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Heat Controller HTS SERIES manual

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Table of contents for the manual

  • Page 1

    Installation, Operation and Maintenace Manual GeoLogix ® HTS Series Split System, T wo Stage, 2-5 T ons 1900 Wellworth Ave., Jackson, Michigan 49203 • Ph. 517-0787-2100 • Fax 517-787-9341 • www .heatcontroller .com THE QUALITY LEADER IN CONDITIONING AIR[...]

  • Page 2

    Model Nomenclature . . . . . . . . . . . . . . . . . . . . 3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . 5 Equipment Selection . . . . . . . . . . . . . . . . . . . . 6 Air Coil Match-up[...]

  • Page 3

    Model Nomenclatur e : for Indoor Split Series The Quality Leader in Conditioning Air Residential Split - 60Hz R410A Rev .: 03 August, 2012 www .heatcontroller .com 3 1 B 0 2 4 D 1 0 1 N N N 4 5 6 7 8 91 0 1 1 1 2 1 3 1 4 024 UNIT SIZE 036 RETURN AIR FLOW CONFIGURA TION V O LTA G E CONTROLS REVISION LEVEL HEA T EXCHANGER OPTIONS CABINET SUPPL Y AIR [...]

  • Page 4

    Safety HEA T CONTROLLER, INC. W A TER-SOURCE HEA T PUMPS Residential Split - 60Hz R410A Rev .: 03 August, 2012 Heat Controller , Inc. W ater-Source Heating and Cooling Systems 4 W ARNING! V erify refrigerant type before proceeding. Units are shipped with R-410A refrigerants. The unit label will indicate which refrigerant is provided. The EarthPure?[...]

  • Page 5

    General Information The Quality Leader in Conditioning Air Residential Split - 60Hz R410A Rev .: 03 August, 2012 www .heatcontroller .com 5  CAUT I O N!   CAUT I O N!  Inspection Upon receipt of the equipment, carefully check the shipment against the bill of lading. Make sure all units have been received. Inspect the packaging of each u[...]

  • Page 6

    HEA T CONTROLLER, INC. W A TER-SOURCE HEA T PUMPS Residential Split - 60Hz R410A Rev .: 03 August, 2012 Heat Controller , Inc. W ater-Source Heating and Cooling Systems 6 Equipment Selection T able 1a: WDG/MWG Indoor Section Matches for AHRI Ratings Compressor Section Model 024 036 048 060 Indoor Section Model 024 036 048 060 Refrigerant HFC-410A M[...]

  • Page 7

    Air Handler Selection Example Figure 1 shows a typical performance table for a heat pump air handler . Suppose the evaporator temperature required is 50ºF , the capacity required is 35,000 Btuh and the air fl ow required is 1,200 CFM. Each evaporator temperature listed in the table shows three wet bulb temperatures. As recommended in the table no[...]

  • Page 8

    HEA T CONTROLLER, INC. W A TER-SOURCE HEA T PUMPS Residential Split - 60Hz R410A Rev .: 03 August, 2012 Heat Controller , Inc. W ater-Source Heating and Cooling Systems 8 Installation NOTICE! Failure to remove shipping brackets from spring-mounted compressors will cause excessive noise, and could cause component failure due to added vibration. The [...]

  • Page 9

    Figure 2: HTS Installation Gasket Swivel Nut Stainless steel snap ring Brass Adaptor Hand Tighten Only! Do Not Overtighten! The Quality Leader in Conditioning Air Residential Split - 60Hz R410A Rev .: 03 August, 2012 www .heatcontroller .com 9 Piping Installation The typical closed loop ground source system is shown in Figure 3. All earth loop pipi[...]

  • Page 10

    HEA T CONTROLLER, INC. W A TER-SOURCE HEA T PUMPS Residential Split - 60Hz R410A Rev .: 03 August, 2012 Heat Controller , Inc. W ater-Source Heating and Cooling Systems 10 Earth loop temperatures can range between 25 and 1 10°F [-4 to 43°C]. Flow rates between 2.25 and 3 gpm per ton [2.41 to 3.23 l/m per kW] of cooling capacity is recommended in [...]

  • Page 11

    The Quality Leader in Conditioning Air Residential Split - 60Hz R410A Rev .: 03 August, 2012 www .heatcontroller .com 11 T able 2: Approximate Fluid V olume (U.S. gal. [L]) per 100’ of Pipe Figure 4: Loop Connection (Indoor Compressor Section) Gr ound-Loop Heat Pump Applications T able 3: Antifreeze Percentages by V olume T ype Minimum T emperatu[...]

  • Page 12

    HEA T CONTROLLER, INC. W A TER-SOURCE HEA T PUMPS Residential Split - 60Hz R410A Rev .: 03 August, 2012 Heat Controller , Inc. W ater-Source Heating and Cooling Systems 12 Open Loop - Ground W ater Systems (“Indoor” Compressor Section Only) The “outdoor” version of the compressor section may not be used with open loop systems due to potenti[...]

  • Page 13

    Figure 9: Water W ell Connections Pressure T ank Shut-Off V alve Boiler Drains Flow Regulator W ater In W ater Out Wa t e r Control Va l v e Optional Filter P/T Plugs Optional Modulating Motorized V alve - For Open Loop Applications A low Cv modulating motorized valve is used for this application to provide more precise control against the higher s[...]

  • Page 14

    W ater Quality Standards HEA T CONTROLLER, INC. W A TER-SOURCE HEA T PUMPS Residential Split - 60Hz R410A Rev .: 03 August, 2012 Heat Controller , Inc. W ater-Source Heating and Cooling Systems 14 T able 4: Water Quality Standards W ater Quality Parameter HX Material Closed Recir culating Open Loop and Recir culating Well Scaling Potential - Primar[...]

  • Page 15

    Line Set Installation Figures 12a through 13b illustrate typical installations with the “indoor” and “outdoor” versions of the compressor section matched to either an air handler (fan coil) or add-on furnace coil. T able 4 shows typical line-set diameters at various lengths. Lineset lengths should be kept to a minimum and should always be i[...]

  • Page 16

    Figure 10: Braze Instructions Figure 1 1: Air Coil Connection Figure 5: Service V alve Positions Fully Insulated Suction Line Fully Insulated Liquid Line Nitrogen Braze V apor Service ports for gauges CCW CCW Rev . 05/31/00 Replace Caps after adjusting service valves HEA T CONTROLLER, INC. W A TER-SOURCE HEA T PUMPS Residential Split - 60Hz R410A R[...]

  • Page 17

    Air pad or extruded polystyrene HWG Series “A” Coil Air T emperature Limit Switch TXV ‘IN’ toward Compressor Section PVC Condensate with vented trap Indoor Compressor Section Air pad or extruded polystyrene PVC Condensate with vented trap Insulated Line Sets Power Disconnects Low V oltage TXV ‘IN’ toward Compressor Section Indoor Compre[...]

  • Page 18

    HEA T CONTROLLER, INC. W A TER-SOURCE HEA T PUMPS Residential Split - 60Hz R410A Rev .: 03 August, 2012 Heat Controller , Inc. W ater-Source Heating and Cooling Systems 18 Refrigeration Installation Evacuation Of The Lineset And Coil The line set and coil must be evacuated to at least 500 microns to remove any moisture and noncondensables. Evacuate[...]

  • Page 19

    The Quality Leader in Conditioning Air Residential Split - 60Hz R410A Rev .: 03 August, 2012 www .heatcontroller .com 19 Refrigeration Installation T urn service valves full out CCW (see T able 5) and then turn back in one-half turn to open service ports. Add the required refrigerant so that the total charge calculated for the unit and line set is [...]

  • Page 20

    HEA T CONTROLLER, INC. W A TER-SOURCE HEA T PUMPS Residential Split - 60Hz R410A Rev .: 03 August, 2012 Heat Controller , Inc. W ater-Source Heating and Cooling Systems 20 Hot Outlet to home Insulated water lines - 5/8” OD, 50 ft maximum (one way) [16mm OD, 15 meters maximum] Powered Wat er Heater Upper element to 120 - 130°F [49 - 54°C] Lower [...]

  • Page 21

    The Quality Leader in Conditioning Air Residential Split - 60Hz R410A Rev .: 03 August, 2012 www .heatcontroller .com 21 The DXM2 microprocessor control monitors the refrigerant and water temperatures to determine when to operate the HWG. The HWG will operate any time the refrigerant temperature is suf fi ciently above the water temperature. Once [...]

  • Page 22

    HEA T CONTROLLER, INC. W A TER-SOURCE HEA T PUMPS Residential Split - 60Hz R410A Rev .: 03 August, 2012 Heat Controller , Inc. W ater-Source Heating and Cooling Systems 22 HWG W ater Piping 1. Using at least 1/2” [12.7mm] I.D. copper , route and install the water piping and valves as shown in Figures 15 or 16. Install an approved anti-scald valve[...]

  • Page 23

    HWG Wiring - Indoor Compressor Section The hot water generator pump power wiring is disabled at the factory to prevent operating the HWG pump “dry .” After all HWG piping is completed and air purged from the water piping, the pump power wires should be applied to terminals on the HWG power block PB2 as shown in the unit wiring diagram. This con[...]

  • Page 24

    HEA T CONTROLLER, INC. W A TER-SOURCE HEA T PUMPS Residential Split - 60Hz R410A Rev .: 03 August, 2012 Heat Controller , Inc. W ater-Source Heating and Cooling Systems 24 Comp Relay 24Vdc EH1 EH2 P6 Off On JW3 c 1 a y c 2 a y CO RV RV LT1 LT1 LT2 LT2 LP LP HP P7 Status Fault CC CCG CO S1 S2 12 1 4 Off On AO2 P11 Gnd T1 P10 T2 T2 T3 T3 T4 T4 T5 P9 [...]

  • Page 25

    The Quality Leader in Conditioning Air Residential Split - 60Hz R410A Rev .: 03 August, 2012 www .heatcontroller .com 25 Thermostat Installation The thermostat should be located on an interior wall in a larger room, away from supply duct drafts. DO NOT locate the thermostat in areas subject to sunlight, drafts or on external walls. The wire access [...]

  • Page 26

    HEA T CONTROLLER, INC. W A TER-SOURCE HEA T PUMPS Residential Split - 60Hz R410A Rev .: 03 August, 2012 Heat Controller , Inc. W ater-Source Heating and Cooling Systems 26 DXM2 Control DXM2 is the next generation in controls is capable of 2-way communication between itself and smart components, like the communicating thermostat, fan motor and con ?[...]

  • Page 27

    The Quality Leader in Conditioning Air Residential Split - 60Hz R410A Rev .: 03 August, 2012 www .heatcontroller .com 27 Figur e 26a: DXM2 La y out and Connections P1 Alarm Relay Comp Relay O Y1 Y2 W G C R AL1 24Vdc EH1 EH2 P6 R C Off On JW3 A OVR ESD C R NSB AL2 JW1 Acc1 Relay Acc2 Relay H COM1 NC1 NO1 COM2 NC2 NO2 P3 CO RV RV LT1 LT1 LT2 LT2 LP L[...]

  • Page 28

    HEA T CONTROLLER, INC. W A TER-SOURCE HEA T PUMPS Residential Split - 60Hz R410A Rev .: 03 August, 2012 Heat Controller , Inc. W ater-Source Heating and Cooling Systems 28 Indoor Split HTS024-060 Wiring Diagram 208-230-/60/1 DXM2[...]

  • Page 29

    The Quality Leader in Conditioning Air Residential Split - 60Hz R410A Rev .: 03 August, 2012 www .heatcontroller .com 29 Unit Commissioning And Operating Conditions T able 9a: Building Operating Limits Operating Limits Environment – Units are designed for indoor installation only . Never install units in areas subject to freezing or where humidit[...]

  • Page 30

    HEA T CONTROLLER, INC. W A TER-SOURCE HEA T PUMPS Residential Split - 60Hz R410A Rev .: 03 August, 2012 Heat Controller , Inc. W ater-Source Heating and Cooling Systems 30 Unit Star t-Up and Operating Conditions Unit and System Checkout BEFORE POWERING SYSTEM, please check the following: UNIT CHECKOUT  Shutoff valves: Insure that all isolation v[...]

  • Page 31

    The Quality Leader in Conditioning Air Residential Split - 60Hz R410A Rev .: 03 August, 2012 www .heatcontroller .com 31 Unit Star t-Up Pr ocedur e  W ARNING !   CAU T I O N !  W ARNING! When the disconnect switch is closed, high voltage is present in some areas of the electrical panel. Exercise caution when working with energized equip[...]

  • Page 32

    HEA T CONTROLLER, INC. W A TER-SOURCE HEA T PUMPS Residential Split - 60Hz R410A Rev .: 03 August, 2012 Heat Controller , Inc. W ater-Source Heating and Cooling Systems 32 Entering Water T emp °F Water Flow GPM/ ton Full Load Cooling - without HWG active Full Load Heating - without HWG active Suction Pressure PSIG Discharge Pressure PSIG Super - h[...]

  • Page 33

    The Quality Leader in Conditioning Air Residential Split - 60Hz R410A Rev .: 03 August, 2012 www .heatcontroller .com 33 Entering Water T emp °F Water Flow GPM/ ton Full Load Cooling - without HWG active Full Load Heating - without HWG active Suction Pressure PSIG Discharge Pressure PSIG Super - heat Sub- cooling Water T emp Rise °F Air T emp Dro[...]

  • Page 34

    HEA T CONTROLLER, INC. W A TER-SOURCE HEA T PUMPS Residential Split - 60Hz R410A Rev .: 03 August, 2012 Heat Controller , Inc. W ater-Source Heating and Cooling Systems 34 Pr ev entiv e Maintenance W ater Coil Maintenance (Direct ground water applications only) If the system is installed in an area with a known high mineral content (125 P .P .M. or[...]

  • Page 35

    The Quality Leader in Conditioning Air Residential Split - 60Hz R410A Rev .: 03 August, 2012 www .heatcontroller .com 35 Basic T r oubleshooting Information General T roubleshooting Basic DXM2 board troubleshooting in general is best summarized as simply verifying inputs and outputs. After this process has been veri fi ed, con fi dence in board o[...]

  • Page 36

    HEA T CONTROLLER, INC. W A TER-SOURCE HEA T PUMPS Residential Split - 60Hz R410A Rev .: 03 August, 2012 Heat Controller , Inc. W ater-Source Heating and Cooling Systems 36 General T o properly con fi gure and troubleshoot advanced control features, and to aid in troubleshooting basic control features, a communicating thermostat or diagnostic tool [...]

  • Page 37

    The Quality Leader in Conditioning Air Residential Split - 60Hz R410A Rev .: 03 August, 2012 www .heatcontroller .com 37 Advanced T r oubleshooting and Con fi guration Information Service Mode The Service Mode provides the installer with several functions for troubleshooting, including Manual Operation, Control Diagnostics, Control Con fi guratio[...]

  • Page 38

    HEA T CONTROLLER, INC. W A TER-SOURCE HEA T PUMPS Residential Split - 60Hz R410A Rev .: 03 August, 2012 Heat Controller , Inc. W ater-Source Heating and Cooling Systems 38 DXM2 Pr ocess Flow Chart  W ARNING !  W ARNING! HAZARDOUS VOL T AGE! DISCONNECT ALL ELECTRIC POWER INCLUDING REMOTE DISCONNECTS BEFORE SERVICING. Failure to disconnect powe[...]

  • Page 39

    The Quality Leader in Conditioning Air Residential Split - 60Hz R410A Rev .: 03 August, 2012 www .heatcontroller .com 39 Functional T r oubleshooting Fault Ht g Clg Possible Cause Solution Main Power Pr oblems X X Green status LED off Check Line V oltage circuit breaker and disconnect Check for line voltage between L1 and L2 on the contactor Check [...]

  • Page 40

    HEA T CONTROLLER, INC. W A TER-SOURCE HEA T PUMPS Residential Split - 60Hz R410A Rev .: 03 August, 2012 Heat Controller , Inc. W ater-Source Heating and Cooling Systems 40 Functional T r oubleshooting No Fault Code Shown X X No compressor operation See 'Only Fan Operates' X X Compressor overload Check and replace if necessary X X Control [...]

  • Page 41

    The Quality Leader in Conditioning Air Residential Split - 60Hz R410A Rev .: 03 August, 2012 www .heatcontroller .com 41 P erformance T r oubleshooting Symptom Ht g Clg Possible Cause Solution Insufficient Capacity/ X X Dirty filter Replace or clean Not Cooling or Heating Rduced or no air flow Check for dirty air filter and clean or replace Pr oper[...]

  • Page 42

    Note: Never connect refrigerant gauges during startup pr ocedures. Conduct water -side analysis using P/T ports to determine water fl ow and temperature dif ference. If water -side analysis shows poor performance, refrigerant troubleshooting may be r equired. Connect refrigerant gauges as a last resort. &XVWRPHUBBBBBBBBBBBBBBBBBBBBBBB[...]

  • Page 43

    Notes: The Quality Leader in Conditioning Air Residential Split - 60Hz R410A Rev .: 03 August, 2012 www .heatcontroller .com 43[...]

  • Page 44

    1900 Wellworth Ave., Jackson, Michigan 49203 • Ph. 517-0787-2100 • Fax 517-787-9341 Visit us on-line at www.heatcontroller.com The Quality Leader in Conditioning Air R M A N U F A C T U R E R C E R T I F I E D T O A R I A S C O M P L Y I N G W I T H I S O S T A N D A R D 1 3 2 5 6 - 1 H E A T P U M P S W A T E R T O A I R B R I N E T O A I R 08[...]