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2. Heat Controller Inc Water Source Heating and Cooling Systems 28 The Quality Leader in Conditioning Air Residential Split 60Hz R410A Rev 03 August 2012 Unit Commissioning And Operating Conditions Operating Limits Environment Units are designed for indoor installation only Never install units in areas subject to freezing or where humidity levels could cause cabinet condensation such as unconditioned spaces subject to 100 outside air Power Supply Voltage utilization shall comply with AHRI standard 110 Determination of operating limits is dependent primarily upon three factors 1 return air temperature 2 water temperature and 3 ambient temperature When any one of these factors is at minimum or maximum levels the other two factors should be at normal levels to insure proper unit operation Extreme variations in temperature and humidity and or corrosive water or air will adversely affect unit performance reliability and service life Consult Table 9a for operating limits Table 9a Building Operating Limits Operating Limits Cooling Heating Air Limits Min ambient air DB 45 F 7 C 39 F 4 C Rated ambient air DB 80 6 F 27 C 68 F 20 C Max ambient air DB 130 F 54 C 85 F 29 C Min entering air DB WB 65 45 F 18 7 C 50 F 10 C 70 50 F Reheat Rated entering air DB WB 80 6 66 2 F 27 19 C 68 F 20 C Max entering air DB WB 100 75 F 38 24 C 80 F 27 C Water
3. Residential Split 60Hz R410A Rev 03 August 2012 Advanced Troubleshooting and Configuration Information Service Mode The Service Mode provides the installer with several functions for troubleshooting including Manual Operation Control Diagnostics Control Configuration and Fault History Manual Operation The Manual Operation mode allows the installer to bypass normal thermostat timings and operating modes to directly activate the thermostat inputs to the DXM2 activate the DXM2 Test mode and directly control the ECM blower internal flow center and proportional valve Control Diagnostics The Control Diagnostics menus allow the installer to see the current status of all DXM2 control switch inputs values of all temperature sensor inputs control voltage ECM blower internal flow center and proportional valve operating status and parameters Dipswitch Configuration The Dipswitch Configuration menus allow the installer to easily see the current DXM2 control configuration Fault History In addition to the fault code the DXM2 stores the status of all control inputs and outputs when a fault condition is detected The fault history covering the last five lockout conditions is stored and may be retrieved from the DXM2 After a specific fault in the fault history is selected the operating mode and time when the fault occurred are displayed with options to select specific control status values when the lockou
4. General Proper indoor coil selection is critical to system efficiency Using an older model coil can affect efficiency and may not provide the customer with rated or advertised EER and COP Coil design and technology have dramatically improved operating efficiency and capacity in the past 20 years Homeowners using an older coil are not reaping these cost savings and comfort benefits NEVER MATCH AN R 22 INDOOR COIL WITH AN R 410A COMPRESSOR SECTION Newer indoor coils have a larger surface area enhanced fin design and grooved tubing These features provide a larger area for heat transfer improving efficiency and expanding capacity Typical older coils may only have one third to one half the face area of these redesigned coils Indoor Coil Selection HTS GeoLogix HCI split system heat pumps are rated in the AHRI directory with a specific indoor coil match GeoLogix HTS models are rated with Heat Controller WDG Series air handlers and MWG Series coils as shown in Table 1a Other brands of air handlers may attain the same AHRI ratings providing that the specifications meet or exceed those listed in Table 1a AND Table 1b However for warranty and federal tax credits an AHRI matched system is required An ECM motor and TXV is required Cap tubes and fixed orifices are not acceptable PSC fans may be used if matched to Table 1b but will not meet AHRI ratings If using PSC fan compressor section must be operated as a single stage
5. 0 5 ppm Maximum Allowable at maximum water temperature 24 C lt 20ppm NR lt 150 ppm NR lt 400 ppm lt 150 ppm lt 1000 ppm lt 375 ppm gt 1000 ppm gt 375 ppm Copper Cupronickel 304 SS 316 SS Titanium Maximum Chloride Levels Erosion and Clogging lt 10 ppm of particles and a maximum velocity of 1 8 m s Filtered for maximum 841 micron 0 84 mm 20 mesh size Particulate Size and Erosion lt 10 ppm lt 1 ppm sandfree for reinjection of particles and a maximum velocity of 1 8 m s Filtered for maximum 841 micron 0 84 mm 20 mesh size Any particulate that is not removed can potentially clog components Rev 3 22 2012 The Water Quality Table provides water quality requirements for coaxial heat exchangers When water properties are outside of those requirements an external secondary heat exchanger must be used to isolate the heat pump heat exchanger from the unsuitable water Failure to do so will void the warranty for the coaxial heat exchanger Notes Closed Recirculating system is identified by a closed pressurized piping system Recirculating open wells should observe the open recirculating design considerations NR Application not recommended No design Maximum 14 Heat Controller Inc Water Source Heating and Cooling Systems The Quality Leader in Conditioning Air A CAUTION A CAUTION R 410A systems operate at higher pressures than R 22 systems Be certain that se
6. 16 os se 45 et 49 37 54 4t 29 45 s2 25 35 22 0 04 950 0 06 1150 0 10 woo 0 80 71 co ve so co 65 49 72 s1 42 so 37 9 11 45 50 53 di 45 48 36 39 42 31 34 36 27 29 1050 f ti 34 36 37 31 32 33 28 29 23 25 24 20 20 TETELE LATE TETEL ETET ett tata 0 02 42 45 47 37 so 42 33 35 37 29 31 32 23 25 1750 Ede 0 04 48 53 57 44 48 52 43 46 34 38 3 20 31 126 103 83 114 ot 71 oo 7e so a4 eo so es 44 OA IO WO A E E D E E 122 108 87 119 95 75 105 so 55 62 ee so sz 61 45 51 Gross coolina capacity MBtuh BR sensible neat capacity MBtuh BF Bypass factor 005 Tr 006 y DH 35 www heatcontroller com HEAT CONTROLLER INC WATER SOURCE HEAT PUMPS Residential Split 60Hz R410A Rev 03 August 2012 Installation NOTICE Failure to remove shipping brackets from spring mounted compressors will cause excessive noise and could cause component failure due to added vibration The installation of water source heat pump units and all associated components parts and accessories which make up the installation shall be in accordance with the regulations of ALL authorities having jurisdiction and MUST conform to all applicable codes It is the responsib
7. C 17 8 Temp F Temp C Temp F 131 0 132 8 134 6 136 4 138 2 140 0 141 8 143 6 145 4 147 2 149 0 150 8 152 6 1 94 154 4 1 88 156 2 1 81 158 0 1 75 159 8 1 69 161 6 1 64 163 4 1 58 165 2 1 53 167 0 1 48 168 8 1 43 170 6 1 39 172 4 1 34 174 2 1 30 176 0 1 26 177 8 1 22 179 6 1 18 181 4 1 14 183 2 185 0 186 8 188 6 190 4 192 2 194 0 195 8 197 6 199 4 201 2 203 0 204 8 206 6 208 4 210 2 212 0 213 8 215 6 217 4 219 2 221 0 222 8 224 6 226 4 228 2 230 0 231 8 233 6 235 4 237 2 239 0 240 8 242 6 244 4 246 2 248 0 249 8 251 6 253 4 a ojo niola A o Ny 2lo lN aja A v Njo www heatcontroller com 35 36 HEAT CONTROLLER INC WATER SOURCE HEAT PUMPS Residential Split 60Hz R410A Rev 03 August 2012 Advanced Troubleshooting and Configuration Information General To properly configure and troubleshoot advanced control features and to aid in troubleshooting basic control features a communicating thermostat or diagnostic tool with similar capabilities should be used System Configuration All factory installed DXM2 controls have their basic configuration parameters set as part of the factory manufacturing and test proc
8. F controlled by the lower element The upper 20 of the tank or 10 gallons will be maintained at 125 F controlled by the upper element Figure 15 Typical HWG Installation Indoor Compressor Section Cold Inlet Shut Off Valve 1 Shut Off Valve 4 8 Powered Water Heater Hot Outlet to home Upper element to 120 130 F 49 54 C Lower element to 100 110 F 38 43 C Shut off Valve 3 Insulated water lines 5 8 OD 50 ft maximum one way 16mm OD 15 meters maximum Field supplied 3 4 brass nipple and T Using a 125 F set point the HWG can heat the lower 40 gallons of water from 100 F to 125 F providing up to 8 330 btu s of heat Using the 150 F set point the HWG can heat the same 40 gallons of water from 100 F to 150 F and the remaining 10 gallons of water from 125 F to 150 F providing a total of up to 18 743 btu s of heat or more than twice as much heat as when using the 125 F set point This example ignored standby losses of the tank When those losses are considered the additional savings are even greater Electric water heaters are recommended If a gas propane or oil water heater is used a second preheat tank must be installed Figure 16 If the electric water heater has only a single center element the dual tank system is recommended to insure a usable entering water temperature for the HWG Typically a sing
9. Improper output setting No pump output signal Low pump voltage No pump feedback signal Bad pump RPM sensor ERV unit has fault Rooftop units only No Fault Code Shown Unit Short Cycles A Unit selection Compressor overload Thermostat position Unit locked out Verify the AO 2 jumper is in the PWM position Check DC voltage between A02 and GND should be between 0 5 and 10 VDC with pump active Check line voltage to the pump Check DC voltage between T1 and GND Voltage should be between 3 and 4 VDC with pump OFF and between 0 and 2 VDC with the pump ON Replace pump if the line voltage and control signals are present at the pump and the pump does not operate Troubleshoot ERV unit fault ee Only Fan Operates Check and replace if necessary Reset power and check operation Check and clean air filte r Reset power or wait 20 minutes for auto exit Unit may be oversized for space check sizing for actual load of space Check and replace if necessary nsure thermostat set for heating or cooling operation Check andcleanairfiter i Reset power or wait 20 minutes for auto ext Check and replace necessary Check for lockout codes reset power Only Fan Runs Compressor overload Thermostat wiring Check compressor overload replace if necessary Check thermostat wiring at DXM2 put in Test Mode and jumper Y1 and R to give call for compressor Heat Controller Inc Water Source Heating and
10. by using the pressure temperature conversion table on the gauge set 4 Subtract the temperature obtained in step 3 from step 1 The difference will be the superheat of the unit or the total number of degrees above saturation temperature Refer to Tables 14a to 15 for superheat ranges at specific entering water conditions Determining Sub Cooling 1 Measure the temperature of the liquid line on the smaller refrigerant line liquid line just outside of the cabinet This location will be adequate for measurement in both modes unless a significant temperature drop in the liquid line is anticipated 2 Determine the condensor pressure high side by attaching refrigerant gauges to the schrader connection on the liquid line service valve If the hot gas discharge line of the compressor is used refer to the appropriate column in Tables 14a to 15 3 Convert the pressure obtained in step 2 to the saturation temperature by using the press temp conversion table on the gauge set 4 Subtract the temperature of Step 3 from the temperature of Step 1 The difference will be the sub cooling value for that unit total degrees below the saturation temperature Refer to Tables 14a or 6b for sub cooling values at specific entering water temperatures www heatcontroller com 19 20 HEAT CONTROLLER INC WATER SOURCE HEAT PUMPS Residential Split 60Hz R410A Rev 03 August 2012 Hot Water Generator The HWG Hot Water Generator or
11. s Water In line to sense the potable water temperature A WARNING A WARNING UNDER NO CIRCUMSTANCES SHOULD THE SENSORS BE DISCONNECTED OR REMOVED FULL LOAD CONDITIONS CAN DRIVE HOT WATER TANK TEMPERATURES FAR ABOVE SAFE TEMPERATURE LEVELS IF SENSORS DISCONNECTED OR REMOVED The DXM2 microprocessor control monitors the refrigerant and water temperatures to determine when to operate the HWG The HWG will operate any time the refrigerant temperature is sufficiently above the water temperature Once the HWG has satisfied the water heating demand during a heat pump run cycle the controller will cycle the pump at regular Intervals to determine if an additional HWG cycle can be utilized When the control is powered and the HWG pump output is active for water temperature sampling or HWG operation the DXM2 status LED will slowly flash On 1 second Off 1 second If the control has detected a HWG fault the DXM2 status LED will flash a numeric fault code as follows High Water Temperature gt 160 F 5 flashes Hot Water Sensor Fault 6 flashes Compressor Discharge Sensor Fault 6 flashes Fault code flashes have a duration of 0 3 seconds with a 10 second pause between fault codes For example a Compressor Discharge sensor fault will be six flashes 0 3 seconds long then a 10 second pause then six flashes again etc A WARNING A WARNING USING A 150 F SETPOINT ON THE HWG WILL RESULT IN WATER TEMPERATURES SUFF
12. section below is completed Powering the pump before all installation steps are completed may damage the pump Water Tank Preparation 1 Turn off power or fuel supply to the hot water tank 2 Connect a hose to the drain valve on the water tank 3 Shut off the cold water supply to the water tank 4 Open the drain valve and open the pressure relief valve or a hot water faucet to drain tank When using an existing tank it should be flushed with cold water after it is drained until the water leaving the drain hose is clear and free of sediment 6 Close all valves and remove the drain hose 7 Install HWG water piping o www heatcontroller com 21 ER HEAT CONTROLLER INC WATER SOURCE HEAT PUMPS Residential Split 60Hz R410A Rev 03 August 2012 Hot Water Generator HWG Water Piping 1 Using at least 1 2 12 7mm I D copper route and install the water piping and valves as shown in Figures 15 or 16 Install an approved anti scald valve if the 150 F HWG setpoint is or will be selected An appropriate method must be employed to purge air from the HWG piping This may be accomplished by flushing water through the HWG as in Figures 15 and 16 or by installing an air vent at the high point of the HWG piping system 2 Insulate all HWG water piping with no less than 3 8 10mm wall closed cell insulation 3 Open both shut off valves and make sure the tank drain valve is closed Water Tank Refill 1 Close
13. 38 15 20 8 5 10 5 32 39 15 20 5 8 7 8 32 39 woo oo NN o EUNN 1 Ert N a N Www KREE Ert N 141 151 374 394 7 12 14 6 16 6 17 23 177 187 392 412 9 14 17 22 14 4 16 4 37 45 141 151 360 380 7 12 10 7 12 7 17 23 181 191 397 417 10 15 17 22 10 8 12 8 38 46 141 151 346 366 7 12 6 9 8 9 17 23 186 196 402 422 11 16 17 22 7 1 9 1 38 46 145 155 473 493 7 12 13 6 15 6 16 22 145 155 458 478 7 12 9 9 11 9 16 22 Operation Not Recommended 145 155 441 461 7 12 6 2 8 2 16 22 Based on 15 methanol antifreeze solution Table 14b Size 036 HTS Two Stage R 410A Typical Unit Operating Pressures and Temperatures Full Load Cooling without HWG active Full Load Heating without HWG active Entering Water Suction Discharge Temp F Pressure Pressure PSIG PSIG Air Temp Suction Discharge Drop F Pressure Pressure DB PSIG PSIG Air Temp Rise F DB Super Sub Water Temp heat cooling Rise F Super Sub Water Temp heat cooling Drop F 122 132 153 173 18 23 9 14 22 1 24 1 19 25 71 81 263 283 5 10 2 5 8 1 10 1 17 23 121 131 145 165 18 23 8 13 16 8 18 8 20 26 75 85 267 287 5 10 2 5 5 9 7 9 18 24 121 131 135 155 18 23 8 13 10 5 12 5 20 26 78 88 270 290 5 10 2 5 3 7 5 7 19 25 131 141 222 242 13 18 10 15 21 9 23 9 19 25 103 113 292 312 6 11 2 5 7 11 5 13 5 23 29 130 140 208 228 13 18 9 14 16 1 18 1 20 26 107 117 296 316 6 11 2 5 7 8 6 10 6
14. Adding refrigerant will increase sub cooling while superheat should remain fairly constant allowing for a slight amount of hunting in TXV systems This increase in subcooling will require 5 minutes or so of operation before it should be measured After values are measured compare to the chart and go to FINAL EVALUATION FINAL EVALUATION In a split system cooling subcooling values can be misleading depending on the location of the measurement Therefore it is recommended that charging be monitored in the heating mode Charge should be evaluated by monitoring the subcooling in the heating mode After initial check of heating sub cooling shut off unit and allow to sit 3 5 minutes until pressures equalize Restart unit in the cooling mode and check the cooling superheat against Tables 14a to 15 If unit runs satisfactorily charging is complete If unit does not perform to specifications the cooling TXV air coil side may need to be readjusted if possible until the cooling superheat values are met Residential Split 60Hz R410A Rev 03 August 2012 Refrigeration Installation Checking Superheat and Subcooling Determining Superheat 1 Measure the temperature of the suction line at a point near the expansion valve bulb 2 Determine the suction pressure by attaching refrigeration gauges to the suction schrader connection at the compressor Convert the pressure obtained in step 2 to saturation temperature boiling point
15. HEAT PUMPS Indoor Split HTS024 060 Wir Residential Spli Rev 94 OC i e i 1 09 082 802 i S YOSSIMANOI i H I MIT A02 VL 289 1 Ge z xs il Nicco dA S LIONS reum emere c raros tut S pue p 310N 33S Ke I KH H Ee Ener JejpueH AN u peo ou05 WXY p cl pfo oe ges p EL Qv er RIAD pue JVISL 6uneoiunuiuop UNIM SUSISAS ma CEN Ee H Sud a ECH Ana Vi Igo 980 I H TRONO I ener ssa ea a s H n FER Ig ol s awna H LIIS 00 VII NUS 3 P4 7 3 we OYIM AYOLIVA TVNUZLNI NO I rete lllkelig gyG G7 if lt i ii n inte 8 a te J ooo y y Lu dy Mirri Rioni dr AR M uA ER LXI DIU Ee NZ 4 bui W Id 19L 1 TOYLNOI WXY 79 209 wun wangNvH siy 1etsgaean UROUS SE 195 ST OVINE UOTIOSJID JOTURIS URSUS UOTIdO AMIN 10A ut pog st AMW uouas wid AQ Q uo da Aj2A OL HOSNIS AWIL one zue suononnsui Zut dg 1oopu aos s1o puer IV pojonuoo WXY UOU 104 MEUS ait mura SALVIA SH MH on oO dur OJA 1M3 10U op S19 PUEH ALY P9 ONUOD NX v 104 6 M BOLVEANED s in 10H 9MH aX i na ns d e eid U J8 WOnMS3LVM aanssaud HOIH smaH OHMS Sunssaed HOIH rondo Supra sig Ota QELA aq JOU Un MOYLOAG ayesuapuoc wonov v LAVIS 10 Old 4 iw i MOLIN SUNSSIMA HOIH dH 10N am D xog WHOL 20 WOT Dn 998 posn oq asnu DATA Pleag HUY Zumas 4061 104 1671 si Sumos oampuoduro 1neJop Zeta AVIR dind Md KEE wondo 3ojerouor A9 10H IM sppotu ur juo dumd soFuEyoxy WH pue OMH L 32078 ENN ONBIM gu Bd
16. Limits Min entering water 20 F 6 7 C 20 F 6 7 C Normal entering water 50 110 F 10 43 C 30 70 F 1 to 2 Max entering water 120 F 49 C 120 F 49 C 1 5 to 3 0 gpm ton 1 6 to 3 2 l m per kW Normal Water Flow Commissioning Conditions Consult Table 9b for commissioning conditions Starting conditions vary depending upon model and are based upon the following notes Notes 1 Conditions in Table 9b are not normal or continuous operating conditions Minimum maximum limits are start up conditions to bring the building space up to occupancy temperatures Units are not designed to operate under these conditions on a regular basis 2 Voltage utilization complies with AHRI Standard 110 Table 9b Building Commissioning Limits Air Limits Min ambient air DB 45 F 7 C 39 F 4 C Rated ambient air DB 80 6 F 27 C 68 F 20 C Max ambient air DB 130 F 54 C 85 F 29 C Min entering air DB WB 60 F 16 C 40 F 4 5 C Rated entering air DB WB 80 6 66 2 F 27 19 C Max entering air DB WB 110 83 F 43 28 C Water Limits Min entering water 20 F 6 7 C 20 F 6 7 C Normal entering water 50 110 F 10 43 C 30 70 F 1 to 21 C Max entering water 1 5 to 3 0 gpm ton E 1 6 to 3 2 Um per kW www heatcontroller com 29 HEAT CONTROLLER INC WATER SOURCE HEAT PUMPS Residential Split 60Hz R410A Rev 03 August 2012 Unit Start Up and Operating Condition
17. Unit short Unit ci Replace cycles Cycles DXM2 No See Only Only Fan See fault codes in table Fan Runs Runs on following page N See Only Yes Only Comp Compressor Runs Runs Did unit lockout after a period of operation No See Does Does unit not Operate operate in in Clg cooling Unit is OK See Performance Troubleshooting for further help Heat Controller Inc Water Source Heating and Cooling Systems The Quality Leader in Conditioning Air Residential Split 60Hz R410A Rev 03 August 2012 Functional Troubleshooting Ra pepe pene frese Reduced or no water flow in cooling Check water flow adjust to proper flow rate Water temperature out of range in cooling Main Power Problems Green status LED off Bring water temp within design parameters Check for dirty air filter and clean or replace Check fan motor operation and airflow restrictions Dirty air coil construction dust etc 00 high of external static Check static vs blower table HP Fault Code 2 High Pressure Air temperature out of range in heating Bring return air temp within design parameters Check superheat subcooling vs typical operating condition table Check switch continuity and operation Replace Thaw heat exchanger Check for refrigerant leaks LP LOC Fault Code 3 Low Pressure Loss of Charge Check charge and start up water flow Check pump operation or
18. avoided could result in minor or moderate injury or product or property damage NOTICE Notification of installation operation or maintenance information which is important but which is not hazard related A WARNING A WARNING Verify refrigerant type before proceeding Units are shipped with R 410A refrigerants The unit label will indicate which refrigerant is provided The EarthPure Application and Service Manual should be read and understood before attempting to service refrigerant circuits with R 410A A WARNING A 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 proficiency requirements A WARNING A 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 A CAUTION A 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 filters will quickly become clogged with construction dirt and debris which may
19. cause system damage Heat Controller Inc Water Source Heating and Cooling Systems The Quality Leader in Conditioning Air Inspection Upon receipt of the equipment carefully check the shipment against the bill of lading Make sure all units have been received Inspect the packaging of each unit and inspect each unit for damage Insure that the carrier makes proper notation of any shortages or damage on all copies of the freight bill and completes a common carrier inspection report Concealed damage not discovered during unloading must be reported to the carrier within 15 days of receipt of shipment If not filed within 15 days the freight company can deny the claim without recourse Note It is the responsibility of the purchaser to file all necessary claims with the carrier Notify your equipment supplier of all damage within fifteen 15 days of shipment Storage Equipment should be stored in its original packaging in a clean dry area Store units in an upright position at all times Stack units a maximum of 3 units high Unit Protection Cover units on the job site with either the original packaging or an equivalent protective covering Cap the open ends of pipes stored on the job site In areas where painting plastering and or spraying has not been completed all due precautions must be taken to avoid physical damage to the units and contamination by foreign material Physical damage and contamination may prevent proper s
20. charging the unit To pressurize the line set attach refrigerant gauges to the service ports and add an inert gas nitrogen or dry carbon dioxide until pressure reaches 60 90 psig 413 620 kPa Never use oxygen or acetylene to pressure test Use a halogen leak tester or a good quality bubble solution to detect leaks on all connections made in the field Check the service valve ports and stem for leaks If a leak is found repair it and repeat the above steps For safety reasons do not pressurize system above 150 psig 1034 kPa System is now ready for evacuation and charging Heat Controller Inc Water Source Heating and Cooling Systems The Quality Leader in Conditioning Air Residential Split 60Hz R410A Rev 03 August 2012 Refrigeration Installation Figure 12 Typical Split Air Handler Installation Indoor Compressor Section Power Disconnects Series TXV IN toward Compressor Section Return Plenum Indoor Compressor Section Low Voltage Air pad or extruded polystyrene Figure 13 Typical Split Add on Coil Fossil Fuel Furnace Installation Indoor Compressor Section Air Temperature Limit Switch TXV IN toward Compressor Section HWG Series A Coil PVC Condensate with vented trap Indoor Compressor Fossil Furnace Section Air pad or extruded polystyrene www heatcontroller com 17 18 HEAT CONTROLLER INC WATER SOURCE HEAT PUMPS Residential S
21. check can eliminate nuisance trip outs and high velocity water flow that could erode heat exchangers Q Unit air coil and filters Insure that filter is clean and accessible Clean air coil of all manufacturing oils Q Unit controls Verify that DXM2 field selection options are properly set Low voltage wiring is complete Q Blower CFM and Water AT is set on communicating thermostats or diagnostic tool Q Service access panels are in place a SYSTEM CHECKOUT System water temperature Check water temperature for proper range and also verify heating and cooling set points for proper operation System pH Check and adjust water pH if necessary to maintain a level between 6 and 8 5 Proper pH promotes longevity of hoses and fittings see Table 4 System flushing Verify that all air is purged from the system Air in the system can cause poor operation or system corrosion Water used in the system must be potable quality initially and clean of dirt piping slag and strong chemical cleaning agents Some antifreeze solutions may require distilled water Internal Flow Controller Verify that it is purged of air and in operating condition System controls Verify that system controls function and operate in the proper sequence Low water temperature cutout Verify that low water temperature cut out controls are set properly LT1 JW3 Miscellaneous Note any questionable aspects of the installation A CAUTION A CAUTIO
22. desuperheater option provides considerable operating cost savings by utilizing excess heat energy from the heat pump to help satisfy domestic hot water requirements The HWG is active throughout the year providing virtually free hot water when the heat pump operates in the cooling mode or hot water at the COP of the heat pump during operation in the heating mode Actual HWG water heating capacities are provided in the appropriate heat pump performance data Heat pumps equipped with the HWG option include a built in water to refrigerant heat exchanger that eliminates the need to tie into the heat pump refrigerant circuit in the field The control circuit and pump are also built in for residential equipment Figure 18 shows a typical example of HWG water piping connections on a unit with built in circulating pump This piping layout reduces scaling potential The temperature set point of the HWG is field selectable to 125 F or 150 F The 150 F setpoint allows more heat storage from the HWG For example consider the amount of heat that can be generated by the HWG when using the 125 F set point versus the amount of heat that can be generated by the HWG when using the 150 F set point In a typical 50 gallon two element electric water heater the lower element should be turned down to 100 F or the lowest setting to get the most from the HWG The tank will eventually stratify so that the lower 80 of the tank or 40 gallons becomes 100
23. heat cooling Drop F 112 122 187 207 18 23 23 28 20 7 22 7 19 25 66 76 261 281 8 13 111 121 167 187 18 23 21 26 15 5 17 5 19 25 69 79 264 284 8 13 111 121 147 167 18 23 20 25 10 2 12 2 19 25 72 82 267 287 8 13 8 10 18 24 6 8 19 25 4 6 19 25 Pod mA mh Sch 125 135 245 265 13 18 19 24 20 9 22 9 20 26 93 103 289 309 7 12 123 133 227 247 13 18 18 23 15 6 17 6 20 26 98 108 295 315 7 12 122 132 208 228 14 19 16 21 10 2 12 2 20 26 103 113 301 321 7 12 11 5 13 5 23 29 8 7 10 7 24 30 5 9 7 9 25 31 7 eee 133 143 314 334 9 14 17 22 20 5 22 5 20 26 123 133 319 339 7 12 132 142 294 314 9 14 16 21 15 2 17 2 20 26 130 140 329 349 7 12 131 141 274 294 10 15 14 19 9 9 11 9 20 26 137 147 336 356 7 12 15 17 28 35 11 5 13 5 29 36 7 9 9 9 30 37 Pod Eu di uh 138 148 401 421 8 13 16 21 19 2 21 2 19 25 167 177 365 385 7 12 137 147 379 399 8 13 15 20 14 3 16 3 19 25 177 187 374 394 7 12 136 146 357 377 9 14 13 18 9 3 11 3 19 25 187 197 388 408 7 12 19 6 21 6 37 45 15 17 38 46 10 3 12 3 39 47 aan ann ann ann ooo ooo ooo ooo 1 ee 144 154 502 522 8 13 14 19 18 20 18 24 143 153 477 497 8 13 13 18 13 3 15 3 18 24 Operation Not Recommended 142 152 452 472 9 14 12 17 8 5 10 5 18 24 Based on 15 methanol antifreeze solution Table 14d Size 060 HTS Two Stage R 410A Typical Unit Operating Pressures and T
24. return duct and or grille size x Restricted return air flow Check power supply and 24VAC voltage before and during operation Check power supply wire size Check compressor starting Need hard start kit Check 24VAC and unit transformer tap for correct power supply voltage Check power supply voltage and 24VAC before and during on Under voltage Over Under Voltage Code 7 Auto Resetting operati Over voltage B Check 24VAC and unit transformer tap for correct power supply voltage Unit Performance ES Heating Mode LT2 gt 125 F Check for poor air flow or overcharged unit Cooling Mode LT1 gt 125 F OR Sentinel Code 8 x LT2 lt 40 F evap pod Thermistor he LT1 and LT2 swapped Reverse position of thermistors x X Blower does not operate Check blower line voltage Check blower low voltage wiring Blower operating with incorrect Wrong unit size selection airflow Check for poor water flow or air flow ECM Fault Code 10 Wrong unit family selection Wrong motor size Incorrect blower selection www heatcontroller com A0 HEAT CONTROLLER INC WATER SOURCE HEAT PUMPS Residential Split 60Hz R410A Rev 03 August 2012 Functional Troubleshooting Possible Cause Faut Hta ciol IFC Fault Code 13 Internal Flow Controller Fault ESD ERV Fault DXM Only x x Green Status LED Code 3 No compressor operation X Compressor overload X X Control board Dirty air filter Unit in Test Mode X X
25. to freezing or where humidity levels could cause cabinet condensation such as unconditioned spaces subject to 100 outside air Consideration should be given to access for easy removal of service access panels Provide sufficient room to make water electrical and line set connections Any access panel screws that would be difficult to remove after the unit is installed should be removed prior to setting the unit Refer to Figure 2 for an illustration of a typical installation Refer to Physical Dimensions section for dimensional data Conform to the following guidelines when selecting unit location 1 Install the unit on a piece of rubber neoprene or other mounting pad material for sound isolation The pad should be at least 3 8 10mm to 1 2 13mm in thickness Extend the pad beyond all four edges of the unit 2 Provide adequate clearance for maintenance and service Do not block access panels with piping conduit or other materials 3 Provide access for servicing the compressor and coils without removing the unit 4 Provide an unobstructed path to the unit within the closet or mechanical room Space should be sufficient to allow removal of the unit if necessary 5 In limited side access installations pre removal of the control box side mounting screws will allow control box removal for future servicing R22 units only 6 Provide access to water valves and fittings and screwdriver access to the unit side panel
26. unit i e wired for either 1st stage or 2nd stage Without the ability to vary the airflow supply air temperatures may not be acceptable if the compressor is allowed to change stages when used with a PSC fan motor Table 1a WDG MWG Indoor Section Matches for AHRI Ratings Compressor Section Model Indoor Section Model Refrigerant HFC 410A Metering Device TXV required N 2 Dimensions 14x17 N N 2 2 24x17 24x17 Cabinet Configuration Upflow Downflow Horizontal Multipoise WDG Series Fan Motor Type HP ECM 1 2 ECM 1 2 ECM 1 Table 1b Tranquility 27 Air Handler Characteristics for Brands other than Above Models Evaporator Nominal Tons Temp F 024 Part Load Capacity MBtuh 19 2 22 4 024 Full Load 24 2 28 2 036 Part Load 25 2 29 2 036 Full Load 34 5 40 1 048 Part Load 34 3 39 9 048 Full Load 46 3 53 8 060 Full Load 54 5 63 3 Nominal tons are at AHRI ISO 13256 1 GLHP conditions Two stage units may be operated in single stage mode if desired where smaller capacity is required For example a model 024 may be used as a 1 1 2 ton unit if locked into 1st stage operation only PSC fan is used unit must be locked into either 1st or 2nd stage An ECM fan is required for two stage operation and for AHRI ratings Size air handler for Full
27. valve 4 Ensure that the HWG valves valves 2 and 3 are open Open the cold water supply valve 1 to fill the tank through the HWG piping This will purge air from the HWG piping 2 Open a hot water faucet to vent air from the system until water flows from faucet turn off faucet Open valve 4 3 Depress the hot water tank pressure relief valve handle to ensure that there is no air remaining in the tank 4 nspect all work for leaks 5 Before restoring power or fuel supply to the water heater adjust the temperature setting on the tank thermostat s to insure maximum utilization of the heat available from the refrigeration system and conserve the most energy On tanks with both upper and lower elements and thermostats the lower element should be turned down to 100 F 38 C or the lowest setting the upper element should be adjusted to 120 130 F 49 54 C Depending upon the specific needs of the customer you may want to adjust the upper element differently On tanks with a single thermostat a preheat tank should be used Fig 16 6 Replace access cover s and restore power or fuel supply Initial Start Up 1 Make sure all valves in the HWG water circuit are fully open 2 Turn on the heat pump and allow it to run for 10 15 minutes 3 Set S3 4 to the ON position enabled to engage the HWG 4 The HWG pump should not run if the compressor is not running 5 The temperature difference between the water entering
28. water valve operation setting Reduced or no water flow Plugged strainer or filter clean or replace in heating LT1 Fault Code 4 Check water flow adjust to proper flow rate Water Low Temperature Inadequate anti freeze level Check antifreeze density with hydrometer Improper low temperature setting 30 F vs 10 F Water temperature out of range Bring water temp within design parameters Bad thermistor Check temp and impedance correlation per chart 1 Check for dirty air filter and clean or replace esoe or no air flow Check fan motor operation and airflow restrictions Dog Too high of external static check static vs blower table Clip LT1 jumper for antifreeze 10 F use Too much cold vent air bring entering air temp within Air temperature out of range d design parameters LT2 Fault Code 5 Low Air Temperature gt Improper low temperature setting 30 F vs 10 F Normal airside applications will require 30 F only Bad thermistor Blocked drain Improper trap XIX x x x x lt Poor drainage Check temp and impedance correlation per chart Check for blockage and clean drain Check trap dimensions and location ahead of vent Check for piping slope away from unit Check slope of unit toward outlet Condensate Fault Code 6 Poor venting check vent location High Condensate Level Moisture on sensor Plugged air filter Replace air filter Find and eliminate rectriction increase
29. 1034313 use 3H TVNOLLdO nei Sen ANIT IWNOILAO mam m m mm OYS se sjopums og doy woy oq Ben ANA BIVM ONILYINCOM AMW avay avah aisen yaj mum ammine 050 Shui secon EE m m e xog 011107 0 saio10s 29 SHFOPUEIS ILO zJAX LIA punoss Arepuooas 1ounojsuel 9 weus NES eje aas i LME MO TV 0 TV U94 1981007 OO 104 iv 1 Busts uue v Ak e FUNLVYIIHIL BILVM NIAVIT LMI sunivaggWal gaien ONINSINI 1M3 TA T 3OVUL 1In2ui aNd t A jddng aru tei 1912919 10 enbz pores oBvyJoa pue 1 SS T2 99 15ntu Su oSupoa Avo HOLIMS SENSI gt 40 501 907 woswag NOTININO aivsN3cNO 02 O N sioYiNoo ven Nyd auvsnzono9 zez SNAM 39VLT0A ANI OH ima iii 10A Aiddng xun uey 1018210 10 jenby poi JOA put SI 24 IM 98804 MOT un OY o Zorn Jona 103 enuey uonesodo pue LSL OJA p RE re sm ren ni ONIBIM 3OVLIOA MOT alJ d 2 stunn avay site soduml AT m SUONNIOS JZITAAILNV Sursn uou 93 LA 10 UoNoaiosd amperodro MOJ sopraord IAITU TLT SE LEUR ei verano IN g m Lee ONIMIM Z9VLI0A NI ANOIOV wem 100AV 1 XOG 10N1N02 sapoo peoo pue HN YM Een snu prun aq 0 SULA TY c eben EENS n 2109 aneres ee E EEN erch pEopaAo Aqpetuoyur paysojord Deeg st 1ossardtio9 1 Saa we WOJ SAL LI aa mal MOSSO DUI eng mn 0220 109 mme avay lt gt SILON YIM SAM Mr 812V1N02 AVTI MUVIV wW 0N3937 23 LS8NS000896 lt 1 01 8 osco zI TWILNAGISSY SMH ZWXG 1 09 0 2 802 090 720 LITdS Aen ON meng aivo Nod TUL
30. 2 0 Um per kw 11 1 14 4 oOomOloo 0 oooo oooo EEN LEE Ee caro spaiaonososipuo s PWOHO AWON UAN o p o 00 0 0 VI Om ONH I NAON e 0 ARwWAO RWNO TMAN RON 1 VI 0 Q0 O 0 QO o lo010O o RO Qoo2o oowvo sswooowvao ONNNNJON OOJ OUJ OU HEEM pe de E PNT peo Table 14a Size 024 HTS Two Stage R 410A Typical Unit Operating Pressures and Temperatures d Full Load Cooling without HWG active Full Load Heating without HWG active Entering Water Suction Discharge Temp F Pressure Pressure PSIG PSIG Air Temp Suction Discharge Drop F Pressure Pressure DB PSIG PSIG Air Temp Rise F DB Super Sub Water Temp heat cooling Rise F Sub Water Temp cooling Drop F 122 132 159 179 13 18 122 132 146 166 13 18 122 132 132 152 14 19 16 7 18 7 18 24 77 87 278 298 12 3 14 3 19 25 79 89 280 300 7 9 9 9 19 25 82 92 282 302 10 15 5 9 7 9 18 24 10 15 4 2 6 2 19 25 10 15 2 7 4 7 20 26 IAA 240 NNA BRA ooo 132 142 186 206 8 13 132 142 172 192 8 13 132 142 158 178 8 13 16 3 18 3 18 24 107 117 314 334 12 1 14 1 19 25 111 121 315 335 7 8 9 8 19 25 115 125 317 337 13 18 8 9 10 9 25 31 13 18 6 7 8 7 26 32 13 18 4 5 6 5 26 32 1 aaa aaa 139 149 281 301 7 12 139 149 267 287 7 12 139 149 253 273 7 12 15 7 17 7 18 24 139 149 350 370 11 6 13 6 18 24 145 155 352 372 7 6 9 6 18 24 152 162 354 374 T E N 15 20 11 3 13 3 31
31. 24 30 130 140 194 214 14 19 9 14 10 3 12 3 20 26 112 122 301 321 6 11 2 5 7 5 7 7 7 24 30 138 148 299 319 8 13 13 18 21 5 23 5 19 25 134 144 322 342 7 12 2 5 7 14 5 16 5 28 35 137 147 280 300 8 13 12 17 15 8 17 8 20 26 140 150 328 358 7 12 2 5 7 11 1 13 1 29 36 137 147 263 283 8 13 12 17 10 12 20 26 146 156 334 354 7 12 2 5 7 7 7 9 7 30 37 142 152 388 408 6 11 13 18 20 5 22 5 18 24 172 182 360 380 8 13 2 5 7 20 5 22 5 36 44 142 152 367 387 7 12 8 13 14 9 16 9 18 24 184 194 369 389 8 13 2 5 7 15 17 37 45 142 152 347 367 7 12 8 13 9 3 11 3 18 24 196 206 378 398 8 13 2 5 7 10 12 39 47 147 157 486 506 6 11 13 18 19 21 18 24 147 157 465 475 7 12 8 13 14 16 18 24 Operation Not Recommended 147 157 444 464 7 12 8 13 9 11 18 24 Based on 15 methanol antifreeze solution Heat Controller Inc Water Source Heating and Cooling Systems The Quality Leader in Conditioning Air Residential Split 60Hz R410A Rev 03 August 2012 Unit Operating Conditions Table 14c Size 048 HTS Two Stage R 410A Typical Unit Operating Pressures and Temperatures Full Load Cooling without HWG active Full Load Heating without HWG active Entering Water Suction Discharge Temp F Pressure Pressure PSIG PSIG Air Temp Suction Discharge Drop F Pressure Pressure DB PSIG PSIG Air Temp Rise F DB Super Sub Water Temp heat cooling Rise F Super Sub Water Temp
32. 36 146 459 479 6 11 8 13 8 3 10 3 19 25 Based on 15 methanol antifreeze solution www heatcontroller com 34 HEAT CONTROLLER INC WATER SOURCE HEAT PUMPS Residential Split 60Hz R410A Rev 03 August 2012 Preventive Maintenance Water Coil Maintenance Direct ground water applications only If the system is installed in an area with a known high mineral content 125 P P M or greater in the water it is best to establish a periodic maintenance schedule with the owner so the coil can be checked regularly Consult the well water applications section of this manual for a more detailed water coil material selection Should periodic coil cleaning be necessary use standard coil cleaning procedures which are compatible with the heat exchanger material and copper water lines Generally the more water flowing through the unit the less chance for scaling Therefore 1 5 gpm per ton 2 0 Um per kW is recommended as a minimum flow Minimum flow rate for entering water temperatures below 50 F 10 C is 2 0 gpm per ton 2 6 Um per kW Water Coil Maintenance All other water loop applications Generally water coil maintenance is not needed for closed loop systems However if the piping is known to have high dirt or debris content it is best to establish a periodic maintenance schedule with the owner so the water coil can be checked regularly Dirty installations are typically the result of
33. Cooling Systems Insufficient Capacity Not Cooling or Heating Properly High Head Pressure Low Suction Pressure Low Dischage Air Temperature in Heating High Humidity Only Compressor Runs Unit Doesn t Operate in Cooling Modulating Valve Troubleshooting Xx X X ES X X X The Quality Leader in Conditioning Air I e x x lt x x x xxx Clg X X Xx x Residential Split 60Hz R410A Rev 03 August 2012 Performance Troubleshooting Dirty filter Replace or clean Check for dirty air filter and clean or replace Rduced or no air flow 7 ET in heatin Check fan motor operation and airflow restrictions 3 Too high of external static check static vs blower table Check for dirty air filter and clean or replace GE or no air flow Check fan motor operation and airflow restrictions i ing Too high of external static check static vs blower table Check supply and return air temperatures at the unit and at Leaky duct work distant duct registers if significantly different duct leaks are present Low refrigerant charge Check superheat and subcooling per chart Restricted metering device Check superheat and subcooling per chart replace x X X X X X x Thermostat improperly located Check location and for air drafts behind stat Unit undersized Recheck loads amp sizing check sensible clg load and heat pump capacity Scaling in water heat exchanger Perform Scaling check and clean
34. HEAT CONTROLLER INC Installation Operation and Maintenace Manual GeoLogix HTS Series Split System Two Stage 2 5 Tons HEAT CONTROLLER INC 1900 Wellworth Ave Jackson Michigan 49203 e Ph 517 0787 2100 e Fax 517 787 9341 e www heatcontroller com THE QUALITY LEADER IN CONDITIONING AIR HEAT CONTROLLER INC WATER SOURCE HEAT PUMPS Residential Split 60Hz R410A Rev 03 August 2012 Table of Contents Model Nomenclature 3 Electrical Line Voltage 23 Sately n iu E EN te wants eee 4 Electrical Low Voltage Wiring 24 Storage EE 5 Low Water Temperature Cutout Selection 24 Pre Installation 5 Thermostat Wiring 0 25 Equipment Selection 6 DXM2 Controls 26 27 Air Coil Match ups LL 6 Wire Diagram 1 6 llle 28 Air Handler Selection 7 Unit Commissioning and Installation 8 9 SEET 29 Water Connections 9 Unit Start Up and Operating Conditions 30 Ground Loop Applications 9 11 Unit Start Up Procedure 30 31 Open Loop Ground Water Systems 12 13 Unit Operating Conditions 32 33 Water Quality Standards 14 Preventive Maintenance 34 SSE ENEE 45 Troubleshooting 35 37 Refrigeration Installation 15 19 DAMA Process ROW CHal burt neprigi 38 Hot Water Generator 20 22 Punelonsbe ore qaos Tioubleshoo
35. ICIENT TO CAUSE SEVERE PHYSICAL INJURY IN THE FORM OF SCALDING OR BURNS EVEN WHEN THE HOT WATER TANK TEMPERATURE SETTING IS VISIBLY SET BELOW 150 F THE 150 F HWG SETPOINT MUST ONLY BE USED ON SYSTEMS THAT EMPLOY AN APPROVED ANTI SCALD VALVE PART NUMBER AVAS4 AT THE HOT WATER STORAGE TANK WITH SUCH VALVE PROPERLY SET TO CONTROL WATER TEMPERATURES DISTRIBUTED TO ALL HOT WATER OUTLETS AT A TEMPERATURE LEVEL THAT PREVENTS SCALDING OR BURNS Residential Split 60Hz R410A Rev 03 August 2012 Hot Water Generator Figure 20 Anti Scald Valve Piping Connections COLD WATER SUPPLY CHECK VALVE ANTI SCALD VALVE S HOT WATER TO HOUSE WATER HEATER A WARNING A WARNING The HWG pump Is fully wired from the factory Use extreme caution when working around the microprocessor control as it contains line voltage connections that presents a shock hazard that can cause severe injury or death The heat pump water piping pump and hot water tank should be located where the ambient temperature does not fall below 50 F 10 C Keep water piping lengths at a minimum DO NOT use a one way length greater than 50 ft one way 15 m See Table 6 for recommended piping sizes and maximum lengths All installations must be in accordance with local codes The installer is responsible for knowing the local requirements and for performing the installation accordingly DO NOT activate the HWG until Initial Start Up
36. Load if operating in two stage mode When selecting an air handler based upon the above conditions choose entering WB temperature of 67 F Use evaporator temperature CFM and capacity requirements as listed above The air handler capacity must be at least at the minimum capacity shown in the table in order for the AHRI rating condition to be valid See Figure 1 for an example selection Heat Controller Inc Water Source Heating and Cooling Systems The Quality Leader in Conditioning Air Residential Split 60Hz R410A Rev 03 August 2012 Equipment Selection Air Handler Selection Example Figure 1 shows a typical performance table for a heat pump air handler Suppose the evaporator temperature required is 50 F the capacity required is 35 000 Btuh and the airflow required is 1 200 CFM Each evaporator temperature listed in the table shows three wet bulb temperatures As recommended in the table notes above select the 67 F WB column At 1 200 CFM the model 003 capacity is 36 MBtuh which is higher than the minimum capacity required of 35 000 Btuh In this example model 003 would be the appropriate match Figure 1 Selecting Air Handler COIL REFRIGERANT TEMPERATURE F EVAPORATOR ea e E E E SS em Evaporator Air Entering Wet Bulb Temperature A EZIO CIA eee ee Oe e 5o 48 38 53 42 32 46 35 24 39 27 20 3o 18 020 28 29 31 25 27 28 22 23 24 19 20 20 16
37. Material Recirculating Water Quality Parameter Open Loop and Recirculating Well Scaling Potential Primary Measurement Above the given limits scaling is likely to occur Scaling indexes should be calculated using the limits below pH Calcium Hardness lt 7 lt Method pH lt 7 5 and Ca Hardness lt 100ppm Index Limits for Probable Scaling Situations Operation outside these limits is not recommended Scaling indexes should be calculated at 66 C for direct use and HWG applications and at 32 C for indirect HX use A monitoring plan should be implemented Ryznar Stability Index 6 0 7 5 If gt 7 5 minimize steel pipe use 0 5 to 0 5 If lt 0 5 minimize steel pipe use Based upon 66 C HWG and Direct well 29 C Indirect Well HX Langelier Saturation Index Iron Fouling Iron Fe Ferrous Bacterial Iron potential lt 0 2 ppm Ferrous If Fe ferrous gt 0 2 ppm with pH 6 8 O2 5 ppm check for iron bacteria lt 0 5 ppm of Oxygen Iron Fouling Above this level deposition will occur Corrosion Prevention 6 8 5 pH Monitor treat as needed 0 5 ppm At HoS gt 0 2 ppm avoid use of copper and copper nickel piping or HX s Rotten egg smell appears at 0 5 ppm level Copper alloy bronze or brass cast components are OK to 0 5 ppm 6 8 5 Minimize steel pipe below 7 and no open tanks with pH 8 Hydrogen Sulfide H5S Ammonia ion as hydroxide chloride nitrate and sulfate compounds
38. N Verify that ALL water valves are open and allow water flow prior to engaging the compressor Freezing of the coax or water lines can permanently damage the heat pump A CAUTION A CAUTION To avoid equipment damage DO NOT leave system filled in a building without heat during the winter unless antifreeze is added to the water loop Heat exchangers never fully drain by themselves and will freeze unless winterized with antifreeze Unit Start up Procedure 1 2 3 Turn the thermostat fan position to ON Blower should start Balance air flow at registers Adjust all valves to their full open position Turn on the line power to all heat pump units Room temperature should be within the minimum maximum ranges of Table 9b During start up checks loop water temperature entering the heat pump should be between 30 F 1 C and 95 F 35 C It is recommended that water to air units be first started in the cooling mode when possible This will allow liquid refrigerant to flow through the filter drier before entering the TXV allowing the filter drier to catch any debris that might be in the system before it reaches the TXV Two factors determine the operating limits of geothermal heat pumps a return air temperature and b water temperature When any one of these factors is at a minimum or maximum level the other factor must be at normal level to insure proper unit operation Two factors determine the
39. OURCE HEAT PUMPS Residential Split 60Hz R410A Rev 03 August 2012 Troubleshooting Form Customer Antifreeze Model Serial Loop type _ Complaint HEATING CYCLE ANALYSIS AIR HANDLER SECTION COMPRESSOR SECTION hh Refrigerant Type TUNN SE HFC 410A N Sch Fy aa a Fy SUCTION COMPRESSOR HEATING EXPANSION VALVE Vw ava COOLING A EXPANSION SRI VALVE DISCHARGE vi F EE D Ce E SE ZE LIQUID LINE F SF PSI PSI Sitia ani WATER INL WAIERQUL L c c 1 0 M or spec catalog to determine flow rate Look up pressure drop in l AIR HANDLER SECTION COMPRESSOR SECTION I WK SARAI SARAI KAN MM R Zeie SUCTION e COMPRESSOR fe fet ee e COOLING EXPANSION VALVE HEATING EXPANSION AAPEEE O E murum rum unam SPS pu DISCHARGE p Es wf Era gnum gran gr E m t e rur rr RH Look up pressure drop in F F 1 0 M or spec catalog to LIQUID EINE Po determine Now rate Ee WATER IW WATEROUL _ ll Cooling expansion valve meters in the cooling mode and bypasses in the heating mode Heating expansion valve meters in the heating mode and bypasses in the cooling mode Heat of Extraction Absorbtion or Heat of Rejection flow rate gpm x temp diff de
40. R SOURCE HEAT PUMPS Residential Split 60Hz R410A Rev 03 August 2012 Ground Water Heat Pump Applications Compressor Section Only Open Loop Ground Water Systems Indoor Compressor Section Only The outdoor version of the compressor section may not be used with open loop systems due to potential freezing of water piping Typical open loop piping is shown in Figure 9 Shut off valves should be included for ease of servicing Boiler drains or other valves should be tee d into the lines to allow acid flushing of the heat exchanger Shut off valves should be positioned to allow flow through the coax via the boiler drains without allowing flow into the piping system P T plugs should be used so that pressure drop and temperature can be measured Piping materials should be limited to copper or PVC SCHB80 Note Due to the pressure and temperature extremes PVC SCH40 is not recommended Water quantity should be plentiful and of good quality Consult Table 4 for water quality guidelines The unit can be ordered with either a copper or cupro nickel water heat exchanger Consult Table 4 for recommendations Copper is recommended for closed loop systems and open loop ground water systems that are not high in mineral content or corrosiveness In conditions anticipating heavy scale formation or in brackish water a cupro nickel heat exchanger is recommended In ground water situations where scaling could be heavy or where biolo
41. Type value must be set for proper operation The valid Blower Type values will be available for the user to scroll through to select the appropriate value from No Blower ECM Blower or PSC configurations Loop Configuration When replacing a control in the field the Loop Configuration value must be set for proper operation The valid Loop Configuration values will be available for the user to scroll through to select the appropriate value from VS PUMP MOD VALVE or OTHER Loop Configuration The Loop Configuration menu allows the installer to set the operating parameters for either an internal flow center or a proportional water valve depending on the unit configuration Heating Delta T The Heating Delta T option allows the target delta T EWT LWT value selection for operating in the heating mode The DXM2 control has set minimum and maximum delta T limits that may not be changed Cooling Delta T The Cooling Delta T option allows the target delta T LWT EWT value selection for operating in the cooling mode The DXM2 control has set minimum and maximum delta T limits that may not be changed Cooling Delta T The Cooling Delta T option allows the target delta T LWT EWT value selection for operating in the cooling mode The DXM2 control has set minimum and maximum delt T limits that may not be changed Heat Controller Inc Water Source Heating and Cooling Systems The Quality Leader in Conditioning Air
42. and leaving the HWG coil should be approximately 5 10 F 3 6 C 6 Allow the unit to operate for 20 to 30 minutes to insure that it is functioning properly Table 6 HWG Water Piping Sizes and Length Unit Nominal Tonnage 2 0 3 0 Nominal HWG Flow gpm 0 8 50 1 2 50 4 0 1 6 45 50 5 0 2 0 25 50 Maximum length is equivalent length in feet one way of type L copper 1 2 Copper max length 3 4 Copper max length NOTICE Make sure the compressor discharge line is connected to the Hot Gas In stub on the Heat Recovery Unit A CAUTION A CAUTION Locate Refrigerant lines to avoid accidental damage by lawnmowers or children A WARNING A WARNING The HWG module is an appliance that operates in conjunction with the heat pump system the hot water system and the electrical system Installation should only be performed by skilled technicians with appropriate training and experience The installation must be in compliance with local codes and ordinances Local plumbing and electrical building codes take precedence over instructions contained herein The Manufacturer accepts no liability for equipment damaged and or personal injury arising from improper installation of the HWG module Heat Controller Inc Water Source Heating and Cooling Systems The Quality Leader in Conditioning Air A WARNING A WARNING To avoid possible injury or death due to electrical shock open th
43. ating mode Water Flow gpm l m For Closed Loop Ground Source or Closed Loop Systems at 3 gpm per ton 3 9 Um per kw For Open Loop Ground Water Systems at 1 5 gpm per ton 2 0 I m per kw c Verify that the compressor is on and that the water temperature fall heating mode is within normal range d Check for vibration noise and water leaks 8 If unit fails to operate properly perform troubleshooting analysis see troubleshooting section in the unit IOM If the check described fails to reveal the problem and the unit still does not operate contact a trained service technician to insure proper diagnosis and repair of the equipment 9 When testing is complete exit the Installer Menu and set thermostat to maintain desired comfort level for normal operation 10 BE CERTAIN TO FILL OUT AND RETURN ALL WARRANTY REGISTRATION PAPERWORK Unit performance may be verified by calculating the unit heat of rejection and heat of extraction Heat of Rejection HR can be calculated and compared to the performance data pages in this IOM The formula for HR is as follows HR TD x GPM x 500 or 485 for anti freeze solutions where TD is the temperature difference between the entering and leaving water and GPM is the flow rate in U S GPM determined by comparing the unit heat exchanger pressure drop to Table 12 Heat of Extraction HE can also be calculated and compared to the performance data pages in this IOM The formula
44. c dehumidification mode operates with dehumidification airflows in the cooling mode when the dehumidification output from thermostat is active Normal heating and cooling airflows are not affected 2 DXM2 board DIP switch S2 7 must be in the auto dehumidification mode for automatic dehumidification www heatcontroller com 25 26 HEAT CONTROLLER INC WATER SOURCE HEAT PUMPS Residential Split 60Hz R410A Rev 03 August 2012 DXM2 Controls DXM2 Control DXM2 is the next generation in controls is capable of 2 way communication between itself and smart components like the communicating thermostat fan motor and configuration diagnostic tool For most residential applications configuration monitoring and diagnostics can be done from the thermostat service tool and there s no need to read LEDs and change DIP switches For details on user settings refer to User Manual part For details on Installer settings not to be used by consumers refer to Installer manual part For details on installer service settings on the configuration diagnostic tool refer to operation manual part For further details on the DXM2 control refer to the DXM2 Application Operation and Maintenace Manual and it is shipped with the unit Thermostat compatibility It is strongly recommended that GeoMax2 communicating thermostat be used with DXM2 control to ensure easy configuration monitoring and diagnostics in PLAIN English o
45. cell insulation All insulation tubing should be sealed using a UV resistant paint or covering to prevent deterioration from sunlight Residential Split 60Hz R410A Rev 03 August 2012 Refrigeration Installation When passing refrigerant lines through a wall seal opening with silicon based caulk Avoid direct contact with water pipes duct work floor joists wall studs floors or other structural components that could transmit compressor vibration Do not suspend refrigerant tubing from joists with rigid straps Do not attach line set to the wall When necessary use hanger straps with isolation sleeves to minimize tranmission of line set vibration to the structure Installing the Lineset at the Compressor Section Braze the line set to the service valve stubs as shown in Figure 10 On installations with long line sets copper adapters may be needed to connect the larger diameter tube to the stubs Nitrogen should be circulated through the system at 2 3 psi 13 8 20 7 kPa to prevent oxidation contamination Use a low silver phos copper braze alloy on all brazed connections Compressor section is shipped with a factory charge Therefore service valves should not be opened until the line set has been leak tested purged and evacuated See Charging the System www heatcontroller com 15 16 HEAT CONTROLLER INC WATER SOURCE HEAT PUMPS Residential Split 60Hz R410A Rev 03 August 2012 Refrigeration I
46. condensation damage to the furnace heat exchanger for add on heat pump applications A high temperature limit switch should be installed as shown in Figures 12b and 13b just upstream of the coil to de energize the compressor any time the furnace is energized to avoid blowing hot air directly into the coil elevating refrigerant pressures during operation The heat pump will trip out on high pressure lockout without some method of disengaging the compressor during furnace operation Alternatively some thermostats with dual fuel mode will automatically de energize the compressor when second stage backup heat is required The TXV should be brazed into place as shown in Figure 11 keeping the IN side toward the compressor section The TXV has an internal check valve and must be installed in the proper direction for operation Always keep the valve body cool with a brazing shield and wet rags to prevent damage to the TXV Attach the bulb to the suction line using the supplied hose clamp Be careful not to overtighten the clamp and deform the bulb NOTICE The air coil should be thoroughly washed with a filming agent dishwasher detergent like Cascade to help condensate drainage Apply a 20 to 1 solution of detergent and water Spray both sides of coil repeat and rinse thoroughly with water Evacuation and Charging the Unit LEAK TESTING The refrigeration line set must be pressurized and checked for leaks before evacuating and
47. dad ss 3942 Heat Controller Inc Water Source Heating and Cooling Systems The Quality Leader in Conditioning Air Residential Split 60Hz R410A Rev 03 August 2012 Model Nomenclature for Indoor Split Series 456 7 8 9 10 12 13 14 12 3 11 1 SERIES HT Heat Controller Two Stage SUPPLY AIR FLOW amp MOTOR CONFIGURATION N NOT APPLICABLE CONFIGURATION S SPLIT UNIT SIZE RETURN AIR FLOW CONFIGURATION 024 N NOT APPLICABLE 036 048 060 REVISION LEVEL HEAT EXCHANGER OPTIONS Copper Cupro Nickel B Current Revision DXM2 Effective 6 29 12 Standard C N VOLTAGE 1 208 230 60 1 WATER CIRCUIT OPTIONS 0 None CONTROLS 1 HWG w Internal Pump D DXM2 Revision B only CABINET 0 Residential www heatcontroller com HEAT CONTROLLER INC WATER SOURCE HEAT PUMPS Residential Split 60Hz R410A Rev 03 August 2012 Safety 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
48. deterioration of iron or galvanized piping or components in the system Open cooling towers requiring heavy chemical treatment and mineral buildup through water use can also contribute to higher maintenance Should periodic coil cleaning be necessary use standard coil cleaning procedures which are compatible with both the heat exchanger material and copper water lines Generally the more water flowing through the unit the less chance for scaling However flow rates over 3 gpm per ton 3 9 Um per kW can produce water or debris velocities that can erode the heat exchanger wall and ultimately produce leaks Hot Water Generator Coils See water coil maintenance for ground water units If the potable water is hard or not chemically softened the high temperatures of the desuperheater will tend to scale even quicker than the water coil and may need more frequent inspections In areas with extremely hard water a HWG is not recommended Filters Filters must be clean to obtain maximum performance Filters should be inspected every month under normal operating conditions and be replaced when necessary Units should never be operated without a filter Washable high efficiency electrostatic filters when dirty can exhibit a very high pressure drop for the fan motor and reduce air flow resulting in poor performance It is especially important to provide consistent washing of these filters in the opposite direction of the normal air flow o
49. e compressor discharge pressure Note that different values from tables 14a to 15 will be obtained due to the pressure losses through the condenser heat exchanger Adding refrigerant will increase sub cooling while superheat should remain fairly constant allowing for a slight amount of hunting in TXV systems This increase in subcooling will require 5 minutes or so of operation before it should be measured After values are measured compare to the chart and go to FINAL EVALUATION PARTIAL CHARGE METHOD Open service valve fully counterclockwise and then turn back in one half turn to open service port Add vaporized Gas into the suction side of the compressor until the pressure in the system reaches approximately 60 70 psig R 22 systems or 100 120 psig R 410A systems Never add liquid refrigerant into the suction side of a compressor Start the unit in heating and add gas to the suction port at a rate not to exceed five pounds 2 27 kg per minute Keep adding refrigerant until the complete charge has been entered Superheat is measured using suction temperature and pressure at the compressor suction line Subcooling should be measured using the liquid line temperature immediately outside the compressor section cabinet and either the liquid line service valve pressure or the compressor discharge pressure Note that different values from tables 14a to 15 will be obtained due to the pressure losses through the condenser heat exchanger
50. e drop of 15 F to 25 F cooling mode c Verify that the compressor is on and that the water temperature rise cooling mode is within normal range Water Flow gpm Um For Closed Loop Ground Source or Closed Loop Systems at 3 gpm per ton 3 9 I m per kw For Open Loop Ground Water Systems at 1 5 gpm per ton 2 0 Um per kw d Check the elevation and cleanliness of the condensate lines Dripping may be a sign of a blocked line Check that the condensate trap is filled to provide a water seal e Turn thermostat to OFF position A hissing noise indicates proper functioning of the reversing valve 7 Allow five 5 minutes between tests for pressure to equalize before beginning heating test a Go into Manual Mode activate Y1 and Y2 for Heating Also manually increase CFM until desired heating CFM is achieved Next adjust pump speed until desired loop temperature difference entering water temperature minus leaving water temperature is achieved For modulating valve adjust valve b Check for warm air delivery at the unit grille within a few minutes after the unit has begun to operate NOTE Units have a five minute time delay in the control circuit that can be bypassed on the DXM2 control board by placing Residential Split 60Hz R410A Rev 03 August 2012 Unit Start Up Procedure the unit in the Test mode as shown in the unit IOM Check for normal air temperature rise of 20 F to 30 F he
51. e end against the rubber gasket and seals the joint HAND TIGHTEN ONLY DO NOT OVERTIGHTEN Figure 3 Water Connections Indoor Compressor Section Swivel Nut Hand Tighten cossssss 0000 AA Only Stainless steel Do Not snap ring Overtighten Gasket aS Brass Adaptor GROUND LOOP HEAT PUMP APPLICATIONS A CAUTION A CAUTION The following instructions represent industry accepted installation practices for closed loop earth coupled heat pump systems Instructions are provided to assist the contractor in installing trouble free ground loops These instructions are recommendations only State provincial and local codes MUST be followed and installation MUST conform to ALL applicable codes It is the responsibility of the installing contractor to determine and comply with ALL applicable codes and regulations Pre Installation Prior to installation locate and mark all existing underground utilities piping etc Install loops for new construction before sidewalks patios driveways and other construction has begun During construction accurately mark all ground loop piping on the plot plan as an aid in avoiding potential future damage to the installation Piping Installation The typical closed loop ground source system is shown in Figure 3 All earth loop piping materials should be limited to polyethylene fusion only for in ground sections of the loop Galvanized or steel fitting
52. e power supply disconnect switch and secure it in an open position during installation A CAUTION A CAUTION Use only copper conductors for field installed electrical wiring Unit terminals are not designed to accept other types of conductors Electrical Line Voltage All field installed wiring including electrical ground must comply with the National Electrical Code as well as all applicable local codes Refer to the unit electrical data for fuse sizes Consult wiring diagram for field connections that must be made by the installing or electrical contractor Table 7 GeoMax 2 HTS Electrical Data Compressor LRA External Pump FLA Residential Split 60Hz R410A Rev 03 August 2012 Electrical Line Voltage All final electrical connections must be made with a length of flexible conduit to minimize vibration and sound transmission to the building General Line Voltage Wiring Be sure the available power is the same voltage and phase shown on the unit serial plate Line and low voltage wiring must be done in accordance with local codes or the National Electric Code whichever is applicable Power Connection Line voltage connection is made by connecting the incoming line voltage wires to the L side of the contactor as shown in Figures 21 Consult Table 7for correct fuse size 208 230 Volt Operation Verify transformer tap with air handler wiring diagram to insure that the transformer tap is s
53. e used on ground water systems to shut off flow when the compressor is not operating Valve kit AMMVA4D is available for use with HTS024 048 and kit AMMVSE is used with HTS060 See Figure 23b or the unit wiring diagram for valve wiring detail Further details on valve operation are described later in this manual Figure 23b Motorized Modulating Water Control Valve Open Loop Ground Water Systems Only DXM 2 pu ERE S kNTEEW I For MWV option place jumper on 0 10V pins Ensure actuator direction switch is set as shown Heat Controller Inc Water Source Heating and Cooling Systems The Quality Leader in Conditioning Air Thermostat Installation The thermostat should be located on an interior wall in a larger room away from supply duct drafts DO NOT locate the thermostat in areas subject to sunlight drafts or on external walls The wire access hole behind the thermostat may in certain cases need to be sealed to prevent erroneous temperature measurement Position the thermostat back plate against the wall so that it appears level and so the thermostat wires protrude through the middle of the back plate Mark the position of the back plate mounting holes and drill holes with a 3 16 5mm bit Install supplied anchors and secure plate to the wall Thermostat wire must be 18 AWG wire Wire the appropriate thermostat as shown in Figure 24 or 25 to the low voltage terminal strip on the DXM2 control board Practically any h
54. eat pump thermostat will work with these units provided it has the correct number of heating and cooling stages However using the communicating thermostat 7602 443 is highly recommended for on site easier configuration monitoring and diagnosis An optional outdoor temperature sensor is available The 7602 452 sensor is a thermistor used as an accessory for thermostat model 7602 443 This sensor provides outdoor air temperature information for the control system as well as an indication of outdoor temperature on the display screen A CAUTION A CAUTION Refrigerant pressure activated water regulating valves should never be used with ClimateMaster equipment A CAUTION A CAUTION Either a communicating thermostat 7602 443 or configuration tool 7602 444 MUST be used to configure and diagnose this unit Residential Split 60Hz R410A Rev 03 August 2012 Electrical Thermostat Wiring Figure 24 Communicating Thermostat Connection to DXM2 Control WDGwith AXM 7602 443Thermostat Control 24Vac Common 24Vac Hot Outdoor Sensor Optional Thermostat Connections C 24V Common for Control Circuit R 24V Supply for Control Circuit A Communications Positive B Communications Negative GND Ground OD Outdoor Temperature Sensor ID Indoor Temperature Sensor Figure 25 Conventional 3 Heat 2 Cool Thermostat Connection to DXM2 and Non AXM Air Handler Notes 1 ECM automati
55. emperatures Ente Full Load Cooling without HWG active Full Load Heating without HWG active ntering Water Suction Discharge Air Temp Suction Discharge Super Sub Water Temp i Super Sub Water Temp Temp E Pressure Pressure boh Drop F Pressure Pressure y PSIG PSIG heat cooling Rise F DB PSIG PSIG heat cooling Drop F Air Temp 117 127 160 180 16 21 8 13 17 5 19 5 16 22 66 76 282 302 9 15 8 13 8 10 116 126 133 153 17 22 6 11 11 9 13 9 16 22 69 79 285 305 9 15 8 13 6 8 115 125 125 145 18 23 5 10 6 3 8 3 16 22 72 82 289 309 9 15 9 14 4 6 126 136 228 248 8 13 8 13 19 8 21 8 20 26 95 105 318 338 9 15 12 17 11 3 13 3 124 134 212 232 11 16 6 11 14 2 16 2 20 26 100 110 321 341 9 15 12 17 8 5 10 5 123 133 195 215 14 19 5 10 8 5 10 5 20 26 105 115 324 344 9 15 12 17 5 7 7 7 130 140 305 325 8 13 10 15 20 3 22 3 21 27 128 138 360 380 8 14 12 17 14 16 129 139 286 306 9 14 9 14 14 8 16 8 21 27 133 143 364 384 8 14 12 17 10 6 12 6 128 138 266 286 11 16 7 12 9 3 11 3 21 27 139 149 368 388 8 14 12 17 7 3 9 8 133 143 398 418 8 13 10 15 19 4 21 4 20 26 173 183 407 427 8 14 13 18 18 2 20 2 132 142 376 396 8 13 9 14 14 1 16 1 20 26 177 187 411 431 8 14 13 18 13 9 15 9 132 142 354 374 8 13 7 12 8 8 10 8 20 26 182 192 415 435 8 14 14 19 9 6 11 6 138 148 505 525 6 11 10 15 18 3 20 3 19 25 137 147 483 503 6 11 9 14 13 3 15 3 19 25 Operation Not Recommended 1
56. ess The System Configuration option under the communicating thermostat Installer menu provides the installer with the ability to adjust ECM target airflows for each operating mode set control options setup the loop configuration and parameters and configure field replacement controls Airflow Selection The Airflow Selection menu allows the installer to adjust the ECM target airflow for each control operating mode as well as independently set the heating and cooling blower off delays ECM Airflows Independent airflow selections may be made for each stage of heating operation each stage of cooling operation with and without dehumidification as well as constant fan operation The DXM2 control has set minimum and maximum airflow limits for each operating mode based on the unit configuration that may not be changed Non ECM Configuration If the DXM2 is not configured to control an ECM blower the airflow selections will not be available on the Airflow Selection menu Heating Cooling Off Delays The heating and cooling mode blower off delay times may be independently adjusted by the user Each delay time may be set between 0 and 255 seconds Option Selection The Option Selection menu allows the installer to set selected control options LT2 Setpoint The LT2 setpoint should be set to ANTI FREEZE ONLY when the unit is configured as a water to water unit with anti freeze in the load side loop For ALL other un
57. et to the correct voltage 208V or 230V Min Circuit Amps 56 0 4 0 17 8 87 0 4 0 25 7 100 0 4 0 31 3 125 0 HWG Wiring Indoor Compressor Section The hot water generator pump power wiring is disabled at the factory to prevent operating the HWG pump dry After all HWG piping is completed and air purged from the water piping the pump power wires should be applied to terminals on the HWG power block PB2 as shown in the unit wiring diagram This connection can also serve as a HWG disable when servicing the unit 4 0 36 9 Figure 21 R 410A Compressor Section Line Voltage Field Wiring See unit wiring diagram for addtional details Unit Power Supply see electrical table for wire and breaker size INDOOR CONTROL Box LAYOUT www heatcontroller com 23 24 HEAT CONTROLLER INC WATER SOURCE HEAT PUMPS Residential Split 60Hz R410A Rev 03 August 2012 Electrical Low Voltage Figure 22 HTS Low Volt ge Field Wiring Low Voltage Field Wiring Low Water Temperature Cutout Selection The DXM2 control allows the field selection of low water or water antifreeze solution temperature limit by clipping jumper JW3 which changes the sensing temperature associated with thermistor LT1 Note that the LT1 thermistor is located on the refrigerant line between the coaxial heat exchanger and expansion d
58. evel drop is your only indication of air in the loop Antifreeze may be added before during or after the flushing procedure However depending upon which time is chosen antifreeze could be wasted when emptying the flush cart tank See antifreeze section for more details Loop static pressure will fluctuate with the seasons Pressures will be higher in the winter months than during the cooling season This fluctuation is normal and should be considered when charging the system initially Run the unit in either heating or cooling for a number of minutes to condition the loop to a homogenous temperature This is a good time for tool cleanup piping insulation etc Then perform final flush and pressurize the loop to a static pressure of 50 75 psi 345 517 kPa winter or 35 40 psi 241 276 kPa summer After pressurization be sure to loosen the plug at the end of the Grundfos loop pump motor s to allow trapped air to be discharged and to insure the motor housing has been flooded This is not required for Taco circulators Insure that the Flow Controller provides adequate flow through the unit by checking pressure drop across the heat exchanger and compare to the pressure drop tables at the back of the manual Antifreeze In areas where minimum entering loop temperatures drop below 40 F 5 C or where piping will be routed through areas subject to freezing antifreeze is required Alcohols and glycols are commonly used as antifree
59. evice TXV Therefore LT1 is sensing refrigerant temperature not water temperature which is a better indication of how water flow rate temperature is affecting the refrigeration circuit The factory setting for LT1 is for systems using water 30 F 1 1 C refrigerant temperature In low water temperature extended range applications with antifreeze most ground loops jumper JW3 should be clipped as shown in Figure 23 to change the setting to 10 F 12 2 C refrigerant temperature a more suitable temperature when using an antifreeze solution All residential units include water refrigerant circuit insulation to prevent internal condensation which is required when operating with entering water temperatures below 59 F 15 C Figure 23 LT1 Limit Setting L Fault Status ane JW3 LT1 jumper should be clipped for low temperature antifreeze operation P11 E P10 P9 T1 T2 T2 T3 T3 T4 T4 T5 T5 Te T6 DXM2 PCB Accessory Connections A terminal paralleling the compressor contactor coil has been provided on the DXM2 control Terminal A is designed to control accessory devices Note This terminal should be used only with 24 Volt signals and not line voltage Terminal A is energized with the compressor contactor Figure 23a Accessory Wiring Terminal Strip Motorized Modulating Water Control Valve Open Loop Ground Water Systems Only An external valve should b
60. for HE is as follows HE TD x GPM x 500 or 485 for anti freeze solutions where TD is the temperature difference between the entering and leaving water and GPM is the flow rate in U S GPM determined by comparing the unit heat exchanger pressure drop to Table 12 If performance during any mode appears abnormal refer to the DXM2 section or troubleshooting section of this manual NOTE To obtain maximum performance the air coil should be cleaned before start up A 10 solution of dishwasher detergent and water is recommended A WARNING A 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 A CAUTION A CAUTION Verify that ALL water valves are open and allow water flow prior to engaging the compressor Freezing of the coax or water lines can permanently damage the heat pump www heatcontroller com 31 32 HEAT CONTROLLER INC WATER SOURCE HEAT PUMPS Residential Split 60Hz R410A Rev 03 August 2012 Unit Operating Conditions Table 12 Two Stage HFC 410A Compressor Section Table 13 Water Temperature Change Through Heat Coax Water Pressure Drop Exchanger Pressure Drop psi Water Flow gpm I m 50 F 70 F For Closed Loop Ground Source or Closed Loop 9 12 Systems at 3 gpm per ton 3 9 I m per kw 5 6 7 A Co For Open Loop Ground Water Systems at 20 26 1 5 gpm per ton
61. g F x _ fluid factor t Btu hr Superheat suction temperature suction saturation temp deg F Subcooling discharge saturation temp liquid line temp deg F tUse 500 for water 485 for antifreeze Note Never connect refrigerant gauges during startup procedures Conduct water side analysis using P T ports to determine water flow and temperature difference If water side analysis shows poor performance refrigerant troubleshooting may be required Connect refrigerant gauges as a last resort Heat Controller Inc Water Source Heating and Cooling Systems The Quality Leader in Conditioning Air Residential Split 60Hz R410A Rev 03 August 2012 Notes www heatcontroller com 43 ENERGY STAR Intertek PARTNER Design specifications and materials subject to change without notice HEAT CONTROLLER INC 1900 Wellworth Ave Jackson Michigan 49203 e Ph 517 0787 2100 Fax 517 787 9341 Visit us on line at www heatcontroller com Part 97B0016N18 LI VU The Quality Leader in Conditioning Air 08 12
62. gical growth such as iron bacteria will be present an open loop system is not recommended Heat exchanger coils may over time lose heat exchange capabilities due to build up of mineral deposits Heat exchangers must only be serviced by a qualified technician as acid and special pumping equipment is required Desuperheater coils can likewise become scaled and possibly plugged In areas with extremely hard water the owner should be informed that the heat exchanger may require occasional acid flushing In some cases the desuperheater option should not be recommended due to hard water conditions and additional maintenance required Water Quality Standards Table 4 should be consulted for water quality requirements Scaling potential should be assessed using the pH Calcium hardness method If the pH 7 5 and the Calcium hardness is less than 100 ppm scaling potential is low If this method yields numbers out of range of those listed the Ryznar Stability and Langelier Saturation indecies should be calculated Use the appropriate scaling surface temperature for the application 150 F 66 C for direct use well water open loop and DHW desuperheater 90 F 32 F for indirect use A monitoring plan should be implemented in these probable scaling situations Other water quality issues such as iron fouling corrosion prevention and erosion and clogging should be referenced in Table 4 Expansion Tank and Pump Use a closed bladder ty
63. if necessary Inlet water too hot or cold Check load loop sizing loop backfill ground moisture Check for dirty air filter and clean or replace Reduced or no air flow Check fan motor operation and airflow restrictions in heatin i 9 Too high of external static check static vs blower table Reduced or no water flow Check pump operation or valve operation setting in cooling Check water flow adjust to proper flow rate Inlet water too hot Check load loop sizing loop backfill ground moisture Air temperature out of range in heating Defective reversing valve Perform RV touch test Bring return air temp within design parameters X X X X Scaling in water heat exchanger Perform Scaling check and clean if necessary Reduced water flow Check pump operation or water valve operation setting in heating Plugged strainer or filter clean or replace Check water flow adjust to proper flow rate Water temperature out of range Bring water temp within design parameters Reduced air fi Check for dirty air filter and clean or replace VE ANTEN Check fan motor operation and airflow restrictions ing Too high of external static check static vs blower table Too much cold vent air bring entering air temp within Air temperature out of range i design parameters Xx x X X X Insufficient charge Check for refrigerant leaks Too high of air flow Check fan motor speed selection and airflow chart Poo
64. ility of the installing contractor to determine and comply with ALL applicable codes and regulations Removing Existing Condensing Unit Where Applicable 1 Pump down condensing unit Close the liquid line service valve of existing condensing unit and start compressor to pump refrigerant back into compressor section Then close suction service valve while compressor is still running to trap refrigerant in outdoor section IMmediately kill power to the condensing unit 2 Disconnect power and low voltage and remove old condensing unit Cut or unbraze line set from unit Remove condensing unit 3 If condensing unit is not operational or will not pump down refrigerant should be recovered using appropriate equipment 4 Replace line set especially if upgrading system from R 22 to R 410A refrigerant If line set cannot be replaced it must be thoroughly flushed before installing new compressor section R 410A compressors use POE oil instead of mineral oil R 22 systems Mineral oil is not compatible with POE oil and could cause system damage if not completely flushed from the line set Indoor Compressor Section Location The HTS indoor compressor section is not designed for outdoor installation Locate the unit in an INDOOR area that allows enough space for service personnel to perform typical maintenance or repairs without removing unit Units are typically installed in a mechanical room or closet Never install units in areas subject
65. it configurations the LT2 setpoint should be set to WATER Motorized Valve The Motorized Valve option should be set to ON when a motorized water valve with end switch wired to the DXM2 Y1 is used with a communicating thermostat For all other system configurations the Motorized Valve option should be set to OFF Unit Configuration Selections under the Unit Configuration menu are normally set at the factory as a normal part of the manufacturing and test process This menu allows the configuration to be modified for special applications or to configure field replacement controls The Unit Configuration menu provides the ability to select the Heat Pump Family Unit Size Blower Type and Loop Type The Heat Pump Family Unit Size and Blower Type are needed to properly operate any particular unit configuration especially those with ECM blowers Heat Pump Family When replacing a control in the field the Heat Pump Family value must be set for proper blower and loop operation The valid family values HTS HE etc are available for the user to scroll through to select the proper value Heat Pump Size When replacing a control in the field the Heat Pump Size value must be set for proper blower operation After a Heat Pump Family has been selected the valid Heat Pump Size values will be available for the user to scroll through to select the proper value Blower Type When replacing a control in the field the Blower
66. l be energized On all subsequent compressor calls the random start delay is omitted Test Mode button Test mode allows the service technician to check the operation of the control in a timely manner By momentarily pressing the TEST pushbutton the DXM2 control enters a 20 minute test mode period in which all time delays are sped up 15 times Figure 26 Test Mode Button P4 e end B a 24V 240Vac 240Vac E P5 N O pen Com NO Fan Enable Fan Speed Pust test button to enter Test Mode and speed up timing and delays for 20 minutes Table 8 Unit Operation Conventional T stat signal Non Communicating ECM fan G Fan only G Y1 G Y1 Y2 G Y1 Y2 W G W G Y1 O G Y1 Y2 O 1 Stage 1 1st stage compressor 1st stage fan operation Stage 2 2nd stage compressor 2nd stage fan operation Stage 3 2nd stage compressor auxiliary electric heat 3rd stage fan operation 2 Stage 1 1st stage compressor 1st stage fan operation reversing valve Stage 2 2nd stage compressor 2nd stage fan operation reversing valve Stage 1 heating Stage 2 heating Stage 3 heating Emergency heat Stage 1 cooling Stage 2 cooling Heat Controller Inc Water Source Heating and Cooling Systems The Quality Leader in Conditioning Air Residential Split 60Hz R410A Rev 03 August 2012 Figure 26a DXM2 Layout and Connections Service tool Communicating Test B
67. le tank of at least 50 gallons 189 liters is used to limit installation costs and space However a dual tank as shown in Figure 16 is the most efficient system providing the maximum storage and temperate source water to the HWG It is always advisable to use water softening equipment on domestic water systems to reduce the scaling potential and lengthen equipment life In extreme water conditions it may be necessary to avoid the use of the HWG option since the potential cost of frequent maintenance may offset or exceed any savings Consult Table 4 for scaling potential tests Figure 16 HWG Double Tank Installation Indoor Compressor Section Hot Outlet to house Cold Inlet from SEI Domestic supply Hot Outlet pper element to 130 F 54 C or owner preference Se T Shut o a Valve 4 Powered 1 Water Heater Lower element to 120 F 49 C Unpowered Water Heater Shut off Valve 3 x Field Supplied 3 4 brass nipple and T nsulated water lines 5 8 OD 50 ft maximum one way 16mm OD 15 meters maximum Heat Controller Inc Water Source Heating and Cooling Systems The Quality Leader in Conditioning Air Installation The HWG is controlled by two sensors and the DXM2 microprocessor control One sensor is located on the compressor discharge line to sense the discharge refrigerant temperature The other sensor is located on the HWG heat exchanger
68. lush the loop with a high volume of water at a minimum velocity of 2 fps 0 6 m s in all piping The steps below must be followed for proper flushing 1 Fillloop with water from a garden hose through the flush cart before using the flush cart pump to insure an even fill 2 Once full the flushing process can begin Do not allow the water level in the flush cart tank to drop below the pump inlet line to avoid air being pumped back out to the earth loop 3 Try to maintain a fluid level in the tank above the return tee so that air cannot be continuously mixed back into the fluid Surges of 50 psi 345 kPa can be used to help purge air pockets by simply shutting off the return valve going into the flush cart reservoir This dead heads the pump to 50 psi 345 kPa To purge dead head the pump until maximum pumping pressure is reached Open the return valve and a pressure surge will be sent through the loop to help purge air pockets from the piping system 4 Notice the drop in fluid level in the flush cart tank when the return valve is shut off If air is adequately purged from the system the level will drop only 1 2 inches 2 5 5 cm in a 10 25 cm diameter PVC flush tank about a half gallon 2 3 liters since liquids are incompressible If the level drops more than this flushing should continue since air is still being compressed in the loop fluid Perform the dead head procedure a number of times Note This fluid l
69. maintain sealed circuit integrity do not install service gauges unless unit operation appears abnormal Reference the operating charts for pressures and temperatures Verify that air and water flow rates are at proper levels before servicing the refrigerant circuit Heat Controller Inc Water Source Heating and Cooling Systems The Quality Leader in Conditioning Air General Troubleshooting Basic DXM2 board troubleshooting in general is best summarized as simply verifying inputs and outputs After this process has been verified confidence in board operation is confirmed and the trouble must be else where Below are some general guidelines required for developing training materials and procedures when applying the DXM2 Control DXM2 Field Inputs All conventional inputs are 24VAC from the thermostat and can be verified using a voltmeter between C and Y1 Y2 W O and G Sensor Inputs All sensor inputs are paired wires connecting each component with the board Therefore continuity on pressure switches can be checked at the board connector The thermistor resistance should be measured with the connector removed so that only the impedance of the thermistor is measured If desired this reading can be compared to the chart shown in the thermistor section of this manual based upon the actual temperature of the thermistor clip An ice bath can be used to check calibration of a thermistor if needed DXM2 Outputs The compresso
70. n the thermostat For example Airflow can NOT be configured without a communicating thermostat or Configuration Diagnostic tool for use with GeoMax2 Field Configuration Options Note In the following field configuration options jumper wires should be clipped ONLY when power is removed from the DXM2 control Water coil low temperature limit setting Jumper 3 JW3 LT1 Low Temp provides field selection of temperature limit setting for LT1 of 30 F or 10 F 1 F or 12 C refrigerant temperature Not Clipped 30 F 1 C Clipped 10 F 12 C A0 2 Configure Modulating Valve field installed acces sory Set A0 2 jumper to IOV if using Modulating Motorized Valve as field installed accessory DIP Switches For residential applications all configuration can be performed in PLAIN ENGLISH on the thermostat No DIP switch changes are required and no LEDs to be observed A CAUTION A CAUTION Do not restart units without inspection and remedy of faulting condition Equipment damage may occur DXM2 Control Start up Operation The control will not operate until all inputs and safety controls are checked for normal conditions The compressor will have a 5 minute anti short cycle delay at power up The first 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 wil
71. nce per month using a high pressure wash similar to those found at self serve car washes Condensate Drain In areas where airborne bacteria may produce a slimy substance in the drain pan it may be necessary to treat the drain pan chemically with an algaecide approximately every three months to minimize the problem The condensate pan may also need to be cleaned periodically to insure indoor air quality The condensate drain can pick up lint and dirt especially with dirty filters Inspect the drain twice a year to avoid the possibility of plugging and eventual overflow Compressor Conduct annual amperage checks to insure that amp draw is no more than 10 greater than indicated on the serial plate data Fan Motors Consult air handler LO M for maintenance requirements Air Coil Consult coil I O M for maintenance requirements The air coil must be cleaned to obtain maximum performance Check once a year under normal operating conditions and if dirty brush or vacuum clean Care must be taken not to damage the aluminum fins while cleaning CAUTION Fin edges are sharp Cabinet Indoor Compressor Section Do not allow water to stay in contact with the cabinet for long periods of time to prevent corrosion of the cabinet sheet metal Generally cabinets are set up from the floor a few inches 7 8 cm to prevent water from entering the cabinet The cabinet can be cleaned using a mild detergent Refrigerant System To
72. ng to help absorb the excess hammer shock This valve regulates the flow using entering and leaving water delta T of the system Entering and leaving water temperature is read on the communicating thermostat or configuration diagnostic service tool Further details on valve operation are described later in this manual Heat Controller Inc Water Source Heating and Cooling Systems The Quality Leader in Conditioning Air Residential Split 60Hz R410A Rev 03 August 2012 Ground Water Heat Pump Applications Water Coil Low Temperature Limit Setting For all open loop systems the 30 F 1 1 C FP1 setting factory setting water should be used to avoid freeze damage to the unit See Low Water Temperature Cutout Selection in this manual for details on the low limit setting A CAUTION A CAUTION Refrigerant pressure activated water regulating valves should never be used with HCI equipment Figure 9 Water Well Connections Water Flow Control Regulator Pressure Valve Tank Water Out ll Optional Filter AS Boiler Drains P T Plugs Optional Modulating Motorized Valve For Open Loop Applications A low Cv modulating motorized valve is used for this application to provide more precise control against the higher System pressure differential of open loop applications The Motorized Modulating Valve is regulated by the Communicating DXM2 board based on entering and leaving water tempe
73. nstallation Figure 10 Braze Instructions _Vapor A e Fully Insulated DOMI S Suction Line e Fully Insulated Liquid Line Nitrogen Braze Replace Caps after adjusting service valves Rev 05 31 00 p rts for gauges Figure 5 Service Valve Positions Service Port Closed Position Description System CCW Full Out CCW Full Out 1 2 turn CW CW Full in Operation Position Open Service Position Open Open Closed Shipping Position Open Installing the Indoor Coil and Lineset Figure 11 shows the installation of the lineset and TXV to a typical indoor coil An indoor coil or air handler fan coil with a TXV is required Coils with cap tubes may not be used If coil includes removable fixed orifice the orifice must be removed and a TXV must be installed as shown in Figure 11 Fasten the copper line set to the coil Nitrogen should be circulated through the system at 2 3 psi 13 8 20 7 kPa to prevent oxidation inside the refrigerant tubing Use a low silver phos copper braze alloy on all brazed connections Figure 11 Air Coil Connection TXV IN toward Bulb Must be compressor section Installed and Insulated Equalizer Line FP2 Sensor XV has internal check valve Add On Heat Pump Applications The HWG Series indoor coil should be located in the supply side of the furnace to avoid
74. nts Locate and verify any hot water generator HWG or other accessory kit located in the compressor section A CAUTION A 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 A CAUTION A 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 filters will quickly become clogged with construction dirt and debris which may cause system damage www heatcontroller com HEAT CONTROLLER INC WATER SOURCE HEAT PUMPS Residential Split 60Hz R410A Rev 03 August 2012 Equipment Selection NOTICE AHRI matched systems are required for warranty and applicable federal tax credits The installation of geothermal heat pump units and all associated components parts and accessories which make up the installation shall be in accordance with the regulations of ALL authorities having jurisdiction and MUST conform to all applicable codes It is the responsibility of the installing contractor to determine and comply with ALL applicable codes and regulations
75. operating limits of geothermal heat pumps a return air temperature and b entering water temperature When either of the factors is at a minimum or maximum level the other factor must be at normal levels to insure proper unit operation a Place the unit in Manual Operation When in manual mode activate Y1 Y2 and O to initiate the cooling mode Also manually increase CFM until desired cooling CFM is achieved Next adjust pump speed until desired loop temperature difference leaving water temperature minus entering water temperature is achieved For modulating valve adjust valve INSTALLER SETTINGS THERMOSTAT CONFIG SYSTEM CONFIG ACCESSORY CONFIG INPUT DEALER INFO HUMIDITY CONFIG TEMPERATURE ALGORITHM DEMAND REDUCTION CNFG SERVICE MODE RESTORY DEFAULTS ATC32U01 SELECT OPTION A Y PREVIOUS Heat Controller Inc Water Source Heating and Cooling Systems The Quality Leader in Conditioning Air SERVICE MODE MANUAL OPERATION CONTROL DIAGNOSTICS DIPSWITCH CONFIG FAULT HISTORY CLEAR FAULT HISTORY SELECT OPTION A Y PREVIOUS ECM PUMP SPEED TEST MODE SELECT OPTION A v 4 PREVIOUS b Check for cool air delivery at the unit grille within a few minutes after the unit has begun to operate NOTE Units have a five minute time delay in the control circuit that can be bypassed on the DXM2 control board by placing the unit in the Test mode as shown in the unit IOM Check for normal air temperatur
76. pe expansion tank to minimize mineral formation due to air exposure The expansion tank should be sized to provide at least one minute continuous run time of the pump using its drawdown capacity rating to prevent pump short cycling Discharge water from the unit is not contaminated in any manner and can be disposed of in various ways depending on local building codes e g recharge well storm sewer drain field adjacent stream or pond etc Most local codes forbid the use of sanitary sewer for disposal Consult your local building and zoning department to assure compliance in your area The pump should be sized to handle the home s domestic water load typically 5 9 gpm 23 41 I m plus the flow rate required for the heat pump Pump sizing and expansion tank must be chosen as complimentary items For example an expansion tank that is too small can causing premature pump failure due to short cycling Variable speed pumping applications should be considered for the inherent energy savings and smaller expansion tank requirements Motorized Modulating Water Control Valve Note the placement of the water control valve in figure 9 Always maintain water pressure in the heat exchanger by placing the water control valve s on the discharge line to prevent mineral precipitation during the off cycle Pilot operated slow closing valves are recommended to reduce water hammer If water hammer persists a mini expansion tank can be mounted on the pipi
77. plit 60Hz R410A Rev 03 August 2012 Refrigeration Installation Evacuation Of The Lineset And Coil The line set and coil must be evacuated to at least 500 microns to remove any moisture and noncondensables Evacuate the system through both service ports in the shipping position full CW in see table 5 to prevent false readings on the gauge because of pressure drop through service ports A vacuum gauge or thermistor capable of accurately meausuring the vacuum depth is crucial in determining if the system is ready for charging If the system meets the requirements in Figure 14 it is ready for charging Figure 14 Evacuation Graph 5000 4500 4000 3500 2 3000 2500 9 2000 1500 1000 500 LEAK IN SYSTEM VACUUM TOO WET TIGHT DRY SYSTEM 0 1 2 3 4 5 8 7 MINUTES Table 6 R 410A Charging Values A NOTICE A NOTICE Use tables 14a to 15 for superheat subcooling values These tables use discharge pressure converted to saturation temperature and liquid line temperature for subcooling calculations If using liquid line pressure subtract 3 F from the table values Charging The System There are two methods of charging a refrigerant system One method is the total charge method where the volume of the system is determined and the refrigerant is measured and added into the evacuated system The other method is the partial charge method where a small initial charge is added to an evacua
78. proximate Fluid Volume U S gal L per 100 of Pipe Figure 4 Loop Connection Indoor Compressor Section Fluid Volume gal liters per 100 30 meters Pipe Pipe Size Volume gal liters d 4 1 15 3 1 25 6 4 23 8 epos Gone Rubber Hose 1 3 9 14 6 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 To Loop Copper Unit Power Disconnect Insulated Hose Kit Polyethylene Wiring Air Pad or Extruded polystyrene insulation board Unit Heat Exchanger Typical 1 0 3 8 10 Dia x 3ft tall Flush Cart Tank 1254mm x 91 4cm tall 10 37 9 NOTICE Cabinet opening around loop piping outdoor compressor section must be sealed to prevent entry of rodents that could potentially damage unit wiring by chewing on the insulation Table 3 Antifreeze Percentages by Volume Type Minimum Temperature for Low Temperature Protection 10 F 12 2 C 15 F 9 4 C 20 F 6 7 C 25 F 3 9 C Methanol 100 USP food grade Propylene Glycol Ethanol 25 38 29 Must not be denatured with any petroleum based product 21 25 25 16 22 20 10 15 14 www heatcontroller com 11 HEAT CONTROLLER INC WATE
79. r performance See Insufficient Capacity Poor performance Too high of air flow Check fan motor speed selection and airflow chart Recheck loads and sizing check sensible clg load and Unit oversized X heat pump capacity Check G wiring at heat pump Jumper G and R for fan operation Jumper G and R for fan operation Check for Line voltage Fan motor relay across blower relay contacts Check fan power enable relay operation if present Fan motor Check for line voltage at motor Check capacitor Check thermostat wiring at or DXM2 Put in Test Mode and then jumper Y1 and W1 to R to give call for fan compressor and electric heat Thermostat wiring Set for cooling demand and check 24VAC on RV coil If RV is stuck run high pressure up by reducing water flow and while operating engage and disengage RV coil voltage to push valve Thermostat setup For DXM2 check for O RV setup not B Check O wiring at heat pump DXM2 requires call for compressor to get RV coil Click Reversing Valve Thermostat wiring Improper output setting Verify the AO 2 jumper is in the 0 10V position No valve output signal Check DC voltage between AO2 and GND Should be O when valve is off and between 3 3v and 10v when valve is on No valve operation Check voltage to the valve Replace valve if voltage and control signals are present at the valve and it does not operate www heatcontroller com 41 HEAT CONTROLLER INC WATER S
80. r relay is 24VAC and can be verified using a voltmeter The Alarm Relay can either be 24VAC as shipped or dry contacts measure continuity during fault for use with DDC by clipping the J4 jumper Electric heat outputs are 24VDC and require a voltmeter set for DC to verify operation When troubleshooting measure from 24VDC terminal to EH or EH2 terminals Test Mode Test Mode can be entered for 20 minutes by pressing the Test button For Diagnostic ease at a conventional thermostat the Alarm Relay will also cycle during test mode The Alarm Relay will cycle on and off similar to the Fault LED to indicate a code representing the last fault at the thermostat Test Mode can also be entered and exited by cycling the G input 3 times within a 60 second time period Residential Split 60Hz R410A Rev 03 August 2012 Basic Troubleshooting Information Sensor Nominal resistance at various temperatures Resistance kOhm 2 99 2 88 2 77 2 67 2 58 2 49 2 40 2 32 2 23 2 16 2 08 2 01 Resistance kOhm 85 34 17 5 84 00 16 9 f 81 38 12 61 70 11 58 40 10 4 55 30 9 k 52 38 8 1 49 64 7 47 05 6 5 44 61 42 32 40 15 38 11 36 18 34 37 32 65 31 03 29 50 28 05 26 69 25 39 24 17 23 02 21 92 20 88 19 90 18 97 18 09 17 26 16 46 15 71 15 00 14 32 13 68 13 07 12 49 11 94 11 42 10 92 10 45 10 00 9 57 9 16 8 78 8 41 8 06 7 72 7 40 7 10 6 81 6 53 6 27 6 01 SAF 5 54 5 33 Temp
81. rature AT The DXM2 board gives a 0 10v signal to determine flow rate The motorized modulating valve defaults to closed position if it loses signal but still has 24V power running to it If the motorized modulating valve loses both signal from the DXM2 board AND 24V power it will remain in the same position it was in when it lost 24V power DO NOT USE open loop units in closed loop applications due to significant pressure drop through the open loop motorized modulating valve Water In To manually open the internal modulating motorized water valve in HTS024 048 push down on the handle to unlock it Then rotate the handle to the open position as shown in Figure 9a This fully opens the valve for flushing Once flushing is complete return the valve handle to its normally closed position To manually open the internal modulating motorized water valve in HTSO60 push down on the lock release button while turning the handle to the open position as shown in Figure 9a This fully opens the valve for flushing Once flushing is complete press the lock release again and return the valve handle to its normally closed position Figure 9a Optional Modulating Motorized Valve Positions Sizes 024 048 Closed Sizes 060 www heatcontroller com 13 HEAT CONTROLLER INC WATER SOURCE HEAT PUMPS Residential Split 60Hz R410A Rev 03 August 2012 Water Quality Standards Table 4 Water Quality Standards HX Closed
82. rvice equipment gauges tools etc is rated for R 410A Some R 22 service equipment may not be acceptable A CAUTION A CAUTION Installation of a factory supplied liquid line bi directional filter drier is required Never install a suction line filter in the liquid line Line Set Installation Figures 12a through 13b illustrate typical installations with the indoor and outdoor versions of the compressor section matched to either an air handler fan coil or add on furnace coil Table 4 shows typical line set diameters at various lengths Lineset lengths should be kept to a minimum and should always be installed with care to avoid kinking Line sets over 60 feet 18 meters long are not recommended due to potential oil transport problems and excessive pressure drop If the line set is kinked or distorted and it cannot be formed back into its original shape the damaged portion of the line should be replaced A restricted line set will effect the performance of the system A reversible heat pump filter drier is installed on the liquid line inside the compressor section cabinet R 22 units only R 410A models are shipped with a filter drier loose inside the cabinet that must be installed in the liquid line at the line set AII brazing should be performed using nitrogen circulating at 2 3 psi 13 8 20 7 kPa to prevent oxidation inside the tubing All linesets should be insulated with a minimum of 1 2 13mm thick closed
83. s Unit and System Checkout BEFORE POWERING SYSTEM please check the following UNIT CHECKOUT Q Shutoff valves Insure that all isolation valves are open Q Line voltage and wiring Verify that voltage is within an acceptable range for the unit and wiring and fuses breakers are properly sized Verify that low voltage wiring is complete Q Unit control transformer Insure that transformer has the properly selected voltage tap Residential 208 230V units are factory wired for 230V operation unless specified otherwise Q Loop water piping is complete and purged of air Water piping is clean Q Antifreeze has been added if necessary Q Entering water and air Insure that entering water and air temperatures are within operating limits of Tables 9a and 9b Q Low water temperature cutout Verify that low water temperature cut out on the DXM2 control is properly set Q Unit fan Manually rotate fan to verify free rotation and insure that blower wheel is secured to the motor shaft Be sure to remove any shipping supports if needed DO NOT oil motors upon start up Fan motors are pre oiled at the factory Check unit fan speed selection and compare to design requirements Q Condensate line Verify that condensate trap is installed and pitched Q HWG pump is disconnected unless piping is completed and air has been purged from the system Q Water flow balancing Record inlet and outlet water temperatures for each heat pump upon startup This
84. s and all electrical connections Air Handler and Coil Installation This manual specifically addresses the compressor section of the system Air handler and coil location and installation should be according to the instructions provided with the air handling coil unit Heat Controller Inc Water Source Heating and Cooling Systems The Quality Leader in Conditioning Air Figure 2 HTS Installation Air Pad or Extruded polystyrene insulation board uti TRS DIRE EA SSC External Flow Controller Mounting The Flow Controller can be mounted beside the unit as shown in Figure 4 Review the Flow Controller installa tion manual for more details Water Connections Residential Distributor Models Residential models utilize swivel piping fittings for water connections that are rated for 450 psi 3101 kPa operat ing pressure The connections have a rubber gasket seal similar to a garden hose gasket which when mated to the flush end of most 1 threaded male pipe fittings pro vides a leak free seal without the need for thread sealing tape or joint compound Insure that the rubber seal is in the swivel connector prior to attempting any connection rubber seals are shipped attached to the swivel connec tor DO NOT OVER TIGHTEN or leaks may occur Line Set Residential Split 60Hz R410A Rev 03 August 2012 Installation The female locking ring is threaded onto the pipe threads which holds the male pip
85. s should not be used at any time due to their tendency to corrode All plastic to metal threaded fittings should be avoided due to their potential to leak in earth coupled applications A flanged fitting should be substituted P T plugs should be used so that flow can be measured using the pressure drop of the unit heat exchanger www heatcontroller com 10 HEAT CONTROLLER INC WATER SOURCE HEAT PUMPS Residential Split 60Hz R410A Rev 03 August 2012 Ground Loop Heat Pump Applications Earth loop temperatures can range between 25 and 110 F 4 to 43 C Flow rates between 2 25 and 3 gpm per ton 2 41 to 3 23 Um per kW of cooling capacity is recommended in these applications Test individual horizontal loop circuits before backfilling Test vertical U bends and pond loop assemblies prior to installation Pressures of at least 100 psi 689 kPa should be used when testing Do not exceed the pipe pressure rating Test entire system when all loops are assembled Flushing the Earth Loop Once piping is completed between the unit Flow Controller and the ground loop Figure 4 the loop is ready for final purging and charging A flush cart with at least a 1 5 hp 1 1 kW pump is required to achieve enough fluid velocity in the loop piping system to purge air and dirt particles An antifreeze solution is used in most areas to prevent freezing All air and debris must be removed from the earth loop piping before operation F
86. t occurred Fault Temp Conditions This option displays the DXM2 temperature and voltage values when the lockout occurred Fault Flow Conditions This option displays the DXM2 ECM blower pump and valve operating parameters when the lockout occurred Fault I O Conditions This option displays the status of the DXM2 physical and communicated inputs and the relay outputs when the lockout occurred Fault Configuration Conditions This option displays the status of the DXM2 option selections when the lockout occurred Fault Possible Causes This option displays a list of potential causes of the stored fault Clear Fault History The Clear Fault History option allows the fault history stored in the non volatile memory of the DXM2 to be cleared www heatcontroller com 37 38 HEAT CONTROLLER INC WATER SOURCE HEAT PUMPS Residential Split 60Hz R410A Rev 03 August 2012 DXM2 Process Flow Chart A WARNING A WARNING HAZARDOUS VOLTAGE DISCONNECT ALL ELECTRIC POWER INCLUDING REMOTE DISCONNECTS BEFORE SERVICING Failure to disconnect power before servicing can cause severe personal injury or death Start DXM2 Functional Troubleshooting Flow Chart Did Unit Check Main Attempt to power see power Start problems Did Unit Lockout at Start up Check fault code on communicating No fault thermostat ATC32 or Configuration shown and Diagnostics Tool ACD01 No See
87. tart up and may result in costly equipment clean up Examine all pipes fittings and valves before installing any of the system components Remove any dirt or debris found in or on these components Pre Installation Installation Operation and Maintenance instructions are provided with each unit Horizontal equipment is designed for installation above false ceiling or in a ceiling plenum Other unit configurations are typically installed in a mechanical room The installation site chosen should include adequate service clearance around the unit Before unit start up read all manuals and become familiar with the unit and its operation Thoroughly check the system before operation Prepare units for installation as follows 1 Compare the electrical data on the unit nameplate with ordering and shipping information to verify that the correct unit has been shipped 2 Keep the cabinet covered with the original packaging until installation is complete and all plastering painting etc is finished 3 Verify refrigerant tubing is free of kinks or dents and that it does not touch other unit components Residential Split 60Hz R410A Rev 03 August 2012 General Information Inspect all electrical connections Connections must be clean and tight at the terminals Loosen compressor bolts on units equipped with compressor spring vibration isolation until the compressor rides freely on the springs Remove shipping restrai
88. ted system and remaining refrigerant added during operation Total Charge Method See Table 4 for the compressor section basic charge For line sets with 3 8 liquid lines add 0 6 ounces of refrigerant to the basic charge for every installed foot of liquid line 0 6 grams per cm Add 1 2 oz per foot 1 1 grams per cm if using 1 2 line Once the total charge is determined the factory pre charge Table 4 is subtracted and the remainder is the amount needed to be added to the system This method should be used with the AHRI matched air handler or coil Heat Controller Inc Water Source Heating and Cooling Systems The Quality Leader in Conditioning Air Turn service valves full out CCW see Table 5 and then turn back in one half turn to open service ports Add the required refrigerant so that the total charge calculated for the unit and line set is now in the system Open the service valve fully counter clockwise so that the stem will backseat and prevent leakage through the schrader port while it is not in use Start unit in the heating mode and measure superheat and subcooling values after 5 minutes of run time See tables 14a to 15 for superheat and sub cooling values Superheat is measured using suction temperature and pressure at the compressor suction line Subcooling should be measured using the liquid line temperature immediately outside the compressor section cabinet and either the liquid line service valve pressure or th
89. utton to connection Stat connection Speed up Time Delays Conventional stat connection s KENE DS ECM Motor Connection AL2 Water Coil Low Temp Cabinet ER Limit Setting temperature NSB sensor with variable Fault Status speed pump OVR Factory low voltage molex connection for dE unit harness Communications and HWG Settings Off On Factory low voltage molex sat EE LL connection for NC1 electric heat COM1 T harness E 6 Configure R modulating valve e or variable COH P11 P10 speed pump o 8 TS o Om m 24V to compressor S S 5 5 g 8 AR 9 3 2 2 SS D 00 lt second stage solenoid e Za 2 E E 3 3 z Use 4 mounting screws for Y2 full go da ca oo ge 3 D 6 sheet metal screw load capacity 3 3 3 ad 38 1 long E Vc az gt U Do Ee gt bei O oS Q D www heatcontroller com 27 ing Diagram 208 230 60 DXM2 60Hz R410A 03 August 2012 NOILdO 9MH Ce
90. ze however your local sales manager should be consulted for the antifreeze best suited to your area Freeze protection should be maintained to 15 F 9 C below the lowest expected entering loop temperature For example if 30 F 1 C is the minimum expected entering loop temperature the leaving loop temperature would be 25 to 22 F 4 to 6 C and freeze protection should be at 15 F 10 C Calculation is as follows 30 F 15 F 15 F 1 C 9 C 10 C All alcohols should be premixed and pumped from a reservoir outside of the building when possible or introduced under the water level to prevent fumes Calculate the total volume of fluid in the piping system Then use the percentage by volume shown in Table 2 for the amount of antifreeze needed Antifreeze concentration should be checked from a well mixed sample using a hydrometer to measure specific gravity Low Water Temperature Cutout Setting DXM2 Control When antifreeze is selected the LT1 jumper JW3 should be clipped to select the low temperature antifreeze 13 F 10 6 C set point and avoid nuisance faults see Low Water Temperature Cutout Selection in this manual NOTE Low water temperature operation requires extended range equipment Heat Controller Inc Water Source Heating and Cooling Systems The Quality Leader in Conditioning Air Residential Split 60Hz R410A Rev 03 August 2012 Ground Loop Heat Pump Applications Table 2 Ap

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