INSTALLATION, OPERATION
& MAINTENANCE MANUAL
R-410A Water-to-Water Series:
HWW Water-Source Heat Pumps
Heat Controller, Inc. • 1900 Wellworth Ave. • Jackson, MI 49203 • (517)787-2100 • 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: Notication 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 prociency 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 veried at start-up. Verication
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 signicantly 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 sufcient room to
make water and electrical connections.. Any access panel
screws that would be difcult 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 specically
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 Teon 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 Teon 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.
Teon 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 congurations 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 verication, 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
Heat Controller, Inc. WATER-TO-WATER (HWW) SERIES Installation & Operation
Ground-Water Heat Pump Applications
Typical open loop piping is shown in Figure 3 [See Page 11].
Shut off valves should be included in case of servicing. Boiler
drains or other valves should be ‘tee’d’ into the line to allow acid
ushing of just the heat exchanger. Pressure temperature plugs
should be used so that ow and temperature can be measured.
Piping materials should be limited to PVC SCH80 or copper.
Due to the pressure and temperature extremes, PVC SCH40
is not recommended. Water quantity should be plentiful and of
good quality. Consult Table 1 for water quality guidelines.
The unit can be ordered with either a copper or cupro-nickel
water heat exchanger. 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 cupronickel heat exchanger is recommended.
In ground water situations where scaling could be heavy or
where biological growth such as iron bacteria will be present,
a closed loop system is recommended. It is recommended to
install an intermediate heat exchanger to isolate an open loop
from the heat pump loop on open well systems. Heat exchangers may over time lose heat exchange capabilities due to a
build up of mineral deposits inside. These can be cleaned only
by a qualied service mechanic as acid and special pumping
equipment are required.
Table 1: Water Quality Standards
WaterÊQuality
Parameter
ScalingÊPotentialÊ-ÊPrimaryÊMeasurement
AboveÊtheÊgivenÊlimits,ÊscalingÊisÊlikelyÊtoÊoccur.ÊÊScalingÊindexesÊshouldÊbeÊcalculatedÊusingÊtheÊlimitsÊbelow
pH/CalciumÊHardness
Method
IndexÊLimitsÊforÊProbableÊScalingÊSituationsÊ-Ê(OperationÊoutsideÊtheseÊlimitsÊisÊnotÊrecommended)
ScalingÊindexesÊshouldÊbeÊcalculatedÊatÊ150¡FÊ[66¡C]ÊforÊdirectÊuseÊandÊHWGÊapplications,ÊandÊatÊ90¡FÊ[32¡C]ÊforÊindirectÊHXÊuse.Ê
AÊmonitoringÊplanÊshouldÊbeÊimplemented.
Ryznar
StabilityÊIndex IfÊ>7.5ÊminimizeÊsteelÊpipeÊuse.
Langelier
SaturationÊIndex
IronÊFouling
IronÊFe2+(Ferrous)
(BacterialÊIronÊpotential)
IronÊFouling
CorrosionÊPrevention
pH
HydrogenÊSulfideÊ(H
AmmoniaÊionÊasÊhydroxide,Êchloride,Ê
nitrateÊandÊsulfateÊcompounds
Maximum
ChlorideÊLevels
S)
2
ErosionÊandÊClogging
ParticulateÊSizeÊand
Erosion
Notes:
• Closed Recirculating system is identified by a
• Recirculating open wells should observe the open recirculating design considerations.
• NR - Application not recommended.
• "-" No design Maximum.
HX
Material
All
All
All
All
All
All
All
All
Copper - <20ppm NR NR
CuproNickel - <150Êppm NR NR
304ÊSS - <400Êppm <250Êppm <150 ppm
316ÊSS - <1000Êppm <550Êppm < 375 ppm
Titanium - >1000Êppm >550Êppm >375 ppm
All
closed pressurized piping system.
Closed
Recirculating
-
- 6.0Ê-Ê7.5
-
-
-
6Ê-Ê8.5
Monitor/treatÊas
needed
- <0.5Êppm
-
<10ÊppmÊofÊparticles
andÊaÊmaximum
velocityÊofÊ6ÊfpsÊ[1.8Êm/s].
FilteredÊforÊmaximum
800ÊmicronÊ[800mm,
20Êmesh]Êsize.
OpenÊLoopÊandÊRecirculatingÊWell
pHÊ<Ê7.5ÊandÊCaÊHardnessÊ<100ppm
IfÊ<-0.5ÊminimizeÊsteelÊpipeÊuse.ÊBasedÊuponÊ150¡FÊ[66¡C]ÊHWGÊand
2+
Ê(ferrous)>0.2ÊppmÊwithÊpHÊ6Ê-Ê8,ÊO2<5ÊppmÊcheckÊforÊironÊbacteria
IfÊFe
AboveÊthisÊlevelÊdepositionÊwillÊoccur.
MinimizeÊsteelÊpipeÊbelowÊ7ÊandÊnoÊopenÊtanksÊwithÊpHÊ<8
AtÊH
S>0.2Êppm,ÊavoidÊuseÊofÊcopperÊandÊcopperÊnickelÊpipingÊorÊHX's.
2
CopperÊalloyÊ(bronzeÊorÊbrass)ÊcastÊcomponentsÊareÊOKÊtoÊ<0.5Êppm.
<10ÊppmÊ(<1ÊppmÊ"sandfree"ÊforÊreinjection)ÊofÊparticlesandÊaÊmaximum
velocityÊofÊ6ÊfpsÊ[1.8Êm/s].ÊFilteredÊforÊmaximumÊ800ÊmicronÊ[800mm,
20Êmesh]Êsize.AnyÊparticulateÊthatÊisÊnotÊremovedÊcanÊpotentially
clogÊcomponents.
RottenÊeggÊsmellÊappearsÊatÊ0.5ÊppmÊlevel.
MaximumÊAllowableÊatÊmaximumÊwaterÊtemperature.
50¡FÊ(10¡C) 75¡FÊ(24¡C) 100ϒF (38ϒC)
-0.5ÊtoÊ+0.5
DirectÊwell,Ê85¡FÊ[29¡C]ÊIndirectÊWellÊHX
<0.2ÊppmÊ(Ferrous)
<0.5ÊppmÊofÊOxygen
6Ê-Ê8.5
<0.5Êppm
Rev.: 01/21/09B
10
Installation & Operation WATER-TO-WATER (HWW) SERIES Heat Controller, Inc.
Ground-Water Heat Pump Applications
In areas with extremely hard water, the owner should be
informed that the heat exchanger may require occasional acid
ushing.
Expansion Tank and Pump
Use a closed, bladder-type expansion tank to minimize mineral
formation due to air exposure, as shown in Figure 3. The
expansion tank should be sized to handle at least one minute
run time of the pump to prevent premature pump failure using
its drawdown capacity rating. Discharge water from the unit
is not contaminated in any manner and can be disposed of in
various ways depending on local building codes; i.e. recharge
well, storm sewer, drain 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.
Low Water Temperature Cut-Out Setting
For all open loop systems the 35°F [1.7°C] FP1 setting (factory
setting-water) should be used to avoid freeze damage to the unit.
See Figure 4 [Page 14]: “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 5 [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.
� CAUTION! �
Low temperature limit system will not allow leaving load
water temperature (cooling mode) or leaving source water
temperature (heating mode) to be below 42°F [5.6°C].
Water Control Valve
Note the placement of the water control valve in Figure 3.
Always maintain water pressure in the heat exchanger by
placing water control valves at the outlet of the unit to prevent
mineral precipitation. Pilot operated or Taco slow closing
valve’s solenoid valves are recommended to reduce water
hammer. If water hammer persists, a mini-expansion tank can
be mounted on the piping to help absorb the excess hammer
shock. Insure that the total ‘VA’ draw of the valve can be
supplied by the unit transformer. For instance the Taco slow
closing valve can draw up to 35VA. This can overload smaller
40 or 50 VA transformers depending on the other controls
employed. A typical pilot operated solenoid valve draws
approximately 15VA.
Flow Regulation
Flow regulation can be accomplished by two methods. First,
most water control valves have a built in ow adjustment. By
measuring the pressure drop through the unit heat exchanger,
ow rate can be determined and compared to Table 8 [Page
28]. Since the pressure is constantly varying, two pressure
gauges might be needed. Simply adjust the water control
valve until the desired ow of 1.5 to 2 gpm per ton is achieved.
Secondly, a ow control device may be installed [see Figure
3]. The devices are typically an orice of plastic material that is
designed to allow a specied ow rate. These are mounted on
the outlet of the water control valve. On occasion, these valves
can produce a velocity noise that can be reduced by applying
some back pressure. This is accomplished by slightly closing
the leaving isolation valve of the well water setup.
Figure 3: Typical Open
Loop/Well Application
11
Air Pad or
Extruded
polystyrene
insulation board
Thermostat Wiring
Unit Power
Disconnect
Water
Control
Valve
P/T Plugs
Flow
Regulator
Boiler
Drains
Pressure
Tank
Water Out
Optional
Filter
Shut-Off
Valve
Water In
Heat Controller, Inc. WATER-TO-WATER (HWW) SERIES Installation & Operation
Ground-Loop Heat Pump Applications
� CAUTION! �
The following instructions represent industry accepted
installation practices for Closed Loop Earth Coupled Heat
Pump Systems. They are provided to assist the contractor in installing trouble free ground loops. These instructions are recommendations only. State and Local Codes
MUST be followed and installation MUST conform to ALL
applicable Codes. It is the responsibility of the Installing
contractor to determine and comply with ALL applicable
Codes and Regulations.
Pre-Installation
Prior to installation, locate and mark all existing underground
utilities, piping, etc. Install loops for new construction before
sidewalks, patios, driveways, and other construction has
begun. During construction, accurately mark all ground loop
piping on the plot plan as an aid in avoiding potential future
damage to the installation.
Piping Installation
All earth loop piping materials should be limited to only
Table 1: Approximate Fluid Volume
(gallon) per 100' of Pipe
Fluid Volume (gal [liters] per 100’ [30 meters) Pipe)
Pipe Size Volume (gal) [liters]
1” 4.1 [15.3]
Copper
Rubber Hose 1” 3.9 [14.6]
Polyethylene
Unit Heat Exchanger Typical 1.0 [3.8]
Flush Cart Tank
1.25” 6.4 [23.8]
2.5” 9.2 [34.3]
3/4” IPS SDR11 2.8 [10.4]
1” iPS SDR11 4.5 [16.7]
1.25” IPS SDR11 8.0 [29.8]
1.5” IPS SDR11 10.9 [40.7]
2” IPS SDR11 18.0 [67.0]
1.25” IPS SCH40 8.3 [30.9]
1.5” IPS SCH40 10.9 [40.7]
2” IPS SCH40 17.0 [63.4]
10” Dia x 3ft tall
[254mm x 91.4cm tall]
10 [37.9]
polyethylene fusion for inground sections of the loop.
Galvanized or steel ttings should not be used at any time
due to their tendency to corrode. All plastic to metal threaded
ttings should be avoided due to their potential to leak in
earth coupled applications and a anged tting substituted.
P/T plugs should be used so that ow can be measured
using the pressure drop of the unit heat exchanger in lieu of
other ow measurement means. Earth loop temperatures can
range between 25 to 110°F [-4 to 43°C], and 2.25 to 3 gpm of
ow per ton [2.9 l/m to 3.9 l/m per kW] of cooling capacity is
recommended in these applications. Upon completion of the
ground loop piping, pressure test the loop to assure a leak free
system. Horizontal Systems: Test individual loops as installed.
Test entire system when all loops are assembled. Vertical
U-Bends and Pond Loop Systems: Test Vertical U-bends and
pond loop assemblies prior to installation with a test pressure
of at least 100 psi [689 kPa].
Flushing the Earth Loop
Upon completion of system installation and testing, ush the
system to remove all foreign objects and purge to remove all
air. Flush the loop rst with the unit isolated to avoid ushing
debris from the loop into the unit heat exchanger
Table 2: Antifreeze Percentages by Volume
Min. Temp. for Low Temp. Protection
Type
Methanol
100% USP
food grade
Propylene
Glycol
Ethanol*
* Must not be denatured with any petroleum based product
10°F
[-12.2°C]
25%
38%
29%
15°F
[-9.4°C]
21%
25%
25%
20°F
[-6.7°C]
16%
22%
20%
25°F
[-3.9°C]
10%
15%
14%
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, anti-freeze is needed. Alcohols and glycols
are commonly used as antifreezes, 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] e.g. 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
water level to prevent fuming. Initially calculate the total
volume of uid in the piping system using Table 1. Then use
the percentage by volume shown in Table 2 for the amount of
antifreeze. Antifreeze concentration should be checked from
a well mixed sample using a hydrometer to measure specic
gravity.
Low Water Temperature Cut-Out 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 [Page 14].
12
Installation & Operation WATER-TO-WATER (HWW) SERIES Heat Controller, Inc.
Figure 1: Typical Ground-Loop Application
Figure 4: Typical Ground-Loop Application
Unit Power
Disconnect
Air Pad or
Extruded
polystyrene
insulation board
Thermostat Wiring
13
Heat Controller, Inc. WATER-TO-WATER (HWW) SERIES Installation & Operation
Electrical-Line Voltage
� CAUTION! �
Use only copper conductors for eld installed electrical
wiring. Unit terminals are not designed to accept other
types of conductors.
General Line Voltage Wiring
Be sure the available power is the same voltage and phase as
that 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.
HWW Power Connection
Line voltage connection is made by connecting the incoming
line voltage wires to L1, L2, and L3 on power distribution
block. Consult electrical data table for correct fuse size.
208 Volt Operation
All 208-230 Volt units are factory wired for 208 Volt. The
transformers may be switched to 230V operation as illustrated
on the wiring diagram by switching the Red (208V) and the
Orange (230V) at the contactor terminal L2.
All eld installed wiring, including electrical ground, must
HWW Electrical Data
Model
HWW036
HWW060
HWW120
Voltage
Code
1 208-230/60/1 187/254 1 16.7 79 0.4 4 16.7 20.8 35
3 208-230/60/3 187/254 1 10.4 73 - - 10.4 13.1 20
4 460/60/3 414/506 1 5.8 38 - - 5.8 7.2 15
5 575/60/3 518/633 1 3.8 36.5 - - 3.8 4.7 15
1 208-230/60/1 187/254 1 26.3 134 0.4 4 26.3 32.9 50
3 208-230/60/3 187/254 1 15.6 110 - - 15.6 19.5 35
4 460/60/3 414/506 1 7.8 52 - - 7.8 9.8 15
5 575/60/3 518/633 1 5.8 38.9 - - 5.8 7.3 15
1 208-230/60/1 187/254 2 26.3 134 0.4 4 52.6 59.2 80
3 208-230/60/3 187/254 2 15.8 110 - - 31.2 35.1 50
4 460/60/3 414/506 2 7.8 52 - - 15.6 17.6 25
5 575/60/3 518/633 2 5.8 38.9 - - 11.6 13.1 15
Voltage
Min/Max
Voltage
Compressor
QTY RLA LRA
� WARNING! �
Disconnect electrical power source to prevent injury or
death from electrical shock.
� 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.
comply with the National Electrical Code as well as all
applicable local codes.
Refer to the unit wiring diagrams for fuse sizes and a
schematic of the eld connections which must be made by the
installing (or electrical) contractor.
Consult the unit wiring diagram located on the inside of the
compressor access panel to ensure proper electrical hookup.
All nal electrical connections must be made with a length of
exible conduit to minimize vibration and sound transmission
to the building.
HWG
Pump
FLA
EXT Loop
Pump
Fla
Total
Unit
FLA
Min
Circuit
Amps
Max
Fuse/
HACR
HACR circuit breaker in USA only
Figure 5: Changing FP1-Low Water Temperature Cutout Setpoint
Thermostat Connections
The aquastat/thermostat should be wired directly to the CXM board
#1. Note: The HWW second stage is wired directly to the CXM #2.
Low Water Temperature Cutout - FP1
The CXM control allows the eld selection of source uid low temperature cutout points. The factory setting of FP1 is set for water
(35°F [1.7°C]). In cold temperature applications jumper JW3 (FP1antifreeze 15°F [-9.4°C]) should be clipped as shown in Figure 4 to
change the setting to 10°F [-12.2°C], a more suitable temperature
when using antifreezes. Never clip JW3 prior to antifreeze being
added to the loop.
14
CXM PCB
JW3-FP1
jumper
should be
clipped
when
antifreeze
is used.
Installation & Operation WATER-TO-WATER (HWW) SERIES Heat Controller, Inc.
Coil
VR 1
6
8
Refrigerant
HP Switch
Circuit #1
VR3
NO
RED
RED
2
4
Refrigerant
HP Switch
Circuit #2
VR3
NO
RED
RED
Coil
Valve
Relay 3
Water
High Pressure
Switch NC
Notes - Disconnect red wire at refrigerant HP switch connect to N.O. contact,
connect new red wire from N.O. contact to refrigerant HP switch.
Valve Relay 1, 2 - 13B0001N01 (SPDT) VR1, VR2
Valve Relay 3 - 13B0004N01 (DPDT) VR3
Coil
VR2
8
Refrigerant
HP Switch
Circuit #1
RED
2
4
Refrigerant
HP Switch
Circuit #2
VR3
NO
RED
RED
Electrical-Accessories
Accessory Connections
24 Volt Accessory Wiring for Units Size 036 and 060
A terminal paralleling the compressor contactor coil has been
provided on the CXM control of the HWW line. “A” has been
CXM Terminal Strip
provided to control accessory devices, such as water valves,
electronic air cleaners, humidiers, etc. Note: This terminal
must be used only with 24 Volt signals and not line voltage
signals. This signal operates with the compressor contactor.
See the wiring schematic for details.
� WARNING! �
Never jumper terminal “A” from CXM board #1 to CXM
board #2 on multi-compressor/control bound units. See
Figure 6 in electrical section of this document for motorized valve wiring.
Figure 6: Field Wiring of 24 Volt Motorized Valve of Units Size 120
These terminals may be
used to power 24 volt
water valves on units
size 036, 060
15
Capacitor
Transformer
CXM Control
Circ Brkr
Contactor -CC
Low Voltage
Connector
CB
HWG PB2
T2
T1
Rev .: 01/21/09B
Unit Power Supply
See electrical table for
wire and breaker size
L2
L1
External Pump
Power Supply
See electrical table for
wire and breaker size
Grnd
Loop PB1
T2
T1
Install HWG Pump
Power after insuring
water is in HWG circuit
Yellow
Grnd
L2
L3
L1
Contactor -C
Grnd
Rev .: 01/21/09B
External Pump
Power Supply
See electrical table for
wire and breaker size
L2
L3
L1
Contactor -C
Grnd
Heat Controller, Inc. WATER-TO-WATER (HWW) SERIES Installation & Operation
Electrical-Line Voltage
All eld installed wiring, including electrical ground, must
comply with the National Electrical Code as well as all applicable local codes.
Refer to the unit wiring diagrams for fuse sizes and a sche-
matic of the eld connections which must be made by the
installing (or electrical) contractor.
Consult the unit wiring diagram located on the inside of
the compressor access panel to ensure proper electrical
hookup.
All nal electrical connections must be made with a length of
exible conduit to minimize vibration and sound transmission
to the building.
HWW036-060 Series Line Voltage Field Wiring Commercial Class (3 phase shown)
208 Volt Operation
All 208-230 Volt units are factory wired for 208 Volt. The
transformers may be switched to 230V operation as illustrated on the wiring diagram. By switching the Red (230V) and
the Orange (208V) at the contactor terminal L2.
HWW120 Series Line Voltage Field Wiring Commercial Class
16
Installation & Operation WATER-TO-WATER (HWW) SERIES Heat Controller, Inc.
CXM Control
Low Voltage
Connector
Rev.: 01/21/09B
Low Voltage
Wiring
Rev .: 01/22/09B
Electrical-Low Voltage
Thermostat Connections
The aquastat/thermostat should be wired directly to the CXM
board as shown in Figure 7a for HWW036-060 and Figure
7b for the HWW120. Note the HWW second stage is wired
directly to the CXM #2.
Figure 7a. HWW036-060 Low Voltage
Field Wiring (CXM board shown)
Figure 7b: HWW120 Low Voltage Field
Wiring (CXM board shown)
L3
L1
Grnd
Power Distribution
Block
L2
Contactor -CC1
Capacitor
CB
Transformer
CXM Control
Contactor -CC
Low Voltage
Connector
Low Voltage
Wiring
L2
L1
Low Voltage
(Not needed on DXM Models
all low voltage wires to DXM #1)
Contactor -CC2
Wiring
Second Stage Call
Transformer
CXM Control #1
Low Voltage
Connector
CXM Control #2
Low Voltage
Connector
Rev.: 01/21/09B
Low Water Temperature Cutout - FP1
The CXM control allows the eld selection of source uid
low temperature cutout points. The factory setting of FP1 is
set for water (30°F). In cold temperature applications jumper
JW3 (FP1- antifreeze 10°F) should be clipped as shown in
Figure 8 to change the setting to 10°F, a more suitable temperature when using antifreezes. It should be noted that the
extended range option should be specied to operate the
HWW Series at entering water temperatures below 60°F.
Figure 8: Changing FP1-Low Water
Temperature Cutout Setpoint
JW3-FP1 jumper
should be clipped
when antifreeze
is used.
CXM Board
17
Heat Controller, Inc. WATER-TO-WATER (HWW) SERIES Installation & Operation
Typical Wiring Diagram Three Phase:
HWW120 Units with CXM Controller
18
Installation & Operation WATER-TO-WATER (HWW) SERIES Heat Controller, Inc.
Typical Wiring Diagram Single Phase:
HWW036-060 Units with CXM Controller
19
Heat Controller, Inc. WATER-TO-WATER (HWW) SERIES Installation & Operation
Description of Operation LED Alarm Relay
Normal Mode On Open
Normal Mode with UPS Warning On Cycle (closed 5 sec., Open 25 sec.)
CXM is non-functional Off Open
Fault Retry Slow Flash Open
Lockout Fast Flash Closed
Over/Under Voltage Shutdown Slow Flash Open (Closed after 15 minutes)
Test Mode - No fault in memory Flashing Code 1 Cycling Code 1
Test Mode - HP Fault in memory Flashing Code 2 Cycling Code 2
Test Mode - LP Fault in memory Flashing Code 3 Cycling Code 3
Test Mode - FP1 Fault in memory Flashing Code 4 Cycling Code 4
Test Mode - FP2 Fault in memory Flashing Code 5 Cycling Code 5
Test Mode - CO Fault in memory Flashing Code 6 Cycling Code 6
Test Mode - Over/Under
shutdown in memory
Flashing Code 7 Cycling Code 7
Test Mode - UPS in memory Flashing Code 8 Cycling Code 8
Test Mode - Swapped Thermistor Flashing Code 9 Cycling Code 9
CXM Controls:
For detailed control information, see the CXM Application,
Operation and Maintenance manual.
Field Selectable Inputs
Test mode: Test mode allows the service technician to check
the operation of the control in a timely manner. By momentarily shorting the test terminals, the CXM control enters a
20 minute test mode period in which all time delays are sped
up 15 times. Upon entering test mode, the status LED will
ash a code representing the last fault. For diagnostic ease
at the thermostat, the alarm relay will also cycle during test
mode. The alarm relay will cycle on and off similar to the
status LED to indicate a code representing the last fault, at
the thermostat. Test mode can be exited by shorting the test
terminals for 3 seconds.
Retry Mode: If the control is attempting a retry of a fault, the
status LED will slow ash (slow ash = one ash every 2
seconds) to indicate the control is in the process of retrying.
Field Conguration Options
Note: In the following eld conguration options, jumper
wires should be clipped ONLY when power is removed from
the CXM control.
Water coil low temperature limit setting: Jumper 3 (JW3-
FP1 Low Temp) provides eld selection of temperature limit
setting for FP1 of 30°F or 10°F [-1°F or -12°C] (refrigerant
temperature).
DIP switch 4: If Set to “EH2 normal,” EH2 will operate as
standard electric heat output.
On = EH2 Normal.
NOTE: Some CXM controls only have a 2 position DIP
switch package. If this is the case, this option can be selected by clipping the jumper which is in position 4
of SW1.
Jumper not clipped = EH2 Normal.
DIP switch 5: Factory Setting - Normal position is “On.” Do
not change selection unless instructed to do so by
the factory.
Table 3a: CXM LED And Alarm
Relay Operations
Not Clipped = 30°F [-1°C]. Clipped = 10°F [-12°C].
Air coil low temperature limit setting: Jumper 2 (JW2-FP2
Low Temp) provides eld selection of temperature limit setting for FP2 of 30°F or 10°F [-1°F or -12°C] (refrigerant temperature). Note: This jumper should only be clipped under
extenuating circumstances, as recommended by the factory.
Not Clipped = 30°F [-1°C]. Clipped = 10°F [-12°C].
Alarm relay setting: Jumper 1 (JW1-AL2 Dry) provides eld
selection of the alarm relay terminal AL2 to be jumpered to
24VAC or to be a dry contact (no connection).
Not Clipped = AL2 connected to R. Clipped = AL2 dry contact (no connection).
DIP Switches
Note: In the following eld conguration options, DIP
switches should only be changed when power is removed
from the CXM control.
DIP switch 1: Unit Performance Sentinel Disable - provides
eld selection to disable the UPS feature.
On = Enabled. Off = Disabled.
DIP switch 2: Stage 2 Selection - provides selection of
whether compressor has an “on” delay. If set to stage 2, the
compressor will have a 3 second delay before energizing.
Also, if set for stage 2, the alarm relay will NOT cycle during
test mode.
On = Stage 1. Off = Stage 2
DIP switch 3: Not Used.
-Slow Flash = 1 ash every 2 seconds
-Fast Flash = 2 ashes every 1 second
-Flash code 2 = 2 quick ashes, 10 second pause, 2 quick
ashes, 10 second pause, etc.
Figure 9: Test Mode Pins
Short test pins
together to enter
Test Mode and
speed-up timing
and delays for
20 minutes.
CXM Board
20
Installation & Operation WATER-TO-WATER (HWW) SERIES Heat Controller, Inc.
Safety Features: CXM Controls
The safety features below are provided to protect the compressor, heat exchangers, wiring and other components
from damage caused by operation outside of design conditions.
Anti-short cycle protection: The control features a 5 minute
anti-short cycle protection for the compressor.
Note: The 5 minute anti-short cycle also occurs at power up.
Random start: The control features a random start upon
power up of 5-80 seconds.
Fault Retry: In Fault Retry mode, the Status LED begins
slowly ashing to signal that the control is trying to recover
from a fault input. The control will stage off the outputs and
then “try again” to satisfy the thermostat input call. Once the
thermostat input call is satised, the control will continue on
as if no fault occurred. If 3 consecutive faults occur without
satisfying the thermostat input call, the control will go into
“lockout” mode. The last fault causing the lockout will be
stored in memory and can be viewed at the “fault” LED or by
going into test mode (CXM board). Note: FP1/FP2 faults
are factory set at only one try.
Lockout: In lockout mode, the status LED will begin fast
ashing. The compressor relay is turned off immediately.
Lockout mode can be “soft” reset by turning off the thermostat (or satisfying the call). A “soft” reset keeps the fault in
memory but resets the control. A “hard” reset (disconnecting power to the control) resets the control and erases fault
memory.
Lockout with emergency heat: While in lockout mode, if W
becomes active (CXM), emergency heat mode will occur.
High pressure switch: When the high pressure switch opens
due to high refrigerant pressures, the compressor relay is
de-energized immediately since the high pressure switch is
in series with the compressor contactor coil. The high pressure fault recognition is immediate (does not delay for 30
continuous seconds before de-energizing the compressor).
will go into lockout mode once the FP1 fault has occurred.
FP1 lockout code = 4
Air coil low temperature (FP2): The FP2 thermistor temperature must be below the selected low temperature limit setting
for 30 continuous seconds during a compressor run cycle to
be recognized as a FP2 fault. The FP2 input is bypassed for
the initial 60 seconds of a compressor run cycle. FP2 is set
at the factory for one try. Therefore, the control will go into
lockout mode once the FP2 fault has occurred.
FP2 lockout code = 5
Condensate overow: The condensate overow sensor must
sense overow level for 30 continuous seconds to be recognized as a CO fault. Condensate overow will be monitored
at all times.
CO lockout code = 6
Over/under voltage shutdown: An over/under voltage condition exists when the control voltage is outside the range of
19VAC to 30VAC. Over/under voltage shut down is a selfresetting safety. If the voltage comes back within range for
at least 0.5 seconds, normal operation is restored. This is
not considered a fault or lockout. If the CXM is in over/under
voltage shutdown for 15 minutes, the alarm relay will close.
Over/under voltage shut down code = 7
Unit Performance Sentinel-UPS (patent pending): The UPS
feature indicates when the heat pump is operating inefciently. A UPS condition exists when:
a) In heating mode with compressor energized,
FP2 is greater than 125°F [52°C] for 30 continuous seconds, or:
b) In cooling mode with compressor energized,
FP1 is greater than 125°F [52°C] for 30 continuous seconds, or:
High pressure lockout code = 2
Example: 2 quick ashes, 10 sec pause, 2 quick ashes, 10
sec. pause, etc.
Low pressure switch: The low pressure switch must be open
and remain open for 30 continuous seconds during “on”
cycle to be recognized as a low pressure fault. If the low
pressure switch is open for 30 seconds prior to compressor power up it will be considered a low pressure (loss of
charge) fault. The low pressure switch input is bypassed for
the initial 60 seconds of a compressor run cycle.
Low pressure lockout code = 3
Water coil low temperature (FP1): The FP1 thermistor temperature must be below the selected low temperature limit
setting for 30 continuous seconds during a compressor run
cycle to be recognized as a FP1 fault. The FP1 input is bypassed for the initial 60 seconds of a compressor run cycle.
FP1 is set at the factory for one try. Therefore, the control
21
Heat Controller, Inc. WATER-TO-WATER (HWW) SERIES Installation & Operation
Safety Features
c) In cooling mode with compressor energized,
FP2 is less than 40°F [4.5°C] for 30 continuous
seconds.
If a UPS condition occurs, the control will immediately go to
UPS warning. The status LED will remain on as if the control
is in normal mode. Outputs of the control, excluding LED
and alarm relay, will NOT be affected by UPS. The UPS
condition cannot occur during a compressor off cycle. During
UPS warning, the alarm relay will cycle on and off. The cycle
rate will be “on” for 5 seconds, “off” for 25 seconds, “on” for
5 seconds, “off” for 25 seconds, etc.
UPS warning code = 8
Swapped FP1/FP2 thermistors: During test mode, the control monitors to see if the FP1 and FP2 thermistors are in the
appropriate places. If the control is in test mode, the control
will lockout with code 9 after 30 seconds if:
a) The compressor is on in the cooling mode and
the FP1 sensor is colder than the FP2 sensor, or:
b) The compressor is on in the heating mode and
the FP2 sensor is colder than the FP1 sensor.
Swapped FP1/FP2 thermistor code = 9.
CXM Controls
Diagnostic Features
The LED on the CXM board advises the technician of the
current status of the CXM control. The LED can display
either the current CXM mode or the last fault in memory if in
test mode. If there is no fault in memory, the LED will ash
Code 1 (when in test mode).
CXM Control Start-up Operation
The control will not operate until all inputs and safety controls are checked for normal conditions. The compressor will
have a 5 minute anti-short cycle delay at power-up. The rst
time after power-up that there is a call for compressor, the
compressor will follow a 5 to 80 second random start delay.
After the random start delay and anti-short cycle delay, the
compressor relay will be energized. On all subsequent compressor calls, the random start delay is omitted.
Unit Commissioning & Operating Conditions
Environment – This unit is designed for indoor installation only.
Do not install in an area subject to freezing or where humidity
levels can cause cabinet condensation.
Power Supply – A voltage variation of +/- 10% of nameplate
utilization voltage is acceptable.
Operation and performance is primarily dependent upon water
temperatures, water ow rates and ambient air temperature. This
water to water heat pump is capable of operating over a wide
temperature range and with ow rates of between 1.5 GPM (.1
l/s) and 3 GPM (.19 l/s) per ton, however usually no more than
one of these factors may be at a minimum or maximum level at
a time.
The commissioning table indicates water temperatures which are
suitable for initial unit commissioning in an environment where
the ow rate and water temperature is not yet stable and to avoid
nuisance shut down of the units freeze and refrigerant pressure
safeties.
The operating Table 4 indicates the maximum and minimum
ranges of the unit.
For more specic unit performance reference the product
catalog, the submittal data sheets or contact your supplier for
assistance.
Table 4: Building Commissioning
BUILDING COMMISSIONING
Cooling Heating
Unit Size 036 060/120 036 060/120
Source Min/Max 50/110 50/120 30/80 30/80
Load Min/Max 60/80 60/90 60/120 60/120
Ambient Min/Max 45/110 39/85
BUILDING OPERATING
COOLING HEATING
Unit Size 036 060/120 036 060/120
Source Min/Max 50/120 50/120 20/80 20/80
Load Min/Max 50/90 50/90 60/130 60/130
Ambient Min/Max 45/110 39/85
22
Installation & Operation WATER-TO-WATER (HWW) SERIES Heat Controller, Inc.
Piping Systems Cleaning & Flushing
Cleaning and ushing of the WLHP piping system is the
single most important step to ensure proper start-up
and continued efcient operation of the system.
Follow the instructions below to properly clean and ush the
system:
1. Verify electrical power to the unit is disconnected.
2. Install the system with the supply hose connected
directly to the return riser valve. Use a single length of
exible hose.
3. Open all air vents. Fill the system with the water. DO
NOT allow system to overow. Bleed all air from the
system. Pressurize and check the system for leaks and
repair appropriately.
4. Verify all strainers are in place. Start the pumps, and
systematically check each vent to ensure all air is bled
from the system.
5. Verify make-up water is available. Adjust make-up water
appropriately to replace the air which was bled from
the system. Check and adjust the water/air level in the
expansion tank.
6. Set the boiler to raise the loop temperature to approximately 85°F [29°C]. Open the a drain at the lowest point
in the system. Adjust the make-up water replacement
rate to equal the rate of bleed.
7. Rell the system and add trisodium phosphate in a
proportion of approximately one pound per 150 gallons [1/2 kg per 750 L] of water (or other equivalent
To avoid possible damage to a plastic (PVC) piping system, do not allow temperatures to exceed 110°F [43°C].
approved cleaning agent). Reset the boiler to raise the
loop temperature to about 100°F [38°C]. Circulate the
solution for a minimum of 8 to 24 hours. At the end of
this period, shut off the circulating pump and drain the
solution. Repeat system cleaning if desired.
8. When the cleaning process is complete, remove the
short-circuited hoses. Reconnect the hoses to the
proper supply, and return connections to each of the
units. Rell the system and bleed off all air.
9. Test the system pH with litmus paper. The system water
should be slightly alkaline (pH 7.5-8.5). Add chemicals,
as appropriate, to maintain acidity levels.
10. When the system is successfully cleaned, ushed,
relled and bled, check the main system panels, safety
cutouts and alarms. Set the controls to properly maintain loop temperatures.
DO NOT use 'stop leak' or any similar chemical agent
in this system. Addition of these chemicals to the loop
water will foul the system and inhibit unit operation.
� CAUTION! �
� CAUTION! �
23
Heat Controller, Inc. WATER-TO-WATER (HWW) SERIES Installation & Operation
Unit & System Checkout
BEFORE POWERING SYSTEM, please check the following:
� WARNING! �
Verify ALL water controls are open and allow water ow
prior to engaging the compressor. Freezing of the coax
or water lines can permanently damage the heat pump.
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.
UNIT CHECKOUT
q Balancing/Shutoff Valves: Ensure all isolation
valves are open, water control valves wired and
open or coax may freeze and burst.
q Line Voltage and Wiring: Ensure Voltage is within
an acceptable range for the unit and wiring and
fuses/breakers are properly sized. Low voltage
wiring is complete.
q Unit Control Transformer: Ensure transformer has
properly selected control voltage tap. 208-230V
units are factory wired for 208V operation unless
specied otherwise.
q Entering Water: Ensure entering water temperatures
are within operating limits of Table 6 [Page 25].
q Low Water Temperature Cutout: Verify low water
temperature cut-out on CXM is properly set.
q System pH: System water pH is 6 - 8.5. Proper pH
promotes longevity of hoses and ttings.
q System Flushing: Verify all hoses are connected
end to end when ushing to ensure debris bypasses unit heat exchanger and water valves etc. Water
used in the system must be potable quality initially
and clean of dirt, piping slag, and strong chemical
cleaning agents. Verify all air is purged from the
system. Air in the system can cause poor operation
or system corrosion.
q Cooling Tower/Boiler: Check equipment for proper
setpoints and operation.
q Standby Pumps: Verify the standby pump is prop-
erly installed and in operating condition.
q System Controls: Verify system controls function
and operate in the proper sequence.
q Low Water Temperature Cutout: Verify low water
temperature cut-out controls are provided for the
outdoor portion of the loop or operating problems
will occur.
q System Control Center: Verify control center and
alarm panel for proper setpoints
and operation.
q Strainers: Verify 20 mesh (841 micron) [0.84mm]
strainers are installed in load and source water pip-
ing. Conrm maintenance schedule for strainers.
q Miscellaneous: Note any questionable aspects of
the installation.
� WARNING! �
To avoid equipment damage, DO NOT leave system
lled in a building without heat during the winter unless
antifreeze is added to system water. Condenser coils
never fully drain by themselves and will freeze unless
winterized with antifreeze.
q Water Flow Balancing: Verify inlet and outlet water
temperatures on both Load and source are recorded for each heat pump upon startup. This check can
eliminate nuisance trip outs and high velocity water
ows that can erode heat exchangers.
q Unit Controls: Verify CXM eld selection options
are proper and complete.
SYSTEM CHECKOUT
q System Water Temperature: Check load and
source water temperature for proper range and
also verify heating and cooling setpoints for proper
operation.
24
Installation & Operation WATER-TO-WATER (HWW) SERIES Heat Controller, Inc.
Unit Start Up Procedures
� 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.
1. Adjust all valves to their full open position. Turn on the
line power to all heat pump units.
2. Operate each unit in the cooling cycle. Loop water
temperature entering the heat pumps should be between 70°F [21°C] and 110° F [43°C].
3. Operate each heat pump in the heating cycle immediately after checking cooling cycle operation. A time
delay will prevent the compressor from re-starting for
approximately ve (5) minutes.
4. Establish a permanent operating record by logging the
unit operating conditions at initial start-up for each unit.
5. If a unit fails to operate, conduct the following checks:
a. Check the voltage and current. They should com-
ply with the electrical specications described on
the unit nameplate.
b. Look for wiring errors. Check for loose terminal
screws where wire connections have been made
on both the line and low-voltage terminal boards.
Table 5: Water Temperature Change
Through Source Heat Exchanger
Water Flow, gpm [l/m]
For Closed Loop: Ground Source or
Closed Loop Systems at 3 gpm per
ton [3.9 l/m per kW]
For Open Loop: Ground Water
Systems at 1.5 gpm per ton
[2.0 l/m per kW]
Rise, Cooling
°F, [°C]
9 - 12
[5 - 6.7]
20 - 26
[11.1 - 14.4]
Drop, Heating
°F, [°C]
4 - 8
[2.2 - 4.4]
10 - 17
[5.6 - 9.4]
c. Check the supply and return piping. They must be
properly connected to the inlet and outlet connections on the unit.
d. If the checks described above fail to reveal the
problem and the unit still will not operate, contact
a trained service technician to ensure proper diagnosis and repair of the equipment.
Note: Units have a ve minute time delay in the control
circuit that can be eliminated on the CXM PCB as shown
in Figure 9 [Page 20]. See controls description for detailed
features of the control.
� WARNING! �
Verify ALL water controls are open and allow water ow
prior to engaging the compressor. Freezing of the coax
or water lines can permanently damage the heat pump.
25
Heat Controller, Inc. WATER-TO-WATER (HWW) SERIES Installation & Operation
Unit Start Up Procedure
Table 6: Coax Water Pressure Drop HWW036-120
26
Installation & Operation WATER-TO-WATER (HWW) SERIES Heat Controller, Inc.
Operating Pressures
TMW036-120 (TMW120 Per Circuit) (60 Hz I-P Units)
Source
Entering
Water
Temp °F
50
80
110
Source
Water
Flow
GPM/ton
1.5
2.3
3.0
1.5
2.3
3.0
1.5
2.3
3.0
Load EWT
°F @ 1.5-3.0
GPM/ton
50 99-106 230-234 11-18 18-25
60 111-122 241-243 11-18 18-25 8-17
70 122-137 251-253 17-25 18-25 8-19
80 126-145 254-258 26-35 18-25 9-20
50 98-105 212-214 18-23 14-20
60 106-117 218-220 18-23 14-20 8-17
70 114-129 225-227 24-32 14-20 9-19
80 117-135 228-230 32-41 14-20 9-20
50 87-101 199-203 12-18 12-18
60 91-113 203-207 12-18 12-18 8-17
70 95-124 204-216 16-34 12-18 9-19
80 107-128 212-217 33-35 12-18 9-20
50 104-111 343-348 9-14 18-25
60 121-132 355-360 9-14 18-25 7-16
70 138-152 367-373 9-14 18-25 8-18
80 148-161 377-381 12-23 18-25 9-20
50 103-111 320-325 8-14 14-21
60 118.-129 328-334 8-14 14-21 8-16
70 132-147 336-344 12-20 14-21 8-18
80 140-172 343-353 19-29 14-21 9-20
50 94-110 305-314 9-13 12-18
60 112-121 313-319 9-13 12-18 8-16
70 121-146 317-329 12-20 12-18 9-18
80 131-151 324-333 18-27 12-18 9-20
50 109-116 483-497 9-13 17-23
60 128-135 494-511 9-13 17-23 6-13
70 147-154 505-525 9-13 17-23 7-15
50 109-116 459-473 9-13 15-20
60 127-135 466-484 9-13 15-20 6-13
70 153-159 473-495 9-13 15-20 7-15
50 100-112 444-431 9-14 12-17
60 120-130 449-467 9-14 12-17 6-14
70 131-152 454-474 9-14 12-17 7-15
80 153-164 463-479 13-21 12-17 8-17
Suction
Pressure
PSIG
Discharge
Pressure
PSIG
Cooling
Super-heat Sub-cooling
Water
Temp
Rise °F
Source
20-28
13-18
9-12
19-28
13-18
8-12
18-26
14-17
8-13
Water
Temp
Drop °F
Load
7-15
7-15
8-16
7-14
7-14
7-15
5-11
5-11
5-12
27
Heat Controller, Inc. WATER-TO-WATER (HWW) SERIES Installation & Operation
Operating Pressures
TMW036-120 (TMW120 Per Circuit) (60 Hz I-P Units)
Source
Entering
Water
Temp °F
20 3.0
50
80
Source
Water
Flow
GPM/ton
1.5
2.3
3.0
1.5
2.3
3.0
Load EWT
°F @ 1.5-3.0
GPM/ton
60 56-63 199-228 4-14 6-14
80 58-65 286-297 4-14 6-14 5-14
90 59-66 310-344 4-14 6-14 4-14
100 61-65 360-385 4-14 6-14 4-14
120 64-69 459-510 4-14 6-14 4-13
60 85-95 212-224 6-11 7-11
80 91-99 290-310 6-11 7-11 6-17
90 92-101 326-338 6-11 7-11 6-17
100 96-103 381-399 6-11 7-11 5-17
120 100-108 474-488 6-11 7-11 4-16
60 95-102 215-228 6-13 7-11
80 98-106 299-313 6-13 7-11 6-18
90 99-108 329-341 6-13 7-11 6-18
100 102-110 384-401 6-13 7-11 6-17
120 106-114 475-491 6-13 7-11 5-17
60 95-107 215-256 6-14 7-15
80 101-110 310-326 6-14 7-15 7-19
90 103-112 329-376 6-14 7-15 6-19
100 105-114 399-414 6-14 7-15 6-18
120 108-118 476-524 6-14 7-15 5-17
60 109-129 225-237 14-26 5-14
80 123-138 314-327 14-26 5-14 8-19
90 130-142 343-357 10-15 5-14 7-19
100 137-147 402-415 10-15 5-14 7-19
120 150-157 493-504 10-15 5-14 6-20
60 111-132 227-239 14-38 6-15
80 135-147 315-330 14-38 6-15 8-20
90 143-152 344-360 10-16 6-15 8-20
100 145-154 405-418 10-16 6-15 7-20
120 156-163 494-507 10-16 6-15 6-20
60 110-149 227-279 19-44 6-18
80 135-150 286-332 19-44 6-18 8-21
90 145-166 345-408 13-23 6-18 8-21
100 148-158 405-420 13-23 6-18 8-21
Suction
Pressure
PSIG
Discharge
Pressure
PSIG
Heating
Super-heat Sub-cooling
Water
Temp
Drop °F
Source
2-6
9-16
6-12
5-9
15-21
10-15
7-12
Water
Temp
Rise °F
Load
5-14
6-17
7-18
7-19
8-18
8-20
9-21
28
Installation & Operation WATER-TO-WATER (HWW) SERIES Heat Controller, Inc.
Preventative Maintenance
Heat Exchanger Maintenance –
(Direct Ground Water Applications Only)
If the installation is performed in an area with a known high
mineral content (125 P.P.M. or greater) in the water, it is best
to establish with the owner a periodic maintenance schedule
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 either the heat exchanger material or copper
water lines. Generally, the more water owing through the
unit the less chance for scaling therefore 2.5 gpm per ton
[2.0 l/m per kW] is recommended as a minimum ow.
Heat Exchanger Maintenance –
(All Other Water Loop Applications)
Generally water coil maintenance is not needed however,
if the installation is located in a system with a known high
dirt or debris content, it is best to establish with the owner a
periodic maintenance schedule so the coil can be checked
regularly. These dirty installations are a result of the deterioration of iron or galvanized piping or components in the
system or open cooling towers requiring heavy chemical
treatment and mineral buildup through water use. 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 owing through the unit, the less chance for
scaling, however 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.
Compressors
Conduct annual amperage checks to ensure amp draw is
no more than 10% greater than that indicated by serial plate
data.
Cabinet
Do not allow water to stay in contact with the cabinet for long
periods of time to prevent corrosion of the cabinet sheet
metal. Generally vertical cabinets are set up from the oor a
few inches for prevention. 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 chart for pressure and temperatures. Verify
that air and water ow rates are at proper levels before servicing the refrigerant circuit.
If the refrigerant circuit is opened for any reason, a new
liquid line lter-drier must be installed.
Clean or replace 20 mesh (841 micron) [0.84mm] strainer/
lters on a timely schedule.
29
Heat Controller, Inc. WATER-TO-WATER (HWW) SERIES Installation & Operation
Refrigeration Troubleshooting Form
Refrigeration Troubleshooting Form
Water-to-Water Units
:etaD putratS:epyT pooL:remotsuC
Model #:
Complaint:
WATER-TO-WATER UNITS
1311
COAX
Load
1210
CONDENSER (HT G)
EVAP ORATOR (CL G)
*Filter drier not us ed
for some R-22 units.
**Turn off HWG before
t roubleshooting.
Voltage
Compressor Amps
1 Suction Temp
2 Suction Press
2a Saturation Temp
2b Superheat
3 Discharge Temp
4 Discharge Press
4a Saturation Temp
4b Subcooling
5 Liquid Line Temp
6 Source Water In Tmp
7 Source Water Out Tmp
8 Source Water In Pres
9 Source Water Out Pres
Press Drop
9a
9b Flow Rate GPM [l/s]
10 Load Water In Temp
11 Load Water Out Temp
12 Load Water In Pres
13 Load Water Out Pres
Press Drop
13a
13b Flow Rate GPM [l/s]
REFRIGERANT: R-22 R-410A R-407C
OPERATING MODE: HEATING COOLING
REFRIG FLOW - HEATING REFRIG FLOW - COOLING
CONDENSER (COOLING)
EVAPORATOR (HEATING)
EXPANSION
VALVE
FILTER
DRIER*
COAX
Source
FP2:
5
HEATING
LIQUID
LINE
FP1:
5
COOLING
LIQUID
LINE
6
8
Heating Cooling
Temp Diff. =
<--Water-to-Water units only
Temp Diff. =
<--Water-to-Water units only
<--Water-to-Water units only
<--Water-to-Water units only
<--Water-to-Water units only
REVERSING
VALVE
7
9
:% & epyT ezeerfitnA:# laireS
HEATING POSITION COOLING POSITION
1
2
HWG**
SUCTION
COMPRESSOR
3
DISCHARGE
4
setoNnoitpircseD
Heat of Extraction (Absorption) or Heat of Rejection:
HE or HR =
Flow Rate x Temp. Diff x Fluid Factor
Fluid Factor: (for Btuh)
500 (Water); 485 (Antifreeze)
30
Fluid Factor: (for kW)
4.18 (Water); 4.05 (Antifreeze)
11/2010
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