Heat Controller HTS024B1D01NNN, HTS036B1D01NNN, HTS048B1D01NNN, HTS060B1D01NNN Installation, Operation And Maintenance Manual

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Installation, Operation and

Maintenace Manual

GeoLogix

HTS Series Split System,

Two Stage, 2-5 Tons

1900 Wellworth Ave., Jackson, Michigan 49203

THE QUALITY LEADER IN CONDITIONING AIR

Ph. 517-0787-2100

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Fax 517-787-9341

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www.heatcontroller.com

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HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS

Residential Split - 60Hz R410A

Rev.: 03 August, 2012

Table of Contents

Model Nomenclature . . . . . . . . . . . . . . . . . . . . 3

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . 5

Equipment Selection . . . . . . . . . . . . . . . . . . . . 6

Air Coil Match-ups . . . . . . . . . . . . . . . . . . . . . . 6

Air Handler Selection . . . . . . . . . . . . . . . . . . . 7

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

Water Connections . . . . . . . . . . . . . . . . . . . . . 9

Ground Loop Applications . . . . . . . . . . . . . . . . 9-11

Open Loop - Ground Water Systems . . . . . . . . 12-13

Water Quality Standards . . . . . . . . . . . . . . . . . 14

Lineset Information . . . . . . . . . . . . . . . . . . . . . 15

Refrigeration Installation . . . . . . . . . . . . . . . . . 15-19

Hot Water Generator . . . . . . . . . . . . . . . . . . . . 20-22

Electrical - Line Voltage . . . . . . . . . . . . . . . . . 23

Electrical - Low Voltage Wiring . . . . . . . . . . . . 24

Low Water Temperature Cutout Selection . . . 24

Thermostat Wiring . . . . . . . . . . . . . . . . . . . . . . 25

DXM2 Controls . . . . . . . . . . . . . . . . . . . . . . . . 26-27

Wire Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Unit Commissioning and

Operating Conditions . . . . . . . . . . . . . . . . . . . . 29

Unit Start-Up and Operating Conditions . . . . . 30

Unit Start-Up Procedure . . . . . . . . . . . . . . . . . 30-31

Unit Operating Conditions . . . . . . . . . . . . . . . . 32-33

Preventive Maintenance . . . . . . . . . . . . . . . . . 34

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 35-37

DXM2 Process Flow Chart. . . . . . . . . . . . . . . . 38

Functional & Performance Troubleshooting . . 39-42

Heat Controller, Inc. Water-Source Heating and Cooling Systems2

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1 2

SERIES

HT = Heat Controller Two Stage

CONFIGURATION

S = SPLIT

REVISION LEVEL

A = Obsolete 6-29-12 B = Current Revision DXM2 Effective 6-29-12

UNIT SIZE

024 036 048 060

Model Nomenclature : for Indoor Split Series

4 5 6 7

VO LTAGE

1 = 208-230/60/1

Residential Split - 60Hz R410A

91011121314

B0 2 4 D1 0 1 N N N

RETURN AIR FLOW CONFIGURATION

N = NOT APPLICABLE

HEAT EXCHANGER OPTIONS

Standard

Rev.: 03 August, 2012

SUPPLY AIR FLOW & MOTOR CONFIGURATION

N = NOT APPLICABLE

Copper

Cupro-Nickel

CONTROLS

C = CXM (Revision A only) D = DXM2 (Revision B only)

WATER CIRCUIT OPTIONS

0 = None 1 = HWG w/Internal Pump

CABINET

0 = Residential

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HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS

Residential Split - 60Hz R410A

Rev.: 03 August, 2012

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: Notiﬁ 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! To avoid equipment damage, DO NOT use these units as a source of heating or cooling during the construction process. The mechanical components and ﬁ lters will quickly become clogged with construction dirt and debris, which may cause system damage.

 WARNING! 

 CAUTION! 

 WARNING! 

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

 WARNING! 

WARNING! To avoid the release of refrigerant into the

atmosphere, the refrigerant circuit of this unit must be serviced only by technicians who meet local, state, and federal proﬁ 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 ﬁ led within 15 days, the freight company can deny the claim without recourse. Note: It is the responsibility of the purchaser to ﬁ le all necessary claims with the carrier. Notify your equipment supplier of all damage within ﬁ 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.

Residential Split - 60Hz R410A

Rev.: 03 August, 2012

General Information

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

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

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

 CAUTION! 

WARNING! All refrigerant discharged from this unit must

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

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, ﬁ 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 conﬁ 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.

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 ﬁ nished.

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

 CAUTION! 

CAUTION! To avoid equipment damage, DO NOT use

these units as a source of heating or cooling during the construction process. The mechanical components and ﬁ lters will quickly become clogged with construction dirt and debris, which may cause system damage.

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HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS

Residential Split - 60Hz R410A

Rev.: 03 August, 2012

Equipment Selection

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

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

General

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

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

Indoor Coil Selection - HTS GeoLogix

HCI split system heat pumps are rated in the AHRI directory with a speciﬁ c indoor coil match. GeoLogix

(HTS) models are rated with Heat Controller WDG Series air handlers and MWG Series coils as shown in Table 1a. Other brands of air handlers may attain the same AHRI ratings providing that the speciﬁ cations meet or exceed those listed in Table 1a AND Table 1b. However, for warranty and federal tax credits, an AHRI matched system is required. An ECM motor and TXV is required. Cap tubes and ﬁ xed oriﬁ ces are not acceptable. PSC fans may be used if matched to Table 1b, but will not meet AHRI ratings. If using PSC fan, compressor section must be operated as a single stage unit (i.e. wired for either 1st stage or 2nd stage). Without the ability to vary the airﬂ ow, supply air temperatures may not be acceptable if the compressor is allowed to change stages when used with a PSC fan motor.

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

Compressor Section Model 024 036 048 060

Indoor Section Model 024 036 048 060

Refrigerant HFC-410A

Metering Device TXV (required)

Air Coil Type Rows Dimensions

Cabinet Conﬁ guration

WDG Series Fan Motor Type - HP ECM - 1/2 ECM - 1/2 ECM - 1 ECM - 1

Table 1b: Tranquility®

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 AHRI/ISO 13256-1 GLHP conditions. Two-stage units may be operated in single-stage mode if desired, where smaller capacity is required.

For example, a model 024 may be used as a 1-1/2 ton unit if “locked” into 1st stage operation only. If PSC fan is used, unit must be “locked” into either 1st or 2nd stage. An ECM fan is required for two-stage operation and for AHRI ratings. Size air handler for “Full Load” if operating in two-stage mode.

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

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

27 Air Handler Characteristics for Brands other than Above Models

N 2

14 x 17

Evaporator

Temp (ºF)

N 2

24 x 17

Upﬂ ow/Downﬂ ow/Horizontal (Multipoise)

CFM

N 2

24 x 17

Capacity

(MBtuh)**

N 3

24 x 17

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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 airﬂ 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

Residential Split - 60Hz R410A

Rev.: 03 August, 2012

Equipment Selection

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HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS

Residential Split - 60Hz R410A

Rev.: 03 August, 2012

Installation

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

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

Removing Existing Condensing Unit (Where Applicable)

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

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

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

4. Replace line set, especially if upgrading system from R-22 to R-410A refrigerant. If line set cannot be replaced, it must be thoroughly ﬂ ushed 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 ﬂ ushed from the line set.

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

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

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

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

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

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

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

Air Handler and Coil Installation

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

Indoor Compressor Section Location

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

Heat Controller, Inc. Water-Source Heating and Cooling Systems8

Gasket

Swivel Nut

Stainless steel

snap ring

Brass Adaptor

Hand Tighten

Only!

Do Not

Overtighten!

The Quality Leader in Conditioning Air

Figure 2: HTS Installation

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

Residential Split - 60Hz R410A

Rev.: 03 August, 2012

Installation

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!

Water Connections-Residential (Distributor) Models Residential models utilize swivel piping ﬁ 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 ﬂ ush end of most 1” threaded male pipe ﬁ ttings pro- vides 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.

GROUND-LOOP HEAT PUMP APPLICATIONS

 CAUTION! 

CAUTION! The following instructions represent industry

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

Pre-Installation

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

Figure 3: Water Connections (Indoor Compressor Section)

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

Piping Installation

The typical closed loop ground source system is shown in Figure 3. All earth loop piping materials should be limited to polyethylene fusion only for in-ground sections of the loop. Galvanized or steel ﬁ ttings should not be used at any time due to their tendency to corrode. All plastic to metal threaded ﬁ ttings should be avoided due to their potential to leak in earth coupled applications. A ﬂ anged ﬁ tting should be substituted. P/T plugs should be used so that ﬂ ow can be measured using the pressure drop of the unit heat exchanger.

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HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS

Residential Split - 60Hz R410A

Rev.: 03 August, 2012

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

Flushing the Earth Loop

Once piping is completed between the unit, Flow Controller and the ground loop (Figure 4), the loop is ready for ﬁ nal purging and charging. A ﬂ ush cart with at least a 1.5 hp [1.1 kW] pump is required to achieve enough ﬂ uid 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 ﬂ ushing.

1. Fill loop with water from a garden hose through the ﬂ ush cart before using the ﬂ ush cart pump to insure an even ﬁ ll.

2. Once full, the ﬂ ushing process can begin. Do not allow the water level in the ﬂ ush 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 ﬂ uid level in the tank above the return tee so that air cannot be continuously mixed back into the ﬂ uid. Surges of 50 psi (345 kPa) can be used to help purge air pockets by simply shutting off the return valve going into the ﬂ ush 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 ﬂ uid level in the ﬂ ush 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 ﬂ ush tank (about a half gallon [2.3 liters]), since liquids are incompressible. If the level drops more than this, ﬂ ushing should continue since air is still being compressed in the loop ﬂ uid. Perform the “dead head” procedure a number of times.

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

Pressures will be higher in the winter months than during the cooling season. This ﬂ uctuation is normal and should be considered when charging the system initially. Run the unit in either heating or cooling for a number of minutes to condition the loop to a homogenous temperature. This is a good time for tool cleanup, piping insulation, etc. Then, perform ﬁ nal ﬂ ush 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 ﬂ ooded. This is not required for Taco circulators. Insure that the Flow Controller provides adequate ﬂ ow 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 ﬂ uid 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 speciﬁ c gravity.

Low Water Temperature Cutout Setting - DXM2 Control

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

Low water temperature operation requires extended range equipment.

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

Loop static pressure will ﬂ uctuate with the seasons.

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

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

Pipe Size Volume (gal) [liters]

1” 4.1 [15.3]

Copper

Rubber Hose 1” 3.9 [14.6]

Polyethylene

Unit Heat

Exchanger

Flush Cart Tank

[254mm x 91.4cm tall]

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]

Typical 1.0 [3.8]

10” Dia x 3ft tall

10 [37.9]

Residential Split - 60Hz R410A

Rev.: 03 August, 2012

Ground-Loop Heat Pump Applications

Figure 4: Loop Connection (Indoor Compressor Section)

To Loop

Flow

Controller

Unit Power Disconnect

Insulated

Hose Kit

AH & Thermostat Wiring

Air Pad or Extruded polystyrene insulation board

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.

P/T Plugs

Table 3: Antifreeze Percentages by Volume

Type

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

Methanol 100% USP food grade Propylene Glycol Ethanol*

* Must not be denatured with any petroleum based product

Minimum Temperature for Low Temperature Protection

25% 38% 29%

21% 25% 25%

16% 22% 20%

10% 15% 14%

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HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS

Residential Split - 60Hz R410A

Rev.: 03 August, 2012

Ground-Water Heat Pump Applications -Compressor Section Only

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

The “outdoor” version of the compressor section may not be used with open loop systems due to potential freezing of water piping. Typical open loop piping is shown in Figure

9. Shut off valves should be included for ease of servicing.

Boiler drains or other valves should be “tee’d” into the lines to allow acid ﬂ ushing of the heat exchanger. Shut off valves should be positioned to allow ﬂ ow through the coax via the boiler drains without allowing ﬂ ow into the piping system. P/T plugs should be used so that pressure drop and temperature can be measured. Piping materials should be limited to copper or PVC SCH80. Note: Due to the pressure and temperature extremes, PVC SCH40 is not recommended.

Water quantity should be plentiful and of good quality. Consult Table 4 for water quality guidelines. The unit can be ordered with either a copper or cupro-nickel water heat exchanger. Consult Table 4 for recommendations. Copper is recommended for closed loop systems and open loop ground water systems that are not high in mineral content or corrosiveness. In conditions anticipating heavy scale formation or in brackish water, a cupro-nickel heat exchanger is recommended. In ground water situations where scaling could be heavy or where biological growth such as iron bacteria will be present, an open loop system is not recommended. Heat exchanger coils may over time lose heat exchange capabilities due to build up of mineral deposits. Heat exchangers must only be serviced by a qualiﬁ ed 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 ﬂ ushing. In some cases, the desuperheater option should not be recommended due to hard water conditions and additional maintenance required.

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 ﬁ eld, 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 ﬂ ow rate required for the heat pump. Pump sizing and expansion tank must be chosen as complimentary items. For example, an expansion tank that is too small can causing premature pump failure due to short cycling. Variable speed pumping applications should be considered for the inherent energy savings and smaller expansion tank requirements.

Motorized Modulating Water Control Valve

Note the placement of the water control valve in ﬁ gure 9. Always maintain water pressure in the heat exchanger by placing the water control valve(s) on the discharge line to prevent mineral precipitation during the off-cycle. Pilot operated slow closing valves are recommended to reduce water hammer. If water hammer persists, a mini-expansion tank can be mounted on the piping to help absorb the excess hammer shock. This valve regulates the ﬂ ow using entering and leaving water delta-T of the system. Entering and leaving water temperature is read on the communicating thermostat or conﬁ guration/diagnostic service tool. Further details on valve operation are described later in this manual.

Water Quality Standards

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

Heat Controller, Inc. Water-Source Heating and Cooling Systems12

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.

 CAUTION! 

CAUTION! Refrigerant pressure activated water regulating

valves should never be used with HCI equipment.

Figure 9: Water Well Connections

Water

Control

Va l v e

Flow

Regulator

Pressure

Tank

Residential Split - 60Hz R410A

Rev.: 03 August, 2012

To manually open the internal modulating motorized water valve in HTS024 - 048 push down on the handle to unlock it. Then rotate the handle to the open position as shown in Figure 9a. This fully opens the valve for ﬂ ushing. Once ﬂ ushing is complete, return the valve handle to its normally closed position.

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

Figure 9a: Optional Modulating Motorized Valve Positions

Sizes 026-049 Sizes 064-072

Sizes 024 - 048 Sizes 060

Closed Closed

Water Out

Shut-Off

Optional

Filter

Boiler

P/T Plugs

Optional Modulating Motorized Valve - For Open Loop Applications

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

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

Drains

Valve

Water In

/RFN5HOHDVH

Open Open

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HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS

Residential Split - 60Hz R410A

Rev.: 03 August, 2012

Water Quality Standards

Table 4: Water Quality Standards

Water Quality

Parameter

Material

Closed

Recirculating

Open Loop and Recirculating Well

Scaling Potential - Primary Measurement

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

pH/Calcium Hardness

Method

All

pH < 7.5 and Ca Hardness <100ppm

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

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

Ryznar Stability Index If >7.5 minimize steel pipe use.

Langelier Saturation Index

All

- 6.0 - 7.5

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

-0.5 to +0.5

Direct well, 29°C Indirect Well HX

Iron Fouling

Iron Fe2+(Ferrous) (Bacterial Iron potential)

Iron Fouling

All

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

If Fe

Above this level deposition will occur .

<0.2 ppm (Ferrous)

<0.5 ppm of Oxygen

Corrosion Prevention

Hydrogen Sulfide (H

Ammonia ion as hydroxide, chloride, nitrate and sulfate compounds

Maximum Chloride Levels

6 - 8.5

All

Copper

Cupronickel

304 S 316 S

Titanium - >1000 ppm >550 ppm >375 ppm

Monitor/treat as

needed

- <0.5 ppm

- <20ppm NR NR

S - <400 ppm <250 pp m <150 ppm S - <1000 ppm <550 ppm < 375 ppm

- <150 ppm NR NR

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

At H

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

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

Rotten egg smell appears at 0.5 ppm level.

Maximum Allowable at maximum water temperature.

10$C24$C38

6 - 8.5

<0.5 ppm

Erosion and Clogging

<10 ppm of particles and a maximum velocity of 1.8 m/s

Particulate Size and Erosion

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

Notes:

&ORVHG5HFLUFXODWLQJV\VWHPLVLGHQWLILHGE\D

5HFLUFXODWLQJRSHQZHOOVVKRXOGREVHUYHWKHRSHQUHFLUFXODWLQJGHVLJQFRQVLGHUDWLRQV

15Application not recommended. 1RGHVLJQ0D[LPXP

All

Filtered for maximum 841 micron [0.84 mm, 20 mesh] size.

closed pressurized piping system.

<10 ppm (<1 ppm "sandfree” for reinjection) of particles and a maximum velocity of 1.8 m/s. Filtered for maximum 841 micron 0.84 mm, 20 mesh] size. Any particulate that is not removed can potentially clog components.

Rev.: 3/22/2012

Heat Controller, Inc. Water-Source Heating and Cooling Systems14

The Quality Leader in Conditioning Air

 CAUTION! 

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.

 CAUTION! 

CAUTION! Installation of a factory supplied liquid line

bi-directional ﬁ lter drier is required. Never install a suction line ﬁ 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.

Residential Split - 60Hz R410A

Rev.: 03 August, 2012

Refrigeration Installation

When passing refrigerant lines through a wall, seal opening with silicon-based caulk. Avoid direct contact with water pipes, duct work, ﬂ oor joists, wall studs, ﬂ 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.”

A reversible heat pump ﬁ lter drier is installed on the liquid line inside the compressor section cabinet (R-22 units only). R-410A models are shipped with a ﬁ lter 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.

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Fully Insulated

Suction Line

Fully Insulated

Liquid Line

Nitrogen Braze

HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS

Residential Split - 60Hz R410A

Rev.: 03 August, 2012

Refrigeration Installation

Figure 10: Braze Instructions

Replace Caps after adjusting

Vapor

service valves

CCW

Figure 11: Air Coil Connection

Bulb (Must be

Installed and Insulated)

Suction Line

Equalizer

Line

TXV (‘IN’ toward

compressor section)

FP2

Sensor

TXV has internal

check valve

Liquid Line

Add-On Heat Pump Applications

The HWG Series 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.

Rev. 05/31/00

Service ports for

gauges

Figure 5: Service Valve Positions

Position Description System

CCW - Full Out Operation Position Open Closed

CCW -Full Out 1/2

turn CW

CW - Full in Shipping Position Closed Open

Service Position Open Open

Service

Port

Installing the Indoor Coil and Lineset

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 ﬁ xed oriﬁ ce, the oriﬁ ce 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.

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 ﬁ lming 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 [413620 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 ﬁ eld. 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.

Heat Controller, Inc. Water-Source Heating and Cooling Systems16

The Quality Leader in Conditioning Air

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

Power Disconnects

Insulated Line Sets

PVC Condensate

Indoor Compressor

Section

with vented trap

Residential Split - 60Hz R410A

Rev.: 03 August, 2012

Refrigeration Installation

WDG

Series

TXV ‘IN’ toward

Compressor Section

Low Voltage

Air pad or extruded

polystyrene

Figure 13: Typical Split/Add-on Coil Fossil Fuel Furnace Installation (Indoor Compressor Section)

Air Temperature

TXV ‘IN’ toward

Compressor Section

Indoor Compressor

Section

Limit Switch

HWG Series

“A” Coil

PVC Condensate

with vented trap

Air pad or extruded

polystyrene

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HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS

Residential Split - 60Hz R410A

Rev.: 03 August, 2012

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 AHRI matched air handler or coil.

Table 6: R-410A Charging Values

 NOTICE! 

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 3ºF from the table values.

Heat Controller, Inc. Water-Source Heating and Cooling Systems18

The Quality Leader in Conditioning Air

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 ﬁ ve 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.”

Residential Split - 60Hz R410A

Rev.: 03 August, 2012

Refrigeration Installation

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 speciﬁ c entering water conditions.

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 signiﬁ cant 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.

4. 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 speciﬁ c entering water temperatures.

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

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HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS

’

Residential Split - 60Hz R410A

Rev.: 03 August, 2012

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 builtin water to refrigerant heat exchanger that eliminates the need to tie into the heat pump refrigerant circuit in the ﬁ eld. The control circuit and pump are also built in for residential equipment. Figure 18 shows a typical example of HWG water piping connections on a unit with built-in circulating pump. This piping layout reduces scaling potential.

The temperature set point of the HWG is ﬁ eld selectable to 125°F or 150°F . The 150°F setpoint allows more heat storage from the HWG. For example, consider the amount of heat that can be generated by the HWG when using the 125°F set point, versus the amount of heat that can be generated by the HWG when using the 150°F set point.

In a typical 50 gallon two-element electric water heater the lower element should be turned down to 100°F, or the lowest setting, to get the most from the HWG. The tank will eventually stratify so that the lower 80% of the tank, or 40 gallons, becomes 100°F (controlled by the lower element). The upper 20% of the tank, or 10 gallons, will be maintained at 125°F (controlled by the upper element).

Using a 125°F set point, the HWG can heat the lower 40 gallons of water from 100°F to 125°F, providing up to 8,330 btu’s of heat. Using the 150°F set point, the HWG can heat the same 40 gallons of water from 100°F to 150°F and the remaining 10 gallons of water from 125°F to 150°F, providing a total of up to 18,743 btu’s of heat, or more than twice as much heat as when using the 125°F set point.

This example ignored standby losses of the tank. When those losses are considered the additional savings are even greater.

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 50 gallons (189 liters) is used to limit installation costs and space. However, a dual tank, as shown in Figure 16, is the most efﬁ cient system, providing the maximum storage and temperate source water to the HWG.

It is always advisable to use water softening equipment on domestic water systems to reduce the scaling potential and lengthen equipment life. In extreme water conditions, it may be necessary to avoid the use of the HWG option since the potential cost of frequent maintenance may offset or exceed any savings. Consult Table 4 for scaling potential tests.

Figure 15: Typical HWG Installation (Indoor Compressor Section)

Hot Outlet

Shut-off

Valve #3

Shut Off Valve #2

Insulated water lines 5/8” OD, 50 ft maximum (one way) [16mm OD, 15 meters maximum]

Heat Controller, Inc. Water-Source Heating and Cooling Systems20

Cold

to home

Inlet

Shut Off Valve #1

Shut Off Valve #4

Upper

element to

120 - 130°F

[49 - 54°C]

Lower

element to

100 - 110°F

[38 - 43°C]

Powered

Water Heater

Field supplied 3/4’ brass nipple and ‘T

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

Hot Outlet to

Cold Inlet from

Domestic supply

Hot Outlet

Shut-off

Valve #3

Shut Off Valve #2

Water Heater

Insulated water lines - 5/8” OD, 50 ft maximum (one way)

[16mm OD, 15 meters maximum]

house

Shut-off

Valve #1

Shut-off

Valve #4

Unpowered

Field Supplied 3/4” brass nipple and “T”

Cold Inlet

Powered

Water Heater

Upper element to 130°F [54°C]

(or owner preference)

Lower element to 120°F [49°C]

The Quality Leader in Conditioning Air

WATER HEATER

CHECK VALVE

8” MAX

HOT WATER

TO HOUSE

ANTI-SCALD

VALV E

ANTI-SCALD

VALVE PIPING

CONNECTIONS

COLD WATER

SUPPLY

Installation

The HWG is controlled by two sensors and the DXM2 microprocessor control. One sensor is located on the compressor discharge line to sense the discharge refrigerant temperature. The other sensor is located on the HWG heat exchanger’s “Water In” line to sense the potable water temperature.

 WARNING! 

WARNING! SHOULD THE SENSORS BE DISCONNECTED OR REMOVED. FULL LOAD CONDITIONS CAN DRIVE HOT WATER TANK TEMPERATURES FAR ABOVE SAFE TEMPERATURE LEVELS IF SENSORS DISCONNECTED OR REMOVED.

The DXM2 microprocessor control monitors the refrigerant and water temperatures to determine when to operate the HWG. The HWG will operate any time the refrigerant temperature is sufﬁ ciently above the water temperature. Once the HWG has satisﬁ ed the water heating demand during a heat pump run cycle, the controller will cycle the pump at regular Intervals to determine if an additional HWG cycle can be utilized.

UNDER NO CIRCUMSTANCES

Residential Split - 60Hz R410A

Rev.: 03 August, 2012

Hot Water Generator

Figure 20: Anti-Scald Valve Piping Connections

When the control is powered and the HWG pump output is active for water temperature sampling or HWG operation, the DXM2 status LED will slowly ﬂ ash (On 1 second, Off 1 second).

If the control has detected a HWG fault, the DXM2 status LED will ﬂ ash a numeric fault code as follows:

High Water Temperature (>160 ºF) 5 ﬂ ashes Hot Water Sensor Fault 6 ﬂ ashes Compressor Discharge Sensor Fault 6 ﬂ ashes

Fault code ﬂ ashes have a duration of 0.3 seconds with

a 10 second pause between fault codes. For example, a “Compressor Discharge sensor fault” will be six ﬂ ashes 0.3 seconds long, then a 10 second pause, then six ﬂ ashes again, etc.

WARNING! WILL RESULT IN WATER TEMPERATURES SUFFICIENT TO CAUSE SEVERE PHYSICAL INJURY IN THE FORM OF SCALDING OR BURNS, EVEN WHEN THE HOT WATER TANK TEMPERATURE SETTING IS VISIBLY SET BELOW 150°F. THE 150°F HWG SETPOINT MUST ONLY BE USED ON SYSTEMS THAT EMPLOY AN APPROVED ANTI-SCALD VALVE (PART NUMBER AVAS4) AT THE HOT WATER STORAGE TANK WITH SUCH VALVE PROPERLY SET TO CONTROL WATER TEMPERATURES DISTRIBUTED TO ALL HOT WATER OUTLETS AT A TEMPERATURE LEVEL THAT PREVENTS SCALDING OR BURNS!

 WARNING! 

USING A 150°F SETPOINT ON THE HWG

WARNING! The HWG pump Is fully wired from the factory. Use extreme caution when working around the microprocessor control as it contains line voltage connections that presents a shock hazard that can cause severe injury or death!

The heat pump, water piping, pump, and hot water tank should be located where the ambient temperature does not fall below 50°F [10°C]. Keep water piping lengths at a minimum. DO NOT use a one way length greater than 50 ft. (one way) [15 m]. See Table 6 for recommended piping sizes and maximum lengths.

All installations must be in accordance with local codes. The installer is responsible for knowing the local requirements, and for performing the installation accordingly. DO NOT activate the HWG until “Initial Start-Up” section, below is completed. Powering the pump before all installation steps are completed may damage the pump.

Water Tank Preparation

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

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

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

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

5. When using an existing tank, it should be ﬂ 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.

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 WARNING! 

HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS

Residential Split - 60Hz R410A

Rev.: 03 August, 2012

Hot Water Generator

HWG Water Piping

1. Using at least 1/2” [12.7mm] I.D. copper, route and install the water piping and valves as shown in Figures 15 or 16. Install an approved anti-scald valve if the 150°F HWG setpoint is or will be selected. An appropriate method must be employed to purge air from the HWG piping. This may be accomplished by ﬂ ushing water through the HWG (as in Figures 15 and 16) or by installing an air vent at the high point of the HWG piping system.

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

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

Water Tank Reﬁ ll

1. Close valve #4. Ensure that the HWG valves (valves #2 and #3) are open. Open the cold water supply (valve #1) to ﬁ ll the tank through the HWG piping. This will purge air from the HWG piping.

2. Open a hot water faucet to vent air from the system until water ﬂ ows from faucet; turn off faucet. Open valve #4.

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 speciﬁ 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 (Fig 16).

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

Table 6: HWG Water Piping Sizes and Length

Unit Nominal Tonnage

2.0 0.8 50 -

3.0 1.2 50 -

4.0 1.6 45 50

5.0 2.0 25 50

*Maximum length is equivalent length (in feet) one way of type L

copper.

NOTICE! Make sure the compressor discharge line is connected to the “Hot Gas In” stub on the Heat Recovery Unit.

Nominal

HWG Flow

(gpm)

1/2" Copper

(max length*)

3/4" Copper

(max length*)

 CAUTION! 

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

 WARNING! 

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.

Initial Start-Up

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

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

3. Set S3-4 to the “ON” position (enabled) to engage the HWG.

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

5. The temperature difference between the water entering and leaving the HWG coil should be approximately 5-10°F [3-6°C].

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

Heat Controller, Inc. Water-Source Heating and Cooling Systems22

The Quality Leader in Conditioning Air

 WARNING! 

WARNING! To avoid possible injury or death due to electrical shock, open the power supply disconnect switch and secure it in an open position during installation.

 CAUTION! 

CAUTION! Use only copper conductors for ﬁ eld installed electrical wiring. Unit terminals are not designed to accept other types of conductors.

Electrical - Line Voltage

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

Residential Split - 60Hz R410A

Rev.: 03 August, 2012

Electrical - Line Voltage

All ﬁ nal electrical connections must be made with a length of ﬂ 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 21. Consult Table 7for 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.

Table 7: GeoMax 2 (HTS) Electrical Data

Model

Compressor

RLA LRA Qty

024 10.7 56.0 1 0.4 4.0 15.1 17.8 25

036 17.0 87.0 1 0.4 4.0 21.4 25.7 40

048 21.5 100.0 1 0.4 4.0 25.9 31.3 50

060 26.0 125.0 1 0.4 4.0 30.4 36.9 60

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.

HWG Pump

FLA

External

Pump

FLA

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

See unit wiring diagram for addtional details.

Unit Power Supply

Total

Unit

FLA

(see electrical

table for wire and

breaker size)

Min

Circuit

Amps

Max

Fuse/

HACR

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HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS

Residential Split - 60Hz R410A

Rev.: 03 August, 2012

Electrical - Low Voltage

Figure 22: HTS Low Voltage Field Wiring

Low Voltage Field Wiring

Low Water Temperature Cutout Selection

The DXM2 control allows the ﬁ eld selection of low water (or water-antifreeze solution) temperature limit by clipping jumper JW3, which changes the sensing temperature associated with thermistor LT1. Note that the LT1 thermistor is located on the refrigerant line between the coaxial heat exchanger and expansion device (TXV). Therefore, LT1 is sensing refrigerant temperature, not water temperature, which is a better indication of how water ﬂ ow rate/temperature is affecting the refrigeration circuit.

The factory setting for LT1 is for systems using water (30°F [-1.1°C] refrigerant temperature). In low water temperature (extended range) applications with antifreeze (most ground loops), jumper JW3 should be clipped as shown in Figure 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].

Accessory Connections

A terminal paralleling the compressor contactor coil has been provided on the DXM2 control. Terminal “A” is designed to control accessory devices. Note: This terminal should be used only with 24 Volt signals and not line voltage. Terminal “A” is energized with the compressor contactor.

Figure 23a: Accessory Wiring

Terminal Strip

DXM2

24VAC

Motorized Modulating Water Control Valve - Open Loop Ground Water Systems Only

An external valve should be used on ground water systems to shut off ﬂ ow when the compressor is not operating. Valve kit AMMV4D is available for use with HTS024-048, and kit AMMV5E is used with HTS060. See Figure 23b or the unit wiring diagram for valve wiring detail. Further details on valve operation are described later in this manual.

Figure 23b: Motorized Modulating Water Control Valve Open Loop Ground Water Systems Only

DXM 2

P11

Figure 23: LT1 Limit Setting

Fault

Status

Off On

1 2 3 4

Off On

1 2 3 4 5 6 7 8

A0-1 A0-2

P11

AO2

Gnd

T2 T2 T3 T3 T4 T4

1 2 3 4 5 6 7 8

P10

JW3

CCH

Relay

Comp Relay

T6 T6

DXM2 PCB

Heat Controller, Inc. Water-Source Heating and Cooling Systems24

LP LT1 LT1 LT2 LT2

RV RV CO

For MWV option, place jumper on 0-10V pins. Ensure actuator direction switch is set as shown.

24Vdc

EH1 EH2

CCG

JW3-LT1

jumper should

be clipped

for low

temperature

(antifreeze)

operation

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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 Figure 24 or 25 to the low voltage terminal strip on the DXM2 control board. Practically any heat pump thermostat will work with these units, provided it has the correct number of heating and cooling stages. However, using the communicating thermostat (7602-443) is highly recommended for on-site, easier conﬁ guration, monitoring and diagnosis. An optional outdoor temperature sensor is available.

The 7602-452 sensor is a thermistor, used as an accessory for thermostat model 7602-443. This sensor provides outdoor air temperature information for the control system, as well as an indication of outdoor temperature on the display screen.

 CAUTION! 

CAUTION! Refrigerant pressure activated water regulating

valves should never be used with ClimateMaster equipment.

 CAUTION! 

CAUTION! Either a communicating thermostat (7602-

443) or conﬁ guration tool (7602-444) MUST be used to conﬁ gure and diagnose this unit.

Residential Split - 60Hz R410A

Rev.: 03 August, 2012

Electrical - Thermostat Wiring

Figure 24: Communicating Thermostat Connection to DXM2 Control

Unit with

WDG

AL1

AXM

Control

Gnd

A+

B-

24V

DXM2

7602-443

ATC32U** Thermostat

24Vac Common

24Vac Hot

Comm +

Comm -

A+

B-

GND

Control

Gnd

A+

B-

24V

Outdoor

Sensor

(Optional)

Remote Indoor

Sensor

(Optional)

Thermostat Connections

C 24V Common for Control Circuit R 24V Supply for Control Circuit A+ Communications (Positive) B – Communications (Negative) GND Ground OD Outdoor Temperature Sensor ID Indoor Temperature Sensor

Figure 25: Conventional 3 Heat / 2 Cool Thermostat Connection to DXM2 and Non-AXM Air Handler

Thermostat

Fan

R C

Compressor

Compressor Stage 2

Auxiliary Heat

Dehumidification

Reversing Valve

24Vac Hot

24Vac Common

Fault LED

Notes:

1) ECM automatic dehumidification mode operates with dehumidification airflows in the cooling mode when the dehumidification output from thermostat is active. Normal heating and cooling airflows are not affected.

2) DXM2 board DIP switch S2-7 must be in the auto dehumidification mode for automatic dehumidification

DXM2 Board

AL1

Non-AXM

Air Handler

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HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS

Residential Split - 60Hz R410A

Rev.: 03 August, 2012

DXM2 Controls

DXM2 Control

DXM2 is the next generation in controls is capable of 2-way communication between itself and smart components, like the communicating thermostat, fan motor and conﬁ guration/ diagnostic tool.

For most residential applications, conﬁ guration, monitoring and diagnostics can be done from the thermostat / service tool and there’s no need to read LEDs and change DIP switches.

For details on user settings, refer to User Manual (part #:

For details on Installer settings (not to be used by consumers), refer to Installer manual (part #:

For details on installer/service settings on the conﬁ guration/ diagnostic tool, refer to operation manual (part #:

For further details on the DXM2 control, refer to the DXM2 Application, Operation and Maintenace Manual and it is shipped with the unit)

Thermostat compatibility

It is strongly recommended that GeoMax2 communicating thermostat be used with DXM2 control, to ensure easy conﬁ guration, monitoring and diagnostics, in PLAIN English, on the thermostat. For example, Airﬂ ow can NOT be conﬁ gured without a communicating thermostat or Conﬁ guration/ Diagnostic tool for use with GeoMax2.

Field Conﬁ guration Options - Note: In the following ﬁ eld conﬁ guration options, jumper wires should be clipped ONLY when power is removed from the DXM2 control.

Water coil low temperature limit setting: Jumper 3 (JW3LT1 Low Temp) provides ﬁ eld selection of temperature limit setting for LT1 of 30°F or 10°F [-1°F or -12°C] (refrigerant temperature).

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

A0-2: Conﬁ gure Modulating Valve (ﬁ eld installed acces- sory)

Set A0-2 jumper to “IOV” if using Modulating Motorized Valve as ﬁ eld installed accessory

DIP Switches - For residential applications, all conﬁ guration can be performed in PLAIN ENGLISH on the thermostat. No DIP switch changes are required and no LEDs to be observed.

 CAUTION! 

CAUTION! Do not restart units without inspection and

remedy of faulting condition. Equipment damage may occur.

DXM2 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 ﬁ rst time after power-up that there is a call for compressor, the compressor will follow a 5 to 80 second random start delay. After the random start delay and anti-short cycle delay, the compressor relay will be energized. On all subsequent compressor calls, the random start delay is omitted.

Test Mode button:

Test mode allows the service technician to check the operation of the control in a timely manner. By momentarily pressing the TEST pushbutton, the DXM2 control enters a 20 minute test mode period in which all time delays are sped up 15 times.

Figure 26: Test Mode Button

Gnd

B-

A+ 24V

(240Vac)

Com

Fan Enable

N.O.

(240Vac)

N.C.

N.O.

Fan Speed

Pust test button to enter Test Mode and speed-up timing and delays for 20 minutes.

Table 8: Unit Operation

Conventional

T-stat signal

(Non-Communicating)

Test

P12

Unit

ECM fan

12V

IN OUT Gnd

G Fan only

G, Y1 Stage 1 heating

G, Y1, Y2 Stage 2 heating

G, Y1, Y2, W Stage 3 heating

G, W Emergency heat

G, Y1, O Stage 1 cooling

G, Y1, Y2, O Stage 2 cooling

1 Stage 1 = 1st stage compressor, 1st stage fan operation Stage 2 = 2nd stage compressor, 2nd stage fan operation Stage 3 = 2nd stage compressor, auxiliary electric heat, 3rd stage fan operation 2 Stage 1 = 1st stage compressor, 1st stage fan operation, reversing valve Stage 2 = 2nd stage compressor, 2nd stage fan operation, reversing valve

Heat Controller, Inc. Water-Source Heating and Cooling Systems26

The Quality Leader in Conditioning Air

Conventional

stat connection

Cabinet

temperature

sensor (with variable speed pump)

Communications

and HWG

Settings

O G

AL1

AL2

NSB

ESD

OVR

NO1

NC1

COM1

NO2

NC2

COM2

COH

COM

Service tool

connection

JW1

Alarm Relay

Acc1

Relay

sU yrotca e

Acc2

Relay

Residential Split - 60Hz R410A

Rev.: 03 August, 2012

Figure 26a: DXM2 Layout and Connections

Communicating

stat connection

Gnd

B-

A+ 24V

Fault

Status

Off On

1 2 3 4

Off On

1 2 3 4 5 6 7 8

P11

Gnd

AO2

Micro

Off On

A0-1 A0-2

T2 T2 T3 T3 T4 T4

Test Button to

Speed up Time Delays

JW3

CCH

Relay

(240Vac)

N.O.

Com

Fan Enable

Test

1 2 3 4 5 6 7 8

P10

N.C.

N.O.

Fan Speed

P12

Relay

Comp Relay

T6 T6

12V

IN OUT Gnd

HP HP

LT1 LT1

LT2 LT2

RV RV CO CO

24Vdc

EH1 EH2

CCG

ECM Motor Connection

Water Coil Low Temp Limit Setting

Factory low voltage molex connection for

unit harness

Factory low

voltage molex

connection for

electric heat

harness

Configure modulating valve or variable speed pump

24V to compressor

second-stage solenoid

for Y2/full

load capacity

Variable

speed pump

water temp

Entering

www.heatcontroller.com

air temp

Leaving

Entering Hot water

Compressor Discharge

Temperature

Use 4 mounting screws

temperature

#6 sheet metal screw 1” long

HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS

Residential Split - 60Hz R410A

Rev.: 03 August, 2012

Indoor Split HTS024-060 Wiring Diagram 208-230-/60/1 DXM2

Heat Controller, Inc. Water-Source Heating and Cooling Systems28

The Quality Leader in Conditioning Air

Residential Split - 60Hz R410A

Rev.: 03 August, 2012

Unit Commissioning And Operating Conditions

Operating Limits

Environment – Units are designed for indoor installation only. Never install units in areas subject to freezing or where humidity levels could cause cabinet condensation (such as unconditioned spaces subject to 100% outside air). Power Supply – Voltage utilization shall comply with AHRI standard 110.

Determination of operating limits is dependent primarily upon three factors: 1) return air temperature. 2) water temperature, and

3) ambient temperature. When any one of these factors is at minimum or maximum levels, the other two factors should be at normal levels to insure proper unit operation. Extreme variations in temperature and humidity and/or corrosive water or air will adversely affect unit performance, reliability, and service life. Consult Table 9a for operating limits.

Table 9a: Building Operating Limits

Operating Limits

Air Limits

Min. ambient air, DB 45ºF [7ºC] 39ºF [4ºC] Rated ambient air, DB 80.6ºF [27ºC] 68ºF [20ºC] Max. ambient air, DB 130ºF [54ºC] 85ºF [29ºC] Min. entering air, DB/WB 65/45ºF [18/7ºC] 50ºF [10ºC]

Rated entering air, DB/WB 80.6/66.2ºF [27/19ºC] 68ºF [20ºC] Max. entering air, DB/WB 100/75ºF [38/24ºC] 80ºF [27ºC]

Water Limits

Min. entering water 20ºF [-6.7ºC] 20ºF [-6.7ºC] Normal entering water 50-110ºF [10-43ºC] 30-70ºF [-1 to 21ºC] Max. entering water 120ºF [49ºC] 120ºF [49ºC]

Normal Water Flow

Cooling Heating

70/50ºF Reheat

Unit

1.5 to 3.0 gpm / ton

[1.6 to 3.2 l/m per kW]

Commissioning Conditions

Consult Table 9b for commissioning conditions. Starting conditions vary depending upon model and are based upon the following notes:

Notes:

1. Conditions in Table 9b are not normal or continuous operating conditions. Minimum/maximum limits are start-up conditions to bring the building space up to occupancy temperatures. Units are not designed to operate under these conditions on a regular basis.

2. Voltage utilization complies with AHRI Standard 110.

Table 9b: Building Commissioning Limits

Commissioning Limits

Air Limits

Min. ambient air, DB 45ºF [7ºC] 39ºF [4ºC] Rated ambient air, DB 80.6ºF [27ºC] 68ºF [20ºC] Max. ambient air, DB 130ºF [54ºC] 85ºF [29ºC] Min. entering air, DB/WB 60ºF [16ºC] 40ºF [4.5ºC] Rated entering air, DB/WB 80.6/66.2ºF [27/19ºC] 68ºF [20ºC] Max. entering air, DB/WB 110/83ºF [43/28ºC] 80ºF [27ºC]

Water Limits

Min. entering water 20ºF [-6.7ºC] 20ºF [-6.7ºC] Normal entering water 50-110ºF [10-43ºC] 30-70ºF [-1 to 21ºC] Max. entering water 120ºF [49ºC] 120ºF [49ºC]

Normal Water Flow

Cooling Heating

Unit

1.5 to 3.0 gpm / ton

[1.6 to 3.2 l/m per kW]

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HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS

Residential Split - 60Hz R410A

Rev.: 03 August, 2012

Unit Start-Up and Operating Conditions

Unit and System Checkout

BEFORE POWERING SYSTEM, please check the following:

UNIT CHECKOUT

 Shutoff valves: Insure that all isolation valves are open.  Line voltage and wiring: Verify that voltage is within an

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

 Unit control transformer: Insure that transformer has the

properly selected voltage tap. Residential 208-230V units are factory wired for 230V operation unless speciﬁ ed otherwise.

 Loop/water piping is complete and purged of air. Water/piping

is clean.

 Antifreeze has been added if necessary.  Entering water and air: Insure that entering water and air

temperatures are within operating limits of Tables 9a and 9b.

 Low water temperature cutout: Verify that low water

temperature cut-out on the DXM2 control is properly set.

 Unit fan: Manually rotate fan to verify free rotation and insure

that blower wheel is secured to the motor shaft. Be sure to remove any shipping supports if needed. DO NOT oil motors upon start-up. Fan motors are pre-oiled at the factory. Check unit fan speed selection and compare to design requirements.

 Condensate line: Verify that condensate trap is installed and

pitched.

 HWG pump is disconnected unless piping is completed and

air has been purged from the system.

 Water ﬂ ow balancing: Record inlet and outlet water

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

 Unit air coil and ﬁ lters: Insure that ﬁ lter is clean and

accessible. Clean air coil of all manufacturing oils.

 Unit controls: Verify that DXM2 ﬁ eld selection options are

properly set. Low voltage wiring is complete.

 Blower CFM and Water ∆T is set on communicating

thermostats or diagnostic tool.

 Service/access panels are in place.

SYSTEM CHECKOUT

 System water temperature: Check water temperature for

proper range and also verify heating and cooling set points for proper operation.

 System pH: Check and adjust water pH if necessary to

maintain a level between 6 and 8.5. Proper pH promotes longevity of hoses and ﬁ ttings (see Table 4).

 System ﬂ ushing: Verify that all air is purged from the system.

Air in the system can cause poor operation or system corrosion. Water used in the system must be potable quality initially and clean of dirt, piping slag, and strong chemical cleaning agents. Some antifreeze solutions may require distilled water.

 Internal Flow Controller: Verify that it is purged of air and in

operating condition.

 System controls: Verify that system controls function and

operate in the proper sequence.

 Low water temperature cutout: Verify that low water

temperature cut-out controls are set properly (LT1 - JW3).

 Miscellaneous: Note any questionable aspects of

the installation.

CAUTION! Verify that ALL water valves are open and allow water ﬂ ow prior to engaging the compressor. Freezing of the coax or water lines can permanently damage the heat pump.

CAUTION! To avoid equipment damage, DO NOT leave system ﬁ lled in a building without heat during the winter unless antifreeze is added to the water loop. Heat exchangers never fully drain by themselves and will freeze unless winterized with antifreeze.

Unit Start-up Procedure

1. Turn the thermostat fan position to “ON.” Blower should start.

2. Balance air ﬂ ow at registers.

3. Adjust all valves to their full open position. Turn on the line power to all heat pump units.

4. Room temperature should be within the minimum-maximum ranges of Table 9b. During start-up checks, loop water temperature entering the heat pump should be between 30°F [-1°C] and 95°F [35°C].

5. It is recommended that water-to-air units be ﬁ rst started in the cooling mode, when possible. This will allow liquid refrigerant to ﬂ ow through the ﬁ lter-drier before entering the TXV, allowing the ﬁ lter-drier to catch any debris that might be in the system before it reaches the TXV.

Two factors determine the operating limits of geothermal heat pumps, (a) return air temperature, and (b) water temperature. When any one of these factors is at a minimum or maximum level, the other factor must be at normal level to insure proper unit operation.

6. Two factors determine the operating limits of geothermal heat pumps, (a) return air temperature, and (b) entering water temperature. When either of the factors is at a minimum or maximum level, the other factor must be at normal levels to insure proper unit operation.

a. Place the unit in Manual Operation. When in manual

mode activate Y1,Y2, and O to initiate the cooling mode. Also manually increase CFM until desired cooling CFM is achieved. Next adjust pump speed % until desired loop temperature difference (leaving water temperature minus entering water temperature) is achieved. (For modulating valve adjust valve %).

THERMOSTAT CONFIG SYSTEM CONFIG ACCESSORY CONFIG INPUT DEALER INFO HUMIDITY CONFIG TEMPERATURE ALGORITHM DEMAND REDUCTION CNFG

SERVICE MODE

RESTORY DEFAULTS

ATC32U01 SELECT OPTION

 CAUTION! 

INSTALLER SETTINGS

Heat Controller, Inc. Water-Source Heating and Cooling Systems30

The Quality Leader in Conditioning Air

9 - 12

20 - 26

4 - 8

10 - 17

SERVICE MODE

MANUAL OPERATION

CONTROL DIAGNOSTICS

DIPSWITCH CONFIG

FAULT HISTORY

CLEAR FAULT HISTORY

SELECT OPTION

PREVIOUS SELECT

MANUAL OPERATING MODE

Y1 COMM OUTPUT OFF

Y2 COMM OUTPUT OFF W COMM OUTPUT OFF O COMM OUTPUT OFF G COMM OUTPUT OFF H COMM OUTPUT OFF DH COMM OUTPUT OFF ECM AIRFLOW 0 PUMP SPEED 0% TEST MODE OFF

SELECT OPTION

PREVIOUS SELECT

b. Check for cool air delivery at the unit grille within a few

minutes after the unit has begun to operate.

NOTE: Units have a ﬁ ve minute time delay in the control circuit that can be bypassed on the DXM2 control board by placing the unit in the “Test” mode as shown in the unit IOM. Check for normal air temperature drop of 15°F to 25°F (cooling mode).

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

temperature rise (cooling mode) is within normal range.

Residential Split - 60Hz R410A

Rev.: 03 August, 2012

Unit Start-Up Procedure

the unit in the “Test” mode as shown in the unit IOM. Check for normal air temperature rise of 20°F to 30°F (heating mode).

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

temperature fall (heating mode) is within normal range.

d. Check for vibration, noise, and water leaks.

8. If unit fails to operate properly, perform troubleshooting analysis (see troubleshooting section in the unit IOM). 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.

9. When testing is complete, exit the Installer Menu and set thermostat to maintain desired comfort level for normal operation.

10. BE CERTAIN TO FILL OUT AND RETURN ALL WARRANTY REGISTRATION PAPERWORK.

Unit performance may be veriﬁ ed by calculating the unit heat of rejection and heat of extraction. Heat of Rejection (HR) can be calculated and compared to the performance data pages in this IOM. The formula for HR is as follows: HR = TD x GPM x 500 (or 485 for anti-freeze solutions), where TD is the temperature difference between the entering and leaving water, and GPM is the ﬂ ow rate in U.S. GPM determined by comparing the unit heat exchanger pressure drop to Table 12.

Heat of Extraction (HE) can also be calculated and compared to the performance data pages in this IOM. The formula for HE is as follows: HE = TD x GPM x 500 (or 485 for anti-freeze solutions), where TD is the temperature difference between the entering and leaving water, and GPM is the ﬂ ow rate in U.S. GPM determined by comparing the unit heat exchanger pressure drop to Table 12.

d. Check the elevation and cleanliness of the condensate

lines. Dripping may be a sign of a blocked line. Check that the condensate trap is ﬁ lled to provide a water seal.

e. Turn thermostat to “OFF” position. A hissing noise

indicates proper functioning of the reversing valve.

7. Allow ﬁ ve (5) minutes between tests for pressure to equalize before beginning heating test.

a. Go into Manual Mode activate Y1, and Y2 for Heating.

Also manually increase CFM until desired heating CFM is achieved. Next adjust pump speed % until desired loop temperature difference (entering water temperature minus leaving water temperature) is achieved. (For modulating valve adjust valve %).

b. Check for warm air delivery at the unit grille within a few

minutes after the unit has begun to operate.

NOTE: Units have a ﬁ ve minute time delay in the control circuit that can be bypassed on the DXM2 control board by placing

If performance during any mode appears abnormal, refer to the DXM2 section or troubleshooting section of this manual.

NOTE: To obtain maximum performance, the air coil should be cleaned before start-up. A 10% solution of dishwasher detergent and water is recommended.

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.

CAUTION! Verify that ALL water valves are open and allow water ﬂ ow prior to engaging the compressor. Freezing of the coax or water lines can permanently damage the heat pump.

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 WARNING! 

 CAUTION! 

HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS

Residential Split - 60Hz R410A

Rev.: 03 August, 2012

Unit Operating Conditions

Table 12: Two-Stage HFC-410A Compressor Section Coax Water Pressure Drop

Model GPM

4.0

026

6.0

7.0

8.0

4.0

038

6.0

8.0

9.0

5.5

049

8.3

11.0

12.0

7.0

064

10.5

14.0

15.0

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

Pressure Drop (psi)

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

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

Entering

Water

Temp °F

30*

110

Water

Flow

GPM/

2.25

ton

1.5

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

*Based on 15% methanol antifreeze solution

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

Discharge

Pressure

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

PSIG

Super-

heat

13-18 13-18 14-19

8-13 8-13 8-13

7-12 7-12 7-12

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

Entering

Water

Temp °F

30*

110

Water

Flow

GPM/

2.25

ton

1.5

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

*Based on 15% methanol antifreeze solution

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

Discharge

Pressure

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

PSIG

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

Heat Controller, Inc. Water-Source Heating and Cooling Systems32

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

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

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

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

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

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

Table 13: Water Temperature Change Through Heat Exchanger

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

Air Temp

Drop °F

19-25 20-26 20-26

18-24 18-24 18-24

Suction

PSIG

77-87 79-89 82-92

Suction

PSIG

71-81 75-85 78-88

Discharge

Pressure

278-298 280-300 282-302

314-334 315-335 317-337

350-370 352-372 354-374

392-412 397-417 402-422

Discharge

Pressure

263-283 267-287 270-290

292-312 296-316 301-321

322-342 328-358 334-354

360-380 369-389 378-398

Pressure

107-117 111-121 115-125

139-149 145-155 152-162

177-187 181-191 186-196

Pressure

103-113 107-117 112-122

134-144 140-150 146-156

172-182 184-194 196-206

Super-

PSIG

10-15 11-16

Operation Not Recommended

Super-

PSIG

Operation Not Recommended

heat

4-9 4-9 4-9

6-11 6-11 6-11

7-12 7-12 7-12

9-14

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

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

Sub-

cooling

2-5 2-5 2-5

2.5-7

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

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Residential Split - 60Hz R410A

Unit Operating Conditions

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

Entering

Water

Temp °F

30*

110

Water

Flow

GPM/

2.25

ton

1.5

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

*Based on 15% methanol antifreeze solution

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

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-

PSIG

heat

8-13 8-13 8-13

7-12 7-12 7-12

Operation Not Recommended

Sub-

cooling

5-10 5-10 5-10

Rev.: 03 August, 2012

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

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

Entering

Water

Temp °F

30*

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

PSIG

66-76 69-79 72-82

Discharge

Pressure

PSIG

282-302 285-305 289-309

318-338 321-341 324-344

360-380 364-384 368-388

407-427 411-431 415-435

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

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

95-105 100-110 105-115

128-138 133-143 139-149

173-183 177-187 182-192

*Based on 15% methanol antifreeze solution

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

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HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS

Residential Split - 60Hz R410A

Rev.: 03 August, 2012

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 ﬂ owing 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 ﬂ ow. Minimum ﬂ ow 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 ﬂ owing through the unit, the less chance for scaling. However, ﬂ ow 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.

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 ﬁ lters. Inspect the drain twice a year to avoid the possibility of plugging and eventual overﬂ ow.

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

Consult coil I.O.M. for maintenance requirements. 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 ﬁ ns 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 ﬂ oor 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 ﬂ ow rates are at proper levels before servicing the refrigerant circuit.

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 ﬁ lter.

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

Heat Controller, Inc. Water-Source Heating and Cooling Systems34

The Quality Leader in Conditioning Air

General Troubleshooting

Basic DXM2 board troubleshooting in general is best summarized as simply verifying inputs and outputs. After this process has been veriﬁ ed, conﬁ dence in board operation is conﬁ rmed and the trouble must be else where. Below are some general guidelines required for developing training materials and procedures when applying the DXM2 Control.

DXM2 Field Inputs

All conventional inputs are 24VAC from the thermostat and can be veriﬁ ed using a voltmeter between C and Y1, Y2, W, O, and G.

Sensor Inputs

All sensor inputs are ‘paired wires’ connecting each component with the board. Therefore continuity on pressure switches can be checked at the board connector.

The thermistor resistance should be measured with the connector removed so that only the impedance of the thermistor is measured. If desired, this reading can be compared to the chart shown in the thermistor section of this manual based upon the actual temperature of the thermistor clip. An ice bath can be used to check calibration of a thermistor if needed.

DXM2 Outputs

The compressor relay is 24VAC and can be veriﬁ ed using a voltmeter. The Alarm Relay can either be 24VAC as shipped or dry contacts (measure continuity during fault) for use with DDC by clipping the J4 jumper. Electric heat outputs are 24VDC and require a voltmeter set for DC to verify operation. When troubleshooting, measure from 24VDC terminal to EH1 or EH2 terminals.

Test Mode

Test Mode can be entered for 20 minutes by pressing the Test button. For Diagnostic ease at a conventional thermostat, the Alarm Relay will also cycle during test mode. The Alarm Relay will cycle on and off similar to the Fault LED to indicate a code representing the last fault, at the thermostat. Test Mode can also be entered and exited by cycling the G input, 3 times within a 60 second time period.

Residential Split - 60Hz R410A

Rev.: 03 August, 2012

Basic Troubleshooting Information

Sensor: Nominal resistance at various temperatures

Temp (ºC) Temp (ºF)

-17.8 0.0 85.34 55 131.0 2.99

-17.5 0.5 84.00 56 132.8 2.88

-16.9 1.5 81.38 57 134.6 2.77

-12 10.4 61.70 58 136.4 2.67

-11 12.2 58.40 59 138.2 2.58

-10 14.0 55.30 60 140.0 2.49

-9 15.8 52.38 61 141.8 2.40

-8 17.6 49.64 62 143.6 2.32

-7 19.4 47.05 63 145.4 2.23

-6 21.2 44.61 64 147.2 2.16

-5 23.0 42.32 65 149.0 2.08

-4 24.8 40.15 66 150.8 2.01

-3 26.6 38.11 67 152.6 1.94

-2 28.4 36.18 68 154.4 1.88

-1 30.2 34.37 69 156.2 1.81 0 32.0 32.65 70 158.0 1.75 1 33.8 31.03 71 159.8 1.69 2 35.6 29.50 72 161.6 1.64 3 37.4 28.05 73 163.4 1.58 4 39.2 26.69 74 165.2 1.53 5 41.0 25.39 75 167.0 1.48 6 42.8 24.17 76 168.8 1.43 7 44.6 23.02 77 170.6 1.39 8 46.4 21.92 78 172.4 1.34 9 48.2 20.88 79 174.2 1.30

10 50.0 19.90 80 176.0 1.26 11 51.8 18.97 81 177.8 1.22 12 53.6 18.09 82 179.6 1.18 13 55.4 17.26 83 181.4 1.14 14 57.2 16.46 84 183.2 1.10 15 59.0 15.71 85 185.0 1.07 16 60.8 15.00 86 186.8 1.04 17 62.6 14.32 87 188.6 1.01 18 64.4 13.68 88 190.4 0.97 19 66.2 13.07 89 192.2 0.94 20 68.0 12.49 90 194.0 0.92 21 69.8 11.94 91 195.8 0.89 22 71.6 11.42 92 197.6 0.86 23 73.4 10.92 93 199.4 0.84 24 75.2 10.45 94 201.2 0.81 25 77.0 10.00 95 203.0 0.79 26 78.8 9.57 96 204.8 0.76 27 80.6 9.16 97 206.6 0.74 28 82.4 8.78 98 208.4 0.72 29 84.2 8.41 99 210.2 0.70 30 86.0 8.06 100 212.0 0.68 31 87.8 7.72 101 213.8 0.66 32 89.6 7.40 102 215.6 0.64 33 91.4 7.10 103 217.4 0.62 34 93.2 6.81 104 219.2 0.60 35 95.0 6.53 105 221.0 0.59 36 96.8 6.27 106 222.8 0.57 37 98.6 6.01 107 224.6 0.55 38 100.4 5.77 108 226.4 0.54 39 102.2 5.54 109 228.2 0.52 40 104.0 5.33 110 230.0 0.51 41 105.8 5.12 111 231.8 0.50 42 107.6 4.92 112 233.6 0.48 43 109.4 4.72 113 235.4 0.47 44 111.2 4.54 114 237.2 0.46 45 113.0 4.37 115 239.0 0.44 46 114.8 4.20 116 240.8 0.43 47 116.6 4.04 117 242.6 0.42 48 118.4 3.89 118 244.4 0.41 49 120.2 3.74 119 246.2 0.40 50 122.0 3.60 120 248.0 0.39 51 123.8 3.47 121 249.8 0.38 52 125.6 3.34 122 251.6 0.37 53 127.4 3.22 123 253.4 0.36 54 129.2 3.10

Resistance

(kOhm)

Temp (ºC) Temp (ºF)

Resistance

(kOhm)

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HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS

Residential Split - 60Hz R410A

Rev.: 03 August, 2012

Advanced Troubleshooting and Conﬁ guration Information

General

To properly conﬁ gure and troubleshoot advanced control features, and to aid in troubleshooting basic control features, a communicating thermostat or diagnostic tool with similar capabilities should be used.

System Conﬁ guration

All factory installed DXM2 controls have their basic conﬁ guration parameters set as part of the factory manufacturing and test process. The System Conﬁ guration option under the communicating thermostat Installer menu provides the installer with the ability to adjust ECM target airﬂ ows for each operating mode, set control options, setup the loop conﬁ guration and parameters, and conﬁ gure ﬁ eld replacement controls.

Airﬂ ow Selection – The Airﬂ ow Selection menu allows the installer to adjust the ECM target airﬂ ow for each control operating mode, as well as independently set the heating and cooling blower off delays.

ECM Airﬂ ows – Independent airﬂ ow selections may be made for each stage of heating operation, each stage of cooling operation with and without dehumidiﬁ cation, as well as constant fan operation. The DXM2 control has set minimum and maximum airﬂ ow limits for each operating mode, based on the unit conﬁ guration that may not be changed.

Unit Size, Blower Type, and Loop Type. The Heat Pump Family, Unit Size, and Blower Type are needed to properly operate any particular unit conﬁ guration, especially those with ECM blowers.

Heat Pump Family – When replacing a control in the Heat Pump Family value must be set for proper blower and loop operation. The valid family values (HTS,HE, etc.) are available for the user to scroll through to select the proper value.

Heat Pump Size – When replacing a control in the ﬁ eld, the Heat Pump Size value must be set for proper blower operation. After a Heat Pump Family has been selected, the valid Heat Pump Size values will be available for the user to scroll through to select the proper value.

Blower Type – When replacing a control in the ﬁ eld, the Blower Type value must be set for proper operation. The valid Blower Type values will be available for the user to scroll through to select the appropriate value from No Blower, ECM Blower, or PSC conﬁ gurations.

Loop Conﬁ guration – When replacing a control in the ﬁ eld, the Loop Conﬁ guration value must be set for proper operation. The valid Loop Conﬁ guration values will be available for the user to scroll through to select the appropriate value from VS PUMP, MOD VALVE, or OTHER.

ﬁ eld, the

Non-ECM Conﬁ guration – If the DXM2 is not conﬁ gured to control an ECM blower, the airﬂ ow selections will not be available on the Airﬂ ow Selection menu.

Heating / Cooling Off Delays – The heating and cooling mode blower off delay times may be independently adjusted by the user. Each delay time may be set between 0 and 255 seconds.

Option Selection – The Option Selection menu allows the installer to set selected control options.

LT2 Setpoint – The LT2 setpoint should be set to ANTIFREEZE ONLY when the unit is conﬁ gured as a water-to- water unit with anti–freeze in the load side loop. For ALL other unit conﬁ gurations, the LT2 setpoint should be set to WATER.

Motorized Valve – The Motorized Valve option should be set to ON when a motorized water valve with end switch wired to the DXM2 Y1 is used with a communicating thermostat. For all other system conﬁ gurations, the Motorized Valve option should be set to OFF.

Unit Conﬁ guration – Selections under the Unit Conﬁ guration menu are normally set at the factory as a normal part of the manufacturing and test process. This menu allows the conﬁ guration to be modiﬁ ed for special applications, or to conﬁ gure ﬁ eld replacement controls. The Unit Conﬁ guration menu provides the ability to select the Heat Pump Family,

Loop Conﬁ guration – The Loop Conﬁ guration menu allows the installer to set the operating parameters for either an internal ﬂ ow center, or a proportional water valve, depending on the unit conﬁ guration.

Heating Delta T – The Heating Delta T option allows the target delta T (EWT – LWT) value selection for operating in the heating mode. The DXM2 control has set minimum and maximum delta T limits that may not be changed. Cooling Delta T – The Cooling Delta T option allows the target delta T (LWT – EWT) value selection for operating in the cooling mode. The DXM2 control has set minimum and maximum delta T limits that may not be changed.

Cooling Delta T – The Cooling Delta T option allows the target delta T (LWT – EWT) value selection for operating in the cooling mode. The DXM2 control has set minimum and maximum delt T limits that may not be changed.

Heat Controller, Inc. Water-Source Heating and Cooling Systems36

The Quality Leader in Conditioning Air

Advanced Troubleshooting and Conﬁ guration Information

Service Mode

The Service Mode provides the installer with several functions for troubleshooting, including Manual Operation, Control Diagnostics, Control Conﬁ guration, and Fault History.

Manual Operation – The Manual Operation mode allows the installer to bypass normal thermostat timings and operating modes, to directly activate the thermostat inputs to the DXM2, activate the DXM2 Test mode, and directly control the ECM blower, internal ﬂ ow center, and proportional valve.

Control Diagnostics – The Control Diagnostics menus allow the installer to see the current status of all DXM2 control switch inputs, values of all temperature sensor inputs, control voltage, ECM blower, internal ﬂ ow center, and proportional valve operating status and parameters.

Dipswitch Conﬁ guration – The Dipswitch Conﬁ guration menus allow the installer to easily see the current DXM2 control conﬁ guration.

Residential Split - 60Hz R410A

Rev.: 03 August, 2012

Fault I/O Conditions – This option displays the status of the DXM2 physical and communicated inputs and the relay outputs when the lockout occurred.

Fault Conﬁ guration Conditions – This option displays the status of the DXM2 option selections when the lockout occurred.

Fault Possible Causes – This option displays a list of potential causes of the stored fault.

Clear Fault History – The Clear Fault History option allows the fault history stored in the non-volatile memory of the DXM2 to be cleared.

Fault History – In addition to the fault code, the DXM2 stores the status of all control inputs and outputs when a fault condition is detected. The fault history covering the last ﬁ ve lockout conditions is stored and may be retrieved from the DXM2. After a speciﬁ c fault in the fault history is selected, the operating mode and time when the fault occurred are displayed, with options to select speciﬁ c control status values when the lockout occurred.

Fault Temp Conditions – This option displays the DXM2 temperature and voltage values when the lockout occurred.

Fault Flow Conditions – This option displays the DXM2 ECM blower, pump, and valve operating parameters when the lockout occurred.

www.heatcontroller.com

HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS

Residential Split - 60Hz R410A

Rev.: 03 August, 2012

DXM2 Process Flow Chart

 WARNING! 

WARNING! HAZARDOUS VOLTAGE! DISCONNECT

ALL ELECTRIC POWER INCLUDING REMOTE DISCONNECTS BEFORE SERVICING. Failure to disconnect power before servicing can cause severe personal injury or death.

See “Unit

short

cycles”

See “Only

Fan Runs”

See “Only

Comp

Runs”

See “Does

not Operate

in Clg”

Attempt to

Lockout at

Yes

Unit Short

Compressor

Did unit lockout

after a period of

operation?

Does unit

operate in

Start

Did Unit

Start?

Yes

Did Unit

Start-up?

Cycles?

Only Fan

Runs?

Only

Runs?

cooling?

Yes

DXM2 Functional Troubleshooting Flow Chart

Yes

Check Main

power (see power

problems)

Check fault code on communicating

thermostat (ATC32) or Configuration

and Diagnostics Tool (ACD01)

See fault codes in table

on following page

No fault

shown

Replace

DXM2

Unit is OK!

‘See Performance

Troubleshooting’ for

further help

Heat Controller, Inc. Water-Source Heating and Cooling Systems38

The Quality Leader in Conditioning Air

Residential Split - 60Hz R410A

Functional Troubleshooting

Fault Htg Clg Possible Cause Solution

Check Line Voltage circuit breaker and disconnect

Main Power Problems

HP Fault Code 2

High Pressure

LP/LOC Fault-Code 3

Low Pressure/Loss of Charge X

LT1 Fault - Code 4

Water Low Temperature

LT2 Fault - Code 5 Low Air Temperature

Condensate Fault-Code High Condensate Level

Over/Under Voltage-Code 7

(Auto Resetting)

Unit Performance Sentinel-Code 8

Swapped Thermistor Code 9

ECM Fault - Code 10

X X Green status LED off

X Reduced or no water flow Check pump operation or valve operation/setting

in cooling

Water temperature out of range in cooling

X Frozen water heat exchanger Thaw heat exchanger

X X Bad HPWS Switch Replace HPWS Switch

X X Insufficient charge Check for refrigerant leaks

X Inadequate anti-freeze level Check antifreeze density with hydrometer

X Water temperature out of range

X X Bad thermistor Check temp and impedance correlation per chart

X X Blocked drain Check for blockage and clean drain X X Improper trap Check trap dimensions and location ahead of vent

X X Restricted return air flow

X X Under v oltage

X X Over v oltage

X Heating Mode LT2>125°F Check for poor air flow or overcharged unit

X X LT1 and LT2 swapped Reverse position of thermistors

X X Blower does not operate

Reduced or no air flow in heating

Air t emperature out of range in heating

Overcharged with refrigerant

Bad HP switch Check switch continuity and operation - Replace

Compressor pump down at startup

Reduced or no water flow in heating

Improper low temperature setting (30°F vs 10°F)

Reduced or no air flow

in cooling

X Air temperature out of range

Improper low temperature setting

(30°F vs 10°F)

X Poor drainage

X Moisture on sensor Check for moisture shorting to air coil

Plugged air filter

Cooling Mode LT1>125°F OR

LT2< 40°F

Blower operating with incorrect airflow

Check for line voltage between L1 and L2 on the contactor Check for 24VAC between R and C on DXM Check primary/secondary voltage on transformer

Check water flow adjust to proper flow rate

Bring water temp within design parameters

Check for dirty air filter and clean or replace Check fan motor operation and airflow restrictions Dirty air coil- construction dust etc.

Too high of external static. Check static vs blower table

Bring return air temp within design parameters

Check superheat/subcooling vs typical operating condition table

Check charge and start-up water flow

Check pump operation or water valve operation/setting

Plugged strainer or filter - clean or replace

Check water flow adjust to proper flow rate

Clip LT1 jumper for antifreeze (10°F) use

Bring water temp within design parameters

Check for dirty air filter and clean or replace Check fan motor operation and airflow restrictions Too high of external static - check static vs blower table

Too much cold vent air - bring entering air temp within design parameters

Normal airside applications will require 30°F only

Check for piping slope away from unit Check slope of unit toward outlet Poor venting - check vent location

Replace air filter

Find and eliminate rectriction - increase return duct and/or grille size

Check power supply and 24VAC voltage before and during operation Check power supply wire size Check compressor starting. Need hard start kit? Check 24VAC and unit transformer tap for correct power

supply voltage

Check power supply voltage and 24VAC before and during operation.

Check 24VAC and unit transformer tap for correct power supply voltage

Check for poor water flow, or air flow

Check blower line voltage

Check blower low voltage wiring

Wrong unit size selection

Wrong unit family selection

Wrong motor size

Incorrect blower selection

Rev.: 03 August, 2012

www.heatcontroller.com

HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS

No Fault Code Shown

X X No compressor operation See 'Only Fan Operates'

X X Compressor overload Check and replace if necessary

X X Control board Reset power and check operation

Unit Short Cycles

X X Dirty air filter Check and clean air filte r X X Unit in 'Test Mode' Reset power or wait 20 minutes for auto exit

X X Unit selection

Unit may be oversized for space - check sizing for actual load of space

X X Compressor overload Check and replace if necessary

Only Fan Runs

X X Thermostat position Insure thermostat set for heating or cooling operation

X X Unit locked out Check for lockout codes - reset power

X X Compressor overload

Check compressor overload - replace if necessary

X X Thermostat wiring

Check thermostat wiring at DXM2 - put in Test Mode and

ESD - ERV Fault (DXM Only) Green Status LED Code 3

ERV unit has fault (Rooftop units only)

Troubleshoot ERV unit fault

jumper Y1 and R to give call for compressor

IFC Fault Code 13 Internal Flow Controller Fault

X Improper output setting Verify the AO-2 jumper is in the PWM positionX

No pump output signal Check DC voltage between A02 and GND - should be

between 0.5 and 10 VDC with pump active

Low pump voltage

Check line voltage to the pump

No pump feedback signal Check DC voltage between T1 and GND. Voltage should

be between 3 and 4 VDC with pump OFF, and between 0 and 2 VDC with the pump ON

Bad pump RPM sensor Replace pump if the line voltage and control signals are

present at the pump, and the pump does not operate

Fault Htg ClgPossible Cause Solution

Residential Split - 60Hz R410A

Rev.: 03 August, 2012

Functional Troubleshooting

Heat Controller, Inc. Water-Source Heating and Cooling Systems40

The Quality Leader in Conditioning Air

Symptom Htg Clg Possible Cause Solution

Insufficient Capacity/

X X Dirty filter Replace or clean

Not Cooling or Heating

Rduced or no air flow

Check for dirty air filter and clean or replace

Properly

in heating

Check fan motor operation and airflow restrictions Too high of external static - check static vs blower table

Reduced or no air flow

Check for dirty air filter and clean or replace

in cooling

Check fan motor operation and airflow restrictions Too high of external static - check static vs blower table

X X Leaky duct work

Check supply and return air temperatures at the unit and at distant duct registers if significantly different, duct leaks

are present X X Low refrigerant charge Check superheat and subcooling per chart X X Restricted metering device Check superheat and subcooling per chart - replace

X Defective reversing va lve Perform RV touch test

X X Thermostat improperly located Check location and for air drafts behind stat

X X Unit undersized

Recheck loads & sizing check sensible clg load and heat

pump capacity

X X Scaling in water heat exchanger Perform Scaling check and clean if necessary

X X Inlet water too hot or cold Check load, loop sizing, loop backfill, ground moisture

High Head Pressure

Reduced or no air flow

Check for dirty air filter and clean or replace

in heating

Check fan motor operation and airflow restrictions

Too high of external static - check static vs blower table

X Reduced or no water flow Check pump operation or valve operation/setting

in cooling

Check water flow adjust to proper flow rate

X Inlet w ater too hot Check load, loop sizing, loop backfill, ground moisture

Air temperature out of range in heating

Bring return air temp within design parameters

X Scaling in water heat exchanger Perform Scaling check and clean if necessary X X Unit over charged Check superheat and subcooling - reweigh in charge X X Non-condensables insystem Vacuum system and reweigh in charge X X Restricted metering device Check superheat and subcooling per chart - replace

Low Suction Pressure

Reduced water flow

Check pump operation or water valve operation/setting

in heating

Plugged strainer or filter - clean or replace Check water flow adjust to proper flow rate

X Water temperature out of range Bring water temp within design parameters

Reduced air flow

Check for dirty air filter and clean or replace

in cooling

Check fan motor operation and airflow restrictions Too high of external static - check static vs blower table

X Air temperature out of range

Too much cold vent air - bring entering air temp within design parameters

X X Insufficient charge Check for refrigerant leaks

Low Dischage Air Temperature in Heating

X Too high of air flow Check fan motor speed selection and airflow chart

X Poor performance See “Insufficient Capacity”

High Humidity

X Too high of air flow Check fan motor speed selection and airflow chart

X Unit oversized

Recheck loads and sizing check sensible clg load and heat pump capacity

Only Compressor Runs

X X Thermostat wiring

Check G wiring at heat pump. Jumper G and R for fan operation.

X X Fan motor relay

Jumper G and R for fan operation. Check for Line voltage across blower relay contacts.

Check fan power enable relay operation (if present)

X X Fan motor Check for line voltage at motor. Check capacitor

X X Thermostat wiring

Check thermostat wiring at or DXM2. Put in Test Mode and then jumper Y1 and W1 to R to give call for fan, compressor and electric heat.

Unit Doesn't Operate in Cooling

X Reversing Valve

Set for cooling demand and check 24VAC on RV coil.

If RV is stuck, run high pressure up by reducing water flow and while operating engage and disengage RV coil voltage to push valve.

X Thermostat setup

X Thermostat wiring

Check O wiring at heat pump. DXM2 requires call for compressor to get RV coil “Click.”

Modulating Valve Troubleshooting

Improper output setting

Verify the AO-2 jumper is in the 0-10V position

No valve operation

Check voltage to the valve

No valve output signal

Check DC voltage between AO2 and GND. Should be O when valve is off and between 3.3v and 10v when valve is on.

Replace valve if voltage and control signals are present at the valve and it does not operate

For DXM2 check for “O” RV setup not “B”.

www.heatcontroller.com

Residential Split - 60Hz R410A

Rev.: 03 August, 2012

Performance Troubleshooting

HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS

Residential Split - 60Hz R410A

Rev.: 03 August, 2012

Troubleshooting Form

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Note: Never connect refrigerant gauges during startup procedures. Conduct water-side analysis using P/T ports to determine water ﬂ ow and temperature difference. If water-side analysis shows poor performance, refrigerant troubleshooting may be required. Connect refrigerant gauges as a last resort.

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Heat Controller, Inc. Water-Source Heating and Cooling Systems42

The Quality Leader in Conditioning Air

Residential Split - 60Hz R410A

Rev.: 03 August, 2012

Notes:

www.heatcontroller.com

Design, speciﬁ cations and materials subject to change without notice.

1900 Wellworth Ave., Jackson, Michigan 49203 • Ph. 517-0787-2100 • Fax 517-787-9341

Visit us on-line at www.heatcontroller.com

The Quality Leader in Conditioning Air

08/12

Part #: 97B0016N18

*97B0016N18*

Heat Controller HTS024B1D01NNN, HTS036B1D01NNN, HTS048B1D01NNN, HTS060B1D01NNN Installation, Operation And Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual