INSTALLATION, OPERATION
& MAINTENANCE MANUAL
Residential Packaged
Geothermal Heat Pump
HEV/H Series
2 to 5 Tons
Heat Controller, Inc. • 1900 Wellworth Ave. • Jackson, MI 49203 • (517)787-2100 • www.heatcontroller.com
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Heat Controller, Inc.
HEV/H SERIES
Installation, Operation & Maintenance
UNIT NOMENCLATURE
HeatController
s
1
2
3
4 5 6
7
9
10
11
12
13
14
HEV
8
HEH
H E H 0 3 6 B 1 D 0 0 A L B
MODEL TYPE
SUPPLY AIR OPTIONS
HE = HEAT CONTROLLER RESIDENTIAL 410A
B = BACK DISCHARGE, HORIZONTAL ONLY
T = TOP DISCHARGE, VERTICAL ONLY
S = STRAIGHT DISCHARGE, HORIZONTAL ONLY
CONFIGURATION
H = HORIZONTAL
V = VERTICAL
RETURN AIR OPTIONS
L = LEFT RETURN w/ 1” Merv 8 Pleated Filter and Frame
R = RIGHT RETURN w/ 1” Merv 8 Pleated Filter and Frame
UNIT SIZE
024
030
036
042
048
060
HEAT EXCHANGER OPTIONS
A = Copper Water Coil w/Tin Plated Air Coil
J = Cupro-Nickel Water Coil w/Tin Plated Air Coil
REVISION LEVEL
WATER CIRCUIT OPTIONS
A = Current Revision
B = Current Revision
for Sizes 024, 036, 060
0 = NONE
1 = HWG w/ INTERNAL PUMP
VOLTAGE
1 = 208-230/60/1
CABINET INSULATION
0 = RESIDENTIAL
CONTROLS
D = DXM 2
DENTIAL CLASS UNITS COME STANDARD w/75 VA TRANSFORMER
NLESS STEEL DRAIN PAN, LOOP PUMP, HWG CONNECTIONS,
MOTOR, AND TWO STAGE SCROLL COMPRESSORS.
S ARE PAINTED POLAR ICE.
3
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Installation, Operation & Maintenance
HEV/H SERIES
Heat Controller, Inc.
Safety
CAUTION: Indicates a potentially hazardous situation or
Warnings, cautions and notices appear throughout this
manual. Read these items carefully before attempting any
installation, service or troubleshooting of the equipment.
an unsafe practice, which if not avoided could result in
minor or moderate injury or product or property damage.
NOTICE: Notification of installation, operation or
maintenance information, which is important, but which is
not hazard-related.
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.
ѥ WARNING! ѥ
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.
ѥ WARNING! ѥ
WARNING! Verify refrigerant type before
proceeding. Units are shipped with
refrigerant.
R-410A
ѥ CAUTION! ѥ
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.
ѥ WARNING! ѥ
WARNING! To avoid the release of
refrigerant into the atmosphere, the
refrigerant circuit of this unit must be
serviced only by technicians who meet local,
state, and federal proficiency requirements.
4
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Heat Controller, Inc.
HEV/H SERIES
Installation, Operation & Maintenance
GENERAL INFORMATION
Inspection
6. Loosen compressor bolts on units equipped with
Upon receipt of the equipment, carefully check the shipment
compressor spring vibration isolation until the
compressor rides freely on the springs. Remove
shipping restraints.
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 Heat Controller of all damage within
fifteen (15) days of shipment.
7.
Some airflow patterns are field convertible (horizontal
units only). Locate the airflow conversion section of
this IOM.
8.Locate and verify any hangers, or other accessory
kits located in the compressor section or blower
section.
ѥ CAUTION! ѥ
CAUTION! DO NOT store or install units
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.
in corrosiveenvironmentsor inlocations
subject to temperature or humidity extremes
(e.g., attics, garages, rooftops, etc.).
Unit Protection
Corrosive conditions and high temperature
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.
or humidity can significantly reduce
performance, reliability, and service life.
Always move units in an upright position.
Tilting units on their sides may cause
equipment damage.
NOTICE! Failure to remove shipping brackets
Examine all pipes, fittings, and valves before installing
any of the system components. Remove any dirt or debris
found in or on these components.
from spring-mounted compressors will cause
excessive noise, and could cause component
failure due to added vibration.
Pre-Installation
Installation, Operation and Maintenance
instructions are provided with each unit. Vertical unit
ѥ CAUTION! ѥ
configurations are typically installed in a mechanical
CAUTION! CUT HAZARD - Failure to follow
room. The installation site chosen should include
adequate ervice clearance around the unit. Before
this cautionmayresultinpersonal injury.
unit start-up, read all manuals and become familiar
Sheet metal parts may have sharp edges
with the unit and its operation. Thoroughly check the
system before operation.
or burrs. Use care and wear appropriate
protective clothing, safety glasses and
gloves when handling parts and servicing
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.
heat pumps.
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. Remove any blower support packaging.
5
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Installation, Operation & Maintenance
HEV/H SERIES
Heat Controller, Inc.
PHYSICAL DATA
Model
024
030
036
042
048
060
Compressor (1 Each)
Copeland UltraTech Two-Stage Scroll
Factory Charge HFC-410a, oz
51
48
54
70
80
84
ECM Fan Motor & Blower
Fan Motor, hp [W]
1/2 [373]
1/2 [373]
1/2 [373]
3/4 [559]
3/4 [559]
1 [746]
9 x 7
[229 x 178]
9 x 7
[229 x 178]
9 x 8
[229 x 203]
9 x 8
[229 x 203]
10 x 10
[254 x 254]
11 x 10
[279 x 254]
Blower Wheel Size (Dia x W), in [mm]
Water Connection Size
Swivel - Residential Class
HWG Water Connection Size
1”
1”
1”
1”
1”
1”
1”
1”
1”
1”
1”
1”
Swivel - Residential Class
Vertical Upflow
20 x 17.25
[508 x 438]
20 x 17.25
[508 x 438]
24 x 21.75
[610 x 552]
24 x 21.75
[610 x 552]
28.75 x 24
[730 x 610]
28.75 x 24
[730 x 610]
Air Coil Dimensions (H x W), in [mm]
Standard Filter - 1” [25.4mm] Throw-
away, qty (in) [mm]
20 x 20
[508 x 508}
20 x 20
[508 x 508}
24 x 24
[610 x 610]
24 x 24
[610 x 610]
28 x 28
[711 x 711]
28 x 28
[711 x 711]
Weight - Operating, lbs [kg]
216 [98.0]
224 [101.6]
229 [103.9]
245 [111.1]
251 [113.8]
260 [117.9]
266 [120.6]
315 [142.9]
322 [146.0]
330 [149.7]
337 [152.9]
Weight - Packaged, lbs [kg]
221 [100.2]
Horizontal
16 x 22
[406 x 559]
16 x 22
[406 x 559]
20 x 25
[508 x 635]
20 x 25
[508 x 635]
20 x 35
[508 x 889]
20 x 35
[508 x 889]
Air Coil Dimensions (H x W), in [mm]
1 - 20 x 24
[508 x 610]
1 - 14 x 20
[356 x 508]
1 - 20 x 24
[508 x 610]
1 - 14 x 20
[356 x 508]
Standard Filter - 1” [25.4 mm]
Pleated MERV 8 Throwaway, in [mm]
18 x 24
[457 x 610]
18 x 24
[457 x 610]
2 - 14 x 20
[356 x 508]
2 - 14 x 20
[356 x 508]
Weight - Operating, lbs [kg]
Weight - Packaged, lbs [kg]
208 [94.3]
213 [96.6]
208 [94.3]
213 [96.6]
233 [105.6]
239 [108.4]
244 [110.7]
250 [113.4]
299 [135.6]
306 [138.8]
314 [142.4]
321 [145.6]
All units have grommet compressor mountings, TXV expansion devices, and 1/2” [12.7mm] & 3/4” [19.1mm] electrical knockouts.
6
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Heat Controller, Inc.
HEV/H SERIES
Installation, Operation & Maintenance
HE - VERTICAL UPFLOW DIMENSIONAL DATA
Overall Cabinet
Vertical
Upflow
Model
A
Width
B
C
Depth
Height
in
cm
22.4
56.9
22.4
56.9
40.5
102.9
024-030
in
cm
22.4
56.9
26.0
66.0
46.5
118.1
036-042
048 -060
in
cm
25.4
64.5
29.3
74.4
50.5
128.3
Water Connections - Standard Units
1
2
3
4
5
Vertical
Upflow
Model
Cond.
HWG In HWG Out
D
Loop
In
E
Loop
Out
Loop
Water
FPT
HWG
FPT
F
G
H
in
cm
3.8
9.6
8.8
22.3
19.5
49.5
13.4
34.0
15.7
39.9
1
2.5
1
2.5
024 - 030
in
cm
3.8
9.6
8.8
22.3
22.1
56.1
15.2
38.6
18.5
47.0
1
2.5
1
2.5
036 - 042
048 - 060
in
cm
4.0
10.2
9.5
24.1
22.1
56.1
15.2
38.6
18.5
47.0
1
2.5
1
2.5
Electrical Knockouts
K
J
L
Vertical
Model
1/2”
1/2”
3/4”
Low
Voltage
Ext
Pump
Power
Supply
in
cm
4.6
11.7
6.1
15.5
7.6
19.3
024 - 060
Notes:
1.While clear access to all removable panels is not required, installer should take care to comply with all building codes and allow
adequate clearance for future field service.
2.Front & Side access is preferred for service access. However, all components may be serviced from the front access panel if side
access is not available.
3.Discharge flange is field installed.
4.Condensate is 3/4” socket.
5. Source water and optional HWG connections are 1” swivel.
7
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Installation, Operation & Maintenance
HEV/H SERIES
Heat Controller, Inc.
HE - VERTICAL UPFLOW DIMENSIONAL DATA
Return Connection
Discharge Connection
Standard Deluxe Filter Frame
Duct Flange Installed (+/- 0.10 in, +/- 2.5mm)
(+/- 0.10 in, +/- 2.5mm)
Vertical
Upflow
Model
M
O
P
Q
S
T
Left
Return
N
Supply
Width
Supply
Depth
Right
Return
R
Return
Depth
Return
Height
U
in
cm
7.4
18.8
4.2
10.7
13.9
35.3
14.0
35.6
6.7
17.0
2.2
5.6
18.0
45.7
18.0
45.7
1.0
2.5
024 - 030
in
cm
7.4
18.8
6.0
15.2
13.9
35.3
14.0
35.6
7.4
18.8
1.4
3.5
22.5
57.1
22.0
55.9
1.0
2.5
036 - 042
048 - 060
in
cm
7.4
18.8
6.0
15.2
13.9
35.3
14.0
35.6
8.4
21.3
2.8
7.1
25.8
65.5
26.2
66.4
1.0
2.5
Auxiliary Electric Heaters mounted externally.
Field Installed
Discharge Flange
Access Panels
Standard Filter Bracket
Air Coil
B
BSP
P
N
P
N
ASP
Opptional
2' [61cm]
Service
O
O
Access
A
CSP
Left Rtn
(Right Rtn
Opposite
Side)
CAP
M
R
Q
R
Air Coil Side
Air Coil Side
Top View-Right Return
Top View-Left Return
S
S
2' [61cm]
Service
Isometric
View
U
U
Air Coil
Air Coil
T
T
C
C
Filter Rack
Shown
Power Supply
EE
3/4" [19.1 mm] HV
5
Knockout
Low Voltage
1/2" [12.7 mm] LV
Knockout
4
2
FF
Low Voltage
1/2" [12.7 mm] LV
Knockout
CSP
CSP
DD
3
1
F
L
H
K
Front
Back
Back
Front
J
D
CSP
Right Return Right View
- Air Coil Opening
Left Return Left View
- Air Coil Opening
U
E
A
Filter Rails Removed
See Aff---- for accessory air filter frame with duct collar
8
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Heat Controller, Inc.
HEV/H SERIES
Installation, Operation & Maintenance
VERTICAL INSTALLATION
Vertical Unit Location
Figure 7:Vertical Unit Mounting
Units are not designed for outdoor installation. Locate
the unit in an INDOOR area that allows enough space
for service personnel to perform typical maintenance or
repairs without removing unit from the mechanical room/
closet. Vertical 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 the filter and access panels.
Provide sufficient room to make water, electrical, and
duct connection(s).
If the unit is located in a confined space, such as a closet,
provisions must be made for return air to freely enter
the space by means of a louvered door, etc. 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 Figures 7 and 8 for typical installation
illustrations. Refer to unit specifications catalog for
dimensional data.
Air Pad or Extruded
polystyrene insulation board
1. Install the unit on a piece of rubber, neoprene or
other mounting pad material for sound isolation. The
pad should be at least 3/8” [10mm] to 1/2” [13mm] in
thickness. Extend the pad beyond all four edges of the
unit.
2. Provide adequate clearance for filter replacement
and drain pan cleaning. Do not block filter access
with piping, conduit or other materials. Refer to unit
specifications for dimensional data.
Figure 8:Typical Vertical Unit Installation
Using Ducted Return Air
Internally insulate supply
duct for first 4’ [1.2m] each
way to reduce noise
3. Provide access for fan and fan motor maintenance
and 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.
Use turning vanes in
supply transition
Flexible canvas duct
connector to reduce
noise and vibration
5. Provide access to water valves and fittings and
screwdriver access to the unit side panels, discharge
collar and all electrical connections.
Rounded return
transition
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.
Internally insulate return
transition duct to reduce
noise
9
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Installation, Operation & Maintenance
HEV/H SERIES
Heat Controller, Inc.
VERTICAL INSTALLATION
Condensate Piping for Vertical Units
Sound Attenuation for Vertical Units
Install condensate trap at each unit with the top of the trap
positioned below the unit condensate drain connection as
shown in Figure 4. Design the depth of the trap (water-
seal) based upon the amount of External Static Pressure
(ESP) capability of the blower (where 2 inches [51mm] of
ESP capability requires 2 inches [51mm] of trap depth). As a
general rule, 1 1/2 inch [38mm] trap depth is the minimum.
Sound attenuation is achieved by enclosing the unit
within a small mechanical room or a closet. Additional
measures for sound control include the following:
1. Mount the unit so that the return air inlet is 90° to
the return air grille. Refer to Figure 9. Install a sound
baffle as illustrated to reduce line-of sight sound
transmitted through return air grilles.
2. Mount the unit on a rubber or neoprene isolation pad to
minimize vibration transmission to the building structure.
Each unit must be installed with its own individual trap and
connection to the condensate line (main) or riser. Provide
a means to flush or blow out the condensate line. DO NOT
install units with a common trap and/or vent.
Figure 9:Vertical Sound Attenuation
Always vent the condensate line when dirt or air can collect
in the line or a long horizontal drain line is required. Also vent
when large units are working against higher external static
pressure than other units connected to the same condensate
main since this may cause poor drainage for all units on
the line. WHEN A VENT IS INSTALLED IN THE DRAIN
LINE, IT MUST BE LOCATED AFTER THE TRAP IN THE
DIRECTION OF THE CONDENSATE FLOW.
Figure 4: Vertical Condensate Drain
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* Some units include a painted drain connection.
Using a threaded pipe or similar device to clear
any excess paint accumulated inside this fitting
may ease final drain line installation.
10
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Heat Controller, Inc.
HEV/H SERIES
Installation, Operation & Maintenance
VERTICAL INSTALLATION
Horizontal Unit Location
Mounting Horizontal Units
Packaged units are not designed for outdoor installation.
Locate the unit in an INDOOR area that allows enough
space for service personnel to perform typical maintenance
or repairs without removing unit from the ceiling. Horizontal
units are typically installed above a false ceiling or in a ceiling
plenum. 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
the filter and access panels. Provide sufficient room to make
water, electrical, and duct connection(s).
Horizontal units have hanger kits pre-installed from the
factory as shown in Figure 5. Figures 7a and 7b shows a
typical horizontal unit installation.
Horizontal heat pumps are typically suspended above a
ceiling or within a soffit using field supplied, threaded rods
sized to support the weight of the unit.
Use four (4) field supplied threaded rods and factory provided
vibration isolators to suspend the unit. Hang the unit clear
of the floor slab above and support the unit by the mounting
bracket assemblies only. DO NOT attach the unit flush with
the floor slab above.
If the unit is located in a confined space, such as a closet,
provisions must be made for return air to freely enter the space
by means of a louvered door or any other method. 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
Figures 7a and 7b for an illustration of a typical installation.
Refer to unit catalog specifications for dimensional data.
Pitch the unit toward the drain as shown in Figure 6 to
improve the condensate drainage. On small units (less
than 2.5 Tons/8.8 kW) ensure that unit pitch does not cause
condensate leaks inside the cabinet.
NOTE: The top panel of a horizontal unit is a structural
component. The top panel of a horizontal unit must never
be removed from an installed unit unless the unit is properly
supported from the bottom. Otherwise, damage to the unit
cabinet may occur.
Conform to the following guidelines when selecting a
unit location:
1. Provide a hinged access door in concealed-spline or
plaster ceilings. Provide removable ceiling tiles in T-bar
or lay-in ceilings. Refer to horizontal unit dimensions for
specific series and model in unit catalog specifications.
Size the access opening to accommodate the service
technician during the removal or replacement of the
compressor and the removal or installation of the unit
itself.
Figure 5: Hanger Bracket
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2. Provide access to hanger brackets, water valves and
fittings. Provide screwdriver clearance to access panels,
discharge collars and all electrical connections.
3. DO NOT obstruct the space beneath the unit with piping,
electrical cables and other items that prohibit future
removal of components or the unit itself.
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4. Use a manual portable jack/lift to lift and support the
weight of the unit during installation and servicing.
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The installation of geothermal heat pump units and all
associated components, parts and accessories which
make up the GHP system 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.
Figure 6: Horizontal Unit Pitch
1/4” (6.4mm) pi
per foot for drai
Drain
Connection
11
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Installation, Operation & Maintenance
HEV/H SERIES
Heat Controller, Inc.
HORIZONTAL INSTALLATION
Figure 7a: Typical Closed Loop Horizontal Unit Installation
3/8" [10mm] threaded rods
(by others)
Return Air
Thermostat
Wiring
Power Wiring
Water
Supply Air
Pressure Ports
Unit Power
Flexible Duct
Connector
Insulated supply duct with
at least one 90 deg elbow
to reduce air noise
Unit Power
Disconnect
(by others)
Water Out
Water In
Ball Valves
Unit Hanger
Flush
Ports
Air Coil - To obtain maximum performance, the air coil should
be cleaned before start-up. A 10% solution of dishwasher
detergent and water is recommended for both sides of the coil.
A thorough water rinse should follow.
Figure 7b: Typical Ground Water Horizontal Unit Installation
3/8" [10mm] threaded rods
(by others)
Return Air
Thermostat
Wiring
Power Wiring
Supply Air
Unit Power
Building
Loop
Flexible Duct
Insulated supply duct with
Connector
at least one 90 deg elbow
Unit Power
Water Out
to reduce air noise
Disconnect
Water In
(by others)
Ball Valves
Unit Hanger
12
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Heat Controller, Inc.
HEV/H SERIES
Installation, Operation & Maintenance
FIELD CONVERSION OF AIR DISCHARGE
Field Conversion of Air Discharge
Figure 8: Left Return Side to Back
Remove Screws
Water
Connection End
Overview - Horizontal units can be field converted
between side (straight) and back (end) discharge using the
instructions below.
Return Air
Note: It is not possible to field convert return air between left
or right return models due to the necessity of refrigeration
copper piping changes.
Preparation - It is best to field convert the unit on the ground
before hanging. If the unit is already hung it should be taken
down for the field conversion.
Side Discharge
Water
Connection End
Rotate
Side to Back Discharge Conversion
Return Air
1.
Place unit in well lit area. Remove the screws as shown
in Figure 8 to free top panel and discharge panel.
Lift out the access panel and set aside. Lift and rotate
the discharge panel to the other position as shown,
being careful with the blower wiring.
2.
3.
4.
5.
6.
7.
Check blower wire routing and connections for tension or
contact with sheet metal edges. Reroute if necessary.
Check refrigerant tubing for contact with
other components.
Reinstall top panel and screws noting that the location
for some screws will have changed.
Manually spin the fan wheel to ensure that the wheel is
not rubbing or obstructed.
Replace access panels.
Move to Side
Replace Screws
Water
Connection End
Return Air
Back to Side Discharge Conversion - If the discharge is
changed from back to side, use above instruction noting that
illustrations will be reversed.
Drain
Discharge Air
Back Discharge
Left vs. Right Return - It is not possible to field convert
return air between left or right return models due to the ne-
cessity of refrigeration copper piping changes. However, the
conversion process of side to back or back to side discharge
for either right or left return configuration is the same. In
some cases, it may be possible to rotate the entire unit 180
degrees if the return air connection needs to be on the op-
posite side. Note that rotating the unit will move the piping to
the other end of the unit.
Figure 9: Right Return Side to Back
Water
Connection End
Return Air
Supply Duct
Side Discharge
Water
Connection End
Return Air
Drain
Back Discharge
Discharge Air
13
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Installation, Operation & Maintenance
HEV/H SERIES
Heat Controller, Inc.
WATER CONNECTION INSTALLATION
External Flow Controller Mounting
which holds the male pipe end against the rubber
The Flow Controller can be mounted beside the unit
as shown in Figure 12. Review the Flow Controller
installation manual for more details.
gasket, and seals the joint. HAND TIGHTEN ONLY! DO
NOT OVERTIGHTEN!
Figure 11:Water Connections
HE
Water Connections-Residential HR Models
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.
Hand Tighten
Only!
Do Not
Swivel Nut
Overtighten!
Stainless steel
snap ring
Brass Adaptor
Gasket
The female locking ring is threaded onto the pipe threads
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
recommended in these applications.
ѥ CAUTION! ѥ
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.
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 Loop
Once piping is completed between the unit, Flow
Controller and the ground loop (Figure 12), 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.
Pre-Installation
Prior to installation, locate and mark all existing
underground utilities, piping, etc. Install loops for new
construction before sidewalks, patios, driveways, and other
construction has begun. During construction, accurately
mark all ground loop piping on the plot plan as an aid in
avoiding potential future damage to the installation.
1. Fill loop with water from a garden hose through the
flush cart before using the flush cart pump to insure
an even fill.
Piping Installation
2. Once full, the flushing process can begin. Do not
allow the water level in the flush cart tank to drop
below the pump inlet line to avoid air being pumped
back out to the earth loop.
3. Try to maintain a fluid level in the tank above the
return tee so that air cannot be continuously mixed
back into the fluid. Surges of 50 psi (345 kPa) can
be used to help purge air pockets by simply shutting
off the return valve going into the flush cart reservoir.
This “dead heads” the pump to 50 psi (345 kPa). To
purge, dead head the pump until maximum pumping
The typical closed loop ground source system is shown
in Figure 12. 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.
14
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Heat Controller, Inc.
HEV/H SERIES
Installation, Operation & Maintenance
GROUND-LOOP HEAT PUMP APPLICATIONS
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.
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:
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
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
being compressed in the loop fluid. Perform the “dead 1 for the amount of antifreeze needed. Antifreeze
head” procedure a number of times.
Note: This fluid level drop is your only indication of air in
the loop.
concentration should be checked from a well mixed
sample using a hydrometer to measure specific gravity.
Low Water Temperature Cutout Setting
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.
DXM2 Control
When antifreeze is selected, the FP1 jumper (JW3)
should be clipped to select the low temperature (an-
tifreeze 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.
Loop static pressure will fluctuate with the seasons.
Pressures will be higher in the winter months than during
the cooling season. This fluctuation is normal and should
be considered when charging the system initially. Run the
unit in either heating or cooling for a number of minutes to
condition the loop to a homogenous temperature. This is
a good time for tool cleanup, piping insulation, etc. Then,
perform final flush and pressurize the loop to a static
pressure of 50-75 psi [345-517 kPa] (winter) or 35-40 psi
[241-276 kPa] (summer). After pressurization, be sure
to loosen the plug at the end of the Grundfos loop pump
motor(s) to allow trapped air to be discharged and to insure
the motor housing has been flooded. This is not required
for Taco circulators. Insure that the Flow Controller provides
adequate flow through the unit by checking pressure drop
across the heat exchanger and compare to the pressure
drop tables at the back of the manual.
Table 1: Approximate Fluid Volume (gal.)
per 100' of Pipe
Fluid Volume (gal [L]/100’ Pipe)
Pipe
Size
Volume (gal) [L]
1”
4.1 [15.5]
6.4 [24.2]
9.2 [34.8]
3.9 [14.8]
2.8 [10.6]
4.5 [17.0]
8.0 [30.3]
10.9 [41.3]
18.0 [68.1]
8.3 [31.4]
10.9 [41.3]
17.0 [64.4]
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
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
Polyethylene
Unit Heat Exchanger
Flush Cart Tank
10” Dia x 3ft
[254mm x 0.9m]
10 [37.9]
Table 2: Antifreeze Percentages by Volume
Table 3. Antifreeze Percentages by Volume
Type
Minimum Temperature for Freeze Protection
10°F [-12.2°C] 15°F [-9.4°C] 20°F [-6.7°C] 25°F [-3.9°C]
Methanol
25%
38%
21%
30%
16%
22%
10%
15%
100% USP food grade Propylene Glycol
15
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Installation, Operation & Maintenance
HEV/H SERIES
Heat Controller, Inc.
GROUND-LOOP HEAT PUMP APPLICATIONS
Figure 12:Typical Ground-Loop Application
Flow
Controller
Unit Power
Disconnect
Insulated
Hose Kit
Thermostat
Wiring
P/T Plugs
Air Pad or Extruded
polystyrene insulation
board
GROUND-WATER HEAT PUMP APPLICATIONS
Open Loop - Ground Water Systems
only be serviced by a qualified technician, as acid and
Typical open loop piping is shown in Figure 1134.. 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
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.
should be limited to copper or PVC SCH80. Note: Due to Water Quality Standards
the pressure and temperature extremes, PVC SCH40
is not recommended.
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
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
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 referenced in Table 3.
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
16
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Heat Controller, Inc.
HEV/H SERIES
Installation, Operation & Maintenance
GROUND-WATER HEAT PUMP APPLICATIONS
Expansion Tank and Pump
Use a closed, bladder-type expansion tank to minimize
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
mineral formation due to air exposure. The expansion
tank should be sized to provide at least one minute
continuous run time of the pump using its drawdown
capacity rating to prevent pump short cycling. Discharge
water from the unit is not contaminated in any manner
and can be disposed of in various ways, depending on
local building codes (e.g. recharge well, storm sewer,
drain field, adjacent stream or pond, etc.). Most local
codes forbid the use of sanitary sewer for disposal.
Consult your local building and zoning department to
assure compliance in your area.
exchanger, and determine flow rate from
T
a
b
l
e
1
0
C
.
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], 2 gpm
per ton (2.6 l/m per kW) is required.
Water Control Valve
Note the placement of the water control valve in
Figure13.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.
Water Coil Low Temperature Limit Setting
For all open loop systems the 30°F [-1.1°C] FP1 setting
(factory setting-water) should be used to avoid freeze
damage to the unit. See “Low Water Temperature Cutout
Selection” in this manual for details on the low limit setting.
Figure 13:Typical Open Loop/Well Application
Unit Power
Disconnect
Flow
Regulator
Water
Control
Valve
Pressure
Tank
Water Out
Water In
Shut-Off
Valve
Air Pad or
Extruded
polystyrene
insulation board
Thermostat
Wiring
Optional
Filter
Boiler
Drains
P/T Plugs
17
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Installation, Operation & Maintenance
HEV/H SERIES
Heat Controller, Inc.
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 66°C for direct use and HWG applications, and at 32°C for indirect HX use.
A monitoring plan should be implemented.
Ryznar
Stability Index
-
6.0 - 7.5
If >7.5 minimize steel pipe use.
All
All
-
-0.5 to +0.5
Langelier
Saturation Index
If <-0.5 minimize steel pipe use. Based upon 66°C HWG and
Direct well, 29°C Indirect Well HX
Iron Fouling
Iron Fe (Ferrous)
2+
-
-
<0.2 ppm (Ferrous)
If Fe2+ (ferrous)>0.2 ppm with pH 6 - 8, O2<5 ppm check for iron bacteria.
All
All
(Bacterial Iron potential)
<0.5 ppm of Oxygen
Above this level deposition will occur.
Iron Fouling
Corrosion Prevention
6 - 8.5
6 - 8.5
pH
All
All
Monitor/treat as
needed
Minimize steel pipe below 7 and no open tanks with pH <8
-
<0.5 ppm
At H S>0.2 ppm, avoid use of copper and copper nickel piping or HX's.
2
Hydrogen Sulfide (H S)
2
Rotten egg smell appears at 0.5 ppm level.
Copper alloy (bronze or brass) cast components are OK to <0.5 ppm.
Ammonia ion as hydroxide, chloride,
nitrate and sulfate compounds
-
<0.5 ppm
All
Maximum Allowable at maximum water temperature.
10$C
<20ppm
24$C
NR
38 C
NR
Copper
Cupronickel
-
-
-
-
-
Maximum
<150 ppm
<400 ppm
<1000 ppm
>1000 ppm
NR
NR
Chloride Levels
304 S
316 S
S
S
<250 ppm
<550 ppm
>550 ppm
<150 ppm
< 375 ppm
>375 ppm
Titanium
All
Erosion and Clogging
<10 ppm of particles
and a maximum
velocity of 1.8 m/s
Filtered for maximum
841 micron [0.84 mm,
20 mesh] size.
<10 ppm (<1 ppm "sandfree” for reinjection) of particles and a maximum
velocity of 1.8 m/s. Filtered for maximum 841 micron 0.84 mm,
20 mesh] size. Any particulate that is not removed can potentially
clog components.
Particulate Size and
Erosion
Rev.: 3/22/2012
The ClimateMaster Water Quality Table provides water quality requirements for ClimateMaster coaxial heat exchangers. When water properties are outside of those
requirements, an external secondary heat exchanger must be used to isolate the heat pump heat exchanger from the unsuitable water. Failure to do so will void the
warranty for the coaxial heat exchanger.
Notes:
‡ꢀ&ORVHGꢀ5HFLUFXODWLQJꢀV\VWHPꢀLVꢀLGHQWLILHGꢀE\ꢀDꢀclosed pressurized piping system.
‡ꢀ5HFLUFXODWLQJꢀRSHQꢀZHOOVꢀVKRXOGꢀREVHUYHꢀWKHꢀRSHQꢀUHFLUFXODWLQJꢀGHVLJQꢀFRQVLGHUDWLRQVꢃ
‡ꢀ15ꢀꢁꢀApplication not recommended.
‡ꢀꢂꢁꢂꢀ1RꢀGHVLJQꢀ0D[LPXPꢃ
18
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Heat Controller, Inc.
HEV/H SERIES
Installation, Operation & Maintenance
HOT WATER GENERATOR
The HWG (Hot Water Generator) or desuperheater option
provides considerable operating cost savings by utilizing
heat energy from the compressor discharge line 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.
Typically a single tank of at least 50 gallons (189 liters) is used
to limit installation costs and space. However, a dual tank, as
shown in Figure 21, is the preferred system, as it provides the
maximum storage and temperate source water to the HWG.
It is always advisable to use water softening equipment on
domestic water systems to reduce the scaling potential and
lengthen equipment life. In extreme water conditions, it may
be necessary to avoid the use of the HWG option since the
potential cost of frequent maintenance may offset or exceed
any savings. Consult Table 3 for scaling potential tests.
Heat pumps equipped with the HWG option include a built-
in water to refrigerant heat exchanger that eliminates the
need to tie into the heat pump refrigerant circuit in the field.
The control circuit and pump are also built in for residential
equipment. Figure 14 shows a typical example of HWG water
piping connections on a unit with built-in circulating pump.
This piping layout prevents sludge/debris from the bottom of
the tank being pulled into the HWG pump.
Figure 14: Typical HWG Installation
Cold
Inlet
Hot Outlet
to home
Shut Off
Valve #1
Shut Off
Valve #4
The temperature set point of the HWG is field selectable
to 125°F or 150°F . The 150°F set point allows more heat
storage from the HWG. For example, consider the amount
of heat that can be stored by the HWG when using the 125°F
set point, versus the amount of heat that can be generated
by the HWG when using the 150°F set point.
Upper
element to
120 - 130°F
[49 - 54°C]
Lower
element to
Powered
Water
Heater
100 - 110°F
[38 - 43°C]
Shut-off
Valve #3
In a typical 50 gallon two-element electric water heater
the lower element should be turned down to 100°F, or the
lowest setting, to get the most from the HWG. The tank will
eventually stratify so that the lower 80% of the tank, or 40
gallons, becomes 100°F (controlled by the lower element).
The upper 20% of the tank, or 10 gallons, will be maintained
at 125°F (controlled by the upper element).
Shut Off
Valve #2
Field supplied 3/4’ brass nipple and ‘T’
Insulated water lines -
5/8” OD, 50 ft maximum (one way)
[16mm OD, 15 meters maximum]
Figure 15: HWG Double Tank Installation
Using a 125°F set point, the HWG can heat the lower 40
gallons of water from 100°F to 125°F, providing up to 8,330
btu’s of heat. Using the 150°F set point, the HWG can heat
the same 40 gallons of water from 100°F to 150°F and the
remaining 10 gallons of water from 125°F to 150°F, providing
a total of up to 18,743 btu’s of heat, or more than twice as
much heat as when using the 125°F set point.
Hot Outlet to
house
Cold Inlet
Cold Inlet from
Domestic supply
Hot Outlet
Upper element to 130°F [54°C]
(or owner preference)
Shut-off
Valve #1
Shut-off
Valve #4
Powered
Lower element to 120°F [49°C]
Water Heater
Unpowered
Dual element electric water heaters are recommended.
If a gas, propane, oil or electric water heater with a
single element is used, a second preheat storage tank
is recommended to insure a usuable entering water
temperature for the HWG.
Water Heater
Shut-off
Valve #3
Shut Off
Valve #2
Field Supplied 3/4” brass nipple and “T”
Insulated water lines - 5/8” OD, 50 ft maximum (one way)
[16mm OD, 15 meters maximum]
ꢀ WARNING! ꢀ
WARNING! A 150°F SETPOINT MAY LEAD TO
SCALDING OR BURNS. THE 150°F SET POINT MUST
ONLY BE USED ON SYSTEMS THAT EMPLOY AN
APPROVED ANTI-SCALD VALVE.
19
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Installation, Operation & Maintenance
HEV/H SERIES
Heat Controller, Inc.
HOT WATER GENERATOR
Installation
ANTI-SCALD
VALVE PIPING
CONNECTIONS
COLD WATER
SUPPLY
The HWG is controlled by two sensors and the DXM2 micro-
processor control. One sensor is located on the compressor
discharge line to sense the discharge refrigerant tempera-
ture. The other sensor is located on the HWG heat exchang-
er’s “Water In” line to sense the potable water temperature.
CHECK VALVE
ANTI-SCALD
VALVE
ꢀ WARNING! ꢀ
C
HOT WATER
TO HOUSE
WARNING! UNDER NO CIRCUMSTANCES SHOULD
THE SENSORS BE DISCONNECTED OR REMOVED.
FULL LOAD CONDITIONS CAN DRIVE HOT
WATER TANK TEMPERATURES FAR ABOVE SAFE
TEMPERATURE LEVELS IF SENSORS DISCONNECTED
OR REMOVED.
M
H
The microprocessor control monitors the refrigerant and
water temperatures to determine when to operate the HWG.
The HWG will operate any time the refrigerant temperature is
sufficiently above the water temperature. Once the HWG has
satisfied the water heating demand during a heat pump run
cycle, the controller will cycle the pump at regular Intervals
to determine if an additional HWG cycle can be utilized.
The microprocessor control Includes 3 DIP switches, SW10
(HWG PUMP TEST), SW11 (HWG TEMP), and SW12 (HWG
STATUS).
WATER HEATER
125°F. This switch Is shipped from the factory in the
“OFF” (125°F) position.
SW10 HWG PUMP TEST. When this switch is in the “ON”
position, the HWG pump is forced to operate even if there is
no call for the HWG. This mode may be beneficial to assist in
purging the system of air during Initial start up. When SW10
is in the “OFF” position, the HWG will operate normally. This
switch is shipped from the factory in the “OFF” (normal)
position. NOTE; If left in the “On” position for 5 minutes, the
pump control will revert to normal operation.
SW12 HWG STATUS. This switch controls operation
of the HWG. When SW12 is in the “ON” position the
HWG is disabled and will not operate. When SW12
is in the “OFF” position the HWG is in the enabled
mode and will operate normally. This switch is shipped
from the factory in the “ON” (disabled) position.
CAUTION: DO NOT PLACE THIS SWITCH IN THE
ENABLED POSITION UNITL THE HWG PIPING IS
CONNECTED, FILLED WITH WATER, AND PURGED
OR PUMP DAMAGE WILL OCCUR.
SW11 HWG TEMP. The control setpoint of the HWG can
be set to either of two temperatures, 125°F or 150°F. When
SW11 is in the “ON” position the HWG setpoint is 150°F.
When SW11 is in the “OFF” position the HWG setpoint is
When the control is powered and the HWG pump
output is not active, the status LED (AN1) will be
“On”. When the HWG pump output is active for water
temperature sampling or HWG operation, the status
LED will slowly flash (On 1 second, Off 1 second).
ꢀ WARNING! ꢀ
WARNING! USING A 150°F SETPOINT ON THE
HWG WILL RESULT IN WATER TEMPERATURES
SUFFICIENT TO CAUSE SEVERE PHYSICAL INJURY
IN THE FORM OF SCALDING OR BURNS, EVEN
WHEN THE HOT WATER TANK TEMPERATURE
SETTING IS VISIBLY SET BELOW 150°F. THE 150°F
HWG SETPOINT MUST ONLY BE USED ON SYSTEMS
THAT EMPLOY AN APPROVED ANTI-SCALD VALVE
(PART NUMBER AVAS4) AT THE HOT WATER
STORAGE TANK WITH SUCH VALVE PROPERLY
SET TO CONTROL WATER TEMPERATURES
DISTRIBUTED TO ALL HOT WATER OUTLETS AT A
TEMPERATURE LEVEL THAT PREVENTS SCALDING
OR BURNS!
If the control has detected a fault, the status LED will
flash a numeric fault code as follows:
Hot Water Sensor Fault
1 flash
Compressor Discharge sensor fault
High Water Temperature (>160oF)
Control Logic Error
2 flashes
3 flashes
4 flashes
Fault code flashes have a duration of 0.4 seconds with
a 3 second pause between fault codes. For example,
a “Compressor Discharge sensor fault” will be four
flashes 0.4 seconds long, then a 3 second pause, then
four flashes again, etc.
20
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Heat Controller, Inc.
HEV/H SERIES
Installation, Operation & Maintenance
HOT WATER GENERATOR
ensure that there is no air remaining in the tank.
4. Inspect all work for leaks.
ꢀ WARNING! ꢀ
5. Before restoring power or fuel supply to the water heater,
adjust the temperature setting on the tank thermostat(s)
to insure maximum utilization of the heat available from
the refrigeration system and conserve the most energy.
On tanks with both upper and lower elements and
thermostats, the lower element should be turned down
to 100°F [38°C] or the lowest setting; the upper element
should be adjusted to 120-130°F [49-54°C]. Depending
upon the specific needs of the customer, you may want
to adjust the upper element differently. On tanks with a
single thermostat, a preheat tank should be used (Fig 21).
6. Replace access cover(s) and restore power or
fuel supply.
WARNING! The HWG pump Is fully wired from the
factory. Use extreme caution when working around
the microprocessor control as it contains line voltage
connections that presents a shock hazard that can cause
severe injury or death!
The heat pump, water piping, pump, and hot water tank
should be located where the ambient temperature does
not fall below 50°F [10°C]. Keep water piping lengths at a
minimum. DO NOT use a one way length greater than 50 ft.
(one way) [15 m]. See Table 4 for recommended piping sizes
and maximum lengths.
All installations must be in accordance with local codes. The
installer is responsible for knowing the local requirements,
and for performing the installation accordingly. DO NOT
activate the HWG (turn DIP 3-4 to the ON position) until
“Initial Start-Up” section, below is completed. Powering the
pump before all installation steps are completed will damage
the pump.
Initial Start-Up
1. Make sure all valves in the HWG water circuit are
fully open.
2. Turn on the heat pump and allow it to run for
10-15 minutes.
3. Set S3-4 to the “ON” position (enabled) to engage the
HWG. See Figure *.
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].
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.
6. Allow the unit to operate for 20 to 30 minutes to insure
that it is functioning properly.
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 1/2” [12.7mm] I.D. copper, route and install
the water piping and valves as shown in Figures 20 or
21. Install an approved anti-scald valve if the 150°F HWG
setpoint is or will be selected. An appropriate method
must be employed to purge air from the HWG piping.
This may be accomplished by flushing water through the
HWG (as in Figures 20 and 21) or by installing an air vent
at the high point of the HWG piping system.
2. Insulate all HWG water piping with no less than 3/8”
[10mm] wall closed cell insulation.
3. Open both shut off valves and make sure the tank drain
valve is closed.
Water Tank Refill
1. Close valve #4. Ensure that the HWG valves (valves #2
and #3) are open. Open the cold water supply (valve #1)
to fill the tank through the HWG piping. This will force
water flow through the HWG and purge air from the
HWG piping.
2. Open a hot water faucet to vent air from the system until
water flows from faucet; turn off faucet. Open valve #4.
3. Depress the hot water tank pressure relief valve handle to
21
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Installation, Operation & Maintenance
HEV/H SERIES
Heat Controller, Inc.
ELECTRICAL - LINE VOLTAGE
Electrical - Line Voltage
All field installed wiring, including electrical ground, must
ѥ WARNING! ѥ
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.
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.
All final electrical connections must be made with a
length of flexible conduit to minimize vibration and sound
transmission to the building.
ѥ CAUTION! ѥ
CAUTION! Use only copper conductors for field
installed electrical wiring. Unit terminals are not
designed to accept other types of conductors.
General Line Voltage Wiring
Be sure the available power is the same voltage and
phase 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.
Electrical Data -
Ext
Compressor
HWG
Pump
FLA
Fan
Motor
FLA
Total
Unit
FLA
Min
Circuit
Amp
Max
Fuse/
HACR
HE
Model
Volt
Code
Voltage
Min/Max
Loop
Pump
FLA
Rated Voltage
RLA
LRA
Qty
024
030
036
042
048
060
1
1
1
1
1
1
208-230/60/1
208-230/60/1
208-230/60/1
208-230/60/1
208-230/60/1
208-230/60/1
197/252
197/252
197/252
197/252
197/252
197/252
11.7
13.1
15.3
17.9
58.3
73.0
83.0
96.0
1
1
1
1
1
1
0.5
0.5
0.5
0.5
0.5
0.5
4.0
4.0
4.0
4.0
4.0
4.0
3.9
3.9
3.9
5.2
5.2
6.9
20.1
21.5
23.7
27.6
30.9
38.5
23.0
24.7
27.5
32.0
36.2
45.2
30
35
40
45
50
70
21.2 104.0
27.1 152.9
HACR circuit break in U.S. only
All fuses Class RK-5
Wire length based on one way measurement with 2% voltage drop
Wire sizes based on 140°F (60°C) copper conductor
22
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Heat Controller, Inc.
HEV/H SERIES
Installation, Operation & Maintenance
ELECTRICAL - POWER WIRING
Blower Speed Selection
Power Connection
PSC (Permanent Split Capacitor) blower fan speed can
Line voltage connection is made by connecting the
be changed by moving the blue wire on the fan motor
incoming line voltage wires to the “L” side of the contactor terminal block to the desired speed as shown in Figure
as shown in Figures 18. Consult Table 4 for correct fuse
size.
19. Units are shipped on the medium speed tap. Consult
engineering design guide for specific unit airflow tables.
Typical unit design delivers rated airflow at nominal
static (0.15 in. w.g. [37Pa]) on medium speed and rated
airflow at a higher static (0.4 to 0.5 in. w.g. [100 to 125
Pa]) on high speed for applications where higher static
is required. Low speed will deliver approximately 85% of
rated airflow at 0.10 in. w.g. [25 Pa].
208 Volt Operation
All residential 208-230 Volt units are factory wired for
230 Volt operation. The transformer may be switched
to the 208V tap as illustrated on the wiring diagram by
switching the red (208V) and the orange (230V) wires at
Special Note for Testing: To achieve rated
AHRI
Field Wiring
airflow forAHRI testing purposes on all PSC products,
it is necessary to change the fan speed to “HI” speed.
When the heat pump has experienced less than 100
operational hours and the coil has not had sufficient time
to be “seasoned”, it is necessary to clean the coil with a
mild surfactant such as Calgon to remove the oils left by
manufacturing processes and enable the condensate to
properly “sheet” off of the coil.
Figure 18: HE Single Phase Line Voltage
Capacitor
Contactor -CC
Grnd
L1
L2
Unit Power Supply
See electrical table for
breaker size
BR
CXM
Control
CB
Low
Voltage
Connector
Figure 19: PSC Motor Speed Selection
Transformer
Connect the blue wire to:
H for High speed fan
M for Medium speed fan
L for Low speed fan
Medium is factory setting
Fan Motor
HWG Wiring
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.
23
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Installation, Operation & Maintenance
HEV/H SERIES
Heat Controller, Inc.
ELECTRICAL - LOW VOLTAGE WIRING
Low Water Temperature Cutout Selection
Thermostat Connections
The DXM2 control allows the field selection of low water (or
water-antifreeze solution) temperature limit by clipping jumper
JW3, which changes the sensing temperature associated
with thermistor LT1. Note that the LT1 thermistor is located on
the refrigerant line between the coaxial heat exchanger and
expansion device (TXV). Therefore, LT1 is sensing refrigerant
temperature, not water temperature, which is a better
indication of how water flow rate/temperature is affecting the
refrigeration circuit.
The thermostat should be wired directly to the
board. See “Electrical – Thermostat” for specific terminal
connections.
DXM2
Figure 21: Low Voltage Field Wiring
Capacitator
The factory setting for LT1 is for systems using water (30°F
[-1.1°C] refrigerant temperature). In low water temperature
(extended range) applications with antifreeze (most ground
loops), jumper JW3 should be clipped as shown in Figure
19 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].
Circ Brkr
Loop PB1
HWG PB2
Grnd
Contactor - CC
BR
Figure 22: LT1 Limit Setting
HP
LP
LP
LT1
LT1
Transformer
Fault
Status
DXM 2
LT2
LT2
RV
RV
CO
CO
Off On
JW3
CB
Off On
Low Voltage
Connector
S3
12
1
Off On
RV
P7
Relay
CCH
24Vdc
Relay
Rev.: 3/24/00
S2
c1
ay
EH1
EH2
A0-1 A0-2
4
S1
Comp
Relay
P6
CCG
c2
ay
CC
P10
P9
P11
T1 T2 T2 T3 T3 T4 T4
Gnd
T5 T5 T6 T6
AO2
DXM2 PCB
JW3-LT1 jumper should be clipped
for low temperature operation
24
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Heat Controller, Inc.
HEV/H SERIES
Installation, Operation & Maintenance
ELECTRICAL - LOW VOLTAGE WIRING
Accessory Connections
A terminal paralleling the compressor contactor coil
Figure 24:Taco Series 500 Valve Wiring
has been provided on the control. Terminal “A” is
DXM2
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 23 or the
specific unit wiring diagram for details.
2
Taco Valve
3
1
Figure 23: Accessory Wiring
Heater Switch
Ufsnjobm!Tusjq
D
Uzqjdbm
Thermostat
35WBD
Xbufs
Wbmwf
B
SBV
Figure 25:Taco EValve Wiring
Water Solenoid Valves
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 23
shows typical wiring for a 24VAC external solenoid valve.
Figures 24 and 25 illustrate typical slow closing water
control valve wiring for Taco 500 series and Taco SBV
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:
SBV
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
electromechanical thermostat. Therefore, only relay or
triac based thermostats should be used.
25
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Installation, Operation & Maintenance
HEV/H SERIES
Heat Controller, Inc.
ELECTRICAL - THERMOSTAT WIRING
Thermostat Installation
Figure 23b: Conventional 3 Heat / 2 Cool Thermostat
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 24a and 24b to the low voltage terminal strip
on the DXM2 control board. Practically any heat pump
thermostat will work with these units, provided it has the
correct number of heating and cooling stages. However,
using the communicating thermostat (ATC32) is highly
recommended for on-site, easier configuration, monitoring
and diagnosis.
Connection to DXM2 Control
Thermostat
DXM2
Board
Y1
Y2
W
Compressor
Compressor Stage 2
Auxiliary Heat
Y1
Y2
W
H
Dehumidification DH
Reversing Valve
Fan
O
G
R
C
L
O
G
24Vac Hot
24Vac Common
Fault LED
R
C
AL1
Notes:
1) ECM automatic dehumidification mode operates with dehumidification airflows
in the cooling mode when the dehumidification output from thermostat is active.
Normal heating and cooling airflows are not affected.
2) DXM2 board DIP switch S2-7 must be in the auto dehumidification mode for
automatic dehumidification
ꢀ CAUTION! ꢀ
CAUTION! Refrigerant pressure activated water regulating
valves should never be used with manufacturer’s
equipment.
3) DH connection not possible with units with internal pump. Use ATC32U**.
4) Only use ATC Communicating Thermostat when using Humidifier (H Input) with
units with internal flow controller.
Figure 24: Typical Thermostat 2 Heat/1 Cool
Connection to DXM2 Control
Figure 23a: Communicating Thermostat Connection to
DXM2 Control
Thermostat
DXM2
Y
Y2/W
O
Y1
W
Compressor
Heating Stage 2
Reversing Valve
Fan
Thermostat
ATC32U**
DXM2
Gnd
A+
O
24Vac Common
24Vac Hot
Comm +
Comm -
C
R
A+
B-
G
G
B-
24Vac Hot
R
R
24V
24Vac Common
Fault LED
C
C
L
AL1
Outdoor
OD
GND
ID
Sensor
(Optiona)
(Using 2 Heat / 1 Cool thermostat is not
recommended if maximum efficiency is desired)
Remote Indoor
Sensor
(Optiona)
26
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Heat Controller, Inc.
HEV/H SERIES
Installation, Operation & Maintenance
ECM BLOWER CONTROL
The ECM fan is controlled directly by the DXM2 control board
that converts thermostat inputs and CFM settings to signals
used by the ECM motor controller. To take full advantage
of the ECM motor features, a communicating multi-stage
thermostat should be used (ATC32U**).
The DXM2 control maintains a selectable operating airflow
[CFM] for each heat pump operating mode. For each
operating mode there are maximum and minimum airflow
limits. See the ECM Blower Performance tables for the
maximum, minimum, and default operating airflows.
Airflow levels are selected using the configuration menus of
a communicating thermostat (ATC32U**) or diagnostic tool
(ACDU**). The configuration menus allow the installer to
independently select and adjust the operating airflow for each
of the operating modes. Air flow can be selected in 25 CFM
increments within the minimum and maximum limits shown
in the ECM Blower Performance Table. The blower operating
modes include:
•
•
•
First Stage Cooling (Y1 & O)
Second Stage Cooling (Y1, Y2, & O)
First Stage Cooling in Dehumidification Mode
(Y1, O, & Dehumid)
•
Second Stage Cooling in Dehumidification Mode
(Y1, Y2, O, & Dehumid)
•
•
•
•
•
First Stage Heating (Y1)
Second Stage Heating (Y1 & Y2)
Third Stage (Auxiliary) Heating (Y1, Y2, & W)
Emergency Heating (W with no Y1 or Y2)
Fan (G with no Y1, Y2, or W)
It is highly recommended that ATC32U** or ACDU**
be used to set dehumidification mode electronically.
For dehumidification settings on other units using the
non-communicating stat, refer to DXM2 AOM (part
#97B0003N15).
The ECM motor includes “soft start” and “ramp down”
features. The soft start feature is a gentle increase of motor
rpm at blower start up. This creates a much quieter blower
start cycle.
The ramp down feature allows the blower to slowly decrease
rpm to a full stop at the end of each blower cycle. This
creates a much quieter end to each blower cycle and adds
overall unit efficiency.
The ramp down feature is eliminated during an ESD
(Emergency Shut Down) situation. When the DXM2 ESD
input is activated, the blower and all other control outputs are
immediately de-activated.
The ramp down feature (also known as the heating or cooling
“Off Delay”) is field selectable by the installer. The allowable
range is 0 to 255 seconds.
27
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Installation, Operation & Maintenance
HEV/H SERIES
Heat Controller, Inc.
BLOWER PERFORMANCE DATA
Table 6: ECM Blower Performance Data Table
Airflow in CFM with wet coil and clean air filter
Cooling Mode
Dehumid Mode
Heating Mode
Fan
Motor
(hp)
Aux/
Emerg
Mode
Max ESP
(in. wg)
Fan Only
Mode
Model
024
Range
Stg 2
Stg 1
Stg 2
Stg 1
Stg 2
Stg 1
Default
Maximum
Minimum
Default
750
850
575
650
650
800
500
600
750
850
575
850
350
850
300
450
1100
375
525
1250
450
600
1475
525
700
1700
600
875
2100
750
750
850
0.75
1/2
1/2
1/2
3/4
3/4
1
600
450
600
450
600
450
650
950
650
800
575
950
650
950
030
036
042
048
060
0.5
0.6
Maximum
Minimum
Default
1100
750
750
1000
750
700
1100
750
1100
525
1100
750
525
525
1125
1250
900
750
975
650
1125
1250
900
750
1125
1250
900
Maximum
Minimum
Default
950
1200
900
800
1250
600
600
600
1300
1475
1050
1500
1700
1200
1875
2100
1500
925
1125
1400
1050
1300
1600
1200
1625
2000
1500
825
1300
1475
1050
1500
1700
1200
1875
2100
1500
925
1300
1475
1050
1500
1700
1350
1875
2100
1500
0.6
Maximum
Minimum
Default
1100
750
1000
750
1475
750
1125
1300
900
975
1125
1700
900
0.75
0.75
Maximum
Minimum
Default
1200
900
1500
1700
1200
1300
1600
1200
1500
2100
1200
Maximum
Minimum
Airflow is controlled within 5% up to the Max ESP shown with wet coil
Factory shipped on default CFM
28
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Heat Controller, Inc.
HEV/H SERIES
Installation, Operation & Maintenance
WIRING DIAGRAM
29
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Installation, Operation & Maintenance
HEV/H SERIES
Heat Controller, Inc.
DXM2 CONTROLS
DXM2 Control
DXM2 Control Start-up Operation
DXM2 is the next generation in controls is capable of 2-way
communication between itself and smart components, like
the communicating thermostat, fan motor and configuration/
diagnostic tool.
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.
For most residential applications, configuration, monitoring
and diagnostics can be done from the thermostat / service
tool and there’s no need to read LEDs and change DIP
switches.
Test Mode button:
Test mode allows the service technician to check the
operation of the control in a timely manner. By momentarily
pressing the TEST pushbutton, the DXM2 control enters a 20
minute test mode period in which all time delays are sped up
15 times.
For details on user settings, refer to User Manual (part #:
For details on Installer settings (not to be used by
consumers), refer to Installer manual (part #:
For details on installer/service settings on the configuration/
diagnostic tool, refer to operation manual (part #:
Figure 25: Test Mode Button
For further details on the DXM2 control, refer to the DXM2
Application, Operation and Maintenance Manual and it is
shipped with the unit.
P4
Gnd
B- A+ 24V
(240Vac)
N.C.
(240Vac)
N.O.
P5
N.O.
Com
Thermostat compatibility
Fan Enable
Fan Speed
It is strongly recommended that GeoMax2 communicating
thermostat be used with DXM2 control, to ensure easy
configuration, monitoring and diagnostics, in PLAIN
English, on the thermostat. For example, Airflow can NOT
be configured without a communicating thermostat or
Configuration/ Diagnostic tool for use with GeoMax2.
Push test button to
enter Test Mode and
speed-up timing and
delays for 20 minutes.
P8
12V
IN
Test
P12
OUT
Gnd
NC
Field Configuration Options - Note: In the following field
configuration options, jumper wires should be clipped ONLY
when power is removed from the DXM2 control.
Table 7c: Unit Operation
Conventional
T-stat signal
(Non-Communicating)
Unit
Water coil low temperature limit setting: Jumper 3 (JW3-
LT1 Low Temp) provides field selection of temperature limit
setting for LT1 of 30°F or 10°F [-1°F or -12°C] (refrigerant
temperature).
ECM fan
Fan only
G
G, Y1
Stage 1 heating1
Stage 2 heating1
Stage 3 heating1
Emergency heat
Stage 1 cooling2
Stage 2 cooling2
Not Clipped = 30°F [-1°C]. Clipped = 10°F [-12°C].
G, Y1, Y2
G, Y1, Y2, W
G, W
A0-2: Configure Modulating Valve (field installed
accessory)
Set A0-2 jumper to “IOV” if using Modulating Motorized
Valve as field installed accessory
G, Y1, O
G, Y1, Y2, O
1
2
Stage 1 = 1st stage compressor, 1st stage fan operation
Stage 2 = 2nd stage compressor, 2nd stage fan operation
Stage 3 = 2nd stage compressor, auxiliary electric heat, 3rd
stage fan operation
Stage 1 = 1st stage compressor, 1st stage fan operation,
reversing valve
DIP Switches – There’s no need to change the DIP switches
on Residential units. All DIP switches in S1 and S2 should
be “on”. In S3, S3-1 should be “on” and the rest should be
“off”. For more details on DIP switches, refer to the DXM2
AOM.
Stage 2 = 2nd stage compressor, 2nd stage fan operation,
reversing valve
ꢀ CAUTION! ꢀ
CAUTION! Do not restart units without inspection and
remedy of faulting condition. Equipment damage may occur.
30
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Heat Controller, Inc.
HEV/H SERIES
Installation, Operation & Maintenance
DXM2 LAYOUT AND CONNECTIONS
Communicating
Service tool
stat connection
connection
P4
C
R
Gnd
B- A+ 24V
(240Vac)
(240Vac)
N.O.
P1
Y1
Y2
W
N.C.
N.O.
P5
Com
Fan Enable
Fan Speed
Test Button
to Speed up
Time Delays
Conventional
O
stat connection
G
P8
R
C
12V
IN
Test
P12
ECM Motor
Connection
AL1
OUT
Gnd
NC
P2
AL2
R
Water Coil
Low Temp
Limit Setting.
JWT-LT1 jumper
should be clipped
for low temp
(antifreeze)
Cabinet
temperature
sensor
(with variable
speed pump)
Micro
U1
1
NSB
C
JW1
HP
HP
LP
LP
LT1
LT1
LT2
LT2
RV
RV
CO
CO
Alarm
Relay
Fault
Status
ESD
OVR
H
operation
Factory low
voltage molex
connection for
unit harness
Off On
A
JW3
Off On
Communications
and HWG
S3
Off On
12
P3
Settings
RV
P7
R
Relay
CCH
Electric heat
connection
NO1
NC1
COM1
NO2
NC2
COM2
R
1
4
24Vdc
Relay
S2
A0-1 A0-2
Acc1
Relay
Accessory
relays refer
to DXM2 AOM
for configuration
EH1
EH2
S1
Comp
Relay
P6
CCG
Configure
Acc2
Relay
Modulating Valve
(Optional)
CC
P10
P9
P11
COH
COM
T1 T2 T2 T3 T3 T4 T4
Gnd
T5 T5 T6 T6
AO2
24V to compressor
Use 4 mounting screws
#6 sheet metal screw
1” long
second-stage solenoid
for Y2/full
load capacity
31
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Installation, Operation & Maintenance
HEV/H SERIES
Heat Controller, Inc.
UNIT COMMISSIONING AND OPERATING CONDITIONS
Operating Limits
Environment – Units are designed for indoor installation only. Never install units in areas subject to freezing or where humidity levels
could cause cabinet condensation (such as unconditioned spaces subject to 100% outside air).
Power Supply – Voltage utilization shall comply with AHRI standard 110, voltage range A.
Determination of operating limits is dependent primarily upon three factors: 1) return air temperature. 2) water temperature,
and 3) ambient temperature. When any one of these factors is at minimum or maximum levels, the other two factors should be
at normal levels to insure proper unit operation. Extreme variations in temperature and humidity and/or corrosive water or air
will adversely affect unit performance, reliability, and service life. Consult Table 9a for operating limits.
Table 9a: Building Operating Limits
Unit
Operating Limits
Cooling
Heating
Air Limits
Min. ambient air, DB
Rated ambient air, DB
Max. ambient air, DB
Min. entering air, DB/WB
45ºF [7ºC]
80.6ºF [27ºC]
130ºF [54ºC]
65/45ºF [18/7ºC]
70/50ºF Reheat
39ºF [4ºC]
68ºF [20ºC]
85ºF [29ºC]
50ºF [10ºC]
Rated entering air, DB/WB 80.6/66.2ºF [27/19ºC]
68ºF [20ºC]
80ºF [27ºC]
Max. entering air, DB/WB
Water Limits
100/75ºF [38/24ºC]
Min. entering water
Normal entering water
Max. entering water
20ºF [-6.7ºC]
50-110ºF [10-43ºC]
120ºF [49ºC]
20ºF [-6.7ºC]
30-70ºF [-1 to 21ºC]
120ºF [49ºC]
1.5 to 3.0 gpm / ton
[1.6 to 3.2 l/m per kW]
Rev.: 4 June, 2012
Normal Water Flow
Commissioning Conditions
Consult Table 9b for commissioning conditions. Starting conditions vary depending upon model and are based upon the
following notes:
Notes:
1. Conditions in Table 9b are not normal or continuous operating conditions. Minimum/maximum limits are start-up conditions
to bring the building space up to occupancy temperatures. Units are not designed to operate under these conditions on a
regular basis.
2. Voltage utilization complies with AHRI Standard 110, voltage range B.
Table 9b: Building Commissioning Limits
Unit
Commissioning Limits
Cooling
Heating
Air Limits
Min. ambient air, DB
Rated ambient air, DB
Max. ambient air, DB
Min. entering air, DB/WB
Rated entering air, DB/WB 80.6/66.2ºF [27/19ºC]
Max. entering air, DB/WB
Water Limits
45ºF [7ºC]
80.6ºF [27ºC]
130ºF [54ºC]
60ºF [16ºC]
39ºF [4ºC]
68ºF [20ºC]
85ºF [29ºC]
40ºF [4.5ºC]
68ºF [20ºC]
80ºF [27ºC]
110/83ºF [43/28ºC]
Min. entering water
Normal entering water
Max. entering water
20ºF [-6.7ºC]
50-110ºF [10-43ºC]
120ºF [49ºC]
20ºF [-6.7ºC]
30-70ºF [-1 to 21ºC]
120ºF [49ºC]
1.5 to 3.0 gpm / ton
[1.6 to 3.2 l/m per kW]
Normal Water Flow
Rev.: 4 June, 2012
32
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Heat Controller, Inc.
HEV/H SERIES
Installation, Operation & Maintenance
UNIT STARTING AND OPERATING CONDITIONS
Starting/Commissioning Conditions
Table 9b: Commissioning Limits
Commissioning Limits
HE Series
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
45°F [7°C]
80.6° [27°C]
110° [43°C]
39°F [4°C]
68° [20°C]
85° [29°C]
40°F [4.5°C]
68°F [20°C]
80°F [27°C]
50/45°F [10/7°C]
80.6/66.2°F [27/19°C]
110/83°F [43/28°C]
Water Limits
Min. entering water
Normal entering water
Max. 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]
1.5 to 3.0 gpm/ton
[1.6 to 3.2 l/m per KWI
Normal Water Flow
33
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Installation, Operation & Maintenance
HEV/H SERIES
Heat Controller, Inc.
UNIT START-UP AND OPERATING CONDITIONS
Unit and System Checkout
operate in the proper sequence.
BEFORE POWERING SYSTEM, please check the following:
ꢁ
ꢁ
Low water temperature cutout: Verify that low water
temperature cut-out controls are set properly
(LT1 - JW3).
Miscellaneous: Note any questionable aspects of
the installation.
UNIT CHECKOUT
ꢁ
ꢁ
Shutoff valves: Insure that all isolation valves are open.
Line voltage and wiring: Verify that voltage is within
an acceptable range for the unit and wiring and fuses/
breakers are properly sized. Verify that low voltage wiring
is complete.
ꢀ CAUTION! ꢀ
CAUTION! Verify that ALL water valves are open and
allow water flow prior to engaging the compressor.
Freezing of the coax or water lines can permanently
damage the heat pump.
ꢁ
ꢁ
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! ꢀ
ꢁ
ꢁ
Antifreeze has been added if necessary.
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.
Entering water and air: Insure that entering water and air
temperatures are within operating limits of Tables 9a and
9b.
ꢁ
ꢁ
Low water temperature cutout: Verify that low water
temperature cut-out on the DXM2 control is properly set.
Unit fan: Manually rotate fan to verify free rotation and
insure that blower wheel is secured to the motor shaft.
Be sure to remove any shipping supports if needed.
DO NOT oil motors upon start-up. Fan motors are pre-
oiled at the factory. Check unit fan speed selection and
compare to design requirements.
Unit Start-up Procedure
1. Turn the thermostat fan position to “ON.” Blower
should start.
2. Balance air flow at registers.
3. Adjust all valves to their full open position. Turn on the
line power to all heat pump units.
4. Room temperature should be within the minimum-
maximum ranges of Table 9b. During start-up checks,
loop water temperature entering the heat pump should
be between 30°F [-1°C] and 95°F [35°C].
5. It is recommended that water-to-air units be first started
in the cooling mode, when possible. This will allow liquid
refrigerant to flow through the filter-drier before entering
the TXV, allowing the filter-drier to catch any debris that
might be in the system before it reaches the TXV.
6. Two factors determine the operating limits of geothermal
heat pumps, (a) return air temperature, and (b) water
temperature. When any one of these factors is at a
minimum or maximum level, the other factor must be at
normal level to insure proper unit operation.
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.
ꢁ
ꢁ
ꢁ
Condensate line: Verify that condensate trap is installed
and pitched.
HWG pump is disconnected unless piping is completed
and air has been purged from the system.
Water flow balancing: Record inlet and outlet water
temperatures for each heat pump upon startup. This
check can eliminate nuisance trip outs and high velocity
water flow that could erode heat exchangers.
Unit air coil and filters: Insure that filter is clean and
accessible. Clean air coil of all manufacturing oils.
Unit controls: Verify that DXM2 field selection options are
properly set. Low voltage wiring is complete.
Blower CFM and Water ∆T is set on communicating
thermostats or diagnostic tool.
ꢁ
ꢁ
ꢁ
ꢁ
Service/access panels are in place.
SYSTEM CHECKOUT
ꢁ
ꢁ
ꢁ
System water temperature: Check water temperature
for proper range and also verify heating and cooling set
points for proper operation.
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 bypassed on the DXM2
control board as shown below in Figure 25. See
controls description for details.
c. Verify that the compressor is on and that the water
flow rate is correct by measuring pressure drop
through the heat exchanger using the pressure ports
and comparing to Table 10.
ꢁ
ꢁ
Internal Flow Controller: Verify that it is purged of air and
in operating condition.
System controls: Verify that system controls function and
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
34
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Heat Controller, Inc.
HEV/H SERIES
Installation, Operation & Maintenance
UNIT START-UP PROCEDURE
Note: Units have a five minute time delay in the
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 (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.
8. When testing is complete, set system to maintain
desired comfort level.
9. BE CERTAIN TO FILL OUT AND FORWARD ALL
WARRANTY REGISTRATION PAPERS TO HEAT
CONTROLLER.
control circuit that can be eliminated on the CXM
control board as shown below in Figure 30. See
controls description for details.
c. Verify that the compressor is on and that the water
flow rate is correct by measuring pressure drop
through the heat exchanger using the P/T plugs
10C.
and comparing to Table
d. Check the elevation and cleanliness of the
condensate lines. Dripping may be a sign of a
blocked line. Check that the condensate trap is
filled to provide a water seal.
e. Refer to Table 9. 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 10 through
12. Verify correct water flow by comparing unit
pressure drop across the heat exchanger versus
,
the data in Table
10C. 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
ѥ WARNING! ѥ
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.
across the heat exchanger to Table
10C.
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].
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.
ѥ CAUTION! ѥ
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.
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.
d. Refer to Table 9. 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 Tabe13. Verify
Figure 30:Test Mode Pins
Short test pins
together to enter Test
Mode and speed-up
timing and delays for
20 minutes.
correct water flow by comparing unit
pressure drop across the heat exchanger versus
the data in
Table 10C. 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 Table 8.
e. Check air temperature rise across the air coil when
35
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Installation, Operation & Maintenance
HEV/H SERIES
Heat Controller, Inc.
UNIT OPERATING CONDITIONS
Table 11: Water Temperature Change Through Heat
Exchanger
Table 10: HE Coax Water Pressure Drop
Pressure Drop (psi)
Model
GPM
30°F
50°F
70°F
90°F
9 - 12
4 - 8
2.5
3.0
3.8
4.5
6.0
0.8
1.2
1.8
2.7
3.9
0.3
0.6
1.1
1.6
2.8
0.2
0.5
0.9
1.2
2.2
0.2
0.5
0.8
1.2
2.0
024
Rev B
10 - 17
20 - 26
3.0
3.8
4.5
6.0
7.5
1.7
2.3
2.7
3.8
5.1
0.9
1.2
1.6
2.4
3.5
0.8
1.1
1.4
2.2
3.1
0.8
1.1
1.4
2.1
2.9
030
4.0
6.0
6.8
8.0
9.0
0.6
1.8
2.3
3.2
4.0
0.1
1.0
1.5
2.2
2.9
0.1
0.7
1.1
1.8
2.4
0.1
0.7
1.1
1.7
2.3
036
Rev B
3.8
5.3
7.5
7.9
10.5
1.7
2.7
4.5
4.8
7.4
1.0
1.8
3.1
3.4
5.4
0.9
1.6
2.8
3.1
4.9
0.9
1.5
2.6
2.9
4.7
042
048
060
4.5
6.0
6.8
9.0
12.0
1.4
2.0
2.5
4.0
6.5
1.1
1.7
2.1
3.4
5.5
0.9
1.4
1.8
3.0
4.9
0.8
1.3
1.7
2.7
4.5
6.0
7.5
9.0
4.0
5.4
6.8
2.6
3.8
4.9
2.4
3.3
4.4
2.4
3.3
4.3
12.0
15.0
10.6
16.2
7.9
12.8
7.0
11.1
6.7
10.1
Table 12: Antifreeze Correction
Cooling
Heating
WPD
Antifreeze
Antifreeze Type
%
EWT 90°F
Sens Cap
EWT 30°F
Corr. Fct.
EWT 30°F
Total Cap
Power
Htg Cap
Power
0
1.000
0.995
0.986
0.978
0.997
0.990
0.982
0.998
0.994
0.986
0.998
0.994
0.988
1.000
0.995
0.986
0.978
0.997
0.990
0.982
0.998
0.994
0.986
0.998
0.994
0.988
1.000
1.003
1.009
1.014
1.002
1.007
1.012
1.002
1.005
1.009
1.002
1.004
1.008
1.000
0.989
0.968
0.947
0.989
0.968
0.949
0.981
0.944
0.917
0.993
0.980
0.966
1.000
0.997
0.990
0.983
0.997
0.990
0.984
0.994
0.983
0.974
0.998
0.994
0.990
1.000
1.070
1.210
1.360
1.070
1.160
1.220
1.140
1.300
1.360
1.040
1.120
1.200
Water
5
15
25
5
Propylene Glycol
15
25
5
Methanol
Ethanol
15
25
5
15
25
Ethylene Glycol
36
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Heat Controller, Inc.
HEV/H SERIES
Installation, Operation & Maintenance
UNIT OPERATING CONDITIONS
Table 13: HE Series Typical Unit Operating Pressures and Temperatures
024 Full Load Cooling - without HWG active Full Load Heating - without HWG active
Entering
Water
Temp °F
Water
Flow
GPM/ton
Suction
Pressure
PSIG
Discharge
Pressure
PSIG
Water
Subcooling Temp Drop
°F
Air Temp
Drop °F
DB
Suction
Pressure
PSIG
Discharge
Pressure
PSIG
Water
Subcooling Temp Drop
°F
Air Temp
Rise °F
DB
Superheat
Superheat
1.5
2.25
3
67-77
72-82
297-317
303-323
309-329
340-360
343-363
346-366
373-393
390-410
401-421
406-426
415-435
423-443
1-6
3-8
2-7
5-10
5-10
5-10
5-10
5-10
5-10
5-10
5-10
3-8
8.0-10.0
5.9-7.9
18-23
20-25
21-27
24-27
26-31
27-32
30-35
33-40
33-36
36-41
37-41
38-43
30*
50
77-87
3-8
3.8-5.8
1.5
2.25
3
127-137
125-135
124-134
132-142
131-141
130-140
140-150
139-149
138-148
144-154
143-153
143-153
244-264
205-225
166-186
327-347
301-321
276-296
457-477
433-453
409-429
530-550
510-530
490-510
8-12
8-12
10-15
8-12
8-12
8-12
6-11
6-11
6-11
4-10
4-10
4-10
9-14
7-12
20.6-22.6
14.5-16.5
8.41-10.41
19.9-21.9
14.0-16.0
8.0-10.0
19-25
19-25
19-25
18-24
18-24
18-24
17-23
17-23
17-23
16-22
16-22
16-22
98-108
104-114
111-121
129-139
137-147
145-155
162-172
170-180
178-188
6-11
11.1-13.1
8.1-10.1
5.2-7.2
6-11
5-10
8-12
10-15
11-16
11-16
14-19
14-19
14-19
1.5
2.25
3
11-16
9-14
14.4-16.4
10.5-12.5
6.5-8.5
70
7-12
1.5
2.25
3
13-18
11-16
9-14
19.9-21.9
13.2-15.2
7.5-9.5
17.5-19.5
12.7-14.7
7.9-9.9
90
3-8
3-8
1.5
2.25
3
13-18
13-18
11-16
18.9-20.9
13.0-15.0
7.11-9.11
110
*Based on 15% Methanol antifreeze solution
030
Full Load Cooling - without HWG active
Full Load Heating - without HWG active
Entering
Water
Temp °F
Water
Flow
GPM/ton
Suction
Pressure
PSIG
Discharge
Pressure
PSIG
Water
Subcooling Temp Drop
°F
Air Temp
Drop °F
DB
Suction
Pressure
PSIG
Discharge
Pressure
PSIG
Water
Subcooling Temp Drop
°F
Air Temp
Rise °F
DB
Superheat
Superheat
1.5
2.25
3
65-75
67-77
311-331
315-335
319-339
353-373
358-378
362-382
390-410
398-418
405-425
430-450
459-479
448-468
9-14
9-14
9-14
9-14
8.0-10.0
6.2-8.2
19-24
20-25
21-26
26-31
26-31
27-32
33-38
33-38
34-39
37-42
39-44
40-45
30*
50
72-82
9-14
9-14
4.3-6.3
1.5
2.25
3
122-132
121-131
121-131
127-137
126-136
125-135
133-143
133-143
132-142
137-147
136-146
135-145
240-260
213-233
186-206
316-336
298-318
280-300
438-458
420-440
401-421
507-527
490-510
473-493
10-15
11-16
11-16
9-14
9-14
9-14
8-13
8-13
8-13
6-11
11-16
9-14
19.5-21.5
15.0-17.0
10.3-12.3
18.8-20.8
14.3-16.3
9.8-11.8
18-23
19-24
19-24
17-22
17-22
17-22
15-20
15-20
15-20
15-20
15-20
15-20
95-105
100-110
105-115
124-134
130-140
137-147
156-166
163-173
170-180
11-16
11-16
12-17
13-18
14-19
15-20
16-21
17-22
18-23
10-15
10-15
10-15
10-15
9-14
10.5-12.5
8.2-10.2
5.8-7.8
7-12
1.5
2.25
3
12-17
11-16
9-14
13.5-15.5
10.5-12.5
7.5-9.5
70
9-14
1.5
2.25
3
14-19
13-18
11-16
16-21
14-19
13-18
17.8-19.8
13.5-15.5
9.2-11.2
8-13
16.5-18.5
12.8-14.8
9.0-11.0
90
8-13
8-13
1.5
2.25
3
17.2-19.2
13.0-15.0
8.8-10.8
110
7-12
7-12
*Based on 15% Methanol antifreeze solution
036
Full Load Cooling - without HWG active
Full Load Heating - without HWG active
Entering
Water
Temp °F
Water
Flow
GPM/ton
Suction
Pressure
PSIG
Discharge
Pressure
PSIG
Water
Subcooling Temp Drop
°F
Air Temp
Drop °F
DB
Suction
Pressure
PSIG
Discharge
Pressure
PSIG
Water
Subcooling Temp Drop
°F
Air Temp
Rise °F
DB
Superheat
Superheat
1.5
2.25
3
60-70
65-75
315-335
321-341
327-347
353-373
361-381
370-390
390-410
400-420
411-431
424-444
439-459
453-473
4-9
11-16
11-16
11-16
12-17
12-17
12-17
12-17
10-15
10-15
9-14
10.0-12.0
6.7-8.7
18-23
19-24
20-25
24-29
25-30
26-31
29-34
31-36
32-37
35-40
37-42
39-44
5-10
30*
50
70-80
6-11
3.4-5.4
1.5
2.25
3
123-133
122-132
121-131
128-138
124-134
119-129
135-145
134-144
132-142
139-149
138-148
137-147
244-264
240-260
235-255
328-348
300-320
273-293
453-473
428-448
402-422
525-545
503-523
480-500
10-15
10-15
11-16
8-13
9-14
9-14
7-12
7-12
8-13
6-11
6-11
6-11
12-17
9-14
20.9-22.9
14.3-16.3
7.8-9.8
17-22
17-22
17-22
16-21
16-21
16-21
16-21
15-20
14-19
13-18
13-18
14-19
88-98
6-11
13.2-15.2
9.0-11.0
4.8-6.8
96-106
105-115
116-126
128-138
139-149
148-158
160-170
173-183
8-13
7-12
9-14
1.5
2.25
3
12-17
10-15
9-14
20.2-22.2
13.8-15.8
7.5-9.5
9-14
17.0-19.0
11.6-13.6
6.1-8.1
70
11-16
13-18
12-17
14-19
16-21
1.5
2.25
3
13-18
11-16
9-14
19.2-21.2
13.1-15.1
7.1-9.1
20.9-22.9
14.2-16.2
7.4-9.4
90
9-14
8-13
1.5
2.25
3
14-19
12-17
10-15
18.5-20.5
12.7-14.7
6.9-8.9
110
*Based on 15% Methanol antifreeze solution
37
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Installation, Operation & Maintenance
HEV/H SERIES
Heat Controller, Inc.
UNIT OPERATING CONDITIONS
Table 13: HE Series Typical Unit Operating Pressures and Temperatures: Continued
042 Full Load Cooling - without HWG active Full Load Heating - without HWG active
Entering
Water
Temp °F
Water
Flow
GPM/ton
Suction
Pressure
PSIG
Discharge
Pressure
PSIG
Water
Temp Rise
°F
Air Temp
Drop °F
DB
Suction
Pressure
PSIG
Discharge
Pressure
PSIG
Water
Temp Drop
°F
Air Temp
Rise °F
DB
Superheat
Subcooling
Superheat
Subcooling
1.5
2.25
3
64-74
67-77
71-81
314-334
317-337
321-341
6-11
6-11
7-12
9-14
9-14
9-14
8.0-10.0
6.0-8.0
4.0-6.0
20-25
20-25
21-26
30*
50
1.5
2.25
3
121-131
120-130
120-130
230-250
200-240
164-184
10-15
11-16
11-16
10-15
8-13
6-11
20.5-22.5
15.2-17.2
9.8-11.8
22-27
22-27
22-27
95-105
100-110
104-114
351-371
356-376
361-381
8-13
9-14
10-15
9-14
9-14
9-14
10.7-12.7
8.1-10.1
5.4-7.4
26-31
27-32
27-32
1.5
2.25
3
127-137
125-135
125-135
305-325
290-310
263-283
8-13
9-13
10-15
10-15
9-14
7-12
19.8-21.8
14.7-16.7
9.5-11.5
20-25
21-26
21-26
124-134
131-141
138-148
386-406
390-410
400-420
11-16
12-17
13-18
8-13
8-13
7-12
13.8-15.8
10.4-12.4
7.0-9.0
32-37
33-37
34-39
70
1.5
2.25
3
133-143
132-142
132-142
426-446
406-426
390-410
7-12
7-12
7-12
11-16
9-14
8-13
19-21
14-16
9-11
19-24
19-24
19-24
157-167
164-174
172-182
423-443
432-452
441-461
13-18
15-20
16-21
5-10
5-10
5-10
16.8-18.8
12.7-14.7
8.5-10.5
38-43
40-45
41-46
90
1.5
2.25
3
137-147
136-146
136-146
494-514
477-497
460-480
5-10
6-11
6-11
11-16
10-15
8-13
18-20
14-16
9-11
18-23
18-23
18-23
110
*Based on 15% Methanol antifreeze solution
048
Full Load Cooling - without HWG active
Full Load Heating - without HWG active
Entering
Water
Temp °F
Water
Flow
GPM/ton
Suction
Pressure
PSIG
Discharge
Pressure
PSIG
Water
Temp Drop
°F
Air Temp
Drop °F
DB
Suction
Pressure
PSIG
Discharge
Pressure
PSIG
Water
Temp Drop
°F
Air Temp
Rise °F
DB
Superheat
Subcooling
Superheat
Subcooling
1.5
2.25
3
61-71
64-74
68-78
290-310
293-313
296-316
9-14
9-14
10-15
5-10
5-10
5-10
7.7-9.7
5.7-7.7
3.7-5.7
18-23
18-23
18-23
30*
50
1.5
2.25
3
124-134
123-133
121-131
250-270
212-232
173-193
11-16
12-17
13-18
13-18
10-15
7-12
20.1-22.1
14.8-16.8
9.5-11.5
19-24
19-24
19-24
88-98
94-104
100-110
319-339
324-344
330-350
11-16
11-16
12-17
6-11
6-11
6-11
10.3-12.3
7.8-9.8
5.3-7.3
24-29
25-30
25-30
1.5
2.25
3
129-139
128-138
127-137
334-354
309-329
284-304
9-14
10-15
10-15
16-21
13-18
10-15
19.6-21.6
14.4-16.4
9.3-11.3
18-23
18-23
18-23
117-127
125-135
133-143
349-369
357-377
365-385
13-18
14-19
15-20
5-10
5-10
4-11
13.4-15.4
10.2-12.2
6.9-8.9
29-34
30-35
31-36
70
1.5
2.25
3
135-145
134-144
132-142
470-490
446-466
422-442
7-12
7-12
8-13
20-25
17-22
15-20
18.9-20.9
13.8-15.8
8.8-10.8
16-21
16-21
16-21
150-160
158-168
166-176
384-404
391-411
399-419
15-20
16-21
17-22
3-8
2-7
2-7
16.6-18.6
12.6-14.6
8.5-10.5
35-40
36-41
37-42
90
1.5
2.25
3
138-148
138-148
137-147
548-568
526-546
505-525
6-11
6-11
6-11
22-27
19-24
17-22
18.6-20.6
13.6-15.6
8.6-10.6
15-20
15-20
15-20
110
*Based on 15% Methanol antifreeze solution
060
Full Load Cooling - without HWG active
Full Load Heating - without HWG active
Entering
Water
Temp °F
Water
Flow
GPM/ton
Suction
Pressure
PSIG
Discharge
Pressure
PSIG
Water
Temp Drop
°F
Air Temp
Drop °F
DB
Suction
Pressure
PSIG
Discharge
Pressure
PSIG
Water
Temp Drop
°F
Air Temp
Rise °F
DB
Superheat
Subcooling
Superheat
Subcooling
1.5
2.25
3
64-74
68-78
71-81
309-329
313-333
317-337
7-12
7-12
8-13
10-15
10-15
10-15
8.4-10.4
6.0-8.0
3.6-5.6
19-24
20-25
20-25
30*
50
1.5
2.25
3
120-130
120-130
118-128
225-245
222-242
220-240
9-14
9-14
9-14
13-18
10-15
9-14
21.8-23.8
14.7-16.7
8.7-10.7
20-25
20-25
20-25
94-104
100-110
105-115
343-363
350-270
356-376
9-14
10-15
10-15
12-18
11-16
10-15
11.3-13.3
8.2-10.2
5.0-8.0
25-30
26-31
26-31
1.5
2.25
3
124-134
124-134
123-133
300-320
278-298
256-276
8-13
8-13
8-13
14-19
11-16
9-14
19.9-21.9
14.1-16.1
8.3-10.3
19-24
19-24
19-24
122-132
130-140
137-147
377-397
386-406
394-414
11-16
12-17
13-18
9-14
8-13
7-12
14.2-16.2
10.3-12.3
6.5-8.5
31-36
31-36
33-38
70
1.5
2.25
3
130-140
129-139
129-139
420-440
400-420
390-410
7-12
7-12
7-12
16-21
12-17
9-14
19.0-21.0
13.4-15.4
7.9-9.9
17-22
17-22
17-22
155-165
165-175
175-185
412-432
423-443
423-443
14-19
15-20
16-21
6-11
5-10
4-9
17.2-19.2
12.6-14.6
7.9-9.9
36-41
37-42
39-44
90
1.5
2.25
3
133-143
132-142
132-142
495-515
475-495
454-474
6-11
6-11
6-11
16-21
13-18
9-14
18.5-20.5
13.1-15.1
7.6-9.6
16-21
16-21
16-21
110
*Based on 15% Methanol antifreeze solution
38
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Heat Controller, Inc.
HEV/H SERIES
Installation, Operation & Maintenance
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
(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
All units have lubricated fan motors. Fan motors should
never be lubricated unless obvious, dry operation
is suspected. Periodic maintenance oiling is not
recommended, as it will result in dirt accumulating in the
excess oil and cause eventual motor failure. Conduct
annual dry operation check and amperage check to
water coil can be checked regularly. Dirty installations are insure amp draw is no more than 10% greater than
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
indicated on serial plate data.
Air Coil
The air coil must be cleaned to obtain maximum
maintenance. Should periodic coil cleaning be necessary, performance. Check once a year under normal operating
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.
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
Do not allow water to stay in contact with the cabinet for
long periods of time to prevent corrosion of the cabinet
sheet metal. Generally, vertical cabinets are set up from
the floor a few inches [7 - 8 cm] to prevent water from
entering the cabinet. The cabinet can be cleaned using a
Hot Water Generator Coils
See water coil maintenance for ground water units. If the
potable water is hard or not chemically softened, the high mild detergent.
temperatures of the desuperheater will tend to scale even
quicker than the water coil and may need more frequent
Refrigerant System
inspections. In areas with extremely hard water, a HWG is To maintain sealed circuit integrity, do not install service
not recommended.
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.
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.
39
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Installation, Operation & Maintenance
HEV/H SERIES
Heat Controller, Inc.
TROUBLESHOOTING
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 DXM2 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 DXM2
board is NOT sending an output signal to the electric heat
board.
General
If operational difficulties are encountered, perform
the preliminary checks below before referring to the
troubleshooting charts.
• Verify that the unit is receiving electrical supply power.
• Make sure the fuses in the fused disconnect switches are
intact.
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 “DXM2 Troubleshooting Process
Flowchart” or “Functional Troubleshooting Chart.”
Test Mode
Test mode can be entered for 20 minutes by pressing the
Test pushbutton. The DXM2 board will automatically exit test
mode after 20 minutes.
DXM2 Board
Advanced Diagnostics
DXM2 board troubleshooting in general is best summarized
as 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 DXM2 control.
If a communicating thermostat or diagnostic tool is
connected to the DXM2, additional diagnostic information
and troubleshooting capabilities are available. The current
status of all DXM2 inputs can be verified, including the
current temperature readings of all temperature inputs.
With a communicating thermostat the current status of the
inputs can be accessed from the Service Information menu.
In the manual operating mode, most DXM2 outputs can
be directly controlled for system troubleshooting. With a
communicating thermostat the manual operating mode can
be accessed from the Installer menu. For more detailed
information on the advanced diagnostics of the DXM2, see
the DXM2 Application, Operation and Maintenance (AOM)
manual (part #97B0003N15).
Field Inputs
Conventional thermostat inputs are 24VAC from the
thermostat and can be verified using a voltmeter between C
and Y1, Y2, W, O, G. 24VAC will be present at the terminal
(for example, between “Y1” and “C”) if the thermostat is
sending an input to the DXM2 board.
Proper communications with a thermostat can be verified
using the Fault LED on the DXM2. If the control is NOT
in the Test mode and is NOT currently locked out or in
a retry delay, the Fault LED on the DXM2 will flash very
slowly (1 second on, 5 seconds off), if the DXM2 is properly
communicating with the thermostat.
DXM2 Troubleshooting Process Flowchart/Functional
Troubleshooting Chart
The “DXM2 Functional Troubleshooting Process Flowchart”
is a quick overview of how to start diagnosing a suspected
problem, using the fault recognition features of the DXM2
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 DXM2 controls. Within the chart are
five columns:
• The “Fault” column describes the symptoms.
• Columns 2 and 3 identify in which mode the fault is likely
to occur, heating or cooling.
• The “Possible Cause column” identifies the most likely
sources of the problem.
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. 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
DXM2 AOM manual. An ice bath can be used to check the
calibration of the thermistor.
• The “Solution” column describes what should be done to
correct the problem.
Outputs
The compressor and reversing valve relays are 24VAC
and can be verified using a voltmeter. For units with PSC
blower motors, the fan relay provides a contact closure to
directly power the blower motor, or provide 24VAC to an
external fan relay. For units with ECM blower motors, the
DXM2 controls the motor using serial communications,
and troubleshooting should be done with a communicating
thermostat or diagnostic tool. 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 voltmeter set for
DC to verify operation. The terminal marked “24VDC” is the
ꢀ WARNING! ꢀ
WARNING! HAZARDOUS VOLTAGE! DISCONNECT
ALL ELECTRIC POWER INCLUDING REMOTE
DISCONNECTS BEFORE SERVICING.
Failure to disconnect power before servicing can cause
severe personal injury or death.
40
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Heat Controller, Inc.
HEV/H SERIES
Installation, Operation & Maintenance
DXM2 PROCESS FLOW CHART
ꢀ WARNING! ꢀ
WARNING! HAZARDOUS VOLTAGE! DISCONNECT
ALL ELECTRIC POWER INCLUDING REMOTE
DISCONNECTS BEFORE SERVICING.
Failure to disconnect power before servicing can cause
severe personal injury or death.
DXM2 Functional
Troubleshooting Flow Chart
Start
Did Unit
Attempt to
Start?
Check Main
power (see power
problems)
No
Yes
Did Unit
Lockout at
Start-up?
Yes
Check fault code on communicating
thermostat (ATC32) or Configuration
and Diagnostics Tool (ACD01)
No fault
shown
No
See “Unit
short
cycles”
Yes
Yes
Yes
Unit Short
Cycles?
Replace
DXM2
No
See fault codes in table
on following page
See “Only
Fan Runs”
Only Fan
Runs?
No
Only
Compressor
Runs?
See “Only
Comp
Runs”
No
Did unit lockout
after a period of
operation?
Yes
No
Does unit
operate in
cooling?
See “Does
not Operate
in Clg”
No
Yes
Unit is OK!
‘See Performance
Troubleshooting’ for
further help
41
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Installation, Operation & Maintenance
HEV/H SERIES
Heat Controller, Inc.
FUNCTIONAL TROUBLESHOOTING
Fault
Htg Clg Possible Cause
Solution
Check Line Voltage circuit breaker and disconnect
Check for line voltage between L1 and L2 on the contactor
Check for 24VAC between R and C on DXM
Main Power Problems
X
X
Green status LED off
Check primary/secondary voltage on transformer
Check pump operation or valve operation/setting
Check water flow adjust to proper flow rate
X
X
Reduced or no water flow
in cooling
Water t emperature out of range in
cooling
Bring water temp within design parameters
Check for dirty air filter and clean or replace
Check fan motor operation and airflow restrictions
Dirty air coil- construction dust etc.
Reduced or no air flow
in heating
HP Fault Code 2
High Pressure
X
X
Too high of external static. Check static vs blower table
Air t emperature out of range in
heating
Bring return air temp within design parameters
Check superheat/subcooling vs typical operating condition
table
X
X
X
X
Overcharged with refrigerant
Bad HP switch
Check switch continuity and operation - Replace
X
X
X
Frozen water heat exchanger
Bad HPWS Switch
Thaw heat exchanger
Replace HPWS Switch
Check for refrigerant leaks
X
X
Insufficient charge
LP/LOC Fault-Code 3
Low Pressure/Loss of Charge
Compressor pump down at start-
up
X
Check charge and start-up water flow
Check pump operation or water valve operation/setting
Plugged strainer or filter - clean or replace
Check water flow adjust to proper flow rate
Check antifreeze density with hydrometer
Reduced or no water flow
in heating
X
LT1 Fault - Code 4
X
X
Inadequate anti-freeze level
Water Low Temperature
Improper low temperature setting
(30°F vs 10°F)
Clip LT1 jumper for antifreeze (10°F) use
X
X
Water t emperature out of range
Bad thermistor
Bring water temp within design parameters
X
X
Check temp and impedance correlation per chart
Check for dirty air filter and clean or replace
Check fan motor operation and airflow restrictions
Too high of external static - check static vs blower table
Reduced or no air flow
in cooling
Too much cold vent air - bring entering air temp within
design parameters
X
Air temperature out of range
LT2 Fault - Code 5
Low Air Temperature
Improper low temperature setting
(30°F vs 10°F)
X
X
Normal airside applications will require 30°F only
Check temp and impedance correlation per chart
X
Bad thermistor
X
X
X
X
Blocked drain
Improper trap
Check for blockage and clean drain
Check trap dimensions and location ahead of vent
Check for piping slope away from unit
Check slope of unit toward outlet
X
Poor drainage
Condensate Fault-Code 6
High Condensate Level
Poor venting - check vent location
Check for moisture shorting to air coil
X
X
Moisture on sensor
Plugged air filter
Replace air filter
X
X
Find and eliminate rectriction - increase return duct
and/or grille size
X
Restricted return air flow
Check power supply and 24VAC voltage before and during
operation
Check power supply wire size
Check compressor starting. Need hard start kit?
X
X
Under voltage
Over/Under Voltage-Code 7
(Auto Resetting)
Check 24VAC and unit transformer tap for correct power
supply voltage
Check power supply voltage and 24VAC before and during
operation.
X
X
X
Over voltage
Check 24VAC and unit transformer tap for correct power
supply voltage
Heating Mode LT2>125°F
Check for poor air flow or overcharged unit
Check for poor water flow, or air flow
Unit Performance
Sentinel-Code 8
Cooling Mode LT1>125°F OR
LT2< 40°F
X
X
X
Swapped Thermistor
Code 9
X
X
LT1 and LT2 swapped
Reverse position of thermistors
Check blower line voltage
Blower does not operate
Check blower low voltage wiring
Blower operating with incorrect
airflow
Wrong unit size selection
Wrong unit family selection
Wrong motor size
ECM Fault - Code 10
Incorrect blower selection
42
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Heat Controller, Inc.
HEV/H SERIES
Installation, Operation & Maintenance
FUNCTIONAL TROUBLESHOOTING (CONT.)
Fault
Htg C
Possible Cause
Solution
lg
No pump output signal
Check DC voltage between A02 and GND - should be
between 0.5 and 10 VDC with pump active
IFC Fault Code 13
Internal Flow
X
X
Controller Fault
Low pump voltage
Check line voltage to the pump
No pump feedback signal
Check DC voltage between T1 and GND. Voltage should
be between 3 and 4 VDC with pump OFF, and between
0 and 2 VDC with the pump ON
Bad pump RPM sensor
Replace pump if the line voltage and control signals are
present at the pump, and the pump does not operate
ESD - ERV Fault (DXM Only)
Green Status LED Code 3
ERV unit has fault
(Rooftop units only)
X
X
Troubleshoot ERV unit fault
X
X
X
X
X
X
No compressor operation
Compressor overload
Control board
See 'Only Fan Operates'
No Fault Code Shown
Unit Short Cycles
Check and replace if necessary
Reset power and check operation
X
X
X
X
Dirty air filter
Unit in 'Test Mode'
Check and clean air filte r
Reset power or wait 20 minutes for auto exit
Unit may be oversized for space - check sizing for actual
load of space
X
X
Unit selection
X
X
X
X
X
X
Compressor overload
Thermostat position
Unit locked out
Check and replace if necessary
Insure thermostat set for heating or cooling operation
Check for lockout codes - reset power
Only Fan Runs
Check compressor overload - replace if necessary
X
X
Compressor overload
Check thermostat wiring at DXM2 - put in Test Mode and
jumper Y1 and R to give call for compressor
X
X
Thermostat wiring
43
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Installation, Operation & Maintenance
HEV/H SERIES
Heat Controller, Inc.
TROUBLESHOOTING FORM
HEATING CYCLE ANALYSIS -
PSI
SAT
°F
AIR
COIL
SUCTION
°F
°F
COMPRESSOR
DISCHARGE
Refrigerant Type
:
EXPANSION
VALVE
COAX
R-410A
HWG
°F
°F
°F
°F
PSI
SAT
FLASH
FP2: HEATING
FP1
°F
PSI
WATER IN
°F
PSI
WATER OUT
GAS LINE
LIQUID LINE
SENSOR
Look up pressure drop in
I.O.M. or spec. catalog to
determine flow rate.
COOLING CYCLE ANALYSIS -
AIR
PSI
SAT
°F
SUCTION
COIL
°F
°F
COMPRESSOR
DISCHARGE
EXPANSION
VALVE
COAX
HWG
°F
°F
°F
°F
PSI
SAT
°F
PSI
WATER IN
°F
PSI
WATER OUT
OTHER SIDE
OF FILTR DR
FP2: FLASH
GAS LINE
FP1: CLG
LIQ LINE
Look up pressure drop in
I.O.M. or spec. catalog to
determine flow rate.
Heat of Extraction (Absorption) or Heat of Rejection =
________ flow rate (gpm) x ________ temp.diff. (deg. F) x ________ fluid factor† = _____________
(Btu/hr)
=
=
=
=
Suction temperature - suction saturation temp.
Discharge saturation temp. - liquid line temp.
Superheat
(deg F)
Subcooling
(deg F)
†Use 500 for water, 485 for antifreeze.
Note: Never connect refrigerant gauges during startup procedures. Conduct water-side analysis
using P/T ports to determine water flow and temperature difference. If water-side analysis shows
poor performance, refrigerant troubleshooting may be required. Connect refrigerant gauges as a
last resort.
44
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Heat Controller, Inc.
HEV/H SERIES
Installation, Operation & Maintenance
45
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Revision History
Date
Page #
All
Description
22 April, 13
024, 036 Rev B Info Added
*97B0016N11*
97B0016N11
4/22/13
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