Heat Controller HSS, HTS SPLIT SYSTEM User Manual

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

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Ground-Loop Heat Pump Applications

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

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

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

Flushing the Earth Loop

Once piping is completed between the unit, Flow Controller and the ground loop (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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