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
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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
filters will quickly become clogged with construction dirt
and debris, which may cause system damage.
NOTICE: Notification 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 proficiency 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 filed within 15 days, the freight company can deny the
claim without recourse. Note: It is the responsibility of the
purchaser to file all necessary claims with the carrier. Notify
your equipment supplier of all damage within fifteen (15) days
of shipment.
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
filters will quickly become clogged with construction dirt
and debris, which may cause system damage.
Examine all pipes, fittings, and valves before installing any of
the system components. Remove any dirt or debris found in
or on these components.
Pre-Installation
Installation, Operation, and Maintenance instructions are
provided with each unit. Horizontal equipment is designed for
installation above false ceiling or in a ceiling plenum. Other
unit configurations are typically installed in a mechanical
room. The installation site chosen should include adequate
service clearance around the unit. Before unit start-up,
read all manuals and become familiar with the unit and its
operation. Thoroughly check the system before operation.
Prepare units for installation as follows:
1. Compare the electrical data on the unit nameplate with
ordering and shipping information to verify that the correct
unit has been shipped.
2. Keep the cabinet covered with the original packaging until
installation is complete and all plastering, painting, etc. is
finished.
3. Verify refrigerant tubing is free of kinks or dents and that
it does not touch other unit components.
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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 specific indoor coil match. GeoLogix® (HTS) models
are rated with Heat Controller WDG Series air handlers
and MWG Series coils as shown in Table 1a. Other brands
of air handlers may attain the same AHRI ratings providing
that the specifications meet or exceed those listed in Table
1a AND Table 1b. However, for warranty and federal tax
credits, an AHRI matched system is required. An ECM motor
and TXV is required. Cap tubes and fixed orifices are not
acceptable. PSC fans may be used if matched to Table 1b,
but will not meet AHRI ratings. If using PSC fan, compressor
section must be operated as a single stage unit (i.e. wired for
either 1st stage or 2nd stage). Without the ability to vary the
airflow, supply air temperatures may not be acceptable if the
compressor is allowed to change stages when used with a
PSC fan motor.
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 efficiency.
Using an older-model coil can affect efficiency and may not
provide the customer with rated or advertised EER and COP.
Coil design and technology have dramatically improved
operating efficiency and capacity in the past 20 years.
Homeowners using an older coil are not reaping these cost
savings and comfort benefits. NEVER MATCH AN R-22
INDOOR COIL WITH AN R-410A COMPRESSOR SECTION.
Newer indoor coils have a larger surface area, enhanced fin
design, and grooved tubing. These features provide a larger
area for heat transfer, improving efficiency and expanding
capacity. Typical older coils may only have one-third to one-
half the face area of these redesigned coils.
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 Configuration
Upflow/Downflow/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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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 airflow required
is 1,200 CFM. Each evaporator temperature listed in the table
shows three wet bulb temperatures. As recommended in the
table notes above, select the 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 difficult to remove
after the unit is installed should be removed prior to setting
the unit. Refer to Figure 2 for an illustration of a typical
installation. Refer to “Physical Dimensions” section for
dimensional data. Conform to the following guidelines when
selecting unit location:
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 sufficient to allow
removal of the unit, if necessary.
5. In limited side access installations, pre-removal of the
control box side mounting screws will allow control box
removal for future servicing (R22 units only).
6. Provide access to water valves and fittings and
screwdriver access to the unit side 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 flushed before installing new
compressor section. R-410A compressors use POE
oil instead of mineral oil (R-22 systems). Mineral oil is
not compatible with POE oil, and could cause system
damage if not completely flushed from the line set.
Air Handler and Coil Installation
This manual specifically addresses the compressor section
of the system. Air handler and coil location and installation
should be according to the instructions provided with the air
handling/coil unit.
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 sufficient room to make
water, electrical, and line set connections.
8
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
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 fittings for water
connections that are rated for 450 psi (3101 kPa) operat-
ing pressure. The connections have a rubber gasket seal
similar to a garden hose gasket, which when mated to
the flush end of most 1” threaded male pipe fittings pro-
vides a leak-free seal without the need for thread sealing
tape or joint compound. Insure that the rubber seal is in
the swivel connector prior to attempting any connection
(rubber seals are shipped attached to the swivel connec-
tor). DO NOT OVER TIGHTEN or leaks may occur.
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 fittings should not be used at any
time due to their tendency to corrode. All plastic to metal
threaded fittings should be avoided due to their potential to
leak in earth coupled applications. A flanged fitting should
be substituted. P/T plugs should be used so that flow can be
measured using the pressure drop of the unit heat exchanger.
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 fluctuation is normal and should be
considered when charging the system initially. Run the unit in
either heating or cooling for a number of minutes to condition
the loop to a homogenous temperature. This is a good time
for tool cleanup, piping insulation, etc. Then, perform final
flush and pressurize the loop to a static pressure of 50-75 psi
[345-517 kPa] (winter) or 35-40 psi [241-276 kPa] (summer).
After pressurization, be sure to loosen the plug at the end
of the Grundfos loop pump motor(s) to allow trapped air to
be discharged and to insure the motor housing has been
flooded. This is not required for Taco circulators. Insure
that the Flow Controller provides adequate flow through the
unit by checking pressure drop across the heat exchanger
and compare to the pressure drop tables at the back of the
manual.
Test individual horizontal loop circuits before backfilling.
Test vertical U-bends and pond loop assemblies prior to
installation. Pressures of at least 100 psi [689 kPa] should be
used when testing. Do not exceed the pipe pressure rating.
Test entire system when all loops are assembled.
Flushing the Earth Loop
Once piping is completed between the unit, Flow Controller
and the ground loop (Figure 4), the loop is ready for final
purging and charging. A flush cart with at least a 1.5 hp
[1.1 kW] pump is required to achieve enough fluid velocity
in the loop piping system to purge air and dirt particles. An
antifreeze solution is used in most areas to prevent freezing.
All air and debris must be removed from the earth loop piping
before operation. 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 flushing.
1. Fill loop with water from a garden hose through the flush
cart before using the flush cart pump to insure an even
fill.
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 flushing process can begin. Do not allow
the water level in the flush cart tank to drop below the
pump inlet line to avoid air being pumped back out to the
earth loop.
3. Try to maintain a fluid level in the tank above the return
tee so that air cannot be continuously mixed back into
the fluid. Surges of 50 psi (345 kPa) can be used to help
purge air pockets by simply shutting off the return valve
going into the flush cart reservoir. This “dead heads” the
pump to 50 psi (345 kPa). To purge, dead head the pump
until maximum pumping pressure is reached. Open the
return valve and a pressure surge will be sent through
the loop to help purge air pockets from the piping system.
4. Notice the drop in fluid level in the flush cart tank when
the return valve is shut off. If air is adequately purged
from the system, the level will drop only 1-2 inches (2.5 -
5 cm) in a 10” (25 cm) diameter PVC flush tank (about a
half gallon [2.3 liters]), since liquids are incompressible.
If the level drops more than this, flushing should continue
since air is still being compressed in the loop fluid.
Perform the “dead head” procedure a number of times.
Calculation is as follows:
30°F - 15°F = 15°F [-1°C - 9°C = -10°C].
All alcohols should be premixed and pumped from a reservoir
outside of the building when possible or introduced under
the water level to prevent fumes. Calculate the total volume
of fluid in the piping system. Then use the percentage by
volume shown in Table 2 for the amount of antifreeze needed.
Antifreeze concentration should be checked from a well
mixed sample using a hydrometer to measure specific gravity.
Low Water Temperature Cutout Setting - DXM2 Control
When antifreeze is selected, the LT1 jumper (JW3) should
be clipped to select the low temperature (antifreeze 13°F
[-10.6°C]) set point and avoid nuisance faults (see “Low
Water Temperature Cutout Selection” in this manual). NOTE:
Low water temperature operation requires extended range
equipment.
Note: This fluid level drop is your only indication of air in
the loop.
Antifreeze may be added before, during or after the flushing
procedure. However, depending upon which time is chosen,
antifreeze could be wasted when emptying the flush cart
tank. See antifreeze section for more details.
Loop static pressure will fluctuate with the seasons.
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 field, adjacent stream
or pond, etc.). Most local codes forbid the use of sanitary
sewer for disposal. Consult your local building and zoning
department to assure compliance in your area.
The “outdoor” version of the compressor section may not
be used with open loop systems due to potential freezing
of water piping. Typical open loop piping is shown in Figure
9. Shut off valves should be included for ease of servicing.
Boiler drains or other valves should be “tee’d” into the lines
to allow acid flushing of the heat exchanger. Shut off valves
should be positioned to allow flow through the coax via the
boiler drains without allowing flow into the piping system. P/T
plugs should be used so that pressure drop and temperature
can be measured. Piping materials should be limited to
copper or PVC 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 flow rate
required for the heat pump. Pump sizing and expansion
tank must be chosen as complimentary items. For example,
an expansion tank that is too small can causing premature
pump failure due to short cycling. Variable speed pumping
applications should be considered for the inherent energy
savings and smaller expansion tank requirements.
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
qualified technician, as acid and special pumping equipment
is required. Desuperheater coils can likewise become scaled
and possibly plugged. In areas with extremely hard water,
the owner should be informed that the heat exchanger
may require occasional acid flushing. In some cases, the
desuperheater option should not be recommended due to
hard water conditions and additional maintenance required.
Motorized Modulating Water Control Valve
Note the placement of the water control valve in figure 9.
Always maintain water pressure in the heat exchanger by
placing the water control valve(s) on the discharge line
to prevent mineral precipitation during the off-cycle. Pilot
operated slow closing valves are recommended to reduce
water hammer. If water hammer persists, a mini-expansion
tank can be mounted on the piping to help absorb the excess
hammer shock. This valve regulates the flow using entering
and leaving water delta-T of the system. Entering and leaving
water temperature is read on the communicating thermostat
or configuration/diagnostic service tool. Further details on
valve operation are described later in this manual.
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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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 flushing. Once
flushing 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 flushing. Once flushing 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 flow rate. The motorized modulating valve
defaults to closed position if it loses signal but still has 24V
power running to it. If the motorized modulating valve loses
both signal from the DXM2 board AND 24V power, it will
remain in the same position it was in when it lost 24V power.
DO NOT USE open loop units in closed loop applications due
to significant pressure drop through the open loop motorized
modulating valve.
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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
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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, floor joists, wall studs,
floors or other structural components that could transmit
compressor vibration. Do not suspend refrigerant tubing
from joists with rigid straps. Do not attach line set to the
wall. When necessary, use hanger straps with isolation
sleeves to minimize tranmission of line set vibration to the
structure.
ꢀ 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 filter drier is required. Never install a suction
line filter 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 filter drier is installed on the liquid
line inside the compressor section cabinet (R-22 units only).
R-410A models are shipped with a filter drier (loose) inside
the cabinet that must be installed in the liquid line at the
line set. 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
filming agent, (dishwasher detergent like Cascade) to help
condensate drainage. Apply a 20 to 1 solution of detergent
and water. Spray both sides of coil, repeat and rinse
thoroughly with water.
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 fixed orifice, the orifice must be
removed and a TXV must be installed as shown in Figure
11. Fasten the copper line set to the coil. Nitrogen should
be circulated through the system at 2-3 psi [13.8-20.7 kPa]
to prevent oxidation inside the refrigerant tubing. Use a low
silver phos-copper braze alloy on all brazed connections.
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 field. Check
the service valve ports and stem for leaks. If a leak is found,
repair it and repeat the above steps. For safety reasons do
not pressurize system above 150 psig [1034 kPa]. System is
now ready for evacuation and charging.
16
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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
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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 specific entering
water conditions.
Determining Sub-Cooling:
1. Measure the temperature of the liquid line on the smaller
refrigerant line (liquid line) just outside of the cabinet. This
location will be adequate for measurement in both modes
unless a significant temperature drop in the liquid line is
anticipated.
PARTIAL CHARGE METHOD - Open service valve fully
counterclockwise and then turn back in one-half turn to open
service port. Add vaporized (Gas) into the suction side of
the compressor until the pressure in the system reaches
approximately 60-70 psig (R-22 systems) or 100-120 psig
(R-410A systems). Never add liquid refrigerant into the suction
side of a compressor. Start the unit in heating and add gas
to the suction port at a rate not to exceed five pounds [2.27
kg] per minute. Keep adding refrigerant until the complete
charge has been entered. Superheat is measured using
suction temperature and pressure at the compressor suction
line. Subcooling should be measured using the liquid line
temperature immediately outside the compressor section
cabinet and either the liquid line service valve pressure or the
compressor discharge pressure. Note that different values
from tables 14a to 15 will be obtained due to the pressure
losses through the condenser heat exchanger. 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
specific 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 specifications 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 field.
The control circuit and pump are also built in for residential
equipment. Figure 18 shows a typical example of HWG water
piping connections on a unit with built-in circulating pump.
This piping layout reduces scaling potential.
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 field selectable
to 125°F or 150°F . The 150°F setpoint allows more heat
storage from the HWG. For example, consider the amount
of heat that can be generated by the HWG when using
the 125°F set point, versus the amount of heat that can be
generated by the HWG when using the 150°F set point.
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 efficient system,
providing the maximum storage and temperate source water
to the HWG.
It is always advisable to use water softening equipment on
domestic water systems to reduce the scaling potential and
lengthen equipment life. In extreme water conditions, it may
be necessary to avoid the use of the HWG option since the
potential cost of frequent maintenance may offset or exceed
any savings. Consult Table 4 for scaling potential tests.
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
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
HotWater Generator
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
sufficiently above the water temperature. Once the HWG has
satisfied the water heating demand during a heat pump run
cycle, the controller will cycle the pump at regular Intervals to
determine if an additional HWG cycle can be utilized.
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 flash (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 flash a numeric fault code as follows:
High Water Temperature (>160 ºF)
Hot Water Sensor Fault
Compressor Discharge Sensor Fault
5 flashes
6 flashes
6 flashes
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 flashes have a duration of 0.3 seconds with
a 10 second pause between fault codes. For example, a
“Compressor Discharge sensor fault” will be six flashes 0.3
seconds long, then a 10 second pause, then six flashes
again, etc.
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 flushed with
cold water after it is drained until the water leaving the
drain hose is clear and free of sediment.
6. Close all valves and remove the drain hose.
7. Install HWG water piping.
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21
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
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 flushing water
through the HWG (as in Figures 15 and 16) or by
installing an air vent at the high point of the HWG piping
system.
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 Refill
1. Close valve #4. Ensure that the HWG valves (valves #2
and #3) are open. Open the cold water supply (valve #1)
to fill the tank through the HWG piping. This will purge air
from the HWG piping.
ꢀ CAUTION! ꢀ
CAUTION! Locate Refrigerant lines to avoid accidental
2. Open a hot water faucet to vent air from the system until
water flows from faucet; turn off faucet. Open valve #4.
3. Depress the hot water tank pressure relief valve handle to
ensure that there is no air remaining in the tank.
4. 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 specific needs of the customer, you may want
to adjust the upper element differently. On tanks with a
single thermostat, a preheat tank should be used (Fig 16).
6. Replace access cover(s) and restore power or
fuel supply.
Initial Start-Up
1. Make sure all valves in the HWG water circuit are
fully open.
2. Turn on the heat pump and allow it to run for
10-15 minutes.
3. Set S3-4 to the “ON” position (enabled) to engage the
HWG.
4. The HWG pump should not run if the compressor is not
running.
5. The temperature difference between the water entering
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
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
Electrical - LineVoltage
All final electrical connections must be made with a length of
flexible 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 field 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 field installed wiring, including electrical ground, must
comply with the National Electrical Code as well as all
applicable local codes. Refer to the unit electrical data for
fuse sizes. Consult wiring diagram for field connections that
must be made by the installing (or electrical) contractor.
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
Residential Split - 60Hz R410A
R e v. : 0 3 A u g u s t , 2 0 1 2
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 field selection of low water (or
water-antifreeze solution) temperature limit by clipping jumper
JW3, which changes the sensing temperature associated
with thermistor LT1. Note that the LT1 thermistor is located
on the refrigerant line between the coaxial heat exchanger
and expansion device (TXV). Therefore, LT1 is sensing
refrigerant temperature, not water temperature, which is
a better indication of how water flow rate/temperature is
affecting the refrigeration circuit.
An external valve should be used on ground water systems
to shut off flow 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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R e v. : 0 3 A u g u s t , 2 0 1 2
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 configuration, 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 configuration tool (7602-444) MUST be used to
configure 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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25
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 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 configuration/
diagnostic tool.
are checked for normal conditions. The compressor will
have a 5 minute anti-short cycle delay at power-up. The first
time after power-up that there is a call for compressor, the
compressor will follow a 5 to 80 second random start delay.
After the random start delay and anti-short cycle delay,
the compressor relay will be energized. On all subsequent
compressor calls, the random start delay is omitted.
For most residential applications, configuration, monitoring
and diagnostics can be done from the thermostat / service
tool and there’s no need to read LEDs and change DIP
switches.
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 configuration/
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
configuration, monitoring and diagnostics, in PLAIN
English, on the thermostat. For example, Airflow can NOT
be configured without a communicating thermostat or
Configuration/ 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 Configuration Options - Note: In the following field
configuration 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 field 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: Configure Modulating Valve (field installed acces-
sory)
Set A0-2 jumper to “IOV” if using Modulating Motorized Valve
as field installed accessory
G, Y1, O
G, Y1, Y2, O
DIP Switches - For residential applications, all configuration
can be performed in PLAIN ENGLISH on the thermostat.
No DIP switch changes are required and no LEDs to be
observed.
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
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
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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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 flow 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 specified otherwise.
Loop/water piping is complete and purged of air. Water/piping
is clean.
ꢁ
ꢁ
ꢀ CAUTION! ꢀ
CAUTION! To avoid equipment damage, DO NOT
leave system filled in a building without heat during the
winter unless antifreeze is added to the water loop. Heat
exchangers never fully drain by themselves and will freeze
unless winterized with antifreeze.
ꢁ
ꢁ
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 flow balancing: Record inlet and outlet water
temperatures for each heat pump upon startup. This check
can eliminate nuisance trip outs and high velocity water flow
that could erode heat exchangers.
Unit Start-up Procedure
1. Turn the thermostat fan position to “ON.” Blower
should start.
2. Balance air flow 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 first started
in the cooling mode, when possible. This will allow liquid
refrigerant to flow through the filter-drier before entering the
TXV, allowing the filter-drier to catch any debris that might
be in the system before it reaches the TXV.
ꢁ
ꢁ
ꢁ
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 filters: Insure that filter is clean and
accessible. Clean air coil of all manufacturing oils.
Unit controls: Verify that DXM2 field 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 fittings (see Table 4).
System flushing: Verify that all air is purged from the system.
Air in the system can cause poor operation or system
corrosion. Water used in the system must be potable quality
initially and clean of dirt, piping slag, and strong chemical
cleaning agents. Some antifreeze solutions may require
distilled water.
Internal Flow Controller: Verify that it is purged of air and in
operating condition.
System controls: Verify that system controls function and
operate in the proper sequence.
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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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 verified by calculating the unit heat of
rejection and heat of extraction. Heat of Rejection (HR) can be
calculated and compared to the performance data pages in this
IOM. The formula for HR is as follows: HR = TD x GPM x 500
b. Check for cool air delivery at the unit grille within a few
minutes after the unit has begun to operate.
NOTE: Units have a five minute time delay in the control circuit
that can be bypassed on the DXM2 control board by placing
the unit in the “Test” mode as shown in the unit IOM. Check for
normal air 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 flow 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 flow 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 filled 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 five (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 flow prior to engaging the compressor.
Freezing of the coax or water lines can permanently
damage the heat pump.
NOTE: Units have a five 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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Residential Split - 60Hz R410A
R e v. : 0 3 A u g u s t , 2 0 1 2
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 filters. Inspect the drain twice a year to
avoid the possibility of plugging and eventual overflow.
If the system is installed in an area with a known high
mineral content (125 P.P.M. or greater) in the water, it is
best to establish a periodic maintenance schedule with the
owner so the coil can be checked regularly. Consult the well
water applications section of this manual for a more detailed
water coil material selection. Should periodic coil cleaning
be necessary, use standard coil cleaning procedures, which
are compatible with the heat exchanger material and copper
water lines. Generally, the more water flowing through the
unit, the less chance for scaling. Therefore, 1.5 gpm per
ton [2.0 l/m per kW] is recommended as a minimum flow.
Minimum flow rate for entering water temperatures below
50°F [10°C] is 2.0 gpm per ton [2.6 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 flowing through the unit, the less chance for
scaling. However, flow 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 fins while cleaning. CAUTION: Fin edges are
sharp.
Cabinet - Indoor Compressor Section
Do not allow water to stay in contact with the cabinet for long
periods of time to prevent corrosion of the cabinet sheet
metal. Generally, cabinets are set up from the floor a few
inches [7 - 8 cm] to prevent water from entering the cabinet.
The cabinet can be cleaned using a mild detergent.
Refrigerant System
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 flow 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 filter.
Washable, high efficiency, electrostatic filters, when dirty,
can exhibit a very high pressure drop for the fan motor and
reduce air flow, resulting in poor performance. It is especially
important to provide consistent washing of these filters (in
the opposite direction of the normal air flow) 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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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 verified, confidence in board operation is
confirmed and the trouble must be else where. Below are
some general guidelines required for developing training
materials and procedures when applying the DXM2 Control.
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 verified using a voltmeter between C and Y1, Y2, W,
O, and G.
Sensor Inputs
All sensor inputs are ‘paired wires’ connecting each
component with the board. Therefore continuity on pressure
switches can be checked at the board connector.
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 verified using a
voltmeter. The Alarm Relay can either be 24VAC as shipped
or dry contacts (measure continuity during fault) for use with
DDC by clipping the J4 jumper. Electric heat outputs are
24VDC and require a voltmeter set for DC to verify operation.
When troubleshooting, measure from 24VDC terminal to 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 Configuration 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 configuration, especially those
with ECM blowers.
To properly configure and troubleshoot advanced control
features, and to aid in troubleshooting basic control features,
a communicating thermostat or diagnostic tool with similar
capabilities should be used.
Heat Pump Family – When replacing a control in the field, the
Heat Pump Family value must be set for proper blower and
loop operation. The valid family values (HTS,HE, etc.) are
available for the user to scroll through to select the proper
value.
System Configuration
All factory installed DXM2 controls have their basic
configuration parameters set as part of the factory
manufacturing and test process. The System Configuration
option under the communicating thermostat Installer menu
provides the installer with the ability to adjust ECM target
airflows for each operating mode, set control options, setup
the loop configuration and parameters, and configure field
replacement controls.
Heat Pump Size – When replacing a control in the field,
the Heat Pump Size value must be set for proper blower
operation. After a Heat Pump Family has been selected, the
valid Heat Pump Size values will be available for the user to
scroll through to select the proper value.
Airflow Selection – The Airflow Selection menu allows the
installer to adjust the ECM target airflow for each control
operating mode, as well as independently set the heating and
cooling blower off delays.
Blower Type – When replacing a control in the field, 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 configurations.
ECM Airflows – Independent airflow selections may be made
for each stage of heating operation, each stage of cooling
operation with and without dehumidification, as well as
constant fan operation. The DXM2 control has set minimum
and maximum airflow limits for each operating mode, based
on the unit configuration that may not be changed.
Loop Configuration – When replacing a control in the
field, the Loop Configuration value must be set for proper
operation. The valid Loop Configuration values will be
available for the user to scroll through to select the
appropriate value from VS PUMP, MOD VALVE, or OTHER.
Non-ECM Configuration – If the DXM2 is not configured
to control an ECM blower, the airflow selections will not be
available on the Airflow Selection menu.
Loop Configuration – The Loop Configuration menu allows
the installer to set the operating parameters for either an
internal flow center, or a proportional water valve, depending
on the unit configuration.
Heating / 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 configured as a water-to-
water unit with anti–freeze in the load side loop. For ALL
other unit configurations, 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 configurations, the Motorized Valve option
should be set to OFF.
Unit Configuration – Selections under the Unit Configuration
menu are normally set at the factory as a normal part of
the manufacturing and test process. This menu allows the
configuration to be modified for special applications, or to
configure field replacement controls. The Unit Configuration
menu provides the ability to select the Heat Pump Family,
36
Heat Controller, Inc. Water-Source Heating and Cooling Systems
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The Quality Leader in Conditioning Air
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R e v. : 0 3 A u g u s t , 2 0 1 2
AdvancedTroubleshooting and Configuration 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 Configuration, and Fault History.
Fault Configuration 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 flow 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 flow center, and proportional
valve operating status and parameters.
Dipswitch Configuration – The Dipswitch Configuration
menus allow the installer to easily see the current DXM2
control configuration.
Fault History – In addition to the fault code, the DXM2 stores
the status of all control inputs and outputs when a fault
condition is detected. The fault history covering the last five
lockout conditions is stored and may be retrieved from the
DXM2. After a specific fault in the fault history is selected,
the operating mode and time when the fault occurred are
displayed, with options to select specific control status values
when the 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
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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
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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 flow
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, specifications 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
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