Split Products
Table of Contents
Model Nomenclature
3
Safety
4
Storage
5
Pre-Installation
5
Equipment Selection
Air Coil Match-ups
6
6-7
8
Air Handler Selection
Installation
9
Water Connections
10-11
11-13
14-15
16
Ground Loop Applications
Open Loop - Ground Water Systems
Water Quality Standards
Refrigeration Installation
Lineset Information
17-22
17
Internal Hot Water Generator
Hot Water Generator Module
Electrical - Line Voltage
Power Wiring
23-24
25-26
27-28
28
Electrical - Low Voltage Wiring
Low Water Temperature Cutout Selection
Water Valve Wiring
29-31
31
31
HSS Series Split System,
11/2 to 5 Tons
Thermostat Wiring
31
CXM Controls
32-34
33
CXM Safety Features
Unit Start-Up and Operating Conditions
HTS Series Split System,
Two Stage, 2-5 Tons
36
Unit Start-Up
and System Checkout Procedure
37-38
39-41
42
Unit Operating Conditions
Preventive Maintenance
Troubleshooting
Outdoor Split
43-44
45-46
47
Geothermal Heat Pumps
Functional & Performance Troubleshooting
Refrigerant Circuit Diagram
Revision Log
48
Installation, Operation &
Maintenance Instructions
Revision: 23 June, 2008
The Quality Leader in Conditioning Air
Residential Split - 60Hz R22 &R410A
Rev.: 5 June, 2008
Model Nomenclature: for Indoor Split Series
4
5
6
7
Model Nomenclature: for Indoor Split Series
NOTE: Above model nomenclature is a general reference. Consult individual specification catalogs for detailed information.
3
HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS
Residential Split - 60Hz R22 &R410A
Rev.: 5 June, 2008
Safety
Safety
x WARNING! x
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: 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.
x CAUTION! x
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.
x WARNING! x
WARNING! Verify refrigerant type before proceeding.
Units are shipped with R-22 and 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.
x WARNING! x
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.
Heat Controller, Inc. Water-Source Heating and Cooling Systems
4
The Quality Leader in Conditioning Air
Residential Split - 60Hz R22 &R410A
Rev.: 5 June, 2008
General Information
Inspection
rides freely on the springs. Remove shipping restraints.
6. REMOVE COMPRESSOR SUPPORT PLATE 1/4”
SHIPPING BOLTS (2 on each side) TO MAXIMIZE
VIBRATION AND SOUND ATTENUATION (R22 indoor
units only).
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.
7. Locate and verify any hot water generator (HWG) or
other accessory kit located in the compressor section.
x CAUTION! x
CAUTION! DO NOT store or install units in corrosive
environments or in locations subject to temperature or
humidity extremes (e.g., attics, garages, rooftops, etc.).
Corrosive conditions and high temperature or humidity can
significantly reduce performance, reliability, and service life.
Always move and store units in an upright position. Tilting
units on their sides may cause equipment damage.
Storage
Equipment should be stored in its original packaging in a
clean, dry area. Store units in an upright position at all times.
Stack units a maximum of 3 units high.
Unit Protection
Cover units on the job site with either the original packaging
or an equivalent protective covering. Cap the open ends of
pipes stored on the job site. In areas where painting, plastering,
and/or spraying has not been completed, all due precautions
must be taken to avoid physical damage to the units and
contamination by foreign material. Physical damage and
contamination may prevent proper start-up and may result in
costly equipment clean-up.
NOTICE! Failure to remove shipping brackets from spring-
mounted compressors will cause excessive noise, and could
cause component failure due to added vibration.
x CAUTION! x
CAUTION! CUT HAZARD - Failure to follow this caution
may result in personal injury. Sheet metal parts may have
sharp edges or burrs. Use care and wear appropriate
protective clothing, safety glasses and gloves when
handling parts and servicing heat pumps.
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.
4. Inspect all electrical connections. Connections must be
clean and tight at the terminals.
5. Loosen compressor bolts on units equipped with
compressor spring vibration isolation until the compressor
5
HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS
Residential Split - 60Hz R22 &R410A
Rev.: 5 June, 2008
Equipment Selection
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.
Indoor Coil Selection - HTS GeoMax 2
HCI split system heat pumps are rated in the ARI directory
with a specific indoor coil match. GeoMax 2 (HTS) models
are rated with Carrier/Bryant FV4 or FE4 series variable
speed air handlers as shown in Table 1a. Other brands of
air handlers may attain the same ARI ratings providing that
the specifications meet or exceed those listed in Table 1a
AND Table 1b. 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 ARI 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.
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: GeoMax 2 (HTS) Air Handler Matches for ARI Ratings
Compressor Section
024
003
036
005
048
006
060
006
Air Handler
Model FV4
Refrigerant
R-410A
Metering Device
TXV (required)
Air Coil
Type
Rows - Fins/in.
Face Area (sq. ft.)
Slope
3 - 14.5
3.46
A
A
A
3 - 14.5
5.93
3 - 14.5
7.42
3 - 14.5
7.42
Cabinet Configuration
Upflow/Downflow/Horizontal (Multipoise)
AC/HP size: 036
AC/HP size: 036
System Type:
HP-Effic AC/HP
CFM Adjust: High
AC/HP size: 048
AC/HP size: 060
System Type:
Comfort AC/HP
CFM Adjust: High
ECM Settings for
ARI Ratings
(FV4 Fan Coil)
System Type:
Comfort AC/HP
CFM Adjust: Nom
System Type:
Comfort AC/HP
CFM Adjust: High
Fan Motor Type - HP
ECM - 1/2
ECM - 1/2
ECM - 3/4
ECM - 3/4
Heat Controller, Inc. Water-Source Heating and Cooling Systems
6
The Quality Leader in Conditioning Air
Residential Split - 60Hz R22 &R410A
Rev.: 5 June, 2008
Equipment Selection
Table 1b: GeoMax 2 (H
T
S) Air Handler Characteristics for Brands other than Above Models
Nominal
Tons*
Evaporator
Temp (ºF)
Capacity
(MBtuh)**
Model*
CFM
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
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
700
1200
1000
1650
1850
* Nominal tons are at ARI/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 026 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 ARI 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 ARI rating condition to be valid. See Figure 1 for an example selection.
Indoor Coil Selection - For HSS R-22 Units
Geothermal split system heat pumps with R-22 refrigerant are rated in the ARI directory with a “generic” indoor coil match and
PSC fan. Selection of air handlers that attain the published ARI ratings must meet or exceed the specifications listed in Table
2. A TXV is required. Cap tubes and fixed orifices are not
acceptable.
Table 2: R-22 Air Handler Characteristics
Nominal
Tons*
Evaporator
Temp (ºF)
Capacity
(MBtuh)**
Model*
CFM
018
024
030
036
042
048
060
1.5
2.0
2.5
3.0
3.5
4.0
5.0
50
47
49
48
45
46
45
600
800
18.5 - 21.3
25.5 - 29.3
31.5 - 36.2
37.0 - 42.5
42.2 - 48.5
50.0 - 57.5
58.0 - 66.7
1000
1200
1400
1600
2000
* Nominal tons are at ARI/ISO 13256-1 GLHP conditions.
**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 ARI rating condition to be valid. See Figure 1 for an example selection.
7
HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS
Residential Split - 60Hz R22 &R410A
Rev.: 5 June, 2008
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
Utilizing the Existing Air Handler or Coil (R22 units only)
It is recommended that a new coil or air handler be installed
with any geothermal split system compressor section due to the
low initial cost of the additional equipment versus the reliability
and benefit of new technology, increased reliability and
warranty. However, if the existing air handler must be used (R22
systems only), the following conditions apply:
• If the existing coil currently uses an orifice, the orifice must be
removed and replaced with a TXV. If the coil utilizes capillary
tubes, it will not operate properly with the geothermal split
system and should be replaced.
• If life expectancy of indoor coil (and associated components
- fan, cabinet, etc.) is less than 7-10 years, indoor section
should be replaced.
Heat Controller, Inc. Water-Source Heating and Cooling Systems
8
The Quality Leader in Conditioning Air
Residential Split - 60Hz R22 &R410A
Rev.: 5 June, 2008
Installation
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.
NOTICE! Failure to remove shipping
brackets from spring-mounted compressors
will cause excessive noise, and could cause
component failure due to added vibration.
The installation of water source heat pump units and all
associated components, parts and accessories which make
up the installation shall be in accordance with the regulations
of ALL authorities having jurisdiction and MUST conform to
all applicable codes. It is the responsibility of the installing
contractor to determine and comply with ALL applicable
codes and regulations.
Removing Existing Condensing Unit (Where Applicable)
1. Pump down condensing unit. Close the liquid line service
valve of existing condensing unit and start compressor
to pump refrigerant back into compressor section. Then,
close suction service valve while compressor is still
running to trap refrigerant in outdoor section. Immediately
kill power to the condensing unit.
Air Handler Installation
This manual specifically addresses the compressor section
of the system. Air handler location and installation should be
according to the instructions provided with the air handling
unit.
2. Disconnect power and low voltage and remove old
condensing unit. Cut or unbraze line set from unit.
Remove condensing unit.
3. If condensing unit is not operational or will not pump
down, refrigerant should be recovered using appropriate
equipment.
4. Replace line set, especially if upgrading system from
R-22 to R-410A refrigerant. If line set cannot be replaced,
it must be thoroughly flushed before installing new
compressor section. R-410A compressors use POE
oil instead of mineral oil (R-22 systems). Mineral oil is
not compatible with POE oil, and could cause system
damage if not completely flushed from the line set.
“Indoor” Compressor Section Location
Both “indoor” and “outdoor” versions of the geothermal split
system compressor section are available. “Indoor” version
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.
Any access panel screws that would be difficult to remove
after the unit is installed should be removed prior to setting the
unit. Refer to Figure 2 for an illustration of a typical installation.
Refer to “Physical Dimensions” section for dimensional data.
Conform to the following guidelines when selecting unit
location:
1. Install the unit on a piece of rubber, neoprene or other
mounting pad material for sound isolation. The pad should
be at least 3/8” [10mm] to 1/2” [13mm] in thickness. Extend
the pad beyond all four edges of the unit.
9
HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS
Residential Split - 60Hz R22 &R410A
Rev.: 5 June, 2008
Installation
Figure 2: HTS/HSS Installation
External Flow Controller Mounting
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!
The Flow Controller can be mounted beside the unit
as shown in Figure 7. Review the Flow Controller
installation manual for more details.
Figure 4: Water Connections (Indoor Compressor Section)
Water Connections-Residential (Distributor) Models
Residential models utilize swivel piping fittings for
water connections that are rated for 450 psi (3101 kPa)
operating 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 provides 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 connector). DO NOT OVER TIGHTEN or leaks may
occur.
HandTighten
Only!
DoNot
SwivelNut
Overtighten!
Stainlesssteel
snapring
BrassAdaptor
Gasket
Heat Controller, Inc. Water-Source Heating and Cooling Systems
10
The Quality Leader in Conditioning Air
Residential Split - 60Hz R22 &R410A
Rev.: 5 June, 2008
Installation
GROUND-LOOP HEAT PUMP APPLICATIONS
x CAUTION! x
Pre-Installation
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.
Prior to installation, locate and mark all existing underground
utilities, piping, etc. Install loops for new construction before
sidewalks, patios, driveways, and other construction has
begun. During construction, accurately mark all ground loop
piping on the plot plan as an aid in avoiding potential future
damage to the installation.
Piping Installation
The typical closed loop ground source system is shown in
Figures 7 and 8. 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.
11
HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS
Residential Split - 60Hz R22 &R410A
Rev.: 5 June, 2008
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.
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 (Figures 7 and 8), 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].
Calculation is as follows:
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.
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.
3. Try to maintain a fluid level in the tank above the return
tee so that air cannot be continuously mixed back into
the fluid. Surges of 50 psi (345 kPa) can be used to help
purge air pockets by simply shutting off the return valve
going into the flush cart reservoir. This “dead heads” the
pump to 50 psi (345 kPa). To purge, dead head the pump
until maximum pumping pressure is reached. Open the
return valve and a pressure surge will be sent through
the loop to help purge air pockets from the piping system.
4. Notice the drop in fluid level in the flush cart tank when
the return valve is shut off. If air is adequately purged
from the system, the level will drop only 1-2 inches (2.5 -
5 cm) in a 10” (25 cm) diameter PVC flush tank (about a
half gallon [2.3 liters]), since liquids are incompressible.
If the level drops more than this, flushing should continue
since air is still being compressed in the loop fluid.
Perform the “dead head” procedure a number of times.
Note: This fluid level drop is your only indication of air in
the loop.
Low Water Temperature Cutout Setting
CXM Control
When antifreeze is selected, the FP1 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.
Antifreeze may be added before, during or after the flushing
procedure. However, depending upon which time is chosen,
antifreeze could be wasted when emptying the flush cart
tank. See antifreeze section for more details.
Loop static pressure will fluctuate with the seasons.
Pressures will be higher in the winter months than during
the cooling season. This fluctuation is normal and should be
considered when charging the system initially. Run the unit in
either heating or cooling for a number of minutes to condition
Heat Controller, Inc. Water-Source Heating and Cooling Systems
12
The Quality Leader in Conditioning Air
Residential Split - 60Hz R22 &R410A
Rev.: 5 June, 2008
Ground-Loop Heat Pump Applications
Table 1: Approximate Fluid Volume (U.S. gal. [L]) per
100' of Pipe
Figure 7: Loop Connection (Indoor
Compressor Section)
Fluid Volume (gal [liters] per 100’ [30 meters) Pipe)
Pipe
Size
Volume (gal) [liters]
1”
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]
1.0 [3.8]
Copper
1.25”
2.5”
Rubber Hose
1”
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
Typical
Polyethylene
Unit Heat Exchanger
Flush Cart Tank
10” Dia x 3ft tall
[254mm x 91.4cm tall]
10 [37.9]
NOTICE! Cabinet opening around loop piping (outdoor
compressor section) must be sealed to prevent entry of
rodents that could potentially damage unit wiring by chewing
on the insulation.
NOTICE! Outdoor compressor section may not be tilted
more than 5 degrees from level. Damage to the compressor
or stress on the loop piping could result if unit is tilted. A
concrete pad, anchor posts and/or soil compaction may be
required to avoid tilting as ground settles.
Table 2: 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
13
HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS
Residential Split - 60Hz R22 &R410A
Rev.: 5 June, 2008
Ground-Water Heat Pump Applications -
“Indoor” Compressor Section Only
Open Loop - Ground Water Systems
(“Indoor” Compressor Section Only)
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 3 for water quality guidelines. The unit can
be ordered with either a copper or cupro-nickel water
heat exchanger. Consult Table 3 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.
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. Insure that the total ‘VA’ draw of the valve
can be supplied by the unit transformer. For instance, a slow
closing valve can draw up to 35VA. This can overload smaller
40 or 50 VA transformers depending on the other controls
in the circuit. A typical pilot operated solenoid valve draws
approximately 15VA (see Figure 24). Note the special wiring
diagrams for slow closing valves (Figures 25 & 26).
Flow Regulation
Flow regulation can be accomplished by two methods. One
method of flow regulation involves simply adjusting the ball
valve or water control valve on the discharge line. Measure
the pressure drop through the unit heat exchanger, and
determine flow rate from Tables 11a through 11b. Since the
pressure is constantly varying, two pressure gauges may
be needed. Adjust the valve until the desired flow of 1.5 to
2 gpm per ton [2.0 to 2.6 l/m per kW] is achieved. A second
method of flow control requires a flow control device mounted
on the outlet of the water control valve. The device is typically
a brass fitting with an orifice of rubber or plastic material
that is designed to allow a specified flow rate. On occasion,
flow control devices may produce velocity noise that can be
reduced by applying some back pressure from the ball valve
located on the discharge line. Slightly closing the valve will
spread the pressure drop over both devices, lessening the
velocity noise. NOTE: When EWT is below 50°F [10°C], a
minimum of 2 gpm per ton (2.6 l/m per kW) is required.
Water Quality Standards
Table 3 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 3.
Expansion Tank and Pump
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
Heat Controller, Inc. Water-Source Heating and Cooling Systems
14
The Quality Leader in Conditioning Air
Residential Split - 60Hz R22 &R410A
Rev.: 5 June, 2008
Ground-Water Heat Pump Applications
Water Coil Low Temperature Limit Setting
Figure 9: Water Well Connections
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.
x CAUTION! x
CAUTION! Many units installed with a factory or field supplied
manual or electric shut-off valve. DAMAGE WILL OCCUR if
shut-off valve is closed during unit operation. A high pressure
switch must be installed on the heat pump side of any field
provided shut-off valves and connected to the heat pump
controls in series with the built-in refrigerant circuit high
pressure switch to disable compressor operation if water
pressure exceeds pressure switch setting. The field installed
high pressure switch shall have a cut-out pressure of 235 psig
and a cut-in pressure of 190 psig. This pressure switch can
be ordered from HCI with a 1/4” internal flare connection as
part number 39B0005N01.
x CAUTION! x
CAUTION! Refrigerant pressure activated water regulating
valves should never be used with HCI equipment.
15
HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS
Residential Split - 60Hz R22 &R410A
Rev.: 5 June, 2008
Water Quality Standards
Table 3: 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 150°F [66°C] for direct use and HWG applications,
and at 90°F [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 150°F [66°C] HWG and
Direct well, 85°F [29°C] Indirect Well HX
Iron Fouling
2+
-
-
Iron Fe
(Ferrous)
<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
All
<0.5 ppm
Maximum Allowable at maximum water temperature.
50°F (10°C)
<20ppm
<150 ppm
<400 ppm
<1000 ppm
>1000 ppm
75°F (24°C)
NR
100ϒF (38ϒC)
NR
Copper
CuproNickel
304 SS
316 SS
Titanium
-
-
-
-
-
Maximum
Chloride Levels
NR
NR
<250 ppm
<550 ppm
>550 ppm
<150 ppm
< 375 ppm
>375 ppm
Erosion and Clogging
<10 ppm of particles
and a maximum
velocity of 6 fps [1.8 m/s].
Filtered for maximum
800 micron [800mm,
20 mesh] size.
<10 ppm (<1 ppm "sandfree" for reinjection) of particlesand a maximum
velocity of 6 fps [1.8 m/s]. Filtered for maximum 800 micron [800mm,
20 mesh] size.Any particulate that is not removed can potentially
clog components.
All
Particulate Size and
Erosion
Rev.: 03/28/08S
Notes:
• Closed Recirculating system is identified by a closed pressurized piping system.
• Recirculating open wells should observe the open recirculating design considerations.
• NR - Application not recommended.
• "-" No design Maximum.
Heat Controller, Inc. Water-Source Heating and Cooling Systems
16
The Quality Leader in Conditioning Air
Residential Split - 60Hz R22 &R410A
Rev.: 5 June, 2008
Refrigeration Installation
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.
x CAUTION! x
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.
x CAUTION! x
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! Installation of a factory supplied liquid line
bi-directional filter drier is required. Never install a suction
line filter in the liquid line.
Line Set Installation
Figures 12a through 13b illustrate typical installations with
the “indoor” and “outdoor” versions of the compressor section
matched to either an air handler (fan coil) or add-on furnace
coil. Table 4 shows typical line-set diameters at various lengths.
Lineset lengths should be kept to a minimum and should always
be installed with care to avoid kinking. Line sets over 60 feet [18
meters] long are not recommended due to potential oil transport
problems and excessive pressure drop. If the line set is kinked
or distorted, and it cannot be formed back into its original shape,
the damaged portion of the line should be replaced. A restricted
line set will effect the performance of the system.
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.”
A reversible heat pump filter drier is installed on the liquid
line inside the compressor section cabinet (R-22 units only).
Installing the Indoor Coil and Lineset
Table 4: Lineset Diameters and Charge Information
Factory†
Charge (oz) Charge (oz)
Basic*
20 Feet [6 meters]
40 Feet [12 meters]
60 Feet [18 meters]
Model
Liquid
Suction
Liquid
Suction
Liquid
Suction
[kg]
[kg]
HSS Series
018
024
030
036
042
048
060
70 [1.98]
74 [2.10]
55 [1.56]
59 [1.67]
93 [2.64]
102 [2.89]
107 [3.03]
115 [3.26]
121 [3.43]
3/8”
3/8”
3/8”
3/8”
3/8”
3/8”
3/8”
3/4”
3/8”
3/8”
3/8”
3/8”
3/8”
3/8”
1/2”
3/4”
3/4”
3/8”
3/8”
3/8”
3/8”
3/8”
1/2”
1/2”
3/4”
7/8”
3/4”
108 [3.06]
117 [3.32]
122 [3.46]
130 [3.69]
136 [3.86]
3/4”
7/8”
7/8”
3/4”
7/8”
7/8”
7/8”
7/8”
7/8”
7/8”
7/8”
1-1/8”
1-1/8”
1-1/8”
1-1/8”
HTS Series
024
036
048
060
90 [2.55]
104 [2.95]
126 [3.57]
168 [4.76]
75 [2.13]
89 [2.52]
111 [3.15]
138 [3.91]
3/8”
3/8”
3/8”
1/2”
3/4”
3/8”
3/8”
3/8”
1/2”
3/4”
7/8”
3/8”
3/8”
1/2”
1/2”
7/8”
7/8”
7/8”
7/8”
7/8”
1-1/8”
1-1/8”
1-1/8”
1-1/8”
• Basic charge includes only the amount required for the condensing unit and the evaporating coil.
An additional amount should be added allowing 0.6oz per ft. for 3/8” [0.6g per cm] and 1.2oz per ft. for 1/2” [1.1g per cm] of lineset used.
†Factory charge is preset for 25’ [7.6 meters] lineset.
17
HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS
Residential Split - 60Hz R22 &R410A
Rev.: 5 June, 2008
Refrigeration Installation
Figure 10: Braze Instructions
Figure 11: Air Coil Connection
Add-On Heat Pump Applications
The 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.
The TXV should be brazed into place as shown in Figure 11,
keeping the “IN” side toward the compressor section. The
TXV has an internal check valve and must be installed in the
proper direction for operation. Always keep the valve body
cool with a brazing shield and wet rags to prevent damage to
the TXV. Attach the bulb to the suction line using the supplied
hose clamp. Be careful not to overtighten the clamp and
deform the bulb.
NOTICE! The air coil should be thoroughly washed with a
filming agent, (dishwasher detergent like Cascade) to help
condensate drainage. Apply a 20 to 1 solution of detergent
and water. Spray both sides of coil, repeat and rinse
thoroughly with water.
Table 5: Service Valve Positions
Service
Port
Closed
Open
Open
Position
Description
System
CCW - Full Out
Operation Position
Service Position
Shipping Position
Open
Open
Evacuation and Charging the Unit
CCW - Full Out 1/2 turn CW
CW - Full In
LEAK TESTING - The refrigeration line set must be 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.
Closed
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.
Heat Controller, Inc. Water-Source Heating and Cooling Systems
18
The Quality Leader in Conditioning Air
Residential Split - 60Hz R22 &R410A
Rev.: 5 June, 2008
Refrigeration Installation
Figure 12a: Typical Split/Air Handler Installation (Indoor Compressor Section)
Power
Disconnects
TXV 'IN' toward
Compressor
Section
Insulated
Linesets
PVC Condensate
with vented trap
Compressor
Section
Low Voltage
Air pad or Extruded
polystryene
Figure 12b: Typical Split/Add-on Coil Fossil Fuel Furnace Installation (Indoor Compressor Section)
Air Temperature
TXV 'IN' toward
Limit Switch
Compressor
Section
PVC Condensate
with vented trap
Compressor
Section
Air pad or Extruded
polystyrene
19
HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS
Residential Split - 60Hz R22 &R410A
Rev.: 5 June, 2008
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
ARI matched air handler.
Figure 14: Evacuation Graph
EXAMPLE: R22 model 048 with 40 feet [12 meters] of
installed liquid line (3/8” O.D.). The basic charge of model
048 is 115 oz [3.26 kg]. The 40 ft. [12 meter] 3/8” line set
requires 24 oz. [0.72 kg] (40 ft. x 0.6 oz./ft = 24 oz. -- 1200cm
x 0.6g/cm = 720g). Total charge = 115 + 24 = 139 oz [3.26 +
0.72 = 3.98 kg]. The compressor section is shipped from the
factory with 130 oz. [3.69 kg] of refrigerant (for 25 ft [7.6m]
lineset), so the amount to be added is 9 oz. [0.29 kg] (total
charge - shipped charge = charge to be added).
Table 6a: R-22 Charging Values
Table 6b: R-410A Charging Values
x NOTICE! x
x NOTICE! x
NOTICE: Use tables 14a to 15 for superheat/subcooling
values. These tables use discharge pressure (converted
to saturation temperature) and liquid line temperature
for subcooling calculations. If using liquid line pressure,
subtract 3°F from the table values.
NOTICE: Use tables 14a to 15 for superheat/subcooling
values. These tables use discharge pressure (converted
to saturation temperature) and liquid line temperature
for subcooling calculations. If using liquid line pressure,
subtract 3°F from the table values.
Heat Controller, Inc. Water-Source Heating and Cooling Systems
20
The Quality Leader in Conditioning Air
Residential Split - 60Hz R22 &R410A
Rev.: 5 June, 2008
Refrigeration Installation
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.”
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.
Checking Superheat and Subcooling
Determining Superheat:
1. Measure the temperature of the suction line at a point
near the expansion valve bulb.
2. Determine the suction pressure by attaching refrigeration
gauges to the suction schrader connection at the
compressor.
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.
Example (R-22 refrigerant):
The temperature of the suction line at the sensing bulb is
50°F. The suction pressure at the compressor is 65 psig
which is equivalent to 38°F saturation temperature from the
R-22 press/temp conversion table on the gauge set.
38°F subtracted from 50°F = 12°F Superheat.
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.”
Determining Sub-Cooling:
1. Measure the temperature of the liquid line on the smaller
refrigerant line (liquid line) just outside of the cabinet.
This location will be adequate for measurement in both
modes unless a significant temperature drop in the liquid
line is anticipated.
2. Determine the condensor pressure (high side) by
attaching refrigerant gauges to the schrader connection
on the liquid line service valve. If the hot gas discharge
line of the compressor is used, refer to the appropriate
column in Tables 14a to 15.
3. Convert the pressure obtained in step 2 to the
saturation temperature by using the press/temp
conversion table on the gauge set.
4. Subtract the temperature of Step 3 from the temperature
of Step 1. The difference will be the sub-cooling value for
that unit (total degrees below the saturation temperature).
Refer to Tables 14a or 6b for sub-cooling values at specific
entering water temperatures.
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
Example (R-22 refrigerant):
The condenser pressure at the service port is 225 psig,
which is equivalent to 110°F saturation temperature.
Discharge pressure is 236 psig at the compressor (113°F
saturation temperature). Measured liquid line temperature
is 100°F. 100°F subtracted from 110°F = 10 degrees sub-
cooling (13 degrees if using the compressor discharge
pressure).
21
HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS
Residential Split - 60Hz R22 &R410A
Rev.: 5 June, 2008
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.
source water to the HWG. Using a concentric or coaxial
hot water tank connection fitting eliminates the need to
tie into the hot water tank cold water piping, but is more
susceptible to scaling. The optional concentric fitting
(part # S69619804) is available from your equipment
supplier and should be installed as shown in Figure
17 for applications with low scaling potential or where
a water softener is used. Consult Table 3 for scaling
potential tests.
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
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 conditions, it may be necessary to avoid the use of
circuit in the field. The control circuit and pump are also the HWG option since the potential cost of frequent
built in for residential equipment. Figure 15 shows a
typical example of HWG water piping connections on
a unit with built-in pump. This piping layout minimizes
scaling potential.
maintenance may offset or exceed any savings.
R-410 systems inherently have a lower hot gas
temperature than R-22 systems because the
equipment is more efficient (i.e. less waste heat
is available). It is possible that energy could be
transferred from the water heater to the hot gas line
instead of from the hot gas line to the water heater
during certain times of the year. To prevent this from
occuring, a temperature switch will deactivate the
pump at those conditions that typically occur in the
cooling mode with entering water temperatures of less
than 50°F [10°C].
Electric water heaters are recommended. If a gas,
propane, or oil water heater is used, a second preheat
tank must be installed (Figure 16). If the electric water
heater has only a single center element, the dual tank
system is recommended to insure a usable entering
water temperature for the HWG.
Typically a single tank of at least 52 gallons (235 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
Figure 15: Typical HWG Installation
(Indoor Compressor Section)
Figure 16: HWG Double Tank Installation
(Indoor Compressor Section)
Heat Controller, Inc. Water-Source Heating and Cooling Systems
22
The Quality Leader in Conditioning Air
Residential Split - 60Hz R22 &R410A
Rev.: 5 June, 2008
HotWater Generator
Figure 17: Alternate HWG Piping with concentric/coaxial
fitting (part #S69619804 not included with unit)
(Indoor Compressor Section)
Water Tank Refill
1. Open the cold water supply to the tank.
2. Open a hot water faucet to vent air from the system until
water flows from the faucet; turn off faucet.
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.
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 (figure
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. Turn the heat pump and heat pump power supply “OFF”
and CONNECT POWER TO THE HWG PUMP as shown
in the unit wiring diagram. Connect the pump power lead
as instructed on the tag attached to the pump wiring.
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].
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.
[15 m].
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
connect the pump wiring until “Initial Start-Up” section, below.
Powering the pump before all installation steps are completed
will damage the pump.
6. Allow the unit to operate for 20 to 30 minutes to insure
that it is functioning properly.
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.
HWG Water Piping
1. Using at least 5/8” [16mm] O.D. copper, route and install
the water piping, valves and air vent as shown in Figures
15 to 18. The air vent MUST be at the high point of the
HWG water piping.
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.
23
HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS
Residential Split - 60Hz R22 &R410A
Rev.: 5 June, 2008
HotWater Generator Module Refrigeration Installation
x CAUTION! x
CAUTION! The HWG module must be installed in an area
x WARNING! x
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.
that is not subject to freezing temperatures.
NOTICE! Make sure the compressor discharge line
is connected to the “Hot Gas In” stub on the Heat
Recovery Unit.
x CAUTION! x
CAUTION! Locate Refrigerant lines to avoid accidental
damage by lawnmowers or children.
Heat Controller, Inc. Water-Source Heating and Cooling Systems
24
The Quality Leader in Conditioning Air
Residential Split - 60Hz R22 &R410A
Rev.: 5 June, 2008
Electrical - LineVoltage
flexible conduit to minimize vibration and sound transmission
x WARNING! x
to the building.
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.
x CAUTION! x
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 21a through 21c. Consult Tables 8a through 8c for
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.
All final electrical connections must be made with a length of
Table 8a: GeoMax 2 (HTS) Series Electrical Data
HWG
Pump
FLA
External
Pump
FLA
Total
Unit
FLA
Min
Circuit
Amps
Max
Fuse/
HACR
Max Wire
Ft.
Compressor
LRA
Min
AWG
Model
RLA
Qty
(m)
024
036
048
060
10.3
16.7
21.2
25.6
52.0
82.0
96.0
118.0
1
1
1
1
0.4
0.4
0.4
0.4
4.0
4.0
4.0
4.0
14.7
21.1
25.6
30.0
17.3
25.3
30.9
36.4
25
40
50
60
10
10
8
107 (32.7)
73 (22.3)
95 (29.2)
81 (24.8)
8
Rated Voltage of 208/230/60/1
HACR circuit breaker in USA only
Min/Max Voltage of 197/254
All fuses Class RK-5
Wire length based on one way measurement with 2% voltage drop
Wire size based on 60°C copper conductor and Minimum Circuit Ampacity.
Table 8b: HSS Series Electrical Data
HWG
Pump
FLA
External
Pump
FLA
Total
Unit
FLA
Min
Circuit
Amps
Max
Fuse/
HACR
Max Wire
Compressor
LRA
Min
AWG
Model
Ft
(m)
RLA
Qty
7.7
40.3
56.0
1
1
1
1
1
1
1
0.40
0.40
0.40
0.40
0.40
0.40
0.40
4.0
4.0
4.0
4.0
4.0
4.0
4.0
12.1
14.7
16.6
17.9
20.9
22.7
29.4
14.0
17.3
19.7
21.3
25.0
27.3
35.7
20
25
30
35
40
45
60
12
10
10
10
10
10
8
76 (23.3)
107 (32.7)
94 (28.7)
87 (26.5)
74 (22.6)
67 (20.7)
82 (25.2)
018
024
030
036
042
048
060
10.3
12.2
13.5
16.5
18.3
25.0
67.0
73.0
95.0
109.0
148.0
Rated Voltage of 208/230/60/1
HACR circuit breaker in USA only
Min/Max Voltage of 197/254
All fuses Class RK-5
Wire length based on one way measurement with 2% voltage drop
Wire size based on 60°C copper conductor and Minimum Circuit Ampacity.
25
HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS
Residential Split - 60Hz R22 &R410A
Rev.: 5 June, 2008
Electrical - LineVoltage
ELECTRICAL - POWER WIRING
Electrical - Line Voltage
Figure 21b: R-22 Indoor Compressor Section Line
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.
Voltage Field Wiring
All final electrical connections must be made with a length of
flexible conduit to minimize vibration and sound transmission
to the building.
General Line Voltage Wiring
Be sure the available power is the same voltage and phase
shown on the unit serial plate. Line and low voltage wiring
must be done in accordance with local codes or the National
Electric Code, whichever is applicable.
Power Connection
208-230 Volt Operation
Line voltage connection is made by connecting the incoming
line voltage wires to the “L” side of the contactor as shown in
Figures 21a through 21c. Consult Tables 8a through 8c for
correct fuse size.
Verify transformer tap with air handler wiring diagram to
insure that the transformer tap is set to the correct voltage,
208V or 230V.
Figure 21a: R-410A Compressor Section Line Voltage
Field Wiring
Unit Power Supply
(see electrical table for wire
and breaker size)
Heat Controller, Inc. Water-Source Heating and Cooling Systems
26
The Quality Leader in Conditioning Air
Residential Split - 60Hz R22 &R410A
Rev.: 5 June, 2008
Electrical - HWGWiring
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.
ELECTRICAL - LOW VOLTAGE WIRING
Thermostat Connections
Low Water Temperature Cutout Selection
The thermostat should be wired directly to the CXM board.
Figures 22a through 22c show low voltage wiring. Note that
the air handler or furnace transformer will be used to power
the CXM board in the compressor section. See “Electrical –
Thermostat” for specific terminal connections.
The CXM 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 FP1. Note that the FP1 thermistor is located on
the refrigerant line between the coaxial heat exchanger and
expansion device (TXV). Therefore, FP1 is sensing refrigerant
temperature, not water temperature, which is a better indication
of how water flow rate/temperature is affecting the refrigeration
circuit.
Figure 22a: HTS Low Voltage Field Wiring
The factory setting for FP1 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].
Low voltage
field wiring
Figure 22b: HSS Low Voltage Field Wiring
Capacitor
Circ Brkr
LoopPB1
HWG PB2
Grnd
Contactor-CC
L1
L2
BR
CXM Contro l
Low Voltage
Connector
27
HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS
Residential Split - 60Hz R22 &R410A
Rev.: 5 June, 2008
Electrical - LowVoltageWiring
Figure 23: FP1 Limit Setting
electromechanical thermostat. Therefore, only relay or triac
based thermostats should be used.
Two-stage HTS Units
Two-stage units should be designed with two parallel valves
for ground water applications to limit water use during first
stage operation. For example, at 1.5 gpm/ton [2.0 l/m per
kW], a model 049 unit requires 6 gpm [23 l/m] for full load
(2nd stage) operation, but only 4 gpm [15 l/m] during 1st
stage operation. Since the unit will operate on first stage
80-90% of the time, significant water savings can be realized
by using two parallel solenoid valves with two flow regulators.
In the example above, stage one solenoid would be installed
with a 4 gpm [15 l/m] flow regulator on the outlet, while stage
two would utilize a 2 gpm [8 l/m] flow regulator. When stage
one is operating, the second solenoid valve will be closed.
When stage two is operating, both valves will be open,
allowing full load flow rate.
JW3-FP1 jumper
should be clipped
for low temperature
operation
CXM PCB
Accessory Connections
A terminal paralleling the compressor contactor coil has been
provided on the CXM control. Terminal “A” is designed to
control accessory devices, such as water valves. Note: This
terminal should be used only with 24 Volt signals and not
line voltage. Terminal “A” is energized with the compressor
contactor. See Figure 24 or the specific unit wiring diagram
for details.
Figure 27 illustrates piping for two-stage solenoid valves.
Review figures 24-26 for wiring of stage one valve. Stage two
valve should be wired between “Y2” (compressor solenoid
-- wire nut connection) and terminal “C.” NOTE: When EWT
is below 50°F [10°C], a minimum of 2 gpm per ton (2.6 l/m
per kW) is required.
Figure 24: Accessory Wiring
Figure 25: AMV Valve Wiring
2
AMV
Taco Valve
3
1
Heater Switch
Water Solenoid Valves - “Indoor” Compressor
Section Only
An external solenoid valve(s) should be used on ground
water installations to shut off flow to the unit when the
compressor is not operating. A slow closing valve may be
required to help reduce water hammer. Figure 24 shows
typical wiring for a 24VAC external solenoid valve. Figures
25 and 26 illustrate typical slow closing water control valve
wiring for Taco 500 series (HCI P/N AVM…) and Taco ESP
series valves. Slow closing valves take approximately
60 seconds to open (very little water will flow before 45
seconds). Once fully open, an end switch allows the
compressor to be energized. Only relay or triac based
electronic thermostats should be used with slow closing
valves. When wired as shown, the slow closing valve will
operate properly with the following notations:
Thermostat
Figure 26: Taco SBV Valve Wiring
1. The valve will remain open during a unit lockout.
2. The valve will draw approximately 25-35 VA through the
“Y” signal of the thermostat.
Note: This valve can overheat the anticipator of an
Heat Controller, Inc. Water-Source Heating and Cooling Systems
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Electrical - LowVoltageWiring
Figure 27: Two-Stage HTS Piping
x CAUTION! x
CAUTION! Refrigerant pressure activated water regulating
valves should never be used with HCI equipment.
Figure 28b: Typical Thermostat Wiring, HSS Single-Stage
Units (2 Heat/1 Cool)
x CAUTION! x
CAUTION! Many units installed with a factory or field supplied
manual or electric shut-off valve. DAMAGE WILL OCCUR if
shut-off valve is closed during unit operation. A high pressure
switch must be installed on the heat pump side of any field
provided shut-off valves and connected to the heat pump
controls in series with the built-in refrigerant circuit high
pressure switch to disable compressor operation if water
pressure exceeds pressure switch setting. The field installed
high pressure switch shall have a cut-out pressure of 235 psig
and a cut-in pressure of 190 psig. This pressure switch can
be ordered from HCI with a 1/4” internal flare connection as
part number 39B0005N01.
ELECTRICAL - THERMOSTAT WIRING
Thermostat Installation
The thermostat should be located on an interior wall in a
larger room, away from supply duct drafts. DO NOT locate
the thermostat in areas subject to sunlight, drafts or on
external walls. The wire access hole behind the thermostat
may in certain cases need to be sealed to prevent erroneous
temperature measurement. Position the thermostat back
plate against the wall so that it appears level and so the
thermostat wires protrude through the middle of the back
plate. Mark the position of the back plate mounting holes and
drill holes with a 3/16” (5mm) bit. Install supplied anchors
and secure plate to the wall. Thermostat wire must be 18
AWG wire. Wire the appropriate thermostat as shown in
Figures 28a and 28b to the low voltage terminal strip on the
CXM control board. Practically any heat pump thermostat will
work with these units, provided it has the correct number of
heating and cooling stages.
Figure 28a: Typical Thermostat Wiring, Two-Stage HTS
Units (3 Heat/2 Cool)
29
HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS
Residential Split - 60Hz R22 &R410A
Rev.: 5 June, 2008
CXM Controls
CXM Control
terminal will continuously output the last fault code of
For detailed control information, see CXM Application,
Operation and Maintenance (IOM) manual.
the controller. If set to “EH2 normal,” EH2 will operate as
standard electric heat output.
On = EH2 Normal. Off = DDC Output at EH2.
NOTE: Some CXM controls only have a 2 position DIP switch
package. If this is the case, this option can be selected by
clipping the jumper which is in position 4
of SW1.
Jumper not clipped = EH2 Normal. Jumper clipped = DDC
Output at EH2.
DIP switch 5: Factory Setting - Normal position is “On.” Do
not change selection unless instructed to do so by
the factory.
Field Selectable Inputs
Test mode: Test mode allows the service technician to check
the operation of the control in a timely manner. By momentarily
shorting the test terminals, the CXM control enters a 20
minute test mode period in which all time delays are sped up
15 times. Upon entering test mode, the status LED will flash
a code representing the last fault. For diagnostic ease at the
thermostat, the alarm relay will also cycle during test mode.
The alarm relay will cycle on and off similar to the status LED
to indicate a code representing the last fault, at the thermostat.
Test mode can be exited by shorting the test terminals for 3
seconds.
-Slow Flash = 1 flash every 2 seconds
-Fast Flash = 2 flashes every 1 second
-Flash code 2 = 2 quick flashes, 10 second pause, 2 quick
flashes, 10 second pause, etc.
Retry Mode: If the control is attempting a retry of a fault, the
status LED will slow flash (slow flash = one flash every 2
seconds) to indicate the control is in the process of retrying.
-On pulse 1/3 second; off pulse 1/3 second
Table 9a: CXM LED And Alarm
Relay Operations
Field Configuration Options
Note: In the following field configuration options, jumper wires
should be clipped ONLY when power is removed from the
CXM control.
Water coil low temperature limit setting: Jumper 3 (JW3-
FP1 Low Temp) provides field selection of temperature limit
setting for FP1 of 30°F or 10°F [-1°F or -12°C] (refrigerant
temperature).
Not Clipped = 30°F [-1°C]. Clipped = 10°F [-12°C].
Air coil low temperature limit setting: Jumper 2 (JW2-FP2
Low Temp) provides field selection of temperature limit
setting for FP2 of 30°F or 10°F [-1°F or -12°C] (refrigerant
temperature). Note: This jumper should only be clipped
under extenuating circumstances, as recommended by
the factory.
Not Clipped = 30°F [-1°C]. Clipped = 10°F [-12°C].
Alarm relay setting: Jumper 1 (JW1-AL2 Dry) provides field
selection of the alarm relay terminal AL2 to be jumpered to
24VAC or to be a dry contact (no connection).
Not Clipped = AL2 connected to R. Clipped = AL2 dry contact
(no connection).
DIP Switches
Note: In the following field configuration options, DIP
switches should only be changed when power is removed
from the CXM control.
DIP switch 1: Unit Performance Sentinel Disable - provides
field selection to disable the UPS feature.
On = Enabled. Off = Disabled.
DIP switch 2: Stage 2 Selection - provides selection of
whether compressor has an “on” delay. If set to stage 2, the
compressor will have a 3 second delay before energizing.
Also, if set for stage 2, the alarm relay will NOT cycle during
test mode.
On = Stage 1. Off = Stage 2
DIP switch 3: Not Used.
DIP switch 4: DDC Output at EH2 - provides selection for
DDC operation. If set to “DDC Output at EH2,” the EH2
Heat Controller, Inc. Water-Source Heating and Cooling Systems
30
The Quality Leader in Conditioning Air
Residential Split - 60Hz R22 &R410A
Rev.: 5 June, 2008
CXM Controls
Safety Features – CXM Control
must be below the selected low temperature limit setting for
30 continuous seconds during a compressor run cycle to be
recognized as a FP2 fault. The FP2 input is bypassed for the
initial 60 seconds of a compressor run cycle. FP2 is set at the
factory for one try. Therefore, the control will go into lockout mode
once the FP2 fault has occurred.
The safety features below are provided to protect the
compressor, heat exchangers, wiring and other components
from damage caused by operation outside of design
conditions.
Anti-short cycle protection: The control features a 5 minute
anti-short cycle protection for the compressor.
FP2 lockout code = 5
Condensate overflow: The condensate overflow sensor
must sense overflow level for 30 continuous seconds to
be recognized as a CO fault. Condensate overflow will be
monitored at all times.
Note: The 5 minute anti-short cycle also occurs at power up.
Random start: The control features a random start upon power
up of 5-80 seconds.
CO lockout code = 6
Fault Retry: In Fault Retry mode, the Status LED begins slowly
flashing to signal that the control is trying to recover from a
fault input. The control will stage off the outputs and then “try
again” to satisfy the thermostat input call. Once the thermostat
input call is satisfied, the control will continue on as if no fault
occurred. If 3 consecutive faults occur without satisfying the
thermostat input call, the control will go into “lockout” mode.
The last fault causing the lockout will be stored in memory and
can be viewed by going into test mode. Note: FP1/FP2 faults
are factory set at only one try.
Over/under voltage shutdown: An over/under voltage condition
exists when the control voltage is outside the range of 19VAC
to 30VAC. Over/under voltage shut down is a self-resetting
safety. If the voltage comes back within range for at least 0.5
seconds, normal operation is restored. This is not considered
a fault or lockout. If the CXM is in over/under voltage shutdown
for 15 minutes, the alarm relay will close.
Over/under voltage shut down code = 7
Unit Performance Sentinel-UPS (patent pending): The UPS
feature indicates when the heat pump is operating inefficiently.
A UPS condition exists when:
Lockout: In lockout mode, the status LED will begin fast
flashing. The compressor relay is turned off immediately.
Lockout mode can be “soft” reset by turning off the thermostat
(or satisfying the call). A “soft” reset keeps the fault in memory
but resets the control. A “hard” reset (disconnecting power to
the control) resets the control and erases fault memory.
Lockout with emergency heat: While in lockout mode, if W
becomes active (CXM), emergency heat mode will occur.
High pressure switch: When the high pressure switch opens due
to high refrigerant pressures, the compressor relay is de-energized
immediately since the high pressure switch is in series with the
compressor contactor coil. The high pressure fault recognition is
immediate (does not delay for 30 continuous seconds before de-
energizing the compressor).
a) In heating mode with compressor energized, FP2 is
greater than 125°F [52°C] for 30 continuous seconds, or:
b) In cooling mode with compressor energized, FP1 is
greater than 125°F [52°C] for 30 continuous seconds, or:
c) In cooling mode with compressor energized, FP2 is less
than 40°F [4.5°C] for 30 continuous seconds. If a UPS
condition occurs, the control will immediately go to UPS
warning. The status LED will remain on as if the control
is in normal mode. Outputs of the control, excluding LED
and alarm relay, will NOT be affected by UPS. The UPS
condition cannot occur during a compressor off cycle.
During UPS warning, the alarm relay will cycle on and
off. The cycle rate will be “on” for 5 seconds, “off” for 25
seconds, “on” for 5 seconds, “off” for 25 seconds, etc.
UPS warning code = 8
Swapped FP1/FP2 thermistors: During test mode, the control
monitors to see if the FP1 and FP2 thermistors are in the
appropriate places. If the control is in test mode, the control will
lockout, with code 9, after 30 seconds if:
a) The compressor is on in the cooling mode and the FP1
sensor is colder than the FP2 sensor, or:
b) The compressor is on in the heating mode and the FP2
sensor is colder than the FP1 sensor.
Swapped FP1/FP2 thermistor code = 9.
High pressure lockout code = 2
Example: 2 quick flashes, 10 sec pause, 2 quick flashes, 10
sec. pause, etc.
Low pressure switch: The low pressure switch must be open and
remain open for 30 continuous seconds during “on” cycle to be
recognized as a low pressure fault. If the low pressure switch
is open for 30 seconds prior to compressor power up it will be
considered a low pressure (loss of charge) fault. The low pressure
switch input is bypassed for the initial 60 seconds of a compressor
run cycle.
Diagnostic Features
Low pressure lockout code = 3
The LED on the CXM board advises the technician of the
current status of the CXM control. The LED can display either
the current CXM mode or the last fault in memory if in test
mode. If there is no fault in memory, the LED will flash Code 1
(when in test mode).
Water coil low temperature (FP1): The FP1 thermistor
temperature must be below the selected low temperature limit
setting for 30 continuous seconds during a compressor run cycle
to be recognized as a FP1 fault. The FP1 input is bypassed for
the initial 60 seconds of a compressor run cycle. FP1 is set at the
factory for one try. Therefore, the control will go into lockout mode
once the FP1 fault has occurred.
FP1 lockout code = 4
Air coil low temperature (FP2): The FP2 thermistor temperature
31
HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS
Residential Split - 60Hz R22 &R410A
Rev.: 5 June, 2008
Heat Controller, Inc. Water-Source Heating and Cooling Systems
32
The Quality Leader in Conditioning Air
Residential Split - 60Hz R22 &R410A
Rev.: 5 June, 2008
CXM Controls
CXM Control Start-up Operation
The control will not operate until all inputs and safety controls
are checked for normal conditions. The compressor will have a
5 minute anti-short cycle delay at power-up. The 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.
Table 9b: Unit Operation
HTS
HSS
HSS
T-stat signal
Variable Speed
Air Handler
Variable Speed
Air Handler
PSC Air Handler
G
Fan only
Fan only
Fan only
Stage 1 heating5
Stage 2 heating5
N/A
G, Y or Y1
G, Y1, Y2
G, Y1, Y2, W
G, W
Stage 1 heating1
Stage 2 heating1
Stage 3 heating1
Emergency heat
Stage 1 cooling2
Stage 2 cooling2
Stage 1 heating3
Stage 2 heating3
Stage 3 heating3
Emergency heat
Stage 1 cooling4
Stage 2 cooling4
Emergency heat
Cooling6
G, Y or Y1, O
G, Y1, Y2, O
N/A
1
Stage 1 = 1st stage compressor, 1st stage fan operation
Stage 2 = 2nd stage compressor, 2nd stage fan operation
Stage 3 = 2nd stage compressor, auxiliary electric heat, 2nd
or 3rd stage fan operation (depending on fan settings)
2
3
Stage 1 = 1st stage compressor, 1st stage fan operation, reversing valve
Stage 2 = 2nd stage compressor, 2nd stage fan operation, reversing valve
Stage 1 = compressor, 1st stage fan operation
Stage 2 = compressor, 2nd stage fan operation
Stage 3 = compressor, auxiliary electric heat, 2nd or 3rd stage fan operation (depending on fan settings)
Stage 1 = compressor, 1st stage fan operation, reversing valve
Stage 2 = compressor, 2nd stage fan operation, reversing valve
Stage 1 = compressor, fan
Stage 2 = compressor, auxiliary electric heat, fan
Cooling = compressor, fan, reversing valve
4
5
6
33
HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS
Residential Split - 60Hz R22 &R410A
Rev.: 5 June, 2008
CXM Controls
Table 10: Nominal resistance at
various temperatures
CXM Thermostat Details
Thermostat Compatibility - Most all heat pump thermostats
can be used with the CXM control. However Heat/Cool stats
are NOT compatible with the CXM.
ϒ
ϒ
ϒ
ϒ
Anticipation Leakage Current - Maximum leakage current
for "Y" is 50 mA and for "W" is 20mA. Triacs can be used
if leakage current is less than above. Thermostats with
anticipators can be used if anticipation current is less than
that specified above.
Thermostat Signals -
• "Y" and "W" have a 1 second recognition time when
being activated or being removed.
• "O" and "G" are direct pass through signals but are
monitored by the micro processor.
• "R" and "C" are from the transformer.
• "AL1" and "AL2" originate from the alarm relay.
• "A" is paralleled with the compressor output for use
with well water solenoid valves.
• The "Y" 1/4" quick connect is a connection point to the
"Y" input terminal P1 for factory use. This "Y" terminal
can be used to drive panel mounted relays such as the
loop pump relay.
Heat Controller, Inc. Water-Source Heating and Cooling Systems
34
The Quality Leader in Conditioning Air
Residential Split - 60Hz R22 &R410A
Rev.: 5 June, 2008
Unit Starting and Operating Conditions
Operating Limits
2. Voltage utilization range complies with ARI
Standard 110.
Environment – “Indoor” compressor section is designed for
indoor installation only. Never install “indoor” compressor
section in areas subject to freezing or where humidity levels
could cause cabinet condensation (such as unconditioned
spaces subject to 100% outside air). “Outdoor” unit is designed
for conditions where ambient air is below freezing (see Table
11).
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.
Power Supply – A voltage variation of +/– 10% of nameplate
utilization voltage is acceptable.
Extreme variations in temperature and humidity and/or
corrosive water or air will adversely affect unit performance,
reliability, and service life.
Starting Conditions
Consult Table 11 for the particular model. Starting conditions
vary depending upon model and are based upon the
following notes:
Notes:
1. Conditions in Table 11 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.
Table 11: Unit Operation
HTS/HSS
Operating 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
Max. entering air, DB/WB
Water Limits
45°F [7°C]
80.6°F [27°C]
39°F [4°C]
68°F [20°C]
85°F [29°C]
40°F [4.5°C]
68°F [20°C]
80°F [27°C]
110°F [43°C]
50°F [10°C]
80.6/66.2°F [27/19°C]
110/83°F [43/28°C]
Min. entering water
30°F [-1°C]
50-110°F [10-43°C]
120°F [49°C]
20°F [-6.7°C]
30-70°F [-1 to 21°C]
90°F [32°C]
Normal entering water
Max. entering water
1.5 to 3.0 gpm/ton
Normal water flow
2.0 to 3.9 l/m per kW
35
HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS
Residential Split - 60Hz R22 &R410A
Rev.: 5 June, 2008
Unit Starting and Operating Conditions
Unit and System Checkout
BEFORE POWERING SYSTEM, please check the following:
�
�
System controls: Verify that system controls function and
operate in the proper sequence.
Low water temperature cutout: Verify that low water
temperature cut-out controls are set properly
(FP1 - JW3).
UNIT CHECKOUT
�
Balancing/shutoff valves: Insure that all isolation valves
are open and water control valves are wired.
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.
�
Miscellaneous: Note any questionable aspects of
the installation.
�
x CAUTION! x
�
�
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! Verify that ALL water control 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.
�
�
Antifreeze has been added if necessary.
NOTICE! Failure to remove shipping
Entering water and air: Insure that entering water and air
temperatures are within operating limits of Table 7.
Low water temperature cutout: Verify that low water
temperature cut-out on the CXM 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 line is open and
properly pitched toward drain.
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 air coil and filters: Insure that filter is clean and
accessible. Clean air coil of all manufacturing oils.
Unit controls: Verify that CXM field selection options are
properly set. Low voltage wiring is complete.
Blower speed is set.
brackets from spring-mounted compressors
will cause excessive noise, and could cause
component failure due to added vibration.
�
�
x CAUTION! x
CAUTION! To avoid equipment damage, DO NOT
leave system filled in a building without heat during the
winter unless antifreeze is added to the water loop. Heat
exchangers never fully drain by themselves and will freeze
unless winterized with antifreeze.
�
�
�
Unit Start-up Procedure
1. 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 11. During start-up checks,
loop water temperature entering the heat pump should
be between 30°F [-1°C] and 95°F [35°C].
5. Two factors determine the operating limits of water
source 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.
a. Adjust the unit thermostat to the warmest setting.
Place the thermostat mode switch in the “COOL”
position. Slowly reduce thermostat setting until the
compressor activates.
�
�
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.
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 3).
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.
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 eliminated on the CXM
control board as shown below in Figure 29. See
controls description for details.
�
Flow Controller pump(s): Verify that the pump(s) is wired
and in operating condition.
c. Verify that the compressor is on and that the water
Heat Controller, Inc. Water-Source Heating and Cooling Systems
36
The Quality Leader in Conditioning Air
Residential Split - 60Hz R22 &R410A
Rev.: 5 June, 2008
Unit Start-Up Procedure
flow rate is correct by measuring pressure drop
through the heat exchanger using the P/T plugs and
comparing to Tables 12a through 12b.
(see troubleshooting section). 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.
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.
8. When testing is complete, set system to maintain
desired comfort level.
9. BE CERTAIN TO FILL OUT AND RETURN ALL
WARRANTY REGISTRATION PAPERWORK.
e. Refer to Table 13. Check the temperature of both
entering and leaving water. If temperature is within
range, proceed with the test. If temperature is outside
of the operating range, check refrigerant pressures
and compare to Tables 14 and 15. Verify correct
water flow by comparing unit pressure drop across
the heat exchanger versus the data in Tables 12a
through 12b. Heat of rejection (HR) can be calculated
and compared to catalog data capacity pages. The
formula for HR for systems with water is as follows:
HR = TD x GPM x 500, 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 pressure drop across the heat
exchanger to Tables 12a through 12b.
Note: If performance during any mode appears abnormal,
refer to the CXM section or troubleshooting section of this
manual. To obtain maximum performance, the air coil should
be cleaned before start-up. A 10% solution of dishwasher
detergent and water is recommended.
x WARNING! x
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.
f. Check air temperature drop across the air coil when
compressor is operating. Air temperature drop should
be between 15°F and 25°F [8°C and 14°C].
x CAUTION! x
CAUTION! Verify that ALL water control 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.
g. Turn thermostat to “OFF” position. A hissing noise
indicates proper functioning of the reversing valve.
6. Allow five (5) minutes between tests for pressure to
equalize before beginning heating test.
a. Adjust the thermostat to the lowest setting. Place the
thermostat mode switch in the “HEAT” position.
b. Slowly raise the thermostat to a higher temperature
until the compressor activates.
c. Check for warm air delivery within a few minutes after
the unit has begun to operate.
Figure 29: Test Mode Pins
Short test pins together
to enter Test Mode and
speed-up timing and delays
for 20 minutes.
d. Refer to Table 13. Check the temperature of both
entering and leaving water. If temperature is within
range, proceed with the test. If temperature is outside
of the operating range, check refrigerant pressures
and compare to Tables 14 and 15 Verify correct water
flow by comparing unit pressure drop across the heat
exchanger versus the data in Tables 12a through
12b. Heat of extraction (HE) can be calculated and
compared to submittal data capacity pages. The
formula for HE for systems with water is as follows:
HE = TD x GPM x 500, 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 pressure drop across the heat
exchanger to Tables 12a through 12b.
e. Check air temperature rise across the air coil when
compressor is operating. Air temperature rise should
be between 20°F and 30°F [11°C and 17°C].
f. Check for vibration, noise, and water leaks.
7. If unit fails to operate, perform troubleshooting analysis
37
HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS
Residential Split - 60Hz R22 &R410A
Rev.: 5 June, 2008
Unit Operating Conditions
Table 12a: Two-Stage HTS R-410A Compressor Section
Coax Water Pressure Drop
Table 13: Water Temperature Change Through Heat
Exchanger
Pressure Drop (psi)
������������� �������������
���������������������
���������������������������������������������
�����������������������������������������
Model
024
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
036
048
060
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 12b: R-22 HSS Compressor Section Coax Water
Pressure Drop
Pressure Drop (psi)
Model
018
GPM
30°F
50°F
70°F
90°F
2
4
5
6
0.6
1.6
2.1
2.8
0.6
1.4
2.0
2.6
0.5
1.3
1.8
2.4
0.5
1.3
1.7
2.3
3
5
6
8
0.6
1.3
1.8
2.9
0.6
1.2
1.7
2.7
0.5
1.1
1.5
2.5
0.5
1.1
1.4
2.3
024
030
036
042
048
060
4
6
8
0.9
1.8
2.9
4.2
0.9
1.7
2.7
3.9
0.8
1.5
2.5
3.6
0.8
1.4
2.3
3.4
10
5
7
9
1.6
2.6
3.9
6.4
1.4
2.4
3.7
5.9
1.3
2.3
3.4
5.5
1.3
2.1
3.2
5.2
12
6
8
11
13
2.1
3.2
5.5
7.3
1.9
3.0
5.1
6.8
1.8
2.8
4.7
6.3
1.7
2.6
4.5
5.9
6
9
12
15
2.1
3.9
6.4
9.4
1.9
3.7
5.9
8.7
1.8
3.4
5.5
8.1
1.7
3.2
5.2
7.6
8
1.2
2.1
3.6
5.0
1.2
2.0
3.4
4.7
1.1
1.8
3.1
4.3
1.0
1.7
2.9
4.1
11
15
18
Heat Controller, Inc. Water-Source Heating and Cooling Systems
38
The Quality Leader in Conditioning Air
Residential Split - 60Hz R22 &R410A
Rev.: 5 June, 2008
Unit Operating Conditions
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
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
90
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
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
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
90
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
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
30
30
30
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
50
50
50
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
70
70
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
90
90
90
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
110
110
110
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
Operation Not Recommended
39
HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS
Residential Split - 60Hz R22 &R410A
Rev.: 5 June, 2008
Unit Operating Conditions
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
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
90
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
Table 15: R-22 HSS Typical Unit Operating Pressures and Temperatures
Full Load Cooling - without HWG active
Full Load Heating - without HWG active
Water
Flow
GPM/
ton
Entering
Water
Temp °F
Suction
Pressure
PSIG
Discharge
Pressure
PSIG
Sub-
cooling
****
Air Temp
Drop °F
DB
Suction
Pressure
PSIG
Discharge
Pressure
PSIG
Sub-
cooling
****
Air Temp
Rise °F
DB
Super-
heat
Water Temp
Rise *** °F
Super-
heat
Water Temp
Drop *** °F
1.5
2.3
3
61-70
62-71
62-71
100-117
92-109
88-104
12-18
12-18
12-18
12-22
12-22
12-22
21-24
13-16
6-11
21-26
21-26
21-26
34-39
37-42
38-44
163-183
165-185
167-186
5-10
5-10
5-10
5-9
5-9
5-9
7.6-8.4
4.8-5.6
3.4-4.2
14-20
16-22
16-22
30
50
70
90
1.5
2.3
3
79-85
75-83
72-82
145-170
130-155
125-150
10-15
10-15
10-15
9-16
9-16
9-16
20-23
12-15
8-12
20-25
20-25
20-25
51-58
53-62
55-65
175-202
178-206
180-208
9-12
9-12
9-12
8-12
8-12
8-12
10.8-11.9
6.7-8.1
5.1-5.9
23-29
24-30
25-31
1.5
2.3
3
78-88
78-90
78-91
180-200
169-187
160-180
8-12
8-12
8-12
7-12
7-12
7-12
19-22
11-14
7-12
19-24
19-24
19-24
71-82
77-89
81-92
215-250
203-235
200-235
10-14
10-14
10-14
6-10
6-10
6-10
14.0-15.2
9.0-10.2
6.7-7.9
28-34
30-37
31-38
1.5
2.3
3
79-82
80-93
80-93
230-272
215-248
208-240
8-10
8-10
8-10
7-11
7-11
7-11
18-21
10-14
6-11
17-23
17-23
17-23
Operation Not Recommended
* Based on Nominal 400 CFM per ton per circuit ariflow and 70°F EAT heating and 80/67°F cooling.
** Cooling air and water numbers can vary greatly with changes in humidity.
*** Water temperature difference based upon 1.5 - 3 GPM per ton of active circuit water flow.
**** Using liquid line pressure.
Heat Controller, Inc. Water-Source Heating and Cooling Systems
40
The Quality Leader in Conditioning Air
Residential Split - 60Hz R22 &R410A
Rev.: 5 June, 2008
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
The air coil must be cleaned to obtain maximum
performance. Check once a year under normal operating
conditions and, if dirty, brush or vacuum clean. Care must
be taken not to damage the aluminum fins while cleaning.
CAUTION: Fin edges are sharp.
Cabinet - “Indoor” Compressor Section
Do not allow water to stay in contact with the cabinet for long
periods of time to prevent corrosion of the cabinet sheet
metal. Generally, cabinets are set up from the floor a few
inches [7 - 8 cm] to prevent water from entering the cabinet.
The cabinet can be cleaned using a mild detergent.
Refrigerant System
To 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.
Hot Water Generator Coils
See water coil maintenance for ground water units. If the
potable water is hard or not chemically softened, the high
temperatures of the desuperheater will tend to scale even
quicker than the water coil and may need more frequent
inspections. In areas with extremely hard water, a HWG is
not recommended.
Filters
Filters must be clean to obtain maximum performance. Filters
should be inspected every month under normal operating
conditions and be replaced when necessary. Units should
never be operated without a filter.
Washable, high efficiency, electrostatic filters, when dirty,
can exhibit a very high pressure drop for the fan motor and
reduce air flow, resulting in poor performance. It is especially
important to provide consistent washing of these filters (in
the opposite direction of the normal air flow) once per month
using a high pressure wash similar to those found at self-
serve car washes.
41
HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS
Residential Split - 60Hz R22 &R410A
Rev.: 5 June, 2008
Troubleshooting
General
Test Mode
If operational difficulties are encountered, perform
the preliminary checks below before referring to the
troubleshooting charts.
Test mode can be entered for 20 minutes by shorting the test
pins. The CXM board will automatically exit test mode after
20 minutes.
• Verify that the unit is receiving electrical supply power.
• Make sure the fuses in the fused disconnect switches
are intact.
CXM Troubleshooting Process Flowchart/Functional
Troubleshooting Chart
After completing the preliminary checks described above,
inspect for other obvious problems such as leaking
connections, broken or disconnected wires, etc. If everything
appears to be in order, but the unit still fails to operate
properly, refer to the “CXM Troubleshooting Process
Flowchart” or “Functional Troubleshooting Chart.”
The “CXM Troubleshooting Process Flowchart” is a quick
overview of how to start diagnosing a suspected problem,
using the fault recognition features of the CXM board. The
“Functional Troubleshooting Chart” on the following page is
a more comprehensive method for identifying a number of
malfunctions that may occur, and is not limited to just the CXM
controls. Within the chart are five columns:
CXM Board
• The “Fault” column describes the symptoms.
• Columns 2 and 3 identify in which mode the fault is likey to
occur, heating or cooling.
• The “Possible Cause column” identifies the most likely
sources of the problem.
CXM board troubleshooting in general is best summarized
as simply verifying inputs and outputs. After inputs and
outputs have been verified, board operation is confirmed and
the problem must be elsewhere. Below are some general
guidelines for troubleshooting the CXM control.
• The “Solution” column describes what should be done to
correct the problem.
Field Inputs
All inputs are 24VAC from the thermostat and can be verified
using a volt meter between C and Y, G, O, W. 24VAC will be
present at the terminal (for example, between “Y” and “C”) if
the thermostat is sending an input to the CXM board.
x WARNING! x
WARNING! HAZARDOUS VOLTAGE! DISCONNECT ALL
ELECTRIC POWER INCLUDING REMOTE DISCONNECTS
BEFORE SERVICING.
Sensor Inputs
All sensor inputs are ‘paired wires’ connecting each component
to the board. Therefore, continuity on pressure switches, for
example can be checked at the board connector.
Failure to disconnect power before servicing can cause
severe personal injury or death.
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 thermistor resistance chart shown in
the CXM IOM manual. An ice bath can be used to check
calibration of the thermistor.
Outputs
The compressor relay is 24VAC and can be verified using a
voltmeter. The fan signal is passed through the board to the
external fan relay (units with PSC motors only). The alarm
relay can either be 24VAC as shipped or dry contacts for use
with DDC controls by clipping the JW1 jumper. Electric heat
outputs are 24VDC “ground sinking” and require a volt meter
set for DC to verify operation. The terminal marked “24VDC”
is the 24VDC supply to the electric heat board; terminal “EH1”
is stage 1 electric heat; terminal “EH2” is stage 2 electric heat.
When electric heat is energized (thermostat is sending a “W”
input to the CXM controller), there will be 24VDC between
terminal “24VDC” and “EH1” (stage 1 electric heat) and/or
“EH2” (stage 2 electric heat). A reading of 0VDC between
“24VDC” and “EH1” or “EH2” will indicate that the CXM board
is NOT sending an output signal to the electric heat board.
Heat Controller, Inc. Water-Source Heating and Cooling Systems
42
The Quality Leader in Conditioning Air
Residential Split - 60Hz R22 &R410A
Rev.: 5 June, 2008
CXM Process Flow Chart
x WARNING! x
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.
43
HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS
Residential Split - 60Hz R22 &R410A
Rev.: 5 June, 2008
FunctionalTroubleshooting
Heat Controller, Inc. Water-Source Heating and Cooling Systems
44
The Quality Leader in Conditioning Air
Residential Split - 60Hz R22 &R410A
Rev.: 5 June, 2008
FunctionalTroubleshooting
PerformanceTroubleshooting
45
HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS
Residential Split - 60Hz R22 &R410A
Rev.: 5 June, 2008
Troubleshooting Form
Note: Never connect refrigerant gauges during startup procedures. Conduct water-side analysis using P/T ports to determine water flow and
temperature difference. If water-side analysis shows poor performance, refrigerant troubleshooting may be required. Connect refrigerant
gauges as a last resort.
Heat Controller, Inc. Water-Source Heating and Cooling Systems
46
The Quality Leader in Conditioning Air
Residential Split - 60Hz R22 &R410A
Rev.: 5 June, 2008
47
08/08
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