Heat Controller Air Conditioner HTS SERIES User Manual

Installation, Operation and  
Maintenace Manual  
GeoLogix®  
HTS Series Split System,  
Two Stage, 2-5 Tons  
1900 Wellworth Ave., Jackson, Michigan 49203 Ph. 517-0787-2100 Fax 517-787-9341 www.heatcontroller.com  
THE QUALITY LEADER IN CONDITIONING AIR  
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The Quality Leader in Conditioning Air  
Residential Split - 60Hz R410A  
R e v. : 0 3 A u g u s t , 2 0 1 2  
Model Nomenclature : for Indoor Split Series  
1 2  
3
4 5 6  
7
8
9
10  
11  
12  
13  
14  
HT S 0 2 4 B 1 D 0 1 N N N  
SERIES  
HT = Heat Controller Two Stage  
SUPPLY AIR FLOW &  
MOTOR CONFIGURATION  
N = NOT APPLICABLE  
CONFIGURATION  
S = SPLIT  
RETURN AIR FLOW CONFIGURATION  
UNIT SIZE  
N = NOT APPLICABLE  
024  
036  
048  
060  
HEAT EXCHANGER OPTIONS  
REVISION LEVEL  
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  
1 = HWG w/Internal Pump  
CONTROLS  
D = DXM2 (Revision B only)  
CABINET  
0 = Residential  
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3
HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS  
Residential Split - 60Hz R410A  
R e v. : 0 3 A u g u s t , 2 0 1 2  
Safety  
Safety  
WARNING! ꢀ  
Warnings, cautions and notices appear throughout this  
manual. Read these items carefully before attempting any  
installation, service or troubleshooting of the equipment.  
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.  
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! ꢀ  
CAUTION: Indicates a potentially hazardous situation or an  
unsafe practice, which if not avoided could result in minor or  
moderate injury or product or property damage.  
CAUTION! To avoid equipment damage, DO NOT use  
these units as a source of heating or cooling during the  
construction process. The mechanical components and  
lters will quickly become clogged with construction dirt  
and debris, which may cause system damage.  
NOTICE: Notication of installation, operation or  
maintenance information, which is important, but which is  
not hazard-related.  
WARNING! ꢀ  
WARNING! Verify refrigerant type before proceeding.  
Units are shipped with R-410A refrigerants. The unit label  
will indicate which refrigerant is provided. The EarthPure®  
Application and Service Manual should be read and  
understood before attempting to service refrigerant circuits  
with R-410A  
WARNING! ꢀ  
WARNING! To avoid the release of refrigerant into the  
atmosphere, the refrigerant circuit of this unit must be  
serviced only by technicians who meet local, state, and  
federal prociency requirements.  
4
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General Information  
Inspection  
4. Inspect all electrical connections. Connections must be  
clean and tight at the terminals.  
Upon receipt of the equipment, carefully check the shipment  
against the bill of lading. Make sure all units have been  
received. Inspect the packaging of each unit, and inspect  
each unit for damage. Insure that the carrier makes proper  
notation of any shortages or damage on all copies of the  
freight bill and completes a common carrier inspection report.  
Concealed damage not discovered during unloading must be  
reported to the carrier within 15 days of receipt of shipment.  
If not led within 15 days, the freight company can deny the  
claim without recourse. Note: It is the responsibility of the  
purchaser to le all necessary claims with the carrier. Notify  
your equipment supplier of all damage within fteen (15) days  
of shipment.  
5. Loosen compressor bolts on units equipped with  
compressor spring vibration isolation until the compressor  
rides freely on the springs. Remove shipping restraints.  
6. Locate and verify any hot water generator (HWG) or other  
accessory kit located in the compressor section.  
CAUTION! ꢀ  
WARNING! All refrigerant discharged from this unit must  
be recovered WITHOUT EXCEPTION. Technicians must  
follow industry accepted guidelines and all local, state,  
and federal statutes for the recovery and disposal of  
refrigerants. If a compressor is removed from this unit,  
refrigerant circuit oil will remain in the compressor. To  
avoid leakage of compressor oil, refrigerant lines of the  
compressor must be sealed after it is removed.  
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  
CAUTION! ꢀ  
Cover units on the job site with either the original packaging  
or an equivalent protective covering. Cap the open ends  
of pipes stored on the job site. In areas where painting,  
plastering, and/or spraying has not been completed, all due  
precautions must be taken to avoid physical damage to the  
units and contamination by foreign material. Physical damage  
and contamination may prevent proper start-up and may  
result in costly equipment clean-up.  
CAUTION! To avoid equipment damage, DO NOT use  
these units as a source of heating or cooling during the  
construction process. The mechanical components and  
lters will quickly become clogged with construction dirt  
and debris, which may cause system damage.  
Examine all pipes, ttings, and valves before installing any of  
the system components. Remove any dirt or debris found in  
or on these components.  
Pre-Installation  
Installation, Operation, and Maintenance instructions are  
provided with each unit. Horizontal equipment is designed for  
installation above false ceiling or in a ceiling plenum. Other  
unit congurations 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  
nished.  
3. Verify refrigerant tubing is free of kinks or dents and that  
it does not touch other unit components.  
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5
HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS  
Residential Split - 60Hz R410A  
R e v. : 0 3 A u g u s t , 2 0 1 2  
Equipment Selection  
Indoor Coil Selection - HTS GeoLogix®  
NOTICE! AHRI matched systems are required for warranty  
and applicable federal tax credits.  
HCI split system heat pumps are rated in the AHRI directory  
with a specic 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 specications 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 xed orices are not  
acceptable. PSC fans may be used if matched to Table 1b,  
but will not meet AHRI ratings. If using PSC fan, compressor  
section must be operated as a single stage unit (i.e. wired for  
either 1st stage or 2nd stage). Without the ability to vary the  
airow, supply air temperatures may not be acceptable if the  
compressor is allowed to change stages when used with a  
PSC fan motor.  
The installation of geothermal heat pump units and all  
associated components, parts, and accessories which make  
up the installation shall be in accordance with the regulations  
of ALL authorities having jurisdiction and MUST conform to  
all applicable codes. It is the responsibility of the installing  
contractor to determine and comply with ALL applicable codes  
and regulations.  
General  
Proper indoor coil selection is critical to system efciency.  
Using an older-model coil can affect efciency and may not  
provide the customer with rated or advertised EER and COP.  
Coil design and technology have dramatically improved  
operating efciency and capacity in the past 20 years.  
Homeowners using an older coil are not reaping these cost  
savings and comfort benets. NEVER MATCH AN R-22  
INDOOR COIL WITH AN R-410A COMPRESSOR SECTION.  
Newer indoor coils have a larger surface area, enhanced n  
design, and grooved tubing. These features provide a larger  
area for heat transfer, improving efciency and expanding  
capacity. Typical older coils may only have one-third to one-  
half the face area of these redesigned coils.  
Table 1a: WDG/MWG Indoor Section Matches for AHRI Ratings  
Compressor Section Model  
Indoor Section Model  
Refrigerant  
024  
024  
036  
036  
048  
048  
060  
060  
HFC-410A  
Metering Device  
TXV (required)  
Air Coil  
Type  
Rows  
N
2
N
2
N
2
N
3
Dimensions  
14 x 17  
24 x 17  
24 x 17  
24 x 17  
Cabinet Conguration  
Upow/Downow/Horizontal (Multipoise)  
ECM - 1/2 ECM - 1  
WDG Series Fan Motor Type - HP  
ECM - 1/2  
ECM - 1  
Table 1b: Tranquility® 27 Air Handler Characteristics for Brands other than Above Models  
Evaporator  
Temp (ºF)  
Capacity  
Model*  
Nominal Tons*  
CFM  
(MBtuh)**  
19.2 - 22.4  
24.2 - 28.2  
25.2 - 29.2  
34.5 - 40.1  
34.3 - 39.9  
46.3 - 53.8  
54.5 - 63.3  
024 - Part Load  
024 - Full Load  
036 - Part Load  
036 - Full Load  
048 - Part Load  
048 - Full Load  
060 - Full Load  
1.5  
2.0  
2.5  
3.0  
3.5  
4.0  
5.0  
50  
52  
51  
50  
47  
48  
48  
530  
880  
700  
1200  
1000  
1650  
1850  
* Nominal tons are at AHRI/ISO 13256-1 GLHP conditions. Two-stage units may be operated in single-stage mode if desired, where smaller capacity is required.  
For example, a model 024 may be used as a 1-1/2 ton unit if “locked” into 1st stage operation only. If PSC fan is used, unit must be “locked” into either 1st or  
2nd stage. An ECM fan is required for two-stage operation and for AHRI ratings. Size air handler for “Full Load” if operating in two-stage mode.  
**When selecting an air handler based upon the above conditions, choose entering WB temperature of 67ºF. Use evaporator temperature, CFM and capacity  
requirements as listed above. The air handler capacity must be at least at the minimum capacity shown in the table in order for the AHRI rating condition to be  
valid. See Figure 1 for an example selection.  
6
Heat Controller, Inc. Water-Source Heating and Cooling Systems  
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The Quality Leader in Conditioning Air  
Residential Split - 60Hz R410A  
R e v. : 0 3 A u g u s t , 2 0 1 2  
Equipment Selection  
Air Handler Selection Example  
Figure 1 shows a typical performance table for a heat pump air  
handler. Suppose the evaporator temperature required is 50ºF,  
the capacity required is 35,000 Btuh and the airow required  
is 1,200 CFM. Each evaporator temperature listed in the table  
shows three wet bulb temperatures. As recommended in the  
table notes above, select the 67ºF WB column. At 1,200 CFM,  
the model 003 capacity is 36 MBtuh, which is higher than the  
minimum capacity required of 35,000 Btuh. In this example,  
model 003 would be the appropriate match.  
Figure 1: Selecting Air Handler  
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7
HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS  
Residential Split - 60Hz R410A  
R e v. : 0 3 A u g u s t , 2 0 1 2  
Installation  
NOTICE! Failure to remove shipping brackets from  
spring-mounted compressors will cause excessive  
noise, and could cause component failure due to added  
vibration.  
Any access panel screws that would be difcult 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:  
The installation of water source heat pump units and all  
associated components, parts and accessories which make  
up the installation shall be in accordance with the regulations  
of ALL authorities having jurisdiction and MUST conform to  
all applicable codes. It is the responsibility of the installing  
contractor to determine and comply with ALL applicable  
codes and regulations.  
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 sufcient 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 ttings and  
screwdriver access to the unit side panels and all  
electrical connections.  
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 ushed before installing new  
compressor section. R-410A compressors use POE  
oil instead of mineral oil (R-22 systems). Mineral oil is  
not compatible with POE oil, and could cause system  
damage if not completely ushed from the line set.  
Air Handler and Coil Installation  
This manual specically addresses the compressor section  
of the system. Air handler and coil location and installation  
should be according to the instructions provided with the air  
handling/coil unit.  
Indoor Compressor Section Location  
The HTS indoor compressor section is not designed for  
outdoor installation. Locate the unit in an INDOOR area  
that allows enough space for service personnel to perform  
typical maintenance or repairs without removing unit.  
Units are typically installed in a mechanical room or closet.  
Never install units in areas subject to freezing or where  
humidity levels could cause cabinet condensation (such  
as unconditioned spaces subject to 100% outside air).  
Consideration should be given to access for easy removal  
of service access panels. Provide sufcient room to make  
water, electrical, and line set connections.  
8
Heat Controller, Inc. Water-Source Heating and Cooling Systems  
Download from Www.Somanuals.com. All Manuals Search And Download.  
The Quality Leader in Conditioning Air  
Residential Split - 60Hz R410A  
R e v. : 0 3 A u g u s t , 2 0 1 2  
Installation  
Figure 2: HTS Installation  
The female locking ring is threaded onto the pipe threads  
which holds the male pipe end against the rubber gasket,  
and seals the joint. HAND TIGHTEN ONLY! DO NOT  
OVERTIGHTEN!  
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 ttings 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 ush end of most 1” threaded male pipe ttings pro-  
vides a leak-free seal without the need for thread sealing  
tape or joint compound. Insure that the rubber seal is in  
the swivel connector prior to attempting any connection  
(rubber seals are shipped attached to the swivel connec-  
tor). DO NOT OVER TIGHTEN or leaks may occur.  
Figure 3: Water Connections (Indoor Compressor Section)  
Swivel Nut  
Hand Tighten  
Only!  
Do Not  
Overtighten!  
Stainless steel  
snap ring  
Gasket  
Brass Adaptor  
GROUND-LOOP HEAT PUMP APPLICATIONS  
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.  
CAUTION! ꢀ  
CAUTION! The following instructions represent industry  
accepted installation practices for closed loop earth  
coupled heat pump systems. Instructions are provided  
to assist the contractor in installing trouble free ground  
loops. These instructions are recommendations only.  
State/provincial and local codes MUST be followed and  
installation MUST conform to ALL applicable codes. It is  
the responsibility of the installing contractor to determine  
and comply with ALL applicable codes and regulations.  
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 ttings should not be used at any  
time due to their tendency to corrode. All plastic to metal  
threaded ttings should be avoided due to their potential to  
leak in earth coupled applications. A anged tting should  
be substituted. P/T plugs should be used so that ow can be  
measured using the pressure drop of the unit heat exchanger.  
Pre-Installation  
Prior to installation, locate and mark all existing underground  
utilities, piping, etc. Install loops for new construction before  
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9
HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS  
Residential Split - 60Hz R410A  
R e v. : 0 3 A u g u s t , 2 0 1 2  
Ground-Loop Heat Pump Applications  
Earth loop temperatures can range between 25 and 110°F [-4  
to 43°C]. Flow rates between 2.25 and 3 gpm per ton [2.41 to  
3.23 l/m per kW] of cooling capacity is recommended in these  
applications.  
Pressures will be higher in the winter months than during  
the cooling season. This uctuation is normal and should be  
considered when charging the system initially. Run the unit in  
either heating or cooling for a number of minutes to condition  
the loop to a homogenous temperature. This is a good time  
for tool cleanup, piping insulation, etc. Then, perform nal  
ush and pressurize the loop to a static pressure of 50-75 psi  
[345-517 kPa] (winter) or 35-40 psi [241-276 kPa] (summer).  
After pressurization, be sure to loosen the plug at the end  
of the Grundfos loop pump motor(s) to allow trapped air to  
be discharged and to insure the motor housing has been  
ooded. This is not required for Taco circulators. Insure  
that the Flow Controller provides adequate ow through the  
unit by checking pressure drop across the heat exchanger  
and compare to the pressure drop tables at the back of the  
manual.  
Test individual horizontal loop circuits before backlling.  
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 nal  
purging and charging. A ush cart with at least a 1.5 hp  
[1.1 kW] pump is required to achieve enough uid velocity  
in the loop piping system to purge air and dirt particles. An  
antifreeze solution is used in most areas to prevent freezing.  
All air and debris must be removed from the earth loop piping  
before operation. Flush the loop with a high volume of water  
at a minimum velocity of 2 fps (0.6 m/s) in all piping. The  
steps below must be followed for proper ushing.  
1. Fill loop with water from a garden hose through the ush  
cart before using the ush cart pump to insure an even  
ll.  
Antifreeze  
In areas where minimum entering loop temperatures drop  
below 40°F [5°C] or where piping will be routed through  
areas subject to freezing, antifreeze is required. Alcohols  
and glycols are commonly used as antifreeze; however  
your local sales manager should be consulted for the  
antifreeze best suited to your area. Freeze protection should  
be maintained to 15°F [9°C] below the lowest expected  
entering loop temperature. For example, if 30°F [-1°C] is the  
minimum expected entering loop temperature, the leaving  
loop temperature would be 25 to 22°F [-4 to -6°C] and freeze  
protection should be at 15°F [-10°C].  
2. Once full, the ushing process can begin. Do not allow  
the water level in the ush cart tank to drop below the  
pump inlet line to avoid air being pumped back out to the  
earth loop.  
3. Try to maintain a uid level in the tank above the return  
tee so that air cannot be continuously mixed back into  
the uid. Surges of 50 psi (345 kPa) can be used to help  
purge air pockets by simply shutting off the return valve  
going into the ush cart reservoir. This “dead heads” the  
pump to 50 psi (345 kPa). To purge, dead head the pump  
until maximum pumping pressure is reached. Open the  
return valve and a pressure surge will be sent through  
the loop to help purge air pockets from the piping system.  
4. Notice the drop in uid level in the ush cart tank when  
the return valve is shut off. If air is adequately purged  
from the system, the level will drop only 1-2 inches (2.5 -  
5 cm) in a 10” (25 cm) diameter PVC ush tank (about a  
half gallon [2.3 liters]), since liquids are incompressible.  
If the level drops more than this, ushing should continue  
since air is still being compressed in the loop uid.  
Perform the “dead head” procedure a number of times.  
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 uid in the piping system. Then use the percentage by  
volume shown in Table 2 for the amount of antifreeze needed.  
Antifreeze concentration should be checked from a well  
mixed sample using a hydrometer to measure specic 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.  
Note: This uid level drop is your only indication of air in  
the loop.  
Antifreeze may be added before, during or after the ushing  
procedure. However, depending upon which time is chosen,  
antifreeze could be wasted when emptying the ush cart  
tank. See antifreeze section for more details.  
Loop static pressure will uctuate with the seasons.  
10  
Heat Controller, Inc. Water-Source Heating and Cooling Systems  
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The Quality Leader in Conditioning Air  
Residential Split - 60Hz R410A  
R e v. : 0 3 A u g u s t , 2 0 1 2  
Ground-Loop Heat Pump Applications  
Table 2: Approximate 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  
Copper  
Size  
1”  
Volume (gal) [liters]  
4.1 [15.3]  
6.4 [23.8]  
9.2 [34.3]  
3.9 [14.6]  
2.8 [10.4]  
4.5 [16.7]  
8.0 [29,8]  
10.9 [40.7]  
18.0 [67.0]  
8.3 [30.9}  
10.9 [40.7]  
17.0 [63.4]  
To Loop  
1.25”  
Flow  
Controller  
2.5”  
Rubber Hose  
1”  
Unit Power  
Disconnect  
3/4” IPS SDR11  
1” IPS SDR11  
1.25” IPS SDR11  
1.5” IPS SDR11  
2” IPS SDR11  
1.25” IPS SCH40  
1.5” IPS SCH40  
2” IPS SCH40  
Insulated  
Hose Kit  
Polyethylene  
AH & Thermostat  
Wiring  
Air Pad or  
Extruded  
polystyrene  
insulation board  
P/T Plugs  
Unit Heat  
Exchanger  
Typical  
1.0 [3.8]  
10 [37.9]  
10” Dia x 3ft tall  
[254mm x 91.4cm tall]  
Flush Cart Tank  
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  
Minimum Temperature for Low Temperature Protection  
Type  
10°F [-12.2°C]  
15°F [-9.4°C]  
20°F [-6.7°C]  
25°F [-3.9°C]  
Methanol  
25%  
38%  
29%  
21%  
25%  
25%  
16%  
22%  
20%  
10%  
15%  
14%  
100% USP food grade Propylene Glycol  
Ethanol*  
* Must not be denatured with any petroleum based product  
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11  
HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS  
Residential Split - 60Hz R410A  
R e v. : 0 3 A u g u s t , 2 0 1 2  
Ground-Water Heat Pump Applications -Compressor Section Only  
Open Loop - Ground Water Systems  
Expansion Tank and Pump  
(“Indoor” Compressor Section Only)  
Use a closed, bladder-type expansion tank to minimize  
mineral formation due to air exposure. The expansion tank  
should be sized to provide at least one minute continuous  
run time of the pump using its drawdown capacity rating to  
prevent pump short cycling. Discharge water from the unit  
is not contaminated in any manner and can be disposed  
of in various ways, depending on local building codes (e.g.  
recharge well, storm sewer, drain eld, adjacent stream  
or pond, etc.). Most local codes forbid the use of sanitary  
sewer for disposal. Consult your local building and zoning  
department to assure compliance in your area.  
The “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 ushing of the heat exchanger. Shut off valves  
should be positioned to allow ow through the coax via the  
boiler drains without allowing ow into the piping system. P/T  
plugs should be used so that pressure drop and temperature  
can be measured. Piping materials should be limited to  
copper or PVC SCH80. Note: Due to the pressure and  
temperature extremes, PVC SCH40 is not recommended.  
The pump should be sized to handle the home’s domestic  
water load (typically 5-9 gpm [23-41 l/m]) plus the ow rate  
required for the heat pump. Pump sizing and expansion  
tank must be chosen as complimentary items. For example,  
an expansion tank that is too small can causing premature  
pump failure due to short cycling. Variable speed pumping  
applications should be considered for the inherent energy  
savings and smaller expansion tank requirements.  
Water quantity should be plentiful and of good quality.  
Consult Table 4 for water quality guidelines. The unit can  
be ordered with either a copper or cupro-nickel water  
heat exchanger. Consult Table 4 for recommendations.  
Copper is recommended for closed loop systems and open  
loop ground water systems that are not high in mineral  
content or corrosiveness. In conditions anticipating heavy  
scale formation or in brackish water, a cupro-nickel heat  
exchanger is recommended. In ground water situations  
where scaling could be heavy or where biological growth  
such as iron bacteria will be present, an open loop system  
is not recommended. Heat exchanger coils may over time  
lose heat exchange capabilities due to build up of mineral  
deposits. Heat exchangers must only be serviced by a  
qualied 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 ushing. In some cases, the  
desuperheater option should not be recommended due to  
hard water conditions and additional maintenance required.  
Motorized Modulating Water Control Valve  
Note the placement of the water control valve in gure 9.  
Always maintain water pressure in the heat exchanger by  
placing the water control valve(s) on the discharge line  
to prevent mineral precipitation during the off-cycle. Pilot  
operated slow closing valves are recommended to reduce  
water hammer. If water hammer persists, a mini-expansion  
tank can be mounted on the piping to help absorb the excess  
hammer shock. This valve regulates the ow using entering  
and leaving water delta-T of the system. Entering and leaving  
water temperature is read on the communicating thermostat  
or conguration/diagnostic service tool. Further details on  
valve operation are described later in this manual.  
Water Quality Standards  
Table 4 should be consulted for water quality requirements.  
Scaling potential should be assessed using the pH/Calcium  
hardness method. If the pH <7.5 and the Calcium hardness  
is less than 100 ppm, scaling potential is low. If this method  
yields numbers out of range of those listed, the Ryznar  
Stability and Langelier Saturation indecies should be  
calculated. Use the appropriate scaling surface temperature  
for the application, 150°F [66°C] for direct use (well water/  
open loop) and DHW (desuperheater); 90°F [32°F] for indirect  
use. A monitoring plan should be implemented in these  
probable scaling situations. Other water quality issues such  
as iron fouling, corrosion prevention and erosion and clogging  
should be referenced in Table 4.  
12  
Heat Controller, Inc. Water-Source Heating and Cooling Systems  
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The Quality Leader in Conditioning Air  
Residential Split - 60Hz R410A  
R e v. : 0 3 A u g u s t , 2 0 1 2  
Ground-Water Heat Pump Applications  
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 ushing. Once  
ushing is complete, return the valve handle to its normally  
closed position.  
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.  
To manually open the internal modulating motorized water  
valve in HTS060, push down on the lock release button while  
turning the handle to the open position as shown in Figure  
9a. This fully opens the valve for ushing. Once ushing is  
complete, press the lock release again and return the valve  
handle to its normally closed position.  
CAUTION! ꢀ  
CAUTION! Refrigerant pressure activated water regulating  
valves should never be used with HCI equipment.  
Figure 9: Water Well Connections  
Figure 9a: Optional Modulating Motorized Valve Positions  
Sizes 024 - 048  
Sizes 060  
Flow  
Regulator  
Water  
Control  
Valve  
Closed  
Closed  
Pressure  
Tank  
Water Out  
Water In  
/RFNꢀ5HOHDVH  
Open  
Open  
Shut-Off  
Valve  
Optional  
Filter  
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 temperature (ΔT). The DXM2 board gives a 0-10v  
signal to determine ow rate. The motorized modulating valve  
defaults to closed position if it loses signal but still has 24V  
power running to it. If the motorized modulating valve loses  
both signal from the DXM2 board AND 24V power, it will  
remain in the same position it was in when it lost 24V power.  
DO NOT USE open loop units in closed loop applications due  
to signicant pressure drop through the open loop motorized  
modulating valve.  
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13  
HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS  
Residential Split - 60Hz R410A  
R e v. : 0 3 A u g u s t , 2 0 1 2  
Water Quality Standards  
Table 4: Water Quality Standards  
Water Quality  
Parameter  
HX  
Material  
Closed  
Recirculating  
Open Loop and Recirculating Well  
Scaling Potential - Primary Measurement  
Above the given limits, scaling is likely to occur. Scaling indexes should be calculated using the limits below  
pH/Calcium Hardness  
Method  
-
All  
pH < 7.5 and Ca Hardness <100ppm  
Index Limits for Probable Scaling Situations - (Operation outside these limits is not recommended)  
Scaling indexes should be calculated at 66°C for direct use and HWG applications, and at 32°C for indirect HX use.  
A monitoring plan should be implemented.  
Ryznar  
Stability Index  
-
6.0 - 7.5  
If >7.5 minimize steel pipe use.  
All  
All  
-
-0.5 to +0.5  
Langelier  
Saturation Index  
If <-0.5 minimize steel pipe use. Based upon 66°C HWG and  
Direct well, 29°C Indirect Well HX  
Iron Fouling  
Iron Fe (Ferrous)  
2+  
-
-
<0.2 ppm (Ferrous)  
If Fe2+ (ferrous)>0.2 ppm with pH 6 - 8, O2<5 ppm check for iron bacteria.  
All  
All  
(Bacterial Iron potential)  
<0.5 ppm of Oxygen  
Above this level deposition will occur.  
Iron Fouling  
Corrosion Prevention  
6 - 8.5  
6 - 8.5  
pH  
All  
All  
Monitor/treat as  
needed  
Minimize steel pipe below 7 and no open tanks with pH <8  
-
<0.5 ppm  
At H S>0.2 ppm, avoid use of copper and copper nickel piping or HX's.  
2
Hydrogen Sulfide (H S)  
2
Rotten egg smell appears at 0.5 ppm level.  
Copper alloy (bronze or brass) cast components are OK to <0.5 ppm.  
Ammonia ion as hydroxide, chloride,  
nitrate and sulfate compounds  
-
<0.5 ppm  
All  
Maximum Allowable at maximum water temperature.  
10$C  
<20ppm  
24$C  
NR  
38 C  
NR  
Copper  
Cupronickel  
-
-
-
-
-
Maximum  
<150 ppm  
<400 ppm  
<1000 ppm  
>1000 ppm  
NR  
NR  
Chloride Levels  
304 S  
316 S  
S
S
<250 ppm  
<550 ppm  
>550 ppm  
<150 ppm  
< 375 ppm  
>375 ppm  
Titanium  
All  
Erosion and Clogging  
<10 ppm of particles  
and a maximum  
velocity of 1.8 m/s  
Filtered for maximum  
841 micron [0.84 mm,  
20 mesh] size.  
<10 ppm (<1 ppm "sandfree” for reinjection) of particles and a maximum  
velocity of 1.8 m/s. Filtered for maximum 841 micron 0.84 mm,  
20 mesh] size. Any particulate that is not removed can potentially  
clog components.  
Particulate Size and  
Erosion  
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:  
‡ꢀ&ORVHGꢀ5HFLUFXODWLQJꢀV\VWHPꢀLVꢀLGHQWLILHGꢀE\ꢀDꢀclosed pressurized piping system.  
‡ꢀ5HFLUFXODWLQJꢀRSHQꢀZHOOVꢀVKRXOGꢀREVHUYHꢀWKHꢀRSHQꢀUHFLUFXODWLQJꢀGHVLJQꢀFRQVLGHUDWLRQVꢃ  
‡ꢀ15ꢀꢁꢀApplication not recommended.  
‡ꢀꢂꢁꢂꢀ1RꢀGHVLJQꢀ0D[LPXPꢃ  
14  
Heat Controller, Inc. Water-Source Heating and Cooling Systems  
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The Quality Leader in Conditioning Air  
Residential Split - 60Hz R410A  
R e v. : 0 3 A u g u s t , 2 0 1 2  
Refrigeration Installation  
When passing refrigerant lines through a wall, seal  
opening with silicon-based caulk. Avoid direct contact  
with water pipes, duct work, oor joists, wall studs,  
oors or other structural components that could transmit  
compressor vibration. Do not suspend refrigerant tubing  
from joists with rigid straps. Do not attach line set to the  
wall. When necessary, use hanger straps with isolation  
sleeves to minimize tranmission of line set vibration to the  
structure.  
CAUTION! ꢀ  
CAUTION! R-410A systems operate at higher pressures  
than R-22 systems. Be certain that service equipment  
(gauges, tools, etc.) is rated for R-410A. Some R-22  
service equipment may not be acceptable.  
CAUTION! ꢀ  
CAUTION! Installation of a factory supplied liquid line  
bi-directional lter drier is required. Never install a suction  
line lter in the liquid line.  
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.”  
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 lter drier is installed on the liquid  
line inside the compressor section cabinet (R-22 units only).  
R-410A models are shipped with a lter drier (loose) inside  
the cabinet that must be installed in the liquid line at the  
line set. All brazing should be performed using nitrogen  
circulating at 2-3 psi [13.8-20.7 kPa] to prevent oxidation  
inside the tubing. All linesets should be insulated with a  
minimum of 1/2” [13mm] thick closed cell insulation. All  
insulation tubing should be sealed using a UV resistant  
paint or covering to prevent deterioration from sunlight.  
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15  
HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS  
Residential Split - 60Hz R410A  
R e v. : 0 3 A u g u s t , 2 0 1 2  
Refrigeration Installation  
Figure 10: Braze Instructions  
Figure 11: Air Coil Connection  
TXV (‘IN’ toward  
compressor section)  
Bulb (Must be  
Installed and  
Insulated)  
Equalizer  
Line  
FP2  
Sensor  
Vapor  
Fully Insulated  
Suction Line  
Suction Line  
TXV has internal  
check valve  
Liquid Line  
Fully Insulated  
Liquid Line  
Add-On Heat Pump Applications  
Nitrogen Braze  
The HWG Series indoor coil should be located in the supply  
side of the furnace to avoid condensation damage to the  
furnace heat exchanger for add-on heat pump applications. A  
high temperature limit switch should be installed as shown in  
Figures 12b and 13b just upstream of the coil to de-energize  
the compressor any time the furnace is energized to avoid  
blowing hot air directly into the coil, elevating refrigerant  
pressures during operation. The heat pump will trip out on  
high pressure lockout without some method of disengaging  
the compressor during furnace operation. Alternatively, some  
thermostats with “dual fuel” mode will automatically de-  
energize the compressor when second stage (backup) heat is  
required.  
Replace Caps after adjusting  
service valves  
CCW  
CCW  
Rev. 05/31/00  
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.  
Service ports for  
gauges  
Figure 5: Service Valve Positions  
Service  
Port  
Position  
Description  
System  
Open  
NOTICE! The air coil should be thoroughly washed with a  
lming agent, (dishwasher detergent like Cascade) to help  
condensate drainage. Apply a 20 to 1 solution of detergent  
and water. Spray both sides of coil, repeat and rinse  
thoroughly with water.  
CCW - Full Out  
Operation Position  
Service Position  
Closed  
CCW -Full Out 1/2  
turn CW  
Open  
Open  
CW - Full in  
Shipping Position Closed Open  
Evacuation and Charging the Unit  
Installing the Indoor Coil and Lineset  
LEAK TESTING - The refrigeration line set must be  
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 xed orice, the orice 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.  
pressurized and checked for leaks before evacuating and  
charging the unit. To pressurize the line set, attach refrigerant  
gauges to the service ports and add an inert gas (nitrogen or  
dry carbon dioxide) until pressure reaches 60-90 psig [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 eld. Check  
the service valve ports and stem for leaks. If a leak is found,  
repair it and repeat the above steps. For safety reasons do  
not pressurize system above 150 psig [1034 kPa]. System is  
now ready for evacuation and charging.  
16  
Heat Controller, Inc. Water-Source Heating and Cooling Systems  
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The Quality Leader in Conditioning Air  
Residential Split - 60Hz R410A  
R e v. : 0 3 A u g u s t , 2 0 1 2  
Refrigeration Installation  
Figure 12: Typical Split/Air Handler Installation (Indoor Compressor Section)  
Power Disconnects  
WDG  
Series  
TXV ‘IN’ toward  
Compressor Section  
Insulated  
Line Sets  
PVC Condensate  
with vented trap  
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  
Section  
Air pad or extruded  
polystyrene  
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17  
HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS  
Residential Split - 60Hz R410A  
R e v. : 0 3 A u g u s t , 2 0 1 2  
Refrigeration Installation  
Evacuation Of The Lineset And Coil  
Charging The System  
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.  
There are two methods of charging a refrigerant system. One  
method is the total charge method, where the volume of the  
system is determined and the refrigerant is measured and  
added into the evacuated system. The other method is the  
partial charge method where a small initial charge is added to  
an evacuated system, and remaining refrigerant added during  
operation.  
Total Charge Method  
See Table 4 for the compressor section basic charge. For line  
sets with 3/8” liquid lines add 0.6 ounces of refrigerant to the  
basic charge for every installed foot of liquid line [0.6 grams  
per cm]. Add 1.2 oz. per foot [1.1 grams per cm] if using  
l/2” line. Once the total charge is determined, the factory  
pre-charge (Table 4) is subtracted and the remainder is the  
amount needed to be added to the system. This method  
should be used with the AHRI matched air handler or coil.  
Figure 14: Evacuation Graph  
Table 6: R-410A Charging Values  
NOTICE! ꢀ  
NOTICE! Use tables 14a to 15 for superheat/subcooling  
values. These tables use discharge pressure (converted  
to saturation temperature) and liquid line temperature  
for subcooling calculations. If using liquid line pressure,  
subtract 3ºF from the table values.  
18  
Heat Controller, Inc. Water-Source Heating and Cooling Systems  
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The Quality Leader in Conditioning Air  
Residential Split - 60Hz R410A  
R e v. : 0 3 A u g u s t , 2 0 1 2  
Refrigeration Installation  
Checking Superheat and Subcooling  
Determining Superheat:  
Turn service valves full out CCW (see Table 5) and then turn  
back in one-half turn to open service ports. Add the required  
refrigerant so that the total charge calculated for the unit  
and line set is now in the system. Open the service valve  
fully counter clockwise so that the stem will backseat and  
prevent leakage through the schrader port while it is not in  
use. Start unit in the heating mode and measure superheat  
and subcooling values after 5 minutes of run time. See tables  
14a to 15 for superheat and sub-cooling values. Superheat  
is measured using suction temperature and pressure at the  
compressor suction line. Subcooling should be measured  
using the liquid line temperature immediately outside the  
compressor section cabinet and either the liquid line service  
valve pressure or the compressor discharge pressure. Note  
that different values from tables 14a to 15 will be obtained due  
to the pressure losses through the condenser heat exchanger.  
Adding refrigerant will increase sub-cooling while superheat  
should remain fairly constant allowing for a slight amount  
of hunting in TXV systems. This increase in subcooling will  
require 5 minutes or so of operation before it should be  
measured. After values are measured, compare to the chart  
and go to “FINAL EVALUATION.”  
1. Measure the temperature of the suction line at a point  
near the expansion valve bulb.  
2. Determine the suction pressure by attaching refrigeration  
gauges to the suction schrader connection at the  
compressor.  
3. Convert the pressure obtained in step 2 to saturation  
temperature (boiling point) by using the pressure/  
temperature conversion table on the gauge set.  
4. Subtract the temperature obtained in step 3 from step 1.  
The difference will be the superheat of the unit or the total  
number of degrees above saturation temperature. Refer to  
Tables 14a to 15 for superheat ranges at specic 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 signicant temperature drop in the liquid line is  
anticipated.  
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 ve pounds [2.27  
kg] per minute. Keep adding refrigerant until the complete  
charge has been entered. Superheat is measured using  
suction temperature and pressure at the compressor suction  
line. Subcooling should be measured using the liquid line  
temperature immediately outside the compressor section  
cabinet and either the liquid line service valve pressure or the  
compressor discharge pressure. Note that different values  
from tables 14a to 15 will be obtained due to the pressure  
losses through the condenser heat exchanger. Adding  
refrigerant will increase sub-cooling while superheat should  
remain fairly constant allowing for a slight amount of hunting  
in TXV systems. This increase in subcooling will require 5  
minutes or so of operation before it should be measured. After  
values are measured, compare to the chart and go to “FINAL  
EVALUATION.”  
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  
specic entering water temperatures.  
FINAL EVALUATION  
- In a split system, cooling subcooling values can be  
misleading depending on the location of the measurement.  
Therefore, it is recommended that charging be monitored in  
the heating mode. Charge should be evaluated by monitoring  
the subcooling in the heating mode. After initial check of  
heating sub-cooling, shut off unit and allow to sit 3-5 minutes  
until pressures equalize. Restart unit in the cooling mode  
and check the cooling superheat against Tables 14a to 15. If  
unit runs satisfactorily, charging is complete. If unit does not  
perform to specications the cooling TXV (air coil side) may  
need to be readjusted (if possible) until the cooling superheat  
values are met.  
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19  
HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS  
Residential Split - 60Hz R410A  
R e v. : 0 3 A u g u s t , 2 0 1 2  
HotWater Generator  
The HWG (Hot Water Generator) or desuperheater option  
provides considerable operating cost savings by utilizing  
excess heat energy from the heat pump to help satisfy  
domestic hot water requirements. The HWG is active  
throughout the year, providing virtually free hot water when  
the heat pump operates in the cooling mode or hot water at  
the COP of the heat pump during operation in the heating  
mode. Actual HWG water heating capacities are provided in  
the appropriate heat pump performance data.  
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.  
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 eld.  
The control circuit and pump are also built in for residential  
equipment. Figure 18 shows a typical example of HWG water  
piping connections on a unit with built-in circulating pump.  
This piping layout reduces scaling potential.  
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.  
The temperature set point of the HWG is eld selectable  
to 125°F or 150°F . The 150°F setpoint allows more heat  
storage from the HWG. For example, consider the amount  
of heat that can be generated by the HWG when using  
the 125°F set point, versus the amount of heat that can be  
generated by the HWG when using the 150°F set point.  
Typically a single tank of at least 50 gallons (189 liters) is  
used to limit installation costs and space. However, a dual  
tank, as shown in Figure 16, is the most efcient 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.  
In a typical 50 gallon two-element electric water heater  
the lower element should be turned down to 100°F, or the  
lowest setting, to get the most from the HWG. The tank will  
eventually stratify so that the lower 80% of the tank, or 40  
gallons, becomes 100°F (controlled by the lower element).  
The upper 20% of the tank, or 10 gallons, will be maintained  
at 125°F (controlled by the upper element).  
Figure 16: HWG Double Tank Installation  
(Indoor Compressor Section)  
Figure 15: Typical HWG Installation  
(Indoor Compressor Section)  
Hot Outlet to  
house  
Cold  
Inlet  
Hot Outlet  
to home  
Cold Inlet  
Cold Inlet from  
Domestic supply  
Shut Off  
Valve #1  
Hot Outlet  
Shut Off  
Valve #4  
Upper  
Upper element to 130°F [54°C]  
element to  
120 - 130°F  
[49 - 54°C]  
Shut-off  
Valve #1  
(or owner preference)  
Shut-off  
Valve #4  
Lower  
element to  
100 - 110°F  
[38 - 43°C]  
Powered  
Water  
Heater  
Powered  
Water Heater  
Lower element to 120°F [49°C]  
Unpowered  
Water Heater  
Shut-off  
Valve #3  
Shut-off  
Valve #3  
Shut Off  
Valve #2  
Shut Off  
Valve #2  
Field supplied 3/4’ brass nipple and ‘T’  
Field Supplied 3/4” brass nipple and “T”  
Insulated water lines -  
5/8” OD, 50 ft maximum (one way)  
[16mm OD, 15 meters maximum]  
Insulated water lines - 5/8” OD, 50 ft maximum (one way)  
[16mm OD, 15 meters maximum]  
20  
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Figure 20: Anti-Scald Valve Piping Connections  
Installation  
ANTI-SCALD  
COLD WATER  
SUPPLY  
The HWG is controlled by two sensors and the DXM2  
microprocessor control. One sensor is located on the  
compressor discharge line to sense the discharge refrigerant  
temperature. The other sensor is located on the HWG heat  
exchanger’s “Water In” line to sense the potable water  
temperature.  
VALVE PIPING  
CONNECTIONS  
CHECK VALVE  
ANTI-SCALD  
VALVE  
C
WARNING! ꢀ  
HOT WATER  
TO HOUSE  
M
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.  
H
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  
sufciently above the water temperature. Once the HWG has  
satised 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.  
WATER HEATER  
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 ash (On 1 second, Off 1 second).  
WARNING! ꢀ  
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!  
If the control has detected a HWG fault, the DXM2 status LED  
will ash a numeric fault code as follows:  
High Water Temperature (>160 ºF)  
Hot Water Sensor Fault  
Compressor Discharge Sensor Fault  
5 ashes  
6 ashes  
6 ashes  
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.  
Fault code ashes have a duration of 0.3 seconds with  
a 10 second pause between fault codes. For example, a  
“Compressor Discharge sensor fault” will be six ashes 0.3  
seconds long, then a 10 second pause, then six ashes  
again, etc.  
All installations must be in accordance with local codes. The  
installer is responsible for knowing the local requirements,  
and for performing the installation accordingly. DO NOT  
activate the HWG until “Initial Start-Up” section, below is  
completed. Powering the pump before all installation steps  
are completed may damage the pump.  
WARNING! ꢀ  
WARNING! USING A 150°F SETPOINT ON THE HWG  
WILL RESULT IN WATER TEMPERATURES SUFFICIENT  
TO CAUSE SEVERE PHYSICAL INJURY IN THE FORM  
OF SCALDING OR BURNS, EVEN WHEN THE HOT  
WATER TANK TEMPERATURE SETTING IS VISIBLY  
SET BELOW 150°F. THE 150°F HWG SETPOINT  
MUST ONLY BE USED ON SYSTEMS THAT EMPLOY  
AN APPROVED ANTI-SCALD VALVE (PART NUMBER  
AVAS4) AT THE HOT WATER STORAGE TANK  
WITH SUCH VALVE PROPERLY SET TO CONTROL  
WATER TEMPERATURES DISTRIBUTED TO ALL HOT  
WATER OUTLETS AT A TEMPERATURE LEVEL THAT  
PREVENTS SCALDING OR BURNS!  
Water Tank Preparation  
1. Turn off power or fuel supply to the hot water tank.  
2. Connect a hose to the drain valve on the water tank.  
3. Shut off the cold water supply to the water tank.  
4. Open the drain valve and open the pressure relief valve  
or a hot water faucet to drain tank.  
5. When using an existing tank, it should be ushed with  
cold water after it is drained until the water leaving the  
drain hose is clear and free of sediment.  
6. Close all valves and remove the drain hose.  
7. Install HWG water piping.  
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HotWater Generator  
Table 6: HWG Water Piping Sizes and Length  
Unit Nominal  
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 ushing water  
through the HWG (as in Figures 15 and 16) or by  
installing an air vent at the high point of the HWG piping  
system.  
1/2" Copper  
3/4" Copper  
Nominal HWG Flow  
(max length*) (max length*)  
Tonnage  
(gpm)  
2.0  
0.8  
50  
50  
45  
25  
-
3.0  
1.2  
-
4.0  
1.6  
50  
50  
5.0  
2.0  
*Maximum length is equivalent length (in feet) one way of type L  
copper.  
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.  
NOTICE! Make sure the compressor discharge line is  
connected to the “Hot Gas In” stub on the Heat Recovery Unit.  
Water Tank Rell  
1. Close valve #4. Ensure that the HWG valves (valves #2  
and #3) are open. Open the cold water supply (valve #1)  
to ll the tank through the HWG piping. This will purge air  
from the HWG piping.  
CAUTION! ꢀ  
CAUTION! Locate Refrigerant lines to avoid accidental  
2. Open a hot water faucet to vent air from the system until  
water ows 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. Inspect all work for leaks.  
damage by lawnmowers or children.  
WARNING! ꢀ  
WARNING! The HWG module is an appliance that operates  
in conjunction with the heat pump system, the hot water  
system and the electrical system. Installation should only be  
performed by skilled technicians with appropriate training  
and experience. The installation must be in compliance with  
local codes and ordinances. Local plumbing and electrical  
building codes take precedence over instructions contained  
herein. The Manufacturer accepts no liability for equipment  
damaged and/or personal injury arising from improper  
installation of the HWG module.  
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 specic 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  
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.  
22  
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Electrical - LineVoltage  
All nal electrical connections must be made with a length of  
exible conduit to minimize vibration and sound transmission  
to the building.  
WARNING! ꢀ  
WARNING! To avoid possible injury or death due to  
electrical shock, open the power supply disconnect switch  
and secure it in an open position during installation.  
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.  
CAUTION! ꢀ  
CAUTION! Use only copper conductors for eld installed  
electrical wiring. Unit terminals are not designed to accept  
other types of conductors.  
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.  
Electrical - Line Voltage  
All eld installed wiring, including electrical ground, must  
comply with the National Electrical Code as well as all  
applicable local codes. Refer to the unit electrical data for  
fuse sizes. Consult wiring diagram for eld connections that  
must be made by the installing (or electrical) contractor.  
208-230 Volt Operation  
Verify transformer tap with air handler wiring diagram to  
insure that the transformer tap is set to the correct voltage,  
208V or 230V.  
Table 7: GeoMax 2 (HTS) Electrical Data  
HWG  
Pump  
FLA  
External  
Pump  
FLA  
Total  
Unit  
FLA  
Min  
Circuit  
Amps  
Max  
Fuse/  
HACR  
Compressor  
LRA  
Model  
RLA  
Qty  
024  
036  
048  
060  
10.7  
17.0  
21.5  
26.0  
56.0  
87.0  
1
1
1
1
0.4  
0.4  
0.4  
0.4  
4.0  
4.0  
4.0  
4.0  
15.1  
21.4  
25.9  
30.4  
17.8  
25.7  
31.3  
36.9  
25  
40  
50  
60  
100.0  
125.0  
Figure 21: R-410A Compressor Section Line Voltage  
Field Wiring  
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.  
See unit wiring diagram for addtional details.  
Unit Power Supply  
(see electrical  
table for wire and  
breaker size)  
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23  
HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS  
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Electrical - LowVoltage  
Accessory Connections  
Figure 22: HTS Low Voltage Field Wiring  
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  
C
DXM2  
24VAC  
P2  
A
Low Voltage Field Wiring  
Low Water Temperature Cutout Selection  
Motorized Modulating Water Control Valve - Open Loop  
Ground Water Systems Only  
The DXM2 control allows the eld selection of low water (or  
water-antifreeze solution) temperature limit by clipping jumper  
JW3, which changes the sensing temperature associated  
with thermistor LT1. Note that the LT1 thermistor is located  
on the refrigerant line between the coaxial heat exchanger  
and expansion device (TXV). Therefore, LT1 is sensing  
refrigerant temperature, not water temperature, which is  
a better indication of how water ow rate/temperature is  
affecting the refrigeration circuit.  
An external valve should be used on ground water systems  
to shut off ow when the compressor is not operating. Valve  
kit AMMV4D is available for use with HTS024-048, and kit  
AMMV5E is used with HTS060. See Figure 23b or the unit  
wiring diagram for valve wiring detail. Further details on valve  
operation are described later in this manual.  
Figure 23b: Motorized Modulating Water Control Valve -  
Open Loop Ground Water Systems Only  
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].  
P3  
DXM 2  
P11  
Figure 23: LT1 Limit Setting  
HP  
LP  
Fault Status  
LP  
LT1  
LT1  
For MWV option, place jumper on 0-10V pins.  
Ensure actuator direction switch is set as shown.  
LT2  
LT2  
RV  
RV  
CO  
CO  
Off On  
JW3  
Off On  
S3  
Off On  
12  
1
RV  
P7  
Relay  
JW3-LT1  
jumper should  
be clipped  
for low  
temperature  
(antifreeze)  
operation  
CCH  
24Vdc  
Relay  
S2  
c1  
ay  
EH1  
EH2  
A0-1 A0-2  
4
S1  
Comp  
Relay  
P6  
CCG  
c2  
ay  
CC  
P10  
P9  
P11  
T1 T2 T2 T3 T3 T4 T4  
Gnd  
T5 T5 T6 T6  
AO2  
DXM2 PCB  
24  
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Electrical -ThermostatWiring  
Thermostat Installation  
Figure 24: Communicating Thermostat Connection to  
DXM2 Control  
The thermostat should be located on an interior wall in a  
larger room, away from supply duct drafts. DO NOT locate  
the thermostat in areas subject to sunlight, drafts or on  
external walls. The wire access hole behind the thermostat  
may in certain cases need to be sealed to prevent erroneous  
temperature measurement. Position the thermostat back  
plate against the wall so that it appears level and so the  
thermostat wires protrude through the middle of the back  
plate. Mark the position of the back plate mounting holes and  
drill holes with a 3/16” (5mm) bit. Install supplied anchors and  
secure plate to the wall. Thermostat wire must be 18 AWG  
wire. Wire the appropriate thermostat as shown in Figure 24  
or 25 to the low voltage terminal strip on the DXM2 control  
board. Practically any heat pump thermostat will work with  
these units, provided it has the correct number of heating  
and cooling stages. However, using the communicating  
thermostat (7602-443) is highly recommended for on-site,  
easier conguration, monitoring and diagnosis. An optional  
outdoor temperature sensor is available.  
Unit with  
WDG  
AXM  
DXM2  
Control  
Control  
7602-443  
Thermostat  
Gnd  
A+  
Gnd  
A+  
24Vac Common  
24Vac Hot  
Comm +  
Comm -  
C
R
A+  
B-  
B-  
B-  
24V  
24V  
Outdoor  
Sensor  
(Optional)  
OD  
GND  
ID  
Remote Indoor  
Sensor  
(Optional)  
Thermostat Connections  
C
R
A+  
B –  
24V Common for Control Circuit  
24V Supply for Control Circuit  
Communications (Positive)  
Communications (Negative)  
GND Ground  
OD  
ID  
Outdoor Temperature Sensor  
Indoor Temperature Sensor  
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.  
Figure 25: Conventional 3 Heat / 2 Cool Thermostat  
Connection to DXM2 and Non-AXM Air Handler  
Thermostat  
DXM2  
Board  
Non-AXM  
Air Handler  
CAUTION! ꢀ  
CAUTION! Refrigerant pressure activated water regulating  
valves should never be used with ClimateMaster  
equipment.  
Y1  
Y2  
W
Compressor  
Y1  
Y2  
W
H
Y1  
Y2  
W
H
Compressor Stage 2  
Auxiliary Heat  
Dehumidification DH  
Reversing Valve  
Fan  
O
G
R
C
L
O
O
G
G
CAUTION! ꢀ  
CAUTION! Either a communicating thermostat (7602-  
443) or conguration tool (7602-444) MUST be used to  
congure and diagnose this unit.  
24Vac Hot  
24Vac Common  
Fault LED  
R
R
C
C
AL1  
AL1  
Notes:  
1) ECM automatic dehumidification mode operates with dehumidification airflows  
in the cooling mode when the dehumidification output from thermostat is active.  
Normal heating and cooling airflows are not affected.  
2) DXM2 board DIP switch S2-7 must be in the auto dehumidification mode for  
automatic dehumidification  
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HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS  
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DXM2 Controls  
DXM2 Control  
DXM2 Control Start-up Operation  
The control will not operate until all inputs and safety controls  
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 conguration/  
diagnostic tool.  
are checked for normal conditions. The compressor will  
have a 5 minute anti-short cycle delay at power-up. The rst  
time after power-up that there is a call for compressor, the  
compressor will follow a 5 to 80 second random start delay.  
After the random start delay and anti-short cycle delay,  
the compressor relay will be energized. On all subsequent  
compressor calls, the random start delay is omitted.  
For most residential applications, conguration, monitoring  
and diagnostics can be done from the thermostat / service  
tool and there’s no need to read LEDs and change DIP  
switches.  
Test Mode button:  
For details on user settings, refer to User Manual (part #:  
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.  
For details on Installer settings (not to be used by  
consumers), refer to Installer manual (part #:  
For details on installer/service settings on the conguration/  
diagnostic tool, refer to operation manual (part #:  
Figure 26: Test Mode Button  
For further details on the DXM2 control, refer to the DXM2  
Application, Operation and Maintenace Manual and it is  
shipped with the unit)  
P4  
Gnd  
B- A+ 24V  
(240Vac)  
N.C.  
(240Vac)  
N.O.  
P5  
N.O.  
Thermostat compatibility  
Com  
Fan Enable  
Fan Speed  
It is strongly recommended that GeoMax2 communicating  
thermostat be used with DXM2 control, to ensure easy  
conguration, monitoring and diagnostics, in PLAIN  
English, on the thermostat. For example, Airow can NOT  
be congured without a communicating thermostat or  
Conguration/ Diagnostic tool for use with GeoMax2.  
Pust test button to  
enter Test Mode and  
speed-up timing and  
delays for 20 minutes.  
P8  
12V  
IN  
Test  
P12  
OUT  
Gnd  
NC  
Field Conguration Options - Note: In the following eld  
conguration options, jumper wires should be clipped ONLY  
when power is removed from the DXM2 control.  
Table 8: Unit Operation  
Water coil low temperature limit setting: Jumper 3 (JW3-  
LT1 Low Temp) provides eld selection of temperature limit  
setting for LT1 of 30°F or 10°F [-1°F or -12°C] (refrigerant  
temperature).  
Conventional  
T-stat signal  
(Non-Communicating)  
Unit  
ECM fan  
Fan only  
G
G, Y1  
Stage 1 heating1  
Stage 2 heating1  
Stage 3 heating1  
Emergency heat  
Stage 1 cooling2  
Stage 2 cooling2  
Not Clipped = 30°F [-1°C]. Clipped = 10°F [-12°C].  
G, Y1, Y2  
G, Y1, Y2, W  
G, W  
A0-2: Congure Modulating Valve (eld installed acces-  
sory)  
Set A0-2 jumper to “IOV” if using Modulating Motorized Valve  
as eld installed accessory  
G, Y1, O  
G, Y1, Y2, O  
DIP Switches - For residential applications, all conguration  
can be performed in PLAIN ENGLISH on the thermostat.  
No DIP switch changes are required and no LEDs to be  
observed.  
1
2
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  
Stage 1 = 1st stage compressor, 1st stage fan operation,  
reversing valve  
CAUTION! ꢀ  
CAUTION! Do not restart units without inspection and  
remedy of faulting condition. Equipment damage may  
occur.  
Stage 2 = 2nd stage compressor, 2nd stage fan operation,  
reversing valve  
26  
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Figure 26a: DXM2 Layout and Connections  
Test Button to  
Speed up Time Delays  
Communicating  
stat connection  
Service tool  
connection  
P4  
C
R
Gnd  
B- A+ 24V  
(240Vac)  
N.C.  
(240Vac)  
N.O.  
P1  
Y1  
Y2  
W
P5  
N.O.  
Com  
Fan Enable  
Fan Speed  
Conventional  
stat connection  
O
G
P8  
12V  
IN  
R
C
Test  
P12  
ECM Motor  
Connection  
AL1  
OUT  
Gnd  
NC  
P2  
AL2  
R
Water Coil  
Low Temp  
Limit Setting  
Cabinet  
temperature  
sensor  
(with variable  
speed pump)  
Micro  
U1  
1
NSB  
C
JW1  
HP  
HP  
LP  
LP  
LT1  
LT1  
LT2  
LT2  
RV  
RV  
CO  
CO  
Alarm  
Relay  
Fault  
Status  
ESD  
OVR  
H
Factory low  
voltage molex  
connection for  
unit harness  
Off On  
A
JW3  
Off On  
Communications  
and HWG  
S3  
Off On  
12  
P3  
Settings  
RV  
Factory low  
voltage molex  
connection for  
electric heat  
harness  
P7  
R
Relay  
CCH  
NO1  
NC1  
COM1  
NO2  
NC2  
COM2  
R
1
4
24Vdc  
Relay  
S2  
A0-1 A0-2  
Acc1  
EH1  
EH2  
Relay  
S1  
Comp  
Relay  
P6  
CCG  
Configure  
Acc2  
Relay  
modulating valve  
or variable  
CC  
P10  
P9  
T5 T5 T6 T6  
P11  
COH  
COM  
speed pump  
T1 T2 T2 T3 T3 T4 T4  
Gnd  
AO2  
24V to compressor  
Use 4 mounting screws  
#6 sheet metal screw  
1” long  
second-stage solenoid  
for Y2/full  
load capacity  
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27  
HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS  
Residential Split - 60Hz R410A  
R e v. : 0 3 A u g u s t , 2 0 1 2  
Indoor Split HTS024-060Wiring Diagram 208-230-/60/1 DXM2  
28  
Heat Controller, Inc. Water-Source Heating and Cooling Systems  
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The Quality Leader in Conditioning Air  
Residential Split - 60Hz R410A  
R e v. : 0 3 A u g u s t , 2 0 1 2  
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  
Unit  
Operating Limits  
Cooling  
Heating  
Air Limits  
Min. ambient air, DB  
Rated ambient air, DB  
Max. ambient air, DB  
Min. entering air, DB/WB  
45ºF [7ºC]  
80.6ºF [27ºC]  
130ºF [54ºC]  
65/45ºF [18/7ºC]  
70/50ºF Reheat  
39ºF [4ºC]  
68ºF [20ºC]  
85ºF [29ºC]  
50ºF [10ºC]  
Rated entering air, DB/WB 80.6/66.2ºF [27/19ºC]  
68ºF [20ºC]  
80ºF [27ºC]  
Max. entering air, DB/WB  
Water Limits  
100/75ºF [38/24ºC]  
Min. entering water  
Normal entering water  
Max. entering water  
20ºF [-6.7ºC]  
50-110ºF [10-43ºC]  
120ºF [49ºC]  
20ºF [-6.7ºC]  
30-70ºF [-1 to 21ºC]  
120ºF [49ºC]  
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  
Unit  
Commissioning Limits  
Cooling  
Heating  
Air Limits  
Min. ambient air, DB  
Rated ambient air, DB  
Max. ambient air, DB  
Min. entering air, DB/WB  
Rated entering air, DB/WB 80.6/66.2ºF [27/19ºC]  
Max. entering air, DB/WB  
Water Limits  
45ºF [7ºC]  
80.6ºF [27ºC]  
130ºF [54ºC]  
60ºF [16ºC]  
39ºF [4ºC]  
68ºF [20ºC]  
85ºF [29ºC]  
40ºF [4.5ºC]  
68ºF [20ºC]  
80ºF [27ºC]  
110/83ºF [43/28ºC]  
Min. entering water  
Normal entering water  
Max. entering water  
20ºF [-6.7ºC]  
50-110ºF [10-43ºC]  
120ºF [49ºC]  
20ºF [-6.7ºC]  
30-70ºF [-1 to 21ºC]  
120ºF [49ºC]  
1.5 to 3.0 gpm / ton  
[1.6 to 3.2 l/m per kW]  
Normal Water Flow  
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29  
HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS  
Residential Split - 60Hz R410A  
R e v. : 0 3 A u g u s t , 2 0 1 2  
Unit Start-Up and Operating Conditions  
Unit and System Checkout  
BEFORE POWERING SYSTEM, please check the following:  
CAUTION! ꢀ  
UNIT CHECKOUT  
CAUTION! Verify that ALL water valves are open and  
allow water ow prior to engaging the compressor.  
Freezing of the coax or water lines can permanently  
damage the heat pump.  
Shutoff valves: Insure that all isolation valves are open.  
Line voltage and wiring: Verify that voltage is within an  
acceptable range for the unit and wiring and fuses/breakers  
are properly sized. Verify that low voltage wiring is complete.  
Unit control transformer: Insure that transformer has the  
properly selected voltage tap. Residential 208-230V units are  
factory wired for 230V operation unless specied otherwise.  
Loop/water piping is complete and purged of air. Water/piping  
is clean.  
CAUTION! ꢀ  
CAUTION! To avoid equipment damage, DO NOT  
leave system lled in a building without heat during the  
winter unless antifreeze is added to the water loop. Heat  
exchangers never fully drain by themselves and will freeze  
unless winterized with antifreeze.  
Antifreeze has been added if necessary.  
Entering water and air: Insure that entering water and air  
temperatures are within operating limits of Tables 9a and 9b.  
Low water temperature cutout: Verify that low water  
temperature cut-out on the DXM2 control is properly set.  
Unit fan: Manually rotate fan to verify free rotation and insure  
that blower wheel is secured to the motor shaft. Be sure to  
remove any shipping supports if needed. DO NOT oil motors  
upon start-up. Fan motors are pre-oiled at the factory. Check  
unit fan speed selection and compare to design requirements.  
Condensate line: Verify that condensate trap is installed and  
pitched.  
HWG pump is disconnected unless piping is completed and  
air has been purged from the system.  
Water ow balancing: Record inlet and outlet water  
temperatures for each heat pump upon startup. This check  
can eliminate nuisance trip outs and high velocity water ow  
that could erode heat exchangers.  
Unit Start-up Procedure  
1. Turn the thermostat fan position to “ON.” Blower  
should start.  
2. Balance air ow at registers.  
3. Adjust all valves to their full open position. Turn on the line  
power to all heat pump units.  
4. Room temperature should be within the minimum-maximum  
ranges of Table 9b. During start-up checks, loop water  
temperature entering the heat pump should be between  
30°F [-1°C] and 95°F [35°C].  
5. It is recommended that water-to-air units be rst started  
in the cooling mode, when possible. This will allow liquid  
refrigerant to ow through the lter-drier before entering the  
TXV, allowing the lter-drier to catch any debris that might  
be in the system before it reaches the TXV.  
6. Two factors determine the operating limits of geothermal  
heat pumps, (a) return air temperature, and (b) water  
temperature. When any one of these factors is at a minimum  
or maximum level, the other factor must be at normal level to  
insure proper unit operation.  
6. Two factors determine the operating limits of geothermal  
heat pumps, (a) return air temperature, and (b) entering  
water temperature. When either of the factors is at a  
minimum or maximum level, the other factor must be at  
normal levels to insure proper unit operation.  
Unit air coil and lters: Insure that lter is clean and  
accessible. Clean air coil of all manufacturing oils.  
Unit controls: Verify that DXM2 eld selection options are  
properly set. Low voltage wiring is complete.  
Blower CFM and Water T is set on communicating  
thermostats or diagnostic tool.  
Service/access panels are in place.  
SYSTEM CHECKOUT  
System water temperature: Check water temperature for  
proper range and also verify heating and cooling set points for  
proper operation.  
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 %).  
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 ttings (see Table 4).  
System ushing: Verify that all air is purged from the system.  
Air in the system can cause poor operation or system  
corrosion. Water used in the system must be potable quality  
initially and clean of dirt, piping slag, and strong chemical  
cleaning agents. Some antifreeze solutions may require  
distilled water.  
Internal Flow Controller: Verify that it is purged of air and in  
operating condition.  
System controls: Verify that system controls function and  
operate in the proper sequence.  
INSTALLER SETTINGS  
THERMOSTAT CONFIG  
SYSTEM CONFIG  
ACCESSORY CONFIG  
INPUT DEALER INFO  
HUMIDITY CONFIG  
TEMPERATURE ALGORITHM  
DEMAND REDUCTION CNFG  
SERVICE MODE  
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.  
RESTORY DEFAULTS  
ATC32U01  
SELECT OPTION  
PREVIOUS  
30  
Heat Controller, Inc. Water-Source Heating and Cooling Systems  
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Residential Split - 60Hz R410A  
R e v. : 0 3 A u g u s t , 2 0 1 2  
Unit Start-Up Procedure  
SERVICE MODE  
MANUAL OPERATION  
the unit in the “Test” mode as shown in the unit IOM. Check for  
normal air temperature rise of 20°F to 30°F (heating mode).  
CONTROL DIAGNOSTICS  
DIPSWITCH CONFIG  
FAULT HISTORY  
4 - 8  
10 - 17  
CLEAR FAULT HISTORY  
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.  
SELECT OPTION  
PREVIOUS  
SELECT  
MANUAL OPERATING MODE  
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.  
Y1  
Y2  
W
O
COMM OUTPUT  
OFF  
OFF  
OFF  
OFF  
OFF  
OFF  
OFF  
0
COMM OUTPUT  
COMM OUTPUT  
COMM OUTPUT  
COMM OUTPUT  
COMM OUTPUT  
COMM OUTPUT  
G
H
DH  
ECM AIRFLOW  
PUMP SPEED  
TEST MODE  
0%  
OFF  
10. BE CERTAIN TO FILL OUT AND RETURN ALL WARRANTY  
REGISTRATION PAPERWORK.  
SELECT OPTION  
PREVIOUS  
SELECT  
Unit performance may be veried 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  
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 ve minute time delay in the control circuit  
that can be bypassed on the DXM2 control board by placing  
the unit in the “Test” mode as shown in the unit IOM. Check for  
normal air temperature drop of 15°F to 25°F (cooling mode).  
(or 485 for anti-freeze solutions), where TD is the temperature  
difference between the entering and leaving water, and GPM  
is the ow rate in U.S. GPM determined by comparing the unit  
heat exchanger pressure drop to Table 12.  
c. Verify that the compressor is on and that the water  
temperature rise (cooling mode) is within normal range.  
Heat of Extraction (HE) can also be calculated and compared  
to the performance data pages in this IOM. The formula for  
HE is as follows: HE = TD x GPM x 500 (or 485 for anti-freeze  
solutions), where TD is the temperature difference between  
the entering and leaving water, and GPM is the ow rate in  
U.S. GPM determined by comparing the unit heat exchanger  
pressure drop to Table 12.  
9 - 12  
20 - 26  
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 lled to provide a water seal.  
e. Turn thermostat to “OFF” position. A hissing noise  
indicates proper functioning of the reversing valve.  
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.  
7. Allow ve (5) minutes between tests for pressure to equalize  
before beginning heating test.  
WARNING! ꢀ  
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 %).  
WARNING! When the disconnect switch is closed, high  
voltage is present in some areas of the electrical panel.  
Exercise caution when working with energized equipment.  
CAUTION! ꢀ  
b. Check for warm air delivery at the unit grille within a few  
minutes after the unit has begun to operate.  
CAUTION! Verify that ALL water valves are open and  
allow water ow prior to engaging the compressor.  
Freezing of the coax or water lines can permanently  
damage the heat pump.  
NOTE: Units have a ve minute time delay in the control circuit  
that can be bypassed on the DXM2 control board by placing  
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31  
HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS  
Residential Split - 60Hz R410A  
R e v. : 0 3 A u g u s t , 2 0 1 2  
Unit Operating Conditions  
Table 12: Two-Stage HFC-410A Compressor Section  
Coax Water Pressure Drop  
Table 13: Water Temperature Change Through Heat  
Exchanger  
Pressure Drop (psi)  
Model  
026  
GPM  
30°F  
50°F  
70°F  
90°F  
4.0  
6.0  
7.0  
8.0  
1.5  
3.1  
4.1  
5.1  
1.3  
2.6  
3.4  
4.3  
1.1  
2.3  
3.0  
3.8  
1.0  
2.1  
2.7  
3.4  
4.0  
6.0  
8.0  
9.0  
1.2  
2.6  
4.5  
5.7  
1.0  
2.5  
4.2  
5.2  
0.8  
2.3  
4.0  
4.8  
0.6  
2.1  
3.7  
4.4  
038  
049  
064  
5.5  
8.3  
11.0  
12.0  
1.1  
2.2  
3.9  
4.5  
0.9  
2.1  
3.6  
4.2  
0.8  
2.0  
3.2  
3.8  
0.7  
1.8  
3.1  
3.5  
7.0  
0.5  
1.9  
3.9  
4.8  
0.3  
1.8  
3.5  
4.3  
0.2  
1.7  
3.2  
3.9  
0.1  
1.6  
2.9  
3.5  
10.5  
14.0  
15.0  
Table 14a: Size 024 HTS Two-Stage R-410A Typical Unit Operating Pressures and Temperatures  
Full Load Cooling - without HWG active  
Discharge  
Full Load Heating - without HWG active  
Discharge  
Water  
Flow  
GPM/  
ton  
Entering  
Water  
Temp °F  
Suction  
Pressure  
PSIG  
Air Temp  
Drop °F  
DB  
Suction  
Pressure  
PSIG  
Air Temp  
Rise °F  
DB  
Super-  
heat  
Sub-  
Water Temp  
Rise °F  
Super-  
heat  
Sub-  
Water Temp  
Drop °F  
Pressure  
PSIG  
Pressure  
PSIG  
cooling  
cooling  
1.5  
2.25  
3
122-132  
122-132  
122-132  
159-179  
146-166  
132-152  
13-18  
13-18  
14-19  
9-14  
7-12  
7-12  
16.7-18.7  
12.3-14.3  
7.9-9.9  
18-24  
19-25  
19-25  
77-87  
79-89  
82-92  
278-298  
280-300  
282-302  
4-9  
4-9  
4-9  
10-15  
10-15  
10-15  
5.9-7.9  
4.2-6.2  
2.7-4.7  
18-24  
19-25  
20-26  
30*  
50  
1.5  
2.25  
3
132-142  
132-142  
132-142  
186-206  
172-192  
158-178  
8-13  
8-13  
8-13  
8-13  
6-11  
6-11  
16.3-18.3  
12.1-14.1  
7.8-9.8  
18-24  
19-25  
19-25  
107-117  
111-121  
115-125  
314-334  
315-335  
317-337  
6-11  
6-11  
6-11  
13-18  
13-18  
13-18  
8.9-10.9  
6.7-8.7  
4.5-6.5  
25-31  
26-32  
26-32  
1.5  
2.25  
3
139-149  
139-149  
139-149  
281-301  
267-287  
253-273  
7-12  
7-12  
7-12  
8-13  
8-13  
7-12  
15.7-17.7  
11.6-13.6  
7.6-9.6  
18-24  
18-24  
18-24  
139-149  
145-155  
152-162  
350-370  
352-372  
354-374  
7-12  
7-12  
7-12  
15-20  
15-20  
15-20  
11.3-13.3  
8.5-10.5  
5.8-7.8  
31-38  
32-39  
32-39  
70  
90  
1.5  
2.25  
3
141-151  
141-151  
141-151  
374-394  
360-380  
346-366  
7-12  
7-12  
7-12  
9-14  
9-14  
8-13  
14.6-16.6  
10.7-12.7  
6.9-8.9  
17-23  
17-23  
17-23  
177-187  
181-191  
186-196  
392-412  
397-417  
402-422  
9-14  
10-15  
11-16  
17-22  
17-22  
17-22  
14.4-16.4  
10.8-12.8  
7.1-9.1  
37-45  
38-46  
38-46  
1.5  
2.25  
3
145-155  
145-155  
145-155  
473-493  
458-478  
441-461  
7-12  
7-12  
7-12  
10-15  
10-15  
9-14  
13.6-15.6  
9.9-11.9  
6.2-8.2  
16-22  
16-22  
16-22  
110  
Operation Not Recommended  
*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  
Discharge  
Full Load Heating - without HWG active  
Discharge  
Water  
Flow  
GPM/  
ton  
Entering  
Water  
Temp °F  
Suction  
Pressure  
PSIG  
Air Temp  
Drop °F  
DB  
Suction  
Pressure  
PSIG  
Air Temp  
Rise °F  
DB  
Super-  
heat  
Sub-  
Water Temp  
Rise °F  
Super-  
heat  
Sub-  
Water Temp  
Drop °F  
Pressure  
PSIG  
Pressure  
PSIG  
cooling  
cooling  
1.5  
2.25  
3
122-132  
121-131  
121-131  
153-173  
145-165  
135-155  
18-23  
18-23  
18-23  
9-14  
8-13  
8-13  
22.1-24.1  
16.8-18.8  
10.5-12.5  
19-25  
20-26  
20-26  
71-81  
75-85  
78-88  
263-283  
267-287  
270-290  
5-10  
5-10  
5-10  
2-5  
2-5  
2-5  
8.1-10.1  
5.9-7.9  
3.7-5.7  
17-23  
18-24  
19-25  
30*  
50  
1.5  
2.25  
3
131-141  
130-140  
130-140  
222-242  
208-228  
194-214  
13-18  
13-18  
14-19  
10-15  
9-14  
9-14  
21.9-23.9  
16.1-18.1  
10.3-12.3  
19-25  
20-26  
20-26  
103-113  
107-117  
112-122  
292-312  
296-316  
301-321  
6-11  
6-11  
6-11  
2.5-7  
2.5-7  
2.5-7  
11.5-13.5  
8.6-10.6  
5.7-7.7  
23-29  
24-30  
24-30  
1.5  
2.25  
3
138-148  
137-147  
137-147  
299-319  
280-300  
263-283  
8-13  
8-13  
8-13  
13-18  
12-17  
12-17  
21.5-23.5  
15.8-17.8  
10-12  
19-25  
20-26  
20-26  
134-144  
140-150  
146-156  
322-342  
328-358  
334-354  
7-12  
7-12  
7-12  
2.5-7  
2.5-7  
2.5-7  
14.5-16.5  
11.1-13.1  
7.7-9.7  
28-35  
29-36  
30-37  
70  
90  
1.5  
2.25  
3
142-152  
142-152  
142-152  
388-408  
367-387  
347-367  
6-11  
7-12  
7-12  
13-18  
8-13  
8-13  
20.5-22.5  
14.9-16.9  
9.3-11.3  
18-24  
18-24  
18-24  
172-182  
184-194  
196-206  
360-380  
369-389  
378-398  
8-13  
8-13  
8-13  
2.5-7  
2.5-7  
2.5-7  
20.5-22.5  
15-17  
10-12  
36-44  
37-45  
39-47  
1.5  
2.25  
3
147-157  
147-157  
147-157  
486-506  
465-475  
444-464  
6-11  
7-12  
7-12  
13-18  
8-13  
8-13  
19-21  
14-16  
9-11  
18-24  
18-24  
18-24  
110  
Operation Not Recommended  
*Based on 15% methanol antifreeze solution  
32  
Heat Controller, Inc. Water-Source Heating and Cooling Systems  
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The Quality Leader in Conditioning Air  
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Unit Operating Conditions  
Table 14c: Size 048 HTS Two-Stage R-410A Typical Unit Operating Pressures and Temperatures  
Full Load Cooling - without HWG active  
Discharge  
Full Load Heating - without HWG active  
Discharge  
Water  
Flow  
GPM/  
ton  
Entering  
Water  
Temp °F  
Suction  
Pressure  
PSIG  
Air Temp  
Drop °F  
DB  
Suction  
Pressure  
PSIG  
Air Temp  
Rise °F  
DB  
Super-  
heat  
Sub-  
Water Temp  
Rise °F  
Super-  
heat  
Sub-  
Water Temp  
Drop °F  
Pressure  
PSIG  
Pressure  
PSIG  
cooling  
cooling  
1.5  
2.25  
3
112-122  
111-121  
111-121  
187-207  
167-187  
147-167  
18-23  
18-23  
18-23  
23-28  
21-26  
20-25  
20.7-22.7  
15.5-17.5  
10.2-12.2  
19-25  
19-25  
19-25  
66-76  
69-79  
72-82  
261-281  
264-284  
267-287  
8-13  
8-13  
8-13  
5-10  
5-10  
5-10  
8-10  
6-8  
4-6  
18-24  
19-25  
19-25  
30*  
1.5  
2.25  
3
125-135  
123-133  
122-132  
245-265  
227-247  
208-228  
13-18  
13-18  
14-19  
19-24  
18-23  
16-21  
20.9-22.9  
15.6-17.6  
10.2-12.2  
20-26  
20-26  
20-26  
93-103  
98-108  
103-113  
289-309  
295-315  
301-321  
7-12  
7-12  
7-12  
5-10  
5-10  
5-10  
11.5-13.5  
8.7-10.7  
5.9-7.9  
23-29  
24-30  
25-31  
50  
70  
1.5  
2.25  
3
133-143  
132-142  
131-141  
314-334  
294-314  
274-294  
9-14  
9-14  
10-15  
17-22  
16-21  
14-19  
20.5-22.5  
15.2-17.2  
9.9-11.9  
20-26  
20-26  
20-26  
123-133  
130-140  
137-147  
319-339  
329-349  
336-356  
7-12  
7-12  
7-12  
5-10  
5-10  
5-10  
15-17  
11.5-13.5  
7.9-9.9  
28-35  
29-36  
30-37  
1.5  
2.25  
3
138-148  
137-147  
136-146  
401-421  
379-399  
357-377  
8-13  
8-13  
9-14  
16-21  
15-20  
13-18  
19.2-21.2  
14.3-16.3  
9.3-11.3  
19-25  
19-25  
19-25  
167-177  
177-187  
187-197  
365-385  
374-394  
388-408  
7-12  
7-12  
7-12  
5-10  
5-10  
5-10  
19.6-21.6  
15-17  
10.3-12.3  
37-45  
38-46  
39-47  
90  
1.5  
2.25  
3
144-154  
143-153  
142-152  
502-522  
477-497  
452-472  
8-13  
8-13  
9-14  
14-19  
13-18  
12-17  
18-20  
13.3-15.3  
8.5-10.5  
18-24  
18-24  
18-24  
110  
Operation Not Recommended  
*Based on 15% methanol antifreeze solution  
Table 14d: Size 060 HTS Two-Stage R-410A Typical Unit Operating Pressures and Temperatures  
Full Load Cooling - without HWG active  
Discharge  
Full Load Heating - without HWG active  
Discharge  
Water  
Flow  
GPM/  
ton  
Entering  
Water  
Temp °F  
Suction  
Pressure  
PSIG  
Air Temp  
Drop °F  
DB  
Suction  
Pressure  
PSIG  
Air Temp  
Rise °F  
DB  
Super-  
heat  
Sub-  
Water Temp  
Rise °F  
Super-  
heat  
Sub-  
Water Temp  
Drop °F  
Pressure  
PSIG  
Pressure  
PSIG  
cooling  
cooling  
1.5  
2.25  
3
117-127  
116-126  
115-125  
160-180  
133-153  
125-145  
16-21  
17-22  
18-23  
8-13  
6-11  
5-10  
17.5-19.5  
11.9-13.9  
6.3-8.3  
16-22  
16-22  
16-22  
66-76  
69-79  
72-82  
282-302  
285-305  
289-309  
9-15  
9-15  
9-15  
8-13  
8-13  
9-14  
8-10  
6-8  
4-6  
21-27  
21-27  
22-28  
30*  
50  
1.5  
2.25  
3
126-136  
124-134  
123-133  
228-248  
212-232  
195-215  
8-13  
11-16  
14-19  
8-13  
6-11  
5-10  
19.8-21.8  
14.2-16.2  
8.5-10.5  
20-26  
20-26  
20-26  
95-105  
100-110  
105-115  
318-338  
321-341  
324-344  
9-15  
9-15  
9-15  
12-17  
12-17  
12-17  
11.3-13.3  
8.5-10.5  
5.7-7.7  
27-33  
28-34  
30-36  
1.5  
2.25  
3
130-140  
129-139  
128-138  
305-325  
286-306  
266-286  
8-13  
9-14  
11-16  
10-15  
9-14  
7-12  
20.3-22.3  
14.8-16.8  
9.3-11.3  
21-27  
21-27  
21-27  
128-138  
133-143  
139-149  
360-380  
364-384  
368-388  
8-14  
8-14  
8-14  
12-17  
12-17  
12-17  
14-16  
10.6-12.6  
7.3-9.3  
33-38  
34-40  
35-41  
70  
90  
1.5  
2.25  
3
133-143  
132-142  
132-142  
398-418  
376-396  
354-374  
8-13  
8-13  
8-13  
10-15  
9-14  
7-12  
19.4-21.4  
14.1-16.1  
8.8-10.8  
20-26  
20-26  
20-26  
173-183  
177-187  
182-192  
407-427  
411-431  
415-435  
8-14  
8-14  
8-14  
13-18  
13-18  
14-19  
18.2-20.2  
13.9-15.9  
9.6-11.6  
42-50  
43-51  
44-52  
1.5  
2.25  
3
138-148  
137-147  
136-146  
505-525  
483-503  
459-479  
6-11  
6-11  
6-11  
10-15  
9-14  
8-13  
18.3-20.3  
13.3-15.3  
8.3-10.3  
19-25  
19-25  
19-25  
110  
Operation Not Recommended  
*Based on 15% methanol antifreeze solution  
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33  
HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS  
Residential Split - 60Hz R410A  
R e v. : 0 3 A u g u s t , 2 0 1 2  
Preventive Maintenance  
Water Coil Maintenance  
Condensate Drain  
(Direct ground water applications only)  
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 lters. Inspect the drain twice a year to  
avoid the possibility of plugging and eventual overow.  
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 owing through the  
unit, the less chance for scaling. Therefore, 1.5 gpm per  
ton [2.0 l/m per kW] is recommended as a minimum ow.  
Minimum ow rate for entering water temperatures below  
50°F [10°C] is 2.0 gpm per ton [2.6 l/m per kW].  
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  
Water Coil Maintenance  
Consult air handler I.O.M. for maintenance requirements.  
(All other water loop applications)  
Generally water coil maintenance is not needed for closed  
loop systems. However, if the piping is known to have  
high dirt or debris content, it is best to establish a periodic  
maintenance schedule with the owner so the water coil  
can be checked regularly. Dirty installations are typically  
the result of deterioration of iron or galvanized piping or  
components in the system. Open cooling towers requiring  
heavy chemical treatment and mineral buildup through water  
use can also contribute to higher maintenance. Should  
periodic coil cleaning be necessary, use standard coil  
cleaning procedures, which are compatible with both the  
heat exchanger material and copper water lines. Generally,  
the more water owing through the unit, the less chance for  
scaling. However, ow rates over 3 gpm per ton (3.9 l/m per  
kW) can produce water (or debris) velocities that can erode  
the heat exchanger wall and ultimately produce leaks.  
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 ns while cleaning. CAUTION: Fin edges are  
sharp.  
Cabinet - Indoor Compressor Section  
Do not allow water to stay in contact with the cabinet for long  
periods of time to prevent corrosion of the cabinet sheet  
metal. Generally, cabinets are set up from the oor a few  
inches [7 - 8 cm] to prevent water from entering the cabinet.  
The cabinet can be cleaned using a mild detergent.  
Refrigerant System  
Hot Water Generator Coils  
To maintain sealed circuit integrity, do not install service  
gauges unless unit operation appears abnormal. Reference  
the operating charts for pressures and temperatures. Verify  
that air and water ow rates are at proper levels before  
servicing the refrigerant circuit.  
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 lter.  
Washable, high efciency, electrostatic lters, when dirty,  
can exhibit a very high pressure drop for the fan motor and  
reduce air ow, resulting in poor performance. It is especially  
important to provide consistent washing of these lters (in  
the opposite direction of the normal air ow) once per month  
using a high pressure wash similar to those found at self-  
serve car washes.  
34  
Heat Controller, Inc. Water-Source Heating and Cooling Systems  
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R e v. : 0 3 A u g u s t , 2 0 1 2  
BasicTroubleshooting Information  
General Troubleshooting  
Sensor: Nominal resistance at various temperatures  
Basic DXM2 board troubleshooting in general is best  
summarized as simply verifying inputs and outputs. After this  
process has been veried, condence in board operation is  
conrmed and the trouble must be else where. Below are  
some general guidelines required for developing training  
materials and procedures when applying the DXM2 Control.  
Resistance  
(kOhm)  
85.34  
84.00  
81.38  
61.70  
58.40  
55.30  
52.38  
49.64  
47.05  
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  
5.77  
5.54  
5.33  
5.12  
4.92  
4.72  
4.54  
4.37  
4.20  
4.04  
3.89  
3.74  
3.60  
3.47  
3.34  
3.22  
3.10  
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  
1.94  
1.88  
1.81  
1.75  
1.69  
1.64  
1.58  
1.53  
1.48  
1.43  
1.39  
1.34  
1.30  
1.26  
1.22  
1.18  
1.14  
1.10  
1.07  
1.04  
1.01  
0.97  
0.94  
0.92  
0.89  
0.86  
0.84  
0.81  
0.79  
0.76  
0.74  
0.72  
0.70  
0.68  
0.66  
0.64  
0.62  
0.60  
0.59  
0.57  
0.55  
0.54  
0.52  
0.51  
0.50  
0.48  
0.47  
0.46  
0.44  
0.43  
0.42  
0.41  
0.40  
0.39  
0.38  
0.37  
0.36  
Temp (ºC) Temp (ºF)  
Temp (ºC) Temp (ºF)  
-17.8  
-17.5  
-16.9  
-12  
-11  
-10  
-9  
0.0  
0.5  
1.5  
55  
56  
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  
154.4  
156.2  
158.0  
159.8  
161.6  
163.4  
165.2  
167.0  
168.8  
170.6  
172.4  
174.2  
176.0  
177.8  
179.6  
181.4  
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  
57  
58  
59  
60  
61  
62  
63  
64  
65  
66  
67  
68  
69  
70  
71  
72  
10.4  
12.2  
14.0  
15.8  
17.6  
19.4  
21.2  
23.0  
24.8  
26.6  
28.4  
30.2  
32.0  
33.8  
35.6  
37.4  
39.2  
41.0  
42.8  
44.6  
46.4  
48.2  
50.0  
51.8  
53.6  
55.4  
57.2  
59.0  
60.8  
62.6  
64.4  
66.2  
68.0  
69.8  
71.6  
73.4  
75.2  
77.0  
78.8  
80.6  
82.4  
84.2  
86.0  
87.8  
89.6  
91.4  
93.2  
95.0  
96.8  
98.6  
100.4  
102.2  
104.0  
105.8  
107.6  
109.4  
111.2  
113.0  
114.8  
116.6  
118.4  
120.2  
122.0  
123.8  
125.6  
127.4  
129.2  
-8  
-7  
-6  
-5  
-4  
-3  
-2  
-1  
0
1
2
3
4
5
6
7
DXM2 Field Inputs  
All conventional inputs are 24VAC from the thermostat and  
can be veried 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.  
73  
74  
75  
76  
77  
78  
79  
80  
81  
82  
83  
84  
85  
86  
87  
88  
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.  
8
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
44  
45  
46  
47  
48  
49  
50  
51  
52  
53  
54  
DXM2 Outputs  
89  
90  
91  
92  
93  
94  
95  
96  
The compressor relay is 24VAC and can be veried using a  
voltmeter. The Alarm Relay can either be 24VAC as shipped  
or dry contacts (measure continuity during fault) for use with  
DDC by clipping the J4 jumper. Electric heat outputs are  
24VDC and require a voltmeter set for DC to verify operation.  
When troubleshooting, measure from 24VDC terminal to EH1  
or EH2 terminals.  
97  
98  
99  
100  
101  
102  
103  
104  
105  
106  
107  
108  
109  
110  
111  
112  
113  
114  
115  
116  
117  
118  
119  
120  
121  
122  
123  
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.  
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35  
HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS  
Residential Split - 60Hz R410A  
R e v. : 0 3 A u g u s t , 2 0 1 2  
AdvancedTroubleshooting and Conguration Information  
Unit Size, Blower Type, and Loop Type. The Heat Pump  
General  
Family, Unit Size, and Blower Type are needed to properly  
operate any particular unit conguration, especially those  
with ECM blowers.  
To properly congure 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.  
Heat Pump Family – When replacing a control in the eld, 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.  
System Conguration  
All factory installed DXM2 controls have their basic  
conguration parameters set as part of the factory  
manufacturing and test process. The System Conguration  
option under the communicating thermostat Installer menu  
provides the installer with the ability to adjust ECM target  
airows for each operating mode, set control options, setup  
the loop conguration and parameters, and congure eld  
replacement controls.  
Heat Pump Size – When replacing a control in the eld,  
the Heat Pump Size value must be set for proper blower  
operation. After a Heat Pump Family has been selected, the  
valid Heat Pump Size values will be available for the user to  
scroll through to select the proper value.  
Airow Selection – The Airow Selection menu allows the  
installer to adjust the ECM target airow for each control  
operating mode, as well as independently set the heating and  
cooling blower off delays.  
Blower Type – When replacing a control in the eld, the  
Blower Type value must be set for proper operation. The  
valid Blower Type values will be available for the user to  
scroll through to select the appropriate value from No Blower,  
ECM Blower, or PSC congurations.  
ECM Airows – Independent airow selections may be made  
for each stage of heating operation, each stage of cooling  
operation with and without dehumidication, as well as  
constant fan operation. The DXM2 control has set minimum  
and maximum airow limits for each operating mode, based  
on the unit conguration that may not be changed.  
Loop Conguration – When replacing a control in the  
eld, the Loop Conguration value must be set for proper  
operation. The valid Loop Conguration values will be  
available for the user to scroll through to select the  
appropriate value from VS PUMP, MOD VALVE, or OTHER.  
Non-ECM Conguration – If the DXM2 is not congured  
to control an ECM blower, the airow selections will not be  
available on the Airow Selection menu.  
Loop Conguration – The Loop Conguration menu allows  
the installer to set the operating parameters for either an  
internal ow center, or a proportional water valve, depending  
on the unit conguration.  
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.  
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.  
Option Selection – The Option Selection menu allows the  
installer to set selected control options.  
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.  
LT2 Setpoint – The LT2 setpoint should be set to ANTI-  
FREEZE ONLY when the unit is congured as a water-to-  
water unit with anti–freeze in the load side loop. For ALL  
other unit congurations, the LT2 setpoint should be set to  
WATER.  
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.  
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 congurations, the Motorized Valve option  
should be set to OFF.  
Unit Conguration – Selections under the Unit Conguration  
menu are normally set at the factory as a normal part of  
the manufacturing and test process. This menu allows the  
conguration to be modied for special applications, or to  
congure eld replacement controls. The Unit Conguration  
menu provides the ability to select the Heat Pump Family,  
36  
Heat Controller, Inc. Water-Source Heating and Cooling Systems  
Download from Www.Somanuals.com. All Manuals Search And Download.  
The Quality Leader in Conditioning Air  
Residential Split - 60Hz R410A  
R e v. : 0 3 A u g u s t , 2 0 1 2  
AdvancedTroubleshooting and Conguration Information  
Service Mode  
Fault I/O Conditions – This option displays the status of  
the DXM2 physical and communicated inputs and the relay  
outputs when the lockout occurred.  
The Service Mode provides the installer with several  
functions for troubleshooting, including Manual Operation,  
Control Diagnostics, Control Conguration, and Fault History.  
Fault Conguration Conditions – This option displays the  
status of the DXM2 option selections when the lockout  
occurred.  
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 ow center, and proportional valve.  
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.  
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 ow center, and proportional  
valve operating status and parameters.  
Dipswitch Conguration – The Dipswitch Conguration  
menus allow the installer to easily see the current DXM2  
control conguration.  
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 ve  
lockout conditions is stored and may be retrieved from the  
DXM2. After a specic fault in the fault history is selected,  
the operating mode and time when the fault occurred are  
displayed, with options to select specic control status values  
when the lockout occurred.  
Fault Temp Conditions – This option displays the DXM2  
temperature and voltage values when the lockout occurred.  
Fault Flow Conditions – This option displays the DXM2 ECM  
blower, pump, and valve operating parameters when the  
lockout occurred.  
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37  
HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS  
Residential Split - 60Hz R410A  
R e v. : 0 3 A u g u s t , 2 0 1 2  
DXM2 Process Flow Chart  
WARNING! ꢀ  
WARNING! HAZARDOUS VOLTAGE! DISCONNECT  
ALL ELECTRIC POWER INCLUDING REMOTE  
DISCONNECTS BEFORE SERVICING.  
Failure to disconnect power before servicing can cause  
severe personal injury or death.  
DXM2 Functional  
Troubleshooting Flow Chart  
Start  
Did Unit  
Attempt to  
Start?  
Check Main  
power (see power  
problems)  
No  
Yes  
Did Unit  
Lockout at  
Start-up?  
Yes  
Check fault code on communicating  
thermostat (ATC32) or Configuration  
and Diagnostics Tool (ACD01)  
No fault  
shown  
No  
See Unit  
short  
cycles”  
Yes  
Yes  
Yes  
Unit Short  
Cycles?  
Replace  
DXM2  
No  
See fault codes in table  
on following page  
See Only  
Fan Runs”  
Only Fan  
Runs?  
No  
Only  
Compressor  
Runs?  
See Only  
Comp  
Runs”  
No  
Did unit lockout  
after a period of  
operation?  
Yes  
No  
Does unit  
operate in  
cooling?  
See Does  
not Operate  
in Clg”  
No  
Yes  
Unit is OK!  
‘See Performance  
Troubleshooting’ for  
further help  
38  
Heat Controller, Inc. Water-Source Heating and Cooling Systems  
Download from Www.Somanuals.com. All Manuals Search And Download.  
The Quality Leader in Conditioning Air  
Residential Split - 60Hz R410A  
R e v. : 0 3 A u g u s t , 2 0 1 2  
FunctionalTroubleshooting  
Fault  
Htg Clg Possible Cause  
Solution  
Check Line Voltage circuit breaker and disconnect  
Check for line voltage between L1 and L2 on the contactor  
Check for 24VAC between R and C on DXM  
Main Power Problems  
X
X
Green status LED off  
Check primary/secondary voltage on transformer  
Check pump operation or valve operation/setting  
Check water flow adjust to proper flow rate  
X
X
Reduced or no water flow  
in cooling  
Water temperature out of range in  
cooling  
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.  
Reduced or no air flow  
in heating  
HP Fault Code 2  
High Pressure  
X
X
Too high of external static. Check static vs blower table  
Air temperature out of range in  
heating  
Bring return air temp within design parameters  
Check superheat/subcooling vs typical operating condition  
table  
X
X
X
X
Overcharged with refrigerant  
Bad HP switch  
Check switch continuity and operation - Replace  
X
X
X
Frozen water heat exchanger  
Bad HPWS Switch  
Thaw heat exchanger  
Replace HPWS Switch  
Check for refrigerant leaks  
X
X
Insufficient charge  
LP/LOC Fault-Code 3  
Low Pressure/Loss of Charge  
Compressor pump down at start-  
up  
X
Check charge and start-up water flow  
Check pump operation or water valve operation/setting  
Plugged strainer or filter - clean or replace  
Check water flow adjust to proper flow rate  
Check antifreeze density with hydrometer  
Reduced or no water flow  
in heating  
X
LT1 Fault - Code 4  
X
X
Inadequate anti-freeze level  
Water Low Temperature  
Improper low temperature setting  
(30°F vs 10°F)  
Clip LT1 jumper for antifreeze (10°F) use  
X
X
Water temperature out of range  
Bad thermistor  
Bring water temp within design parameters  
X
X
Check temp and impedance correlation per chart  
Check for dirty air filter and clean or replace  
Check fan motor operation and airflow restrictions  
Too high of external static - check static vs blower table  
Reduced or no air flow  
in cooling  
Too much cold vent air - bring entering air temp within  
design parameters  
X
Air temperature out of range  
LT2 Fault - Code 5  
Low Air Temperature  
Improper low temperature setting  
(30°F vs 10°F)  
X
X
Normal airside applications will require 30°F only  
Check temp and impedance correlation per chart  
X
Bad thermistor  
X
X
X
X
Blocked drain  
Improper trap  
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  
X
Poor drainage  
Condensate Fault-Code 6  
High Condensate Level  
Poor venting - check vent location  
Check for moisture shorting to air coil  
Replace air filter  
X
X
Moisture on sensor  
Plugged air filter  
X
X
Find and eliminate rectriction - increase 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?  
X
X
Under voltage  
Over/Under Voltage-Code 7  
(Auto Resetting)  
Check 24VAC and unit transformer tap for correct power  
supply voltage  
Check power supply voltage and 24VAC before and during  
operation.  
X
X
X
Over voltage  
Check 24VAC and unit transformer tap for correct power  
supply voltage  
Heating Mode LT2>125°F  
Check for poor air flow or overcharged unit  
Check for poor water flow, or air flow  
Unit Performance  
Sentinel-Code 8  
Cooling Mode LT1>125°F OR  
LT2< 40°F  
X
X
X
Swapped Thermistor  
Code 9  
X
X
LT1 and LT2 swapped  
Reverse position of thermistors  
Check blower line voltage  
Blower does not operate  
Check blower low voltage wiring  
Blower operating with incorrect  
airflow  
Wrong unit size selection  
Wrong unit family selection  
Wrong motor size  
ECM Fault - Code 10  
Incorrect blower selection  
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39  
HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS  
Residential Split - 60Hz R410A  
R e v. : 0 3 A u g u s t , 2 0 1 2  
FunctionalTroubleshooting  
Fault  
Htg C  
Possible Cause  
Improper output setting  
No pump output signal  
Solution  
lg  
IFC Fault Code 13  
Internal Flow  
Controller Fault  
X
X
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  
Low pump voltage  
Check line voltage to the pump  
No pump feedback signal  
Check DC voltage between T1 and GND. Voltage should  
be between 3 and 4 VDC with pump OFF, and between  
0 and 2 VDC with the pump ON  
Bad pump RPM sensor  
Replace pump if the line voltage and control signals are  
present at the pump, and the pump does not operate  
ESD - ERV Fault (DXM Only)  
Green Status LED Code 3  
ERV unit has fault  
(Rooftop units only)  
X
X
Troubleshoot ERV unit fault  
X
X
X
X
X
X
No compressor operation  
Compressor overload  
Control board  
See 'Only Fan Operates'  
No Fault Code Shown  
Unit Short Cycles  
Check and replace if necessary  
Reset power and check operation  
X
X
X
X
Dirty air filter  
Unit in 'Test Mode'  
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  
X
X
Unit selection  
X
X
X
X
X
X
Compressor overload  
Thermostat position  
Unit locked out  
Check and replace if necessary  
Insure thermostat set for heating or cooling operation  
Check for lockout codes - reset power  
Only Fan Runs  
Check compressor overload - replace if necessary  
X
X
Compressor overload  
Check thermostat wiring at DXM2 - put in Test Mode and  
jumper Y1 and R to give call for compressor  
X
X
Thermostat wiring  
40  
Heat Controller, Inc. Water-Source Heating and Cooling Systems  
Download from Www.Somanuals.com. All Manuals Search And Download.  
The Quality Leader in Conditioning Air  
Residential Split - 60Hz R410A  
R e v. : 0 3 A u g u s t , 2 0 1 2  
PerformanceTroubleshooting  
Symptom  
Htg Clg Possible Cause  
Solution  
X
X
Dirty filter  
Replace or clean  
Check for dirty air filter and clean or replace  
Check fan motor operation and airflow restrictions  
Rduced or no air flow  
in heating  
X
Too high of external static - check static vs blower table  
Check for dirty air filter and clean or replace  
Check fan motor operation and airflow restrictions  
Too high of external static - check static vs blower table  
Check supply and return air temperatures at the unit and at  
distant duct registers if significantly different, duct leaks  
are present  
Check superheat and subcooling per chart  
Check superheat and subcooling per chart - replace  
Perform RV touch test  
Reduced or no air flow  
in cooling  
X
X
Insufficient Capacity/  
Not Cooling or Heating  
Properly  
X
Leaky duct work  
X
X
X
X
X
X
Low refrigerant charge  
Restricted metering device  
Defective reversing valve  
Thermostat improperly located  
X
X
Check location and for air drafts behind stat  
Recheck loads & sizing check sensible clg load and heat  
pump capacity  
X
X
X
Unit undersized  
X
X
Scaling in water heat exchanger Perform Scaling check and clean 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  
Check fan motor operation and airflow restrictions  
Reduced or no air flow  
in heating  
X
Too high of external static - check static vs blower table  
X
X
Reduced or no water flow  
in cooling  
Inlet water too hot  
Check pump operation or valve operation/setting  
Check water flow adjust to proper flow rate  
Check load, loop sizing, loop backfill, ground moisture  
High Head Pressure  
Air temperature out of range in  
heating  
X
Bring return air temp within design parameters  
X
X
X
X
Scaling in water heat exchanger Perform Scaling check and clean if necessary  
X
X
X
Unit overcharged  
Non-condensables insystem  
Restricted metering device  
Check superheat and subcooling - reweigh in charge  
Vacuum system and reweigh in charge  
Check superheat and subcooling per chart - replace  
Check pump operation or water valve operation/setting  
Plugged strainer or filter - clean or replace  
Reduced water flow  
in heating  
X
X
Check water flow adjust to proper flow rate  
Water temperature out of range  
Bring water temp within design parameters  
Check for dirty air filter and clean or replace  
Check fan motor operation and airflow restrictions  
Too high of external static - check static vs blower table  
Too much cold vent air - bring entering air temp within  
design parameters  
Low Suction Pressure  
Reduced air flow  
in cooling  
X
X
X
Air temperature out of range  
Insufficient charge  
X
Check for refrigerant leaks  
Low Dischage Air  
Temperature in Heating  
X
X
Too high of air flow  
Check fan motor speed selection and airflow chart  
Poor performance  
Too high of air flow  
See “Insufficient Capacity”  
Check fan motor speed selection and airflow chart  
X
X
High Humidity  
Recheck loads and sizing check sensible clg load and  
heat pump capacity  
Unit oversized  
Check G wiring at heat pump. Jumper G and R for fan  
operation.  
X
X
X
X
Thermostat wiring  
Jumper G and R for fan operation. Check for Line voltage  
across blower relay contacts.  
Fan motor relay  
Check fan power enable relay operation (if present)  
Check for line voltage at motor. Check capacitor  
Only Compressor Runs  
X
X
X
X
Fan motor  
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.  
X
Reversing Valve  
Unit Doesn't Operate in  
Cooling  
X
X
Thermostat setup  
Thermostat wiring  
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.”  
Verify the AO-2 jumper is in the 0-10V position  
Improper output setting  
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.  
X
X
Modulating Valve  
Troubleshooting  
Check voltage to the valve  
No valve operation  
Replace valve if voltage and control signals are present at  
the valve and it does not operate  
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41  
HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS  
Residential Split - 60Hz R410A  
R e v. : 0 3 A u g u s t , 2 0 1 2  
Troubleshooting Form  
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Note: Never connect refrigerant gauges during startup procedures. Conduct water-side analysis using P/T ports to determine water ow  
and temperature difference. If water-side analysis shows poor performance, refrigerant troubleshooting may be required. Connect refrigerant  
gauges as a last resort.  
42  
Heat Controller, Inc. Water-Source Heating and Cooling Systems  
Download from Www.Somanuals.com. All Manuals Search And Download.  
The Quality Leader in Conditioning Air  
Residential Split - 60Hz R410A  
R e v. : 0 3 A u g u s t , 2 0 1 2  
Notes:  
Download from Www.Somanuals.com. All Manuals Search And Download.  
43  
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Design, specications and materials subject to change without notice.  
1900 Wellworth Ave., Jackson, Michigan 49203 Ph. 517-0787-2100 Fax 517-787-9341  
Part #: 97B0016N18  
*97B0016N18*  
The Quality Leader in Conditioning Air  
08/12  
Download from Www.Somanuals.com. All Manuals Search And Download.  

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