8

036

7 9

042

8 11 13

048

9 12 15

060

11 15 18

Table 13: Water Temperature Change Through Heat Exchanger

Pressure Drop (psi)

30°F 50°F 70°F 90°F

1.5

3.1

4.1

5.1

1.2

2.6

4.5

5.7

1.1

2.2

3.9

4.5

0.5

1.9

3.9

4.8

1.3

2.6

3.4

4.3

1.0

2.5

4.2

5.2

0.9

2.1

3.6

4.2

0.3

1.8

3.5

4.3

1.1

2.3

3.0

3.8

0.8

2.3

4.0

4.8

0.8

2.0

3.2

3.8

0.2

1.7

3.2

3.9

1.0

2.1

2.7

3.4

0.6

2.1

3.7

4.4

0.7

1.8

3.1

3.5

0.1

1.6

2.9

3.5

Pressure Drop (psi)

30°F 50°F 70°F 90°F

0.6

1.6

2.1

2.8

0.6

1.3

1.8

2.9

0.9

1.8

2.9

4.2

1.6

2.6

3.9

6.4

2.1

3.2

5.5

7.3

2.1

3.9

6.4

9.4

1.2

2.1

3.6

5.0

0.6

1.4

2.0

2.6

0.6

1.2

1.7

2.7

0.9

1.7

2.7

3.9

1.4

2.4

3.7

5.9

1.9

3.0

5.1

6.8

1.9

3.7

5.9

8.7

1.2

2.0

3.4

4.7

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

0.5

1.3

1.8

2.4

0.5

1.1

1.5

2.5

0.8

1.5

2.5

3.6

1.3

2.3

3.4

5.5

1.8

2.8

4.7

6.3

1.8

3.4

5.5

8.1

1.1

1.8

3.1

4.3

0.5

1.3

1.7

2.3

0.5

1.1

1.4

2.3

0.8

1.4

2.3

3.4

1.3

2.1

3.2

5.2

1.7

2.6

4.5

5.9

1.7

3.2

5.2

7.6

1.0

1.7

2.9

4.1

The Quality Leader in Conditioning Air

Residential Split - 60Hz R22 &R410A

Unit Operating Conditions

Table 14a: Size 024 HTS Two-Stage R-410A Typical Unit Operating Pressures and Temperatures

Entering

Water

Temp °F

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

122-132 122-132 122-132

132-142 132-142 132-142

139-149 139-149 139-149

141-151 141-151 141-151

145-155 145-155 145-155

Table 14b: Size 036 HTS Two-Stage R-410A Typical Unit Operating Pressures and Temperatures

Entering

Water

Temp °F

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

122-132 121-131 121-131

131-141 130-140 130-140

138-148 137-147 137-147

142-152 142-152 142-152

147-157 147-157 147-157

Full Load Cooling - without HWG active Full Load Heating - without HWG active

Discharge

Pressure

PSIG

159-179 146-166 132-152

186-206 172-192 158-178

281-301 267-287 253-273

374-394 360-380 346-366

473-493 458-478 441-461

Super-

heat

13-18 13-18 14-19

8-13 8-13 8-13

7-12 7-12 7-12

Sub-

cooling

9-14 7-12 7-12

8-13 6-11 6-11

8-13 8-13 7-12

9-14 9-14 8-13

10-15 10-15

9-14

Water Temp

Rise °F

16.7-18.7

12.3-14.3

7.9-9.9

16.3-18.3

12.1-14.1

7.8-9.8

15.7-17.7

11.6-13.6

7.6-9.6

14.6-16.6

10.7-12.7

6.9-8.9

13.6-15.6

9.9-11.9

6.2-8.2

Air Temp

Drop °F

18-24 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

77-87 79-89 82-92

107-117 111-121 115-125

139-149 145-155 152-162

177-187 181-191 186-196

Discharge

Pressure

PSIG

278-298 280-300 282-302

314-334 315-335 317-337

350-370 352-372 354-374

392-412 397-417 402-422

Super-

heat

4-9 4-9 4-9

6-11 6-11 6-11

7-12 7-12 7-12

9-14

10-15

11-16

Operation Not Recommended

Sub-

cooling

10-15 10-15 10-15

13-18 13-18 13-18

15-20 15-20 15-20

17-22 17-22 17-22

Full Load Cooling - without HWG active Full Load Heating - without HWG active

Discharge

Pressure

PSIG

153-173 145-165 135-155

222-242 208-228 194-214

299-319 280-300 263-283

388-408 367-387 347-367

486-506 465-475 444-464

Super-

heat

18-23 18-23 18-23

13-18 13-18 14-19

8-13 8-13 8-13

6-11 7-12 7-12

Sub-

cooling

9-14 8-13 8-13

10-15

9-14 9-14

13-18 12-17 12-17

13-18

8-13 8-13

13-18

8-13 8-13

Water Temp

Rise °F

22.1-24.1

16.8-18.8

10.5-12.5

21.9-23.9

16.1-18.1

10.3-12.3

21.5-23.5

15.8-17.8 10-12

20.5-22.5

14.9-16.9

9.3-11.3

19-21 14-16

9-11

Air Temp

Drop °F

19-25 20-26 20-26

18-24 18-24 18-24

Suction

Pressure

PSIG

71-81 75-85 78-88

103-113 107-117 112-122

134-144 140-150 146-156

172-182 184-194 196-206

Discharge

Pressure

PSIG

263-283 267-287 270-290

292-312 296-316 301-321

322-342 328-358 334-354

360-380 369-389 378-398

Super-

heat

5-10 5-10 5-10

6-11 6-11 6-11

7-12 7-12 7-12

8-13 8-13 8-13

Operation Not Recommended

Sub-

cooling

2-5 2-5 2-5

2.5-7

Rev.: 5 June, 2008

Water Temp

Drop °F

5.9-7.9

4.2-6.2

2.7-4.7

8.9-10.9

6.7-8.7

4.5-6.5

11.3-13.3

8.5-10.5

5.8-7.8

14.4-16.4

10.8-12.8

7.1-9.1

Water Temp

Drop °F

8.1-10.1

5.9-7.9

3.7-5.7

11.5-13.5

8.6-10.6

5.7-7.7

14.5-16.5

11.1-13.1

7.7-9.7

20.5-22.5 15-17 10-12

Air Temp

Rise °F

18-24 19-25 20-26

25-31 26-32 26-32

31-38 32-39 32-39

37-45 38-46 38-46

Air Temp

Rise °F

17-23 18-24 19-25

23-29 24-30 24-30

28-35 29-36 30-37

36-44 37-45 39-47

Table 14c: Size 048 HTS Two-Stage R-410A Typical Unit Operating Pressures and Temperatures

Entering

Water

Temp °F

30 30 30

50 50 50

70 70 70

90 90 90

110 110 110

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

112-122 111-121 111-121

125-135 123-133 122-132

133-143 132-142 131-141

138-148 137-147 136-146

144-154 143-153 142-152

Full Load Cooling - without HWG active Full Load Heating - without HWG active

Discharge

Pressure

PSIG

187-207 167-187 147-167

245-265 227-247 208-228

314-334 294-314 274-294

401-421 379-399 357-377

502-522 477-497 452-472

Super-

heat

18-23 18-23 18-23

13-18 13-18 14-19

9-14 9-14

10-15

8-13 8-13 9-14

Sub-

cooling

23-28 21-26 20-25

19-24 18-23 16-21

17-22 16-21 14-19

16-21 15-20 13-18

14-19 13-18 12-17

Water Temp

Rise °F

20.7-22.7

15.5-17.5

10.2-12.2

20.9-22.9

15.6-17.6

10.2-12.2

20.5-22.5

15.2-17.2

9.9-11.9

19.2-21.2

14.3-16.3

9.3-11.3

18-20

13.3-15.3

8.5-10.5

Air Temp

Drop °F

19-25 19-25 19-25

20-26 20-26 20-26

19-25 19-25 19-25

18-24 18-24 18-24

Suction

Pressure

PSIG

66-76 69-79 72-82

93-103 98-108

103-113

123-133 130-140 137-147

167-177 177-187 187-197

Discharge

Pressure

PSIG

261-281 264-284 267-287

289-309 295-315 301-321

319-339 329-349 336-356

365-385 374-394 388-408

Super-

heat

8-13 8-13 8-13

7-12 7-12 7-12

Operation Not Recommended

Sub-

cooling

5-10 5-10 5-10

www.heatcontoller.com

Water Temp

Drop °F

8-10

6-8 4-6

11.5-13.5

8.7-10.7

5.9-7.9

15-17

11.5-13.5

7.9-9.9

19.6-21.6 15-17

10.3-12.3

Air Temp

Rise °F

18-24 19-25 19-25

23-29 24-30 25-31

28-35 29-36 30-37

37-45 38-46 39-47

HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Unit Operating Conditions

Table 14d: Size 060 HTS Two-Stage R-410A Typical Unit Operating Pressures and Temperatures

Entering

Water

Temp °F

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

117-127 116-126 115-125

126-136 124-134 123-133

130-140 129-139 128-138

133-143 132-142 132-142

138-148 137-147 136-146

Full Load Cooling - without HWG active Full Load Heating - without HWG active

Discharge

Pressure

PSIG

160-180 133-153 125-145

228-248 212-232 195-215

305-325 286-306 266-286

398-418 376-396 354-374

505-525 483-503 459-479

Super-

heat

16-21 17-22 18-23

8-13 11-16 14-19

8-13

9-14 11-16

8-13

6-11

Sub-

cooling

8-13 6-11 5-10

10-15

9-14 7-12

10-15

9-14 7-12

10-15

9-14 8-13

Water Temp

Rise °F

17.5-19.5

11.9-13.9

6.3-8.3

19.8-21.8

14.2-16.2

8.5-10.5

20.3-22.3

14.8-16.8

9.3-11.3

19.4-21.4

14.1-16.1

8.8-10.8

18.3-20.3

13.3-15.3

8.3-10.3

Air Temp

Drop °F

16-22 16-22 16-22

20-26 20-26 20-26

21-27 21-27 21-27

20-26 20-26 20-26

19-25 19-25 19-25

Suction

Pressure

PSIG

66-76 69-79 72-82

95-105 100-110 105-115

128-138 133-143 139-149

173-183 177-187 182-192

Discharge

Pressure

282-302 285-305 289-309

318-338 321-341 324-344

360-380 364-384 368-388

407-427

411-431

415-435

PSIG

Super-

heat

9-15 9-15 9-15

8-14 8-14 8-14

Operation Not Recommended

Sub-

cooling

8-13 8-13 9-14

12-17 12-17 12-17

13-18 13-18 14-19

Water Temp

Drop °F

8-10

6-8 4-6

11.3-13.3

8.5-10.5

5.7-7.7

14-16

10.6-12.6

7.3-9.3

18.2-20.2

13.9-15.9

9.6-11.6

Air Temp

Rise °F

21-27 21-27 22-28

27-33 28-34 30-36

33-38 34-40 35-41

42-50 43-51 44-52

Table 15: R-22 HSS Typical Unit Operating Pressures and Temperatures

Entering

Water

Temp °F

Water

Flow

GPM/

ton

1.5

2.3

1.5

2.3

1.5

2.3

1.5

2.3

Suction

Pressure

PSIG

61-70 62-71

62-71

79-85 75-83

72-82

78-88 78-90

78-91

79-82 80-93

80-93

* Based on Nominal 400 CFM per ton per circuit ariflow and 70°F EAT heating and 80/67°F cooling.

** Cooling air and water numbers can vary greatly with changes in humidity. *** Water temperature difference based upon 1.5 - 3 GPM per ton of active circuit water flow. **** Using liquid line pressure.

Full Load Cooling - without HWG active Full Load Heating - without HWG active

Discharge

Pressure

PSIG

100-117

92-109 88-104

145-170 130-155 125-150

180-200 169-187 160-180

230-272 215-248 208-240

Super-

12-18 12-18 12-18

10-15 10-15 10-15

8-12 8-12 8-12

8-10 8-10 8-10

heat

Sub-

cooling

****

12-22 12-22 12-22

9-16 9-16 9-16

7-12 7-12 7-12

7-11 7-11 7-11

Water Temp

Rise *** °F

21-24 13-16

6-11

20-23 12-15

8-12

19-22

11-14

7-12

18-21 10-14

6-11

Air Temp

Drop °F

21-26 21-26 21-26

20-25 20-25 20-25

19-24 19-24 19-24

17-23 17-23 17-23

Suction Pressure

PSIG

34-39 37-42 38-44

51-58 53-62 55-65

71-82 77-89 81-92

Discharge

Pressure

163-183 165-185 167-186

175-202 178-206 180-208

215-250 203-235 200-235

PSIG

Super-

heat

5-10 5-10 5-10

9-12 9-12 9-12

10-14 10-14 10-14

Operation Not Recommended

Sub-

cooling

****

5-9 5-9 5-9

8-12 8-12 8-12

6-10 6-10 6-10

Water Temp

Drop *** °F

7.6-8.4

4.8-5.6

3.4-4.2

10.8-11.9

6.7-8.1

5.1-5.9

14.0-15.2

9.0-10.2

6.7-7.9

Air Temp

Rise °F

14-20 16-22 16-22

23-29 24-30 25-31

28-34 30-37 31-38

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

The Quality Leader in Conditioning Air

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.

Residential Split - 60Hz R22 &R410A

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

Consult air handler I.O.M. for maintenance requirements.

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 - “Indoor” Compressor Section

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, 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.

Rev.: 5 June, 2008

Filters

Filters must be clean to obtain maximum performance. Filters should be inspected every month under normal operating conditions and be replaced when necessary. Units should never be operated without a filter.

Washable, high efficiency, electrostatic filters, when dirty, can exhibit a very high pressure drop for the fan motor and reduce air flow, resulting in poor performance. It is especially important to provide consistent washing of these filters (in the opposite direction of the normal air flow) once per month using a high pressure wash similar to those found at selfserve car washes.

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HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Troubleshooting

General

If operational difficulties 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 “CXM Troubleshooting Process Flowchart” or “Functional Troubleshooting Chart.”

CXM Board

CXM board troubleshooting in general is best summarized as simply verifying inputs and outputs. After inputs and outputs have been verified, board operation is confirmed and the problem must be elsewhere. Below are some general guidelines for troubleshooting the CXM control.

Field Inputs

All inputs are 24VAC from the thermostat and can be verified using a volt meter between C and Y, G, O, W. 24VAC will be present at the terminal (for example, between “Y” and “C”) if the thermostat is sending an input to the CXM board.

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.

Test Mode

Test mode can be entered for 20 minutes by shorting the test pins. The CXM board will automatically exit test mode after 20 minutes.

CXM Troubleshooting Process Flowchart/Functional Troubleshooting Chart

The “CXM Troubleshooting Process Flowchart” is a quick overview of how to start diagnosing a suspected problem, using the fault recognition features of the CXM 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 CXM controls. Within the chart are five columns:

• The “Fault” column describes the symptoms.

• Columns 2 and 3 identify in which mode the fault is likey to

occur, heating or cooling.

• The “Possible Cause column” identifies the most likely

sources of the problem.

• The “Solution” column describes what should be done to

correct the problem.

x WARNING! x

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.

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 CXM IOM manual. An ice bath can be used to check calibration of the thermistor.

Outputs

The compressor relay is 24VAC and can be verified using a voltmeter. The fan signal is passed through the board to the external fan relay (units with PSC motors only). 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 volt meter 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 CXM 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 CXM board is NOT sending an output signal to the electric heat board.

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

The Quality Leader in Conditioning Air

CXM Process Flow Chart

x WARNING! x

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.

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

www.heatcontoller.com

HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Functional Troubleshooting

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

The Quality Leader in Conditioning Air

Functional Troubleshooting

Performance Troubleshooting

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

www.heatcontoller.com

HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

Troubleshooting Form

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.

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

The Quality Leader in Conditioning Air

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

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08/08

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