Heatcontroller HWW120 User Manual

INSTALLATION, OPERATION

& MAINTENANCE MANUAL

R-410A Water-to-Water Series:

HWW Water-Source Heat Pumps

Heat Controller, Inc. • 1900 Wellworth Ave. • Jackson, MI 49203 • [phone] • www.heatcontroller.com

Installation & Operation WATER-TO-WATER (HWW) SERIES Heat Controller, Inc.

TABLE OF CONTENTS

Model Nomenclature ..................................................2

Storage .......................................................................4

Pre-Installation............................................................4

Physical Data..............................................................5

Dimensional Data .......................................................6

Unit Installation ...........................................................7

Piping Installation .......................................................7

Load Plumbing Installation .........................................8

Water Loop Applications .............................................9

Open Loop - Ground Water Systems .......................10

Water Quality Standards ..........................................10

Ground Loop Applications ................................... 11-13

Electrical - Line Voltage .......................................14,16

Electrical - Accessories.............................................15

Water Valve Wiring ................................................... 15

Electrical - Low Voltage Wiring .................................17

Electrical Wiring Schematics ...............................18-19

CXM Controls ......................................................20-22

Piping System Cleaning & Flushing .........................23

Unit and System Checkout Procedure .....................24

Start Up Procedure ..............................................25-26

Operating Pressures............................................27-28

Preventive Maintenance ........................................... 29

Refrigeration Troubleshooting Form .........................30

1

Heat Controller, Inc. WATER-TO-WATER (HWW) SERIES Installation & Operation

HEAT CONTROLLER OEM PRICE LIST

H W W A0 3 6 C1 1 0 C F C

1 2 3 4 5 6 7

8

9 10 11 12 13 14

HW = HEAT CONTROLLER SERIES HIGH EFFICIENCY

MODEL TYPE

W = WATER TO WATER

CONFIGURATION

UNIT SIZE

036 - 1,3,4
060 - 1,3,4,5
120 - 1,3,4,5

REVISION LEVEL

A = CURRENT

VOLTAGE

CONTROLS

0 = RESIDENTIAL ( 208-230/60/1 ONLY)

CABINET INSULATION

HOT WATER GENERATOR OPTIONS

C = Copper

SOURCE WATER COIL OPTIONS

N = Cupro-Nickel

C = Copper

LOAD WATER COIL OPTIONS

N = Cupro-Nickel

0 = NONE
1 = HWG w/INTERNAL PUMP (RESIDENTIAL)

F = FRONT

WATER CONNECTION LOCATION

1 = COMMERCIAL EXTENDED RANGE

VOLTAGE

2 = HWG COIL ONLY (COMMERCIAL)

C = CXM (ETL for USA & CANADA)

1 = 208-230/60/1 - 410A
3 = 208-230/60/3 - 410A
4 = 460/60/3 - 410A
5 = 575/60/3 - 410A

}

HWW HIGH EFFICIENCY Water-to-Water HFC-410a Heat Pumps

HWW HIGH EFFICIENCY Water-to-Water R-410A Heat Pumps

Entering Water Temperature Range: 20 - 110°F (-6.7 - 43.3°C)
Sizes 036, 060 & 120

HWW Model Structure

A=CURRENT 036
B=CURRENT 060, 120

Basic Unit Description:

The basic unit price includes sealed heat pump refrigerant circuit.

• Cabinet- Heavy gauge galvanized steel with polyester powder

• Cabinet - Heavy gauge galvanized steel with black polyester powder

coat paint – multiple removable panels for service access – interior

coat paint – multiple removable panels for service access – stainless

surfaces lined with 1/2 inch dual density acoustic type glass

steel front access panel(s) – interior surfaces lined with ½ inch dual

ber insulation – IPT water connections – high and low voltage

density acoustic type glass  ber insulation – IPT water connections –

knockouts.

high and low voltage knockouts.

• Controls - Solid state control system with seven standard safeties

including anti-short cycle, over voltage, under voltage, high refrigerant
pressure, loss of refrigerant charge, low source water temperature,
low load water temperature – run and fault lights on cabinet exterior –
alarm contact for remote monitoring of fault condition ( eld selectable
for dry contact or 24vac).

• Refrigerant Circuit - Compressor(s) – coaxial source and load heat

exchangers – revering valve(s) –  lter driers(s) – thermal expansion
valve(s) – high pressure and loss of charge switches – high and low
side Schrader ports for service – non-ozone depleting HFC-410a
refrigerant.

polyster powder

• Compressor(s) - High ef ciency scroll compressor - internally sprung

and externally isolated using dual vibration isolation system for
quiet operation. Mounting system includes rubber grommet mounts
between the compressor and a mounting tray then another set of
rubber mounts between the mounting tray and unit base pan.

• Reversing Valve - 4-way pilot operated, solenoid activated in cooling

mode.

• Safety Agency Listing - Product is ETL Listed.

• Application - May be applied in water loop heat pump, ground water

heat pump, and ground loop heat pump applications.

R-410A

2

Installation & Operation WATER-TO-WATER (HWW) SERIES Heat Controller, Inc.

General Information

Safety

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

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

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

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

NOTICE: Notication of installation, operation or maintenance

information, which is important, but which is not hazard­related.

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

lters will quickly become clogged with construction dirt

and debris, which may cause system damage.

� WARNING! �

� CAUTION! �

� 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 prociency requirements.

3

Heat Controller, Inc. WATER-TO-WATER (HWW) SERIES Installation & Operation

General Information

Inspection

Upon receipt of the equipment, carefully check the shipment
against the bill of lading. Make sure all units have been re­ceived. Inspect the carton or crating of each unit, and inspect
each unit for damage. Assure the carrier makes proper nota­tion of any shortages or damage on all copies of the freight bill
and completes a common carrier inspection report. Concealed
damage not discovered during unloading must be reported

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

within 15 days, the freight company can deny the claim without
recourse. Note: It is the responsibility of the purchaser to

le all necessary claims with the carrier.

Storage

Equipment should be stored in its original packaging in a
clean, dry area. Store units in an upright position at all times.
The stack limit for HWW36, 060 and 120 is three.

Unit Protection

Cover units on the job site with either shipping packaging,

vinyl lm, or an equivalent protective covering. Cap the open

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

Examine all pipes, ttings, and valves before installing any of

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

Pre-Installation

Installation, Operation, and Maintenance instructions are
provided with each unit. 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:

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

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

� CAUTION! �

CAUTION! All three phase scroll compressors must

have direction of rotation veried at start-up. Verication

is achieved by checking compressor Amp draw. Amp
draw will be substantially lower compared to nameplate
values. Additionally, reverse rotation results in an ele­vated sound level compared to correct rotation. Reverse
rotation will result in compressor internal overload trip
within several minutes. Verify compressor type before
proceeding.

� CAUTION! �

CAUTION! DO NOT store or install units in corrosive

environments or in locations subject to temperature or
humidity extremes (e.g., attics, garages, rooftops, etc.).
Corrosive conditions and high temperature or humid-

ity can signicantly reduce performance, reliability, and

service life. Always move and store units in an upright
position. Tilting units on their sides may cause equip­ment damage.

� CAUTION! �

CAUTION! CUT HAZARD - Failure to follow this caution

may result in personal injury. Sheet metal parts may
have sharp edges or burrs. Use care and wear appropri­ate protective clothing, safety glasses and gloves when
handling parts and servicing heat pumps.

NOTICE! Failure to remove shipping brackets from
spring-mounted compressors will cause excessive

noise, and could cause component failure due to

added vibration.

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 shipping packaging
until installation is complete and all plastering, painting,

etc. is nished.

4

Installation & Operation WATER-TO-WATER (HWW) SERIES Heat Controller, Inc.

Unit Physical Data

Model 036 060 120

Compressor (qty) Scroll (1) Scroll (2)

Factory Charge R410A (lbs) [kg] Per Circuit 4.5 [2.04] 5.5 [2.49] 5.5 [2.49]

Water Connection Size

Source/Load (in)

HWG (in)

Weight - Operating (lbs) [kg] 348 [158] 360 [163] 726 [329]

Weight - Packaged (lbs) [kg] 373 [169] 385 [175] 770 [349]

Water Volume (Source)

Gallons (Liters) 0.96 (3.64) 1.33 (5.04) 2.65 (10.02)

Dual isolated compressor mounting
Balanced port expansion valve (TXV)
Insulated Source and Load Water Coils standard
Insulated Refrigerant Circuit standard
Compressor on (green) and fault (red) light

Residential 1" Swivel 1” Swivel

Commercial 3/4” IPT 1” IPT

Residential 1" Swivel 1” Swivel

Commercial 1/2” IPT 1/2” IPT

1-1/2 IPT

1/2" IPT

5

Heat Controller, Inc. WATER-TO-WATER (HWW) SERIES Installation & Operation

1

2

3

4

5

Service Access

Required

Service Access

Optional

Service Access

B

C

A

1.3

(3.3 cm)

2.7

(6.9 cm)

7.3

(18.5

cm)

(4.3 cm)

Unit Dimensional Data: HWW 036–120

C

Optional

B

1.0

(2.5 cm)

M

1.8

1.0

(2.5 cm)

A

5

6

4

3

2

(4.6 cm)

F

Notes:

1. Front & side access is preferred for service
access. However, all components may be
serviced from the front access panel if side

J

H

G

access is not available.

2. While clear access to all removable panels
is not required, installer should take care
to comply with all building codes and allow

adequate clearance for future eld services.

L

K

1

E

D

A

7.3

(18.5

cm)

1.7

(4.3 cm)

Required

Service Access

B

5

1.3

(3.3 cm)

2.7

(6.9 cm)

3

1

6

4

2

Water to

Water

036-060

120

C

Optional

Service Access

Required

Service Access

Overall Cabinet

A

DepthBWidthCHeight

in. 30.6 25.4 33 2.7 9.4 19.4 24.5 27.9 30.4 20.9 22.9 30.9

cm. 77.8 64.5 83.8 6.9 23.9 49.3 62.2 70.9 77.2 53.1 58.2 78.5

in. 30.6 52.9 37 25.2 25.2 30.1 30.1 34.9 34.9 29.9 31.9 34.4

cm. 77.8 134.4 94 64.0 64.0 76.5 76.5 88.6 88.6 75.9 81.0 87.4

1 2 3 4 5 6

D

Source

(Outdoor)

Water In

Source

(Outdoor)

Water Out

Water Connections

E

Load

(Indoor)

Water In

Electric Access Plugs

F

(Indoor)

Water Out

G

Load

Return In

H

HWG

J
HWG
Water

Out

K

Low

Voltage

L

External

Pump

M

Power

Supply

6

Installation & Operation WATER-TO-WATER (HWW) SERIES Heat Controller, Inc.

Swivel

Unit Installation

HWW Unit Location

These units are not designed for outdoor installation. Locate
the unit in an INDOOR area that allows enough space for ser­vice personnel to perform typical maintenance or repairs.

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.

Locate the unit in an indoor area that allows easy removal of
access panels, and has enough space for service personnel

to perform maintenance or repair. Provide sufcient room to

make water and electrical connections.. Any access panel
screws that would be difcult to remove after the unit is in­stalled should be removed prior to setting the unit. These units
are not approved for outdoor installation and, therefore, must
be installed inside the structure being conditioned. Do not
locate in areas where ambient conditions are not maintained
within 40-100°F [4-38°C].

Piping Installation

Installation of Supply and Return Piping

Follow these piping guidelines.

1. Install a drain valve at the base of each supply and

return riser to facilitate system ushing.

2. Install shut-off / balancing valves and unions at each
unit to permit unit removal for servicing.

3. Place strainers at the inlet of each system
circulating pump.

4. Select the proper hose length to allow slack between
connection points. Hoses may vary in length by +2% to

-4% under pressure.

5. Exceeding the minimum bend radius may cause the

hose to collapse which reduces water ow rate. Install

an angle adapter to avoid sharp bends in the hose
when the radius falls below the required minimum and
causes a slight kink.

� WARNING! �

Piping must comply with all applicable codes.

Optional pressure-rated hose assemblies designed specically

for use with Heat Controller units are available. Similar hoses
can be obtained from alternate suppliers. Supply and return

hoses are tted with swivel-joint ttings at one end to prevent

kinking during installation.

� WARNING! �

Do not bend or kink supply lines or hoses.

Insulation is not required on loop water piping except where
the piping runs through unheated areas or outside the build­ing or when the loop water temperature is below the minimum
expected dew point of the pipe ambient temperature. Insula­tion is required if loop water temperature drops below the dew
point.

Pipe joint compound is not necessary when Teon threaded
tape is pre-applied to hose assemblies or when ared-end

connections are used. If pipe joint compound is preferred,
use compound only in small amounts on the pipe threads of

the tting adapters. Prevent sealant from reaching the ared

surfaces of the joint.

Note: When anti-freeze is used in the loop, assure that it is
compatible with Teon tape or pipe joint
compound employed.

Maximum allowable torque for brass ttings is 30 ft-lbs [41
N-m]. If a torque wrench is not available, tighten nger-tight
plus one quarter turn. Tighten steel ttings as necessary.

� CAUTION! �

Corrosive system water requires corrosion resistant ttings

and hoses and possibly water treatment.

Refer to Figure 1 for an illustration of a Supply/Return Hose
Kit. Male adapters secure hose assemblies to the unit and ris­ers. Install hose assemblies properly and check them regularly
to avoid system failure and reduced service life.

Hand Tighten

Only !

Swivel Nut

Stainless steel

snap ring

Gasket

Do Not

Overtighten !

Brass Adaptor

Figure 1: Supply/Return Hose Kit

Rib Crimped

Length

(2 ft [0.6m] Length Standard)

7

Brass
Fitting

Brass

Fitting

EPT

Heat Controller, Inc. WATER-TO-WATER (HWW) SERIES Installation & Operation

Piping Installation

Load Plumbing Installation

HWW Unit Load Plumbing

The applications are too varied to describe in this document.
However, some basic guidelines will be presented. Much of
the discussions on water loop applications would be valid for
the load plumbing discussion as well. All plumbing should
conform to local codes with the following considerations:

Wide temperature variation applications such as
heating/cooling coils:

- Employ piping materials that are rated for the maxi­mum temperature and pressure combination. This
excludes PVC for most heating applications.

- Insure that load water ow in high temperature heat­ing applications is at least 3 gpm per ton [3.9 l/m per
kW] to improve performance and reduce nuisance
high pressure faults.

- DO NOT employ plastic to metal threaded joints

- Utilize a pressure tank and air separator vent system
to equalize pressure and remove air.

Swimming Pool Hot Tub Applications:

- Load coax should be isolated with secondary heat
exchanger constructed of anti-corrosion material in all

chlorine/bromine uid applications.

Potable Water Applications:

- Load coax material should always be vented double
walled for use in potable water systems.

- Insure load water ow in high temperature heating

applications is at least 3 gpm per ton to improve
performance and reduce nuissance to high pressure
faults.

NOTE:
Heat Controller strongly recommends all piping

connections, both internal and external to the unit, be

pressure tested by an appropriate method prior to any

nishing of the interior space or before access to all
connections is limited. Test pressure may not exceed
the maximum allowable pressure for the unit and all
components within the water system. Heat Controller
will not be responsible or liable for damages from
water leaks due to inadequate or lack of a pressurized
leak test, or damages caused by exceeding the
maximum pressure rating during installation.

8

Installation & Operation WATER-TO-WATER (HWW) SERIES Heat Controller, Inc.

Water-Loop Heat Pump Applications

Commercial systems typically include a number of units
plumbed to a common piping system. Any unit plumbing
maintenance work can introduce air into the piping system,
therefore air elimination equipment is a major portion of the
mechanical room plumbing. In piping systems expected to
utilize water temperatures below 50°F [10°C], 1/2” [13mm]
closed cell insulation is required on all piping surfaces to
eliminate condensation. Metal to plastic threaded joints should
never be employed due to their tendency to leak over time.

Teon tape thread sealant is recommended for FPT water

connections (commercial class) to minimize internal fouling
of the heat exchanger. Do not overtighten connections and
route piping so as not to interfere with service or maintenance
access. Hose kits are available from Heat Controller in

different congurations for connection between the system.
The piping system should be ushed to remove dirt, piping

chips, and other foreign material prior to operation. See
Piping System Cleaning and Flushing Procedures later in this

document. The ow rate is usually set between 2.25 gpm and

3 gpm per ton [2.9 l/m and 4.5 l/m per kW] of cooling capacity.
Heat Controller recommends 2.5 gpm per ton [3.2 l/m per
kW] for most applications of water loop heat pumps. To insure
proper maintenance and servicing, P/T ports are imperative

for temperature and ow verication, as well as performance

checks. See Figure 2 for typical water-loop application
installation.

Figure 2: Typical Water-Loop Application

Cooling Tower/Boiler Systems typically utilize a
common loop maintained 60-90°F [16-32°C]. The use of a
closed circuit evaporative cooling tower with a secondary
heat exchanger between the tower and the water loop
is recommended. If an open type cooling tower is used

continuously, chemical treatment and ltering will be

necessary.

Low Water Temperature Cutout Setting

CXM Control: When an antifreeze is selected, the FP1
jumper (JW3) should be clipped to select the low temperature
(Antifreeze 15°F [-9.4°C]) setpoint to avoid nuisance faults.
See Figure 5: Low Water Temperature Cutout - FP1.

� WARNING! �

Never jumper terminal “A” from CXM board #1 to CXM
board #2 on multi-compressor/control bound units. See
Figure 6 [Page 15] in electrical section of this document
for motorized valve wiring.

� CAUTION! �

CAUTION! Many units are installed with a factory or

eld supplied manual or electric shut-off valve. DAMAGE

WILL OCCUR if shut-off valve is closed during unit
operation. A high pressure switch must be installed on

the heat pump side of any eld provided shut-off valves

and connected to the heat pump controls in series with
the built-in refrigerant circuit high pressure switch to
disable compressor operation if water pressure exceeds

pressure switch setting. The eld installed high pressure

switch shall have a cut-out pressure of 300 psig and a
cut-in pressure of 250 psig.

Air Pad or
Extruded
polystyrene
insulation board

Thermostat Wiring

Unit Power
Disconnect

Load Plumbing

Connection

Y-Strainer

with blow-off

valve

Stainless steel braid
hose with integral “J”

swivel

Optional

Balancing

Valve

Ball Valve with

integral P/T plug

Optional Low

Pressure Drop

Water Control

Valve

Ball Valve with

integral P/T plug

Water In

Building

Water Out

Loop

9