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INSTALLATION, OPERATION
& MAINTENANCE MANUAL
R-410A Water-to-Water Series:
HWW Water-Source Heat Pumps
Heat Controller, Inc. • 1900 Wellworth Ave. • Jackson, MI 49203 • (517)787-2100 • www.heatcontroller.com
Installation & Operation WATER-TO-WATER (HWW) SERIES Heat Controller, Inc.
TABLE OF CONTENTS
Model Nomenclature ..................................................2
Storage .......................................................................4
Pre-Installation............................................................4
Physical Data..............................................................5
Dimensional Data .......................................................6
Unit Installation ...........................................................7
Piping Installation .......................................................7
Load Plumbing Installation .........................................8
Water Loop Applications .............................................9
Open Loop - Ground Water Systems .......................10
Water Quality Standards ..........................................10
Ground Loop Applications ...................................11-13
Electrical - Line Voltage .......................................14,16
Electrical - Accessories.............................................15
Water Valve Wiring ...................................................15
Electrical - Low Voltage Wiring .................................17
Electrical Wiring Schematics ...............................18-19
CXM Controls ......................................................20-22
Piping System Cleaning & Flushing .........................23
Unit and System Checkout Procedure .....................24
Start Up Procedure ..............................................25-26
Operating Pressures............................................27-28
Preventive Maintenance ...........................................29
Refrigeration Troubleshooting Form .........................30
1
Heat Controller, Inc. Installation & Operation
Entering Water Temperature Range: 20 - 110°F (-6.7 - 43.3°C)
Sizes 036, 060 & 120
HWW Model Structure
1 2 3
H W W
MODEL TYPE
HW = HEAT CONTROLLER SERIES HIGH EFFICIENCY
CONFIGURATION
W = WATER TO WATER
4 5 6
0 3 6
UNIT SIZE
036 - 1,3,4
060 - 1,3,4,5
120 - 1,3,4,5
}
VOLTAGE
REVISION LEVEL
7
A
VOLTAGE
1 = 208-230/60/1 - 410A
3 = 208-230/60/3 - 410A
4 = 460/60/3 - 410A
5 = 575/60/3 - 410A
8
1
CONTROLS
C = CXM (ETL for USA & CANADA)
9
C
10 11 12 13 14
1 0 C F C
LOAD WATER COIL OPTIONS
C = Copper
N = Cupro-Nickel
WATER CONNECTION LOCATION
F = FRONT
SOURCE WATER COIL OPTIONS
C = Copper
N = Cupro-Nickel
HOT WATER GENERATOR OPTIONS
0 = NONE
1 = HWG w/INTERNAL PUMP (RESIDENTIAL)
2 = HWG COIL ONLY (COMMERCIAL)
CABINET INSULATION
0 = RESIDENTIAL ( 208-230/60/1 ONLY)
1 = COMMERCIAL EXTENDED RANGE
Basic Unit Description:
The basic unit price includes sealed heat pump refrigerant circuit.
• Cabinet Heavy gauge galvanized steel with black polyester powder coat paint – multiple removable panels for service access – stainless steel front access panel(s) – interior surfaces lined with ½ inch dual density acoustic type glass knockouts.
ber insulation – IPT water connections –
• Controls Solid state control system with seven standard safeties including anti-short cycle, over voltage, under voltage, high refrigerant pressure, loss of refrigerant charge, low source water temperature, low load water temperature – run and fault lights on cabinet exterior – alarm contact for remote monitoring of fault condition ( eld selectable for dry contact or 24vac).
• Refrigerant Circuit Compressor(s) – coaxial source and load heat exchangers – revering valve(s) – lter driers(s) – thermal expansion valve(s) – high pressure and loss of charge switches – high and low side Schrader ports for service – non-ozone depleting HFC-410a refrigerant.
R-410A
• Compressor(s) High ef ciency scroll compressor - internally sprung and externally isolated using dual vibration isolation system for quiet operation. Mounting system includes rubber grommet mounts between the compressor and a mounting tray then another set of rubber mounts between the mounting tray and unit base pan.
• Reversing Valve 4-way pilot operated, solenoid activated in cooling mode.
• Safety Agency Listing Product is ETL Listed.
• Application May be applied in water loop heat pump, ground water heat pump, and ground loop heat pump applications.
2
7 May, 2009 Page 21
Installation & Operation WATER-TO-WATER (HWW) SERIES Heat Controller, Inc.
General Information
Safety
Warnings, cautions and notices appear throughout this manual. Read these items carefully before attempting any installation, service or troubleshooting of the equipment.
DANGER:Indicates an immediate hazardous situation, which if not avoided will result in death or serious injury. DANGER labels on unit access panels must be observed.
WARNING: Indicates a potentially hazardous situation, which if not avoided could result in death or serious injury.
CAUTION: Indicates a potentially hazardous situation or an unsafe practice, which if not avoided could result in minor or moderate injury or product or property damage.
NOTICE: Notification of installation, operation or maintenance information, which is important, but which is not hazardrelated.
� WARNING! �
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.
� CAUTION! �
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.
� WARNING! �
WARNING! To avoid the release of refrigerant into the atmosphere, the refrigerant circuit of this unit must be serviced only by technicians who meet local, state, and federal proficiency requirements.
3
Heat Controller, Inc. WATER-TO-WATER (HWW) SERIES
General Information
Inspection
Upon receipt of the equipment, carefully check the shipment against the bill of lading. Make sure all units have been received. Inspect the carton or crating of each unit, and inspect each unit for damage. Assure 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.
Storage
Equipment should be stored in its original packaging in a clean, dry area. Store units in an upright position at all times.
The stack limit for HWW36, 060 and 120 is three.
Unit Protection
Cover units on the job site with either shipping packaging, vinyl film, 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.
Examine all pipes, fittings, and valves before installing any of the system components. Remove any dirt or trash found in or on these components.
Installation & Operation
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.
� CAUTION! �
CAUTION! All three phase scroll compressors must have direction of rotation verified at start-up. Verification is achieved by checking compressor Amp draw. Amp draw will be substantially lower compared to nameplate values. Additionally, reverse rotation results in an elevated sound level compared to correct rotation. Reverse rotation will result in compressor internal overload trip within several minutes. Verify compressor type before proceeding.
� CAUTION! �
CAUTION!
DO NOT store or install units in corrosive environments or in locations subject to temperature or humidity extremes (e.g., attics, garages, rooftops, etc.).
Corrosive conditions and high temperature or humidity can significantly reduce performance, reliability, and service life. Always move and store units in an upright position. Tilting units on their sides may cause equipment damage.
� CAUTION! �
CAUTION! CUT HAZARD - Failure to follow this caution may result in personal injury. Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing, safety glasses and gloves when handling parts and servicing heat pumps.
Pre-Installation
Installation, Operation, and Maintenance instructions are provided with each unit. The installation site chosen should include adequate service clearance around the unit. Before unit start-up, read all manuals and become familiar with the unit and its operation. Thoroughly check the system before operation.
Prepare units for installation as follows:
1. Compare the electrical data on the unit nameplate with ordering and shipping information to verify that the correct unit has been shipped.
2. Keep the cabinet covered with the shipping packaging until installation is complete and all plastering, painting, etc. is finished.
NOTICE! Failure to remove shipping brackets from spring-mounted compressors will cause excessive noise, and could cause component failure due to added vibration.
4
Installation & Operation
Unit Physical Data
Model
Compressor (qty)
Factory Charge R410A (lbs) [kg] Per Circuit
Water Connection Size
Residential
Source/Load (in)
Commercial
Residential
HWG (in)
Commercial
Weight - Operating (lbs) [kg]
Weight - Packaged (lbs) [kg]
Water Volume (Source)
Gallons (Liters)
Dual isolated compressor mounting
Balanced port expansion valve (TXV)
Insulated Source and Load Water Coils standard
Insulated Refrigerant Circuit standard
Compressor on (green) and fault (red) light
WATER-TO-WATER (HWW) SERIES
036 060
4.5 [2.04]
Scroll (1)
5.5 [2.49]
1" Swivel
3/4” IPT
1" Swivel
1/2” IPT
348 [158]
373 [169]
0.96 (3.64)
1” Swivel
1” IPT
1” Swivel
1/2” IPT
360 [163]
385 [175]
1.33 (5.04)
120
Scroll (2)
5.5 [2.49]
1-1/2 IPT
1/2" IPT
726 [329]
770 [349]
2.65 (10.02)
Heat Controller, Inc.
5
Heat Controller, Inc. WATER-TO-WATER (HWW) SERIES
Unit Dimensional Data: HWW 036–120
C
Optional
Service Access
B
M
L
K
C
Optional
Service Access
B
M
L
K
A
1.0
5 6
4
3
2
1
Required
Service Access
E
D
F
G
H
J
A
1.0
5 6
4
3
2
1
Required
Service Access
E
D
F
G
H
J
B
C
1.3
(3.3 cm)
Installation & Operation
5
3
1
A
(18.5 cm)
4
6
2
Required
Service Access
B
C
Notes:
1. Front & side access is preferred for service
1.3
serviced from the front access panel if side access is not available.
2. 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 services.
5
3
1
A
(18.5 cm)
4
6
2
Required
Service Access
Water to
Water
036-060
120 in.
cm.
in.
cm.
Overall Cabinet
A
Depth
30.6
77.8
30.6
77.8
B
Width
25.4
64.5
52.9
134.4
C
Height
33
83.8
37
94
1
D
Source
(Outdoor)
Water In
2.7
6.9
25.2
64.0
2
E
Source
(Outdoor)
Water Out
9.4
23.9
25.2
64.0
Water Connections
3
F
Load
(Indoor)
Water In
4
G
Load
(Indoor)
Water Out
19.4
49.3
30.1
76.5
24.5
62.2
30.1
76.5
5
H
HWG
Return In
27.9
70.9
34.9
88.6
6
J
HWG
Water
Out
30.4
77.2
34.9
88.6
Electric Access Plugs
K
Low
Voltage
L
External
Pump
20.9
53.1
29.9
75.9
22.9
58.2
31.9
81.0
M
Power
Supply
30.9
78.5
34.4
87.4
6
Installation & Operation WATER-TO-WATER (HWW) SERIES
Unit Installation
HWW Unit Location
These 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.
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.
Piping Installation
Installation of Supply and Return Piping
Follow these piping guidelines.
1. Install a drain valve at the base of each supply and return riser to facilitate system flushing.
2. Install shut-off / balancing valves and unions at each unit to permit unit removal for servicing.
3. Place strainers at the inlet of each system circulating pump.
4. Select the proper hose length to allow slack between connection points. Hoses may vary in length by +2% to
-4% under pressure.
5. Exceeding the minimum bend radius may cause the hose to collapse which reduces water flow rate. Install an angle adapter to avoid sharp bends in the hose when the radius falls below the required minimum and causes a slight kink.
� WARNING! �
Piping must comply with all applicable codes.
Heat Controller, Inc.
Locate the unit in an indoor area that allows easy removal of access panels, and has enough space for service personnel to perform maintenance or repair. Provide sufficient room to make water and electrical connections.. Any access panel screws that would be difficult to remove after the unit is installed should be removed prior to setting the unit. These units are not approved for outdoor installation and, therefore, must be installed inside the structure being conditioned. Do not locate in areas where ambient conditions are not maintained within 40-100°F [4-38°C].
� WARNING! �
Do not bend or kink supply lines or hoses.
Insulation is not required on loop water piping except where the piping runs through unheated areas or outside the building or when the loop water temperature is below the minimum expected dew point of the pipe ambient temperature. Insulation is required if loop water temperature drops below the dew point.
Pipe joint compound is not necessary when Teflon threaded tape is pre-applied to hose assemblies or when flared-end connections are used. If pipe joint compound is preferred, use compound only in small amounts on the pipe threads of the fitting adapters. Prevent sealant from reaching the flared surfaces of the joint.
Note: When anti-freeze is used in the loop, assure that it is compatible with Teflon tape or pipe joint compound employed.
Maximum allowable torque for brass fittings is 30 ft-lbs [41
N-m]. If a torque wrench is not available, tighten finger-tight plus one quarter turn. Tighten steel fittings as necessary.
Optional pressure-rated hose assemblies designed specifically for use with Heat Controller units are available. Similar hoses can be obtained from alternate suppliers. Supply and return hoses are fitted with swivel-joint fittings at one end to prevent kinking during installation.
Refer to Figure 1 for an illustration of a Supply/Return Hose
Kit. Male adapters secure hose assemblies to the unit and risers. Install hose assemblies properly and check them regularly to avoid system failure and reduced service life.
� CAUTION! �
Corrosive system water requires corrosion resistant fittings and hoses and possibly water treatment.
Figure 1: Supply/Return Hose Kit
Rib Crimped
Swivel
Brass
Fitting
Brass
Fitting
Hand Tighten
Only !
Do Not
Overtighten!
Length
(2 ft [0.6m] Length Standard)
EPT Swivel Nut
Stainless steel snap ring
Gasket Brass Adaptor
Reborde Acanalado
Accesorio
Giratorio de Bronce
Accesorio de Bronce
7
Longitud
(Long. Estándar de 2 pies)
MPT
Heat Controller, Inc. WATER-TO-WATER (HWW) SERIES Installation & Operation
Piping Installation
Load Plumbing Installation
HWW Unit Load Plumbing
The applications are too varied to describe in this document.
However, some basic guidelines will be presented. Much of the discussions on water loop applications would be valid for the load plumbing discussion as well. All plumbing should conform to local codes with the following considerations:
Wide temperature variation applications such as heating/cooling coils:
- Employ piping materials that are rated for the maximum temperature and pressure combination. This excludes PVC for most heating applications.
- Insure that load water flow in high temperature heating applications is at least 3 gpm per ton [3.9 l/m per kW] to improve performance and reduce nuisance high pressure faults.
- DO NOT employ plastic to metal threaded joints
- Utilize a pressure tank and air separator vent system to equalize pressure and remove air.
Swimming Pool Hot Tub Applications:
- Load coax should be isolated with secondary heat exchanger constructed of anti-corrosion material in all
8 chlorine/bromine fluid applications.
Potable Water Applications:
- Load coax material should always be vented double walled for use in potable water systems.
- Insure load water flow in high temperature heating applications is at least 3 gpm per ton to improve performance and reduce nuissance to high pressure faults.
NOTE:
Heat Controller strongly recommends all piping connections, both internal and external to the unit, be pressure tested by an appropriate method prior to any finishing of the interior space or before access to all connections is limited. Test pressure may not exceed the maximum allowable pressure for the unit and all components within the water system. Heat Controller will not be responsible or liable for damages from water leaks due to inadequate or lack of a pressurized leak test, or damages caused by exceeding the maximum pressure rating during installation.
Installation & Operation WATER-TO-WATER (HWW) SERIES Heat Controller, Inc.
Water-Loop Heat Pump Applications
Commercial systems typically include a number of units plumbed to a common piping system. Any unit plumbing maintenance work can introduce air into the piping system, therefore air elimination equipment is a major portion of the mechanical room plumbing. In piping systems expected to utilize water temperatures below 50°F [10°C], 1/2” [13mm] closed cell insulation is required on all piping surfaces to eliminate condensation. Metal to plastic threaded joints should never be employed due to their tendency to leak over time.
Teflon tape thread sealant is recommended for FPT water connections (commercial class) to minimize internal fouling of the heat exchanger. Do not overtighten connections and route piping so as not to interfere with service or maintenance access. Hose kits are available from Heat Controller in different configurations for connection between the system.
The piping system should be flushed to remove dirt, piping chips, and other foreign material prior to operation. See
Piping System Cleaning and Flushing Procedures later in this document. The flow rate is usually set between 2.25 gpm and
3 gpm per ton [2.9 l/m and 4.5 l/m per kW] of cooling capacity.
Heat Controller recommends 2.5 gpm per ton [3.2 l/m per kW] for most applications of water loop heat pumps. To insure proper maintenance and servicing, P/T ports are imperative for temperature and flow verification, as well as performance checks. See Figure 2 for typical water-loop application installation.
Figure 2: Typical Water-Loop Application
Cooling Tower/Boiler Systems typically utilize a common loop maintained 60-90°F [16-32°C]. The use of a closed circuit evaporative cooling tower with a secondary heat exchanger between the tower and the water loop is recommended. If an open type cooling tower is used continuously, chemical treatment and filtering will be necessary.
Low Water Temperature Cutout Setting
CXM Control: When an antifreeze is selected, the FP1 jumper (JW3) should be clipped to select the low temperature
(Antifreeze 15°F [-9.4°C]) setpoint to avoid nuisance faults.
See Figure 5: Low Water Temperature Cutout - FP1.
� WARNING! �
Never jumper terminal “A” from CXM board #1 to CXM board #2 on multi-compressor/control bound units. See
Figure 6 [Page 15] in electrical section of this document for motorized valve wiring.
� CAUTION! �
CAUTION!
Many units are installed with a factory or field supplied manual or electric shut-off valve. DAMAGE
WILL OCCUR if shut-off valve is closed during unit operation. A high pressure switch must be installed on the heat pump side of any field provided shut-off valves and connected to the heat pump controls in series with the built-in refrigerant circuit high pressure switch to disable compressor operation if water pressure exceeds pressure switch setting. The field installed high pressure switch shall have a cut-out pressure of 300 psig and a cut-in pressure of 250 psig.
Unit Power
Disconnect hose with integral “J” swivel
Optional
Balancing
Valve
Optional Low
Pressure Drop
Air Pad or
Extruded polystyrene insulation board
Thermostat Wiring with blow-off valve
Ball Valve with integral P/T plug
Building
Loop
Water Out
Water In
9
Heat Controller, Inc. WATER-TO-WATER (HWW) SERIES Installation & Operation
Ground-Water Heat Pump Applications
Typical open loop piping is shown in Figure 3 [See Page 11].
Shut off valves should be included in case of servicing. Boiler drains or other valves should be ‘tee’d’ into the line to allow acid flushing of just the heat exchanger. Pressure temperature plugs should be used so that flow and temperature can be measured.
Piping materials should be limited to PVC SCH80 or copper.
Due to the pressure and temperature extremes, PVC SCH40 is not recommended. Water quantity should be plentiful and of good quality. Consult Table 1 for water quality guidelines.
The unit can be ordered with either a copper or cupro-nickel water heat exchanger. 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 cupronickel heat exchanger is recommended.
In ground water situations where scaling could be heavy or where biological growth such as iron bacteria will be present, a closed loop system is recommended. It is recommended to install an intermediate heat exchanger to isolate an open loop from the heat pump loop on open well systems. Heat exchangers may over time lose heat exchange capabilities due to a build up of mineral deposits inside. These can be cleaned only by a qualified service mechanic as acid and special pumping equipment are required.
Table 1: Water Quality Standards
WaterÊQuality
Parameter
HX
Material
Closed
Recirculating
OpenÊLoopÊandÊRecirculatingÊWell
ScalingÊPotentialÊ-ÊPrimaryÊMeasurement
AboveÊtheÊgivenÊlimits,ÊscalingÊisÊlikelyÊtoÊoccur.ÊÊScalingÊindexesÊshouldÊbeÊcalculatedÊusingÊtheÊlimitsÊbelow pH/CalciumÊHardness
Method
All
pHÊ<Ê7.5ÊandÊCaÊHardnessÊ<100ppm
IndexÊLimitsÊforÊProbableÊScalingÊSituationsÊ-Ê
(OperationÊoutsideÊtheseÊlimitsÊisÊnotÊrecommended)
ScalingÊindexesÊshouldÊbeÊcalculatedÊatÊ150¡FÊ[66¡C]ÊforÊdirectÊuseÊandÊHWGÊapplications,ÊandÊatÊ90¡FÊ[32¡C]ÊforÊindirectÊHXÊuse.Ê
AÊmonitoringÊplanÊshouldÊbeÊimplemented.
Ryznar
StabilityÊIndex
All
6.0Ê-Ê7.5
IfÊ>7.5ÊminimizeÊsteelÊpipeÊuse.
Langelier
All
-
SaturationÊIndex
-0.5ÊtoÊ+0.5
IfÊ<-0.5ÊminimizeÊsteelÊpipeÊuse.ÊBasedÊuponÊ150¡FÊ[66¡C]ÊHWGÊand
DirectÊwell,Ê85¡FÊ[29¡C]ÊIndirectÊWellÊHX
IronÊFouling
IronÊFe 2+ (Ferrous)
(BacterialÊIronÊpotential)
All
-
<0.2ÊppmÊ(Ferrous)
IfÊFe 2+ Ê(ferrous)>0.2ÊppmÊwithÊpHÊ6Ê-Ê8,ÊO2<5ÊppmÊcheckÊforÊironÊbacteria
-
IronÊFouling All
<0.5ÊppmÊofÊOxygen
AboveÊthisÊlevelÊdepositionÊwillÊoccur.
CorrosionÊPrevention
6Ê-Ê8.5
6Ê-Ê8.5
pH All Monitor/treatÊas needed
-
MinimizeÊsteelÊpipeÊbelowÊ7ÊandÊnoÊopenÊtanksÊwithÊpHÊ<8
<0.5Êppm
HydrogenÊSulfideÊ(H2S)
All
CopperÊalloyÊ(bronzeÊorÊbrass)ÊcastÊcomponentsÊareÊOKÊtoÊ<0.5Êppm.
AmmoniaÊionÊasÊhydroxide,Êchloride,Ê nitrateÊandÊsulfateÊcompounds All
-
<0.5Êppm
Maximum
ChlorideÊLevels
Copper
CuproNickel
304ÊSS
316ÊSS
Titanium
-
-
-
-
-
MaximumÊAllowableÊatÊmaximumÊwaterÊtemperature.
50¡FÊ(10¡C)
<20ppm
<150Êppm
<400Êppm
<1000Êppm
>1000Êppm
75¡FÊ(24¡C)
NR
NR
<250Êppm
<550Êppm
>550Êppm
100 ϒ F (38
NR
NR
ϒ
<150 ppm
< 375 ppm
>375 ppm
C)
ErosionÊandÊClogging
ParticulateÊSizeÊand
Erosion
All
<10ÊppmÊofÊparticles andÊaÊmaximum velocityÊofÊ6ÊfpsÊ[1.8Êm/s].
FilteredÊforÊmaximum
800ÊmicronÊ[800mm,
20Êmesh]Êsize.
<10ÊppmÊ(<1ÊppmÊ"sandfree"ÊforÊreinjection)ÊofÊparticlesandÊaÊmaximum velocityÊofÊ6ÊfpsÊ[1.8Êm/s].ÊFilteredÊforÊmaximumÊ800ÊmicronÊ[800mm,
20Êmesh]Êsize.AnyÊparticulateÊthatÊisÊnotÊremovedÊcanÊpotentially clogÊcomponents.
Rev.: 01/21/09B
Notes:
• Closed Recirculating system is identified by a closed pressurized piping system.
• Recirculating open wells should observe the open recirculating design considerations.
• NR - Application not recommended.
• "-" No design Maximum.
10
Installation & Operation WATER-TO-WATER (HWW) SERIES Heat Controller, Inc.
Ground-Water Heat Pump Applications
In areas with extremely hard water, the owner should be informed that the heat exchanger may require occasional acid flushing.
Expansion Tank and Pump
Use a closed, bladder-type expansion tank to minimize mineral formation due to air exposure, as shown in Figure 3. The expansion tank should be sized to handle at least one minute run time of the pump to prevent premature pump failure using its drawdown capacity rating. Discharge water from the unit is not contaminated in any manner and can be disposed of in various ways depending on local building codes; i.e. 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.
Low Water Temperature Cut-Out Setting
For all open loop systems the 35°F [1.7°C] FP1 setting (factory setting-water) should be used to avoid freeze damage to the unit.
See Figure 4 [Page 14]: “Low Water Temperature Cutout - FP1”.
� WARNING! �
Never jumper terminal “A” from CXM board #1 to CXM board #2 on multi-compressor/control bound units. See
Figure 5 [Page 15] in electrical section of this document for motorized valve wiring.
� CAUTION! �
CAUTION!
Many units are installed with a factory or field supplied manual or electric shut-off valve. DAMAGE WILL
OCCUR if shut-off valve is closed during unit operation.
A high pressure switch must be installed on the heat pump side of any field provided shut-off valves and connected to the heat pump controls in series with the built-in refrigerant circuit high pressure switch to disable compressor operation if water pressure exceeds pressure switch setting. The field installed high pressure switch shall have a cut-out pressure of 300 psig and a cut-in pressure of 250 psig.
� CAUTION! �
Low temperature limit system will not allow leaving load water temperature (cooling mode) or leaving source water temperature (heating mode) to be below 42°F [5.6°C].
Water Control Valve
Note the placement of the water control valve in Figure 3.
Always maintain water pressure in the heat exchanger by placing water control valves at the outlet of the unit to prevent mineral precipitation. Pilot operated or Taco slow closing valve’s solenoid 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 the Taco slow closing valve can draw up to 35VA. This can overload smaller
40 or 50 VA transformers depending on the other controls employed. A typical pilot operated solenoid valve draws approximately 15VA.
Flow Regulation
Flow regulation can be accomplished by two methods. First, most water control valves have a built in flow adjustment. By measuring the pressure drop through the unit heat exchanger, flow rate can be determined and compared to Table 8 [Page
28]. Since the pressure is constantly varying, two pressure gauges might be needed. Simply adjust the water control valve until the desired flow of 1.5 to 2 gpm per ton is achieved.
Secondly, a flow control device may be installed [see Figure
3]. The devices are typically an orifice of plastic material that is designed to allow a specified flow rate. These are mounted on the outlet of the water control valve. On occasion, these valves can produce a velocity noise that can be reduced by applying some back pressure. This is accomplished by slightly closing the leaving isolation valve of the well water setup.
Figure 3: Typical Open
Loop/Well Application
11
Extruded insulation board
Thermostat Wiring
Flow
Regulator
Water Out
Water In
P/T Plugs Boiler
Drains
Heat Controller, Inc. WATER-TO-WATER (HWW) SERIES Installation & Operation
Ground-Loop Heat Pump Applications
� CAUTION! �
The following instructions represent industry accepted installation practices for Closed Loop Earth Coupled Heat
Pump Systems. They are provided to assist the contractor in installing trouble free ground loops. These instructions are recommendations only. State 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.
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.
Piping Installation
All earth loop piping materials should be limited to only polyethylene fusion for inground 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 and a flanged fitting substituted.
P/T plugs should be used so that flow can be measured using the pressure drop of the unit heat exchanger in lieu of other flow measurement means. Earth loop temperatures can range between 25 to 110°F [-4 to 43°C], and 2.25 to 3 gpm of flow per ton [2.9 l/m to 3.9 l/m per kW] of cooling capacity is recommended in these applications. Upon completion of the ground loop piping, pressure test the loop to assure a leak free system. Horizontal Systems: Test individual loops as installed.
Test entire system when all loops are assembled. Vertical
U-Bends and Pond Loop Systems: Test Vertical U-bends and pond loop assemblies prior to installation with a test pressure of at least 100 psi [689 kPa].
Flushing the Earth Loop
Upon completion of system installation and testing, flush the system to remove all foreign objects and purge to remove all air. Flush the loop first with the unit isolated to avoid flushing debris from the loop into the unit heat exchanger
Table 1: Approximate Fluid Volume
(gallon) per 100' of Pipe
Fluid Volume (gal [liters] per 100’ [30 meters) Pipe)
Pipe Size Volume (gal) [liters]
Copper
Rubber Hose
Polyethylene
Unit Heat Exchanger
Flush Cart Tank
1”
1.25”
2.5”
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
10” Dia x 3ft tall
[254mm x 91.4cm tall]
4.1 [15.3]
6.4 [23.8]
9.2 [34.3]
3.9 [14.6]
2.8 [10.4]
4.5 [16.7]
8.0 [29.8]
10.9 [40.7]
18.0 [67.0]
8.3 [30.9]
10.9 [40.7]
17.0 [63.4]
1.0 [3.8]
10 [37.9]
Table 2: Antifreeze Percentages by Volume
Type
Methanol
100% USP food grade
Propylene
Glycol
Ethanol*
Min. Temp. for Low Temp. Protection
10°F
[-12.2°C]
25%
15°F
[-9.4°C]
21%
20°F
[-6.7°C]
16%
25°F
[-3.9°C]
10%
38% 25% 22% 15%
29% 25% 20% 14%
* Must not be denatured with any petroleum based product
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, anti-freeze is needed. Alcohols and glycols are commonly used as antifreezes, however your local sales manager should be consulted for the antifreeze best suited to your area. Freeze protection should be maintained to 15°F
[9°C] below the lowest expected entering loop temperature.
For example, if 30°F [-1°C] is the minimum expected entering loop temperature, the leaving loop temperature would be
25 to 22°F [-4 to -6°C] and freeze protection should be at
15°F [-10°C] e.g. 30°F - 15°F = 15°F [-1°C - 9°C = -10°C]. All
12 alcohols should be premixed and pumped from a reservoir outside of the building when possible or introduced under water level to prevent fuming. Initially calculate the total volume of fluid in the piping system using Table 1. Then use the percentage by volume shown in Table 2 for the amount of antifreeze. Antifreeze concentration should be checked from a well mixed sample using a hydrometer to measure specific gravity.
Low Water Temperature Cut-Out Setting CXM Control:
When an antifreeze is selected, the FP1 jumper [JW3] should be clipped to select the low temperature (Antifreeze 15°F [-9.4°C]) setpoint to avoid nuisance faults. See Figure 5 [Page 14].
Installation & Operation WATER-TO-WATER (HWW) SERIES Heat Controller, Inc.
Unit Power
Disconnect
Air Pad or
Extruded polystyrene insulation board
Thermostat Wiring
13
Heat Controller, Inc. WATER-TO-WATER (HWW) SERIES Installation & Operation
Electrical-Line Voltage
� 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 as that 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.
HWW Power Connection
Line voltage connection is made by connecting the incoming line voltage wires to L1, L2, and L3 on power distribution block. Consult electrical data table for correct fuse size.
208 Volt Operation
All 208-230 Volt units are factory wired for 208 Volt. The transformers may be switched to 230V operation as illustrated on the wiring diagram by switching the Red (208V) and the
Orange (230V) at the contactor terminal L2.
All field installed wiring, including electrical ground, must
HWW Electrical Data
Model
Voltage
Code
Voltage
Min/Max
Voltage
Compressor
HWW036
1
3
4
208-230/60/1
208-230/60/3
460/60/3
187/254
187/254
414/506
QTY RLA
1
1
1
16.7
10.4
5.8
LRA
79
73
38
� WARNING! �
Disconnect electrical power source to prevent injury or death from electrical shock.
� 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.
comply with the National Electrical Code as well as all applicable local codes.
Refer to the unit wiring diagrams for fuse sizes and a schematic of the field connections which must be made by the installing (or electrical) contractor.
Consult the unit wiring diagram located on the inside of the compressor access panel to ensure proper electrical hookup.
All final electrical connections must be made with a length of flexible conduit to minimize vibration and sound transmission to the building.
HWG
Pump
FLA
0.4
-
-
EXT Loop
Pump
Fla
4
-
-
Total
Unit
FLA
16.7
10.4
5.8
Min
Circuit
Amps
20.8
13.1
7.2
Max
Fuse/
HACR
35
20
15
HWW060
HWW120
5
3
4
5
1
5
1
3
4
575/60/3
208-230/60/1
208-230/60/3
460/60/3
575/60/3
208-230/60/1
208-230/60/3
460/60/3
575/60/3
518/633
187/254
187/254
414/506
518/633
187/254
187/254
414/506
518/633
1
2
2
1
2
2
1
1
1
3.8
26.3
15.6
7.8
5.8
26.3
15.8
7.8
5.8
36.5
134
110
52
38.9
134
110
52
38.9
-
-
-
-
0.4
-
0.4
-
-
-
-
-
-
-
4
-
-
4
3.8
26.3
15.6
7.8
5.8
52.6
31.2
15.6
11.6
4.7
32.9
19.5
9.8
7.3
59.2
35.1
17.6
13.1
15
15
80
50
25
15
50
35
15
HACR circuit breaker in USA only
Figure 5: Changing FP1-Low Water Temperature Cutout Setpoint
Thermostat Connections
The aquastat/thermostat should be wired directly to the CXM board
#1. Note: The HWW second stage is wired directly to the CXM #2.
CXM PCB
JW3-FP1 jumper should be clipped when antifreeze is used.
Low Water Temperature Cutout - FP1
The CXM control allows the field selection of source fluid low temperature cutout points. The factory setting of FP1 is set for water
(35°F [1.7°C]). In cold temperature applications jumper JW3 (FP1- antifreeze 15°F [-9.4°C]) should be clipped as shown in Figure 4 to change the setting to 10°F [-12.2°C], a more suitable temperature when using antifreezes. Never clip JW3 prior to antifreeze being added to the loop.
14
Installation & Operation WATER-TO-WATER (HWW) SERIES Heat Controller, Inc.
Electrical-Accessories
Accessory Connections
A terminal paralleling the compressor contactor coil has been provided on the CXM control of the HWW line. “A” has been provided to control accessory devices, such as water valves, electronic air cleaners, humidifiers, etc. Note: This terminal must be used only with 24 Volt signals and not line voltage signals. This signal operates with the compressor contactor.
High Pressure
Switch NC
Relay 3
� WARNING! �
Never jumper terminal “A” from CXM board #1 to CXM board #2 on multi-compressor/control bound units. See
Figure 6 in electrical section of this document for motorized valve wiring.
RED
6 8
RED
24 Volt Accessory Wiring for Units Size 036 and 060
CXM Terminal Strip
HP Switch
Circuit #1
These terminals may be used to power 24 volt water valves on units size 036, 060
Figure 6: Field Wiring of 24 Volt Motorized Valve of Units Size 120
VR 1
Water
Coil
Valve
Relay 3
Coil
RED
6
VR3
NO
8
RED Refrigerant
Circuit #1
Notes - Disconnect red wire at refrigerant HP switch connect to N.O. contact, connect new red wire from N.O. contact to refrigerant HP switch.
Valve Relay 1, 2 - 13B0001N01 (SPDT) VR1, VR2
Valve Relay 3 - 13B0004N01 (DPDT) VR3
VR 1
Coil
VR2
Coil
Water
High Pressure
Switch NC
Valve
Relay 3
Coil
Notes - Disconnect red wire at refrigerant HP switch connect to N.O. contact, connect new red wire from N.O. contact to refrigerant HP switch.
Valve Relay 1, 2 - 13B0001N01 (SPDT) VR1, VR2
Valve Relay 3 - 13B0004N01 (DPDT) VR3
RED
6 8
VR2
RED
Coil
Refrigerant
Circuit #1
Water
High Pressure
Switch NC
Valve
Relay 3
Coil
RED
2 4
RED
Refrigerant
Circuit #2
RED
2
VR3
NO
4
RED
HP Switch
Circuit #2
RED
6
VR3
NO
8
RED
Refrigerant
HP Switch
Circuit #1
RED
2 4
RED
Refrigerant
Circuit #2
15
RED
2
VR3
NO
4
RED
HP Switch
Circuit #2
Contactor -CC
Unit Power Supply
See electrical table for wire and breaker size
Capacitor
Transformer
CB
L2 L1
Grnd
Low Voltage
Connector
CXM Control
HWG PB2
T2 T1
Circ Brkr
Yellow
Install HWG Pump
Power after insuring water is in HWG circuit
Grnd
Loop PB1
T2 T1
Contactor -CC
Unit Power Supply
See electrical table for wire and breaker size
Capacitor
Transformer
CB
External Pump
Power Supply
See electrical table for wire and breaker size
Rev .: 01/21/09B
Grnd
L2 L1
Heat Controller, Inc.
Low Voltage
Connector
HWG PB2
T2 T1
WATER-TO-WATER (HWW) SERIES
Yellow
Installation & Operation
All field installed wiring, including electrical ground, must comply with the National Electrical Code as well as all applicable local codes.
Refer to the unit wiring diagrams for fuse sizes and a schematic of the field connections which must be made by the
Install HWG Pump
Power after insuring water is in HWG circuit
208 Volt Operation
All 208-230 Volt units are factory wired for 208 Volt. The transformers may be switched to 230V operation as illustrated on the wiring diagram. By switching the Red (230V) and the Orange (208V) at the contactor terminal L2.
See electrical table for wire and breaker size
Consult the unit wiring diagram located on the inside of the compressor access panel to ensure proper electrical hookup.
Grnd
Rev .: 01/21/09B
All final electrical connections must be made with a length of flexible conduit to minimize vibration and sound transmission to the building.
HWW036-060 Series Line Voltage Field Wiring Commercial Class (3 phase shown)
Contactor -C
L3
L2
L1
Grnd
HWW120 Series Line Voltage Field Wiring Commercial Class
16
Capacitor
CB
Transformer
Contactor -CC
L2
L1
CXM Control
Rev.: 01/21/09B
Installation & Operation WATER-TO-WATER (HWW) SERIES
Electrical-Low Voltage
Thermostat Connections
The aquastat/thermostat should be wired directly to the CXM board as shown in Figure 7a for HWW036-060 and Figure
7b for the HWW120. Note the HWW second stage is wired directly to the CXM #2.
Figure 7a. HWW036-060 Low Voltage
Field Wiring (CXM board shown)
Heat Controller, Inc.
Figure 7b: HWW120 Low Voltage Field
Wiring (CXM board shown)
Contactor -CC1
Grnd
L1 L2 L3
Power Distribution
Block
Capacitor
CB
Transformer
Contactor -CC
L2
L1
Contactor -CC2
Transformer
CXM Control #1
CXM Control
Low Voltage
Connector
Low Voltage
Connector
CXM Control #2
Second Stage Call all low voltage wires to DXM #1)
Low Voltage
Connector
Rev.: 01/21/09B
Rev .: 01/22/09B
Low Water Temperature Cutout - FP1
The CXM control allows the field selection of source fluid low temperature cutout points. The factory setting of FP1 is set for water (30°F). In cold temperature applications jumper
JW3 (FP1- antifreeze 10°F) should be clipped as shown in
Figure 8 to change the setting to 10°F, a more suitable temperature when using antifreezes. It should be noted that the extended range option should be specified to operate the
HWW Series at entering water temperatures below 60°F.
Figure 8: Changing FP1-Low Water
Temperature Cutout Setpoint
Contactor -CC1
Grnd
L1 L2 L3
Power Distribution
Block
CXM Board
JW3-FP1 jumper should be clipped when antifreeze is used.
Contactor -CC2
17
Transformer
CXM Control #1
Low Voltage
Connector
CXM Control #2
Second Stage Call
(Not needed on DXM Models all low voltage wires to DXM #1)
Low Voltage
Connector
Rev .: 01/22/09B
Heat Controller, Inc. WATER-TO-WATER (HWW) SERIES
Typical Wiring Diagram Three Phase:
HWW120 Units with CXM Controller
Installation & Operation
18
Installation & Operation WATER-TO-WATER (HWW) SERIES
Typical Wiring Diagram Single Phase:
HWW036-060 Units with CXM Controller
Heat Controller, Inc.
19
Heat Controller, Inc. WATER-TO-WATER (HWW) SERIES Installation & Operation
CXM Controls:
For detailed control information, see the CXM Application,
Operation and Maintenance manual.
Field Selectable Inputs
Test mode: Test mode allows the service technician to check the operation of the control in a timely manner. By momentarily shorting the test terminals, the CXM control enters a
20 minute test mode period in which all time delays are sped up 15 times. Upon entering test mode, the status LED will flash a code representing the last fault. For diagnostic ease at the thermostat, the alarm relay will also cycle during test mode. The alarm relay will cycle on and off similar to the status LED to indicate a code representing the last fault, at the thermostat. Test mode can be exited by shorting the test terminals for 3 seconds.
Retry Mode: If the control is attempting a retry of a fault, the status LED will slow flash (slow flash = one flash every 2 seconds) to indicate the control is in the process of retrying.
Field Configuration Options
Note: In the following field configuration options, jumper wires should be clipped ONLY when power is removed from the CXM control.
Water coil low temperature limit setting: Jumper 3 (JW3-
FP1 Low Temp) provides field selection of temperature limit setting for FP1 of 30°F or 10°F [-1°F or -12°C] (refrigerant temperature).
Not Clipped = 30°F [-1°C]. Clipped = 10°F [-12°C].
Air coil low temperature limit setting: Jumper 2 (JW2-FP2
Low Temp) provides field selection of temperature limit setting for FP2 of 30°F or 10°F [-1°F or -12°C] (refrigerant temperature). Note: This jumper should only be clipped under extenuating circumstances, as recommended by the factory.
Not Clipped = 30°F [-1°C]. Clipped = 10°F [-12°C].
Alarm relay setting: Jumper 1 (JW1-AL2 Dry) provides field selection of the alarm relay terminal AL2 to be jumpered to
24VAC or to be a dry contact (no connection).
Not Clipped = AL2 connected to R. Clipped = AL2 dry contact (no connection).
DIP Switches
Note: In the following field configuration options, DIP switches should only be changed when power is removed from the CXM control.
DIP switch 1: Unit Performance Sentinel Disable - provides field selection to disable the UPS feature.
On = Enabled. Off = Disabled.
DIP switch 2: Stage 2 Selection - provides selection of whether compressor has an “on” delay. If set to stage 2, the compressor will have a 3 second delay before energizing.
Also, if set for stage 2, the alarm relay will NOT cycle during test mode.
On = Stage 1. Off = Stage 2
DIP switch 3: Not Used.
DIP switch 4: If Set to “EH2 normal,” EH2 will operate as standard electric heat output.
On = EH2 Normal.
NOTE: Some CXM controls only have a 2 position DIP switch package. If this is the case, this option can be selected by clipping the jumper which is in position 4 of SW1.
Jumper not clipped = EH2 Normal.
DIP switch 5: Factory Setting - Normal position is “On.” Do not change selection unless instructed to do so by the factory.
Table 3a: CXM LED And Alarm
Relay Operations
Description of Operation
Normal Mode
Normal Mode with UPS Warning
CXM is non-functional
Fault Retry
Lockout
Over/Under Voltage Shutdown
LED
On
On
Off
Slow Flash
Fast Flash
Slow Flash
Test Mode - No fault in memory Flashing Code 1
Alarm Relay
Open
Cycle (closed 5 sec., Open 25 sec.)
Open
Open
Closed
Open (Closed after 15 minutes)
Cycling Code 1
Test Mode - HP Fault in memory Flashing Code 2
Test Mode - LP Fault in memory Flashing Code 3
Test Mode - FP1 Fault in memory Flashing Code 4
Test Mode - FP2 Fault in memory Flashing Code 5
Test Mode - CO Fault in memory Flashing Code 6
Test Mode - Over/Under shutdown in memory
Test Mode - UPS in memory
Flashing Code 7
Flashing Code 8
Test Mode - Swapped Thermistor Flashing Code 9
Cycling Code 2
Cycling Code 3
Cycling Code 4
Cycling Code 5
Cycling Code 6
Cycling Code 7
Cycling Code 8
Cycling Code 9
-Slow Flash = 1 flash every 2 seconds
-Fast Flash = 2 flashes every 1 second
-Flash code 2 = 2 quick flashes, 10 second pause, 2 quick flashes, 10 second pause, etc.
Figure 9: Test Mode Pins
Short test pins together to enter
Test Mode and speed-up timing and delays for
20 minutes.
CXM Board
20
Installation & Operation WATER-TO-WATER (HWW) SERIES Heat Controller, Inc.
Safety Features: CXM Controls
The safety features below are provided to protect the compressor, heat exchangers, wiring and other components from damage caused by operation outside of design conditions.
Anti-short cycle protection: The control features a 5 minute anti-short cycle protection for the compressor.
Note: The 5 minute anti-short cycle also occurs at power up.
Random start: The control features a random start upon power up of 5-80 seconds.
Fault Retry: In Fault Retry mode, the Status LED begins slowly flashing to signal that the control is trying to recover from a fault input. The control will stage off the outputs and then “try again” to satisfy the thermostat input call. Once the thermostat input call is satisfied, the control will continue on as if no fault occurred. If 3 consecutive faults occur without satisfying the thermostat input call, the control will go into
“lockout” mode. The last fault causing the lockout will be stored in memory and can be viewed at the “fault” LED or by going into test mode (CXM board). Note: FP1/FP2 faults are factory set at only one try.
Lockout: In lockout mode, the status LED will begin fast flashing. The compressor relay is turned off immediately.
Lockout mode can be “soft” reset by turning off the thermostat (or satisfying the call). A “soft” reset keeps the fault in memory but resets the control. A “hard” reset (disconnecting power to the control) resets the control and erases fault memory.
Lockout with emergency heat: While in lockout mode, if W becomes active (CXM), emergency heat mode will occur.
High pressure switch: When the high pressure switch opens due to high refrigerant pressures, the compressor relay is de-energized immediately since the high pressure switch is in series with the compressor contactor coil. The high pressure fault recognition is immediate (does not delay for 30 continuous seconds before de-energizing the compressor).
High pressure lockout code = 2
Example: 2 quick flashes, 10 sec pause, 2 quick flashes, 10 sec. pause, etc.
Low pressure switch: The low pressure switch must be open and remain open for 30 continuous seconds during “on” cycle to be recognized as a low pressure fault. If the low pressure switch is open for 30 seconds prior to compressor power up it will be considered a low pressure (loss of charge) fault. The low pressure switch input is bypassed for the initial 60 seconds of a compressor run cycle.
Low pressure lockout code = 3
Water coil low temperature (FP1): The FP1 thermistor temperature must be below the selected low temperature limit setting for 30 continuous seconds during a compressor run cycle to be recognized as a FP1 fault. The FP1 input is bypassed for the initial 60 seconds of a compressor run cycle.
FP1 is set at the factory for one try. Therefore, the control will go into lockout mode once the FP1 fault has occurred.
FP1 lockout code = 4
Air coil low temperature (FP2): The FP2 thermistor temperature must be below the selected low temperature limit setting for 30 continuous seconds during a compressor run cycle to be recognized as a FP2 fault. The FP2 input is bypassed for the initial 60 seconds of a compressor run cycle. FP2 is set at the factory for one try. Therefore, the control will go into lockout mode once the FP2 fault has occurred.
FP2 lockout code = 5
Condensate overflow: The condensate overflow sensor must sense overflow level for 30 continuous seconds to be recognized as a CO fault. Condensate overflow will be monitored at all times.
CO lockout code = 6
Over/under voltage shutdown: An over/under voltage condition exists when the control voltage is outside the range of
19VAC to 30VAC. Over/under voltage shut down is a selfresetting safety. If the voltage comes back within range for at least 0.5 seconds, normal operation is restored. This is not considered a fault or lockout. If the CXM is in over/under voltage shutdown for 15 minutes, the alarm relay will close.
Over/under voltage shut down code = 7
Unit Performance Sentinel-UPS (patent pending): The UPS feature indicates when the heat pump is operating inefficiently. A UPS condition exists when: a) In heating mode with compressor energized,
FP2 is greater than 125°F [52°C] for 30 continuous seconds, or: b) In cooling mode with compressor energized,
FP1 is greater than 125°F [52°C] for 30 continuous seconds, or:
21
Heat Controller, Inc. WATER-TO-WATER (HWW) SERIES Installation & Operation
Safety Features
c) In cooling mode with compressor energized,
FP2 is less than 40°F [4.5°C] for 30 continuous seconds.
If a UPS condition occurs, the control will immediately go to
UPS warning. The status LED will remain on as if the control is in normal mode. Outputs of the control, excluding LED and alarm relay, will NOT be affected by UPS. The UPS condition cannot occur during a compressor off cycle. During
UPS warning, the alarm relay will cycle on and off. The cycle rate will be “on” for 5 seconds, “off” for 25 seconds, “on” for
5 seconds, “off” for 25 seconds, etc.
UPS warning code = 8
Swapped FP1/FP2 thermistors: During test mode, the control monitors to see if the FP1 and FP2 thermistors are in the appropriate places. If the control is in test mode, the control will lockout with code 9 after 30 seconds if: a) The compressor is on in the cooling mode and the FP1 sensor is colder than the FP2 sensor, or: b) The compressor is on in the heating mode and the FP2 sensor is colder than the FP1 sensor.
Swapped FP1/FP2 thermistor code = 9.
CXM Controls
Diagnostic Features
The LED on the CXM board advises the technician of the current status of the CXM control. The LED can display either the current CXM mode or the last fault in memory if in test mode. If there is no fault in memory, the LED will flash
Code 1 (when in test mode).
CXM Control Start-up Operation
The control will not operate until all inputs and safety controls are checked for normal conditions. The compressor will have a 5 minute anti-short cycle delay at power-up. The first time after power-up that there is a call for compressor, the compressor will follow a 5 to 80 second random start delay.
After the random start delay and anti-short cycle delay, the compressor relay will be energized. On all subsequent compressor calls, the random start delay is omitted.
Unit Commissioning & Operating Conditions
Environment – This unit is designed for indoor installation only.
Do not install in an area subject to freezing or where humidity levels can cause cabinet condensation.
Power Supply – A voltage variation of +/- 10% of nameplate utilization voltage is acceptable.
Operation and performance is primarily dependent upon water temperatures, water flow rates and ambient air temperature. This water to water heat pump is capable of operating over a wide temperature range and with flow rates of between 1.5 GPM (.1 l/s) and 3 GPM (.19 l/s) per ton, however usually no more than one of these factors may be at a minimum or maximum level at a time.
The commissioning table indicates water temperatures which are suitable for initial unit commissioning in an environment where the flow rate and water temperature is not yet stable and to avoid nuisance shut down of the units freeze and refrigerant pressure safeties.
The operating Table 4 indicates the maximum and minimum ranges of the unit.
For more specific unit performance reference the product catalog, the submittal data sheets or contact your supplier for assistance.
Table 4: Building Commissioning
Unit Size
BUILDING COMMISSIONING
Cooling Heating
036 060/120 036 060/120
Source Min/Max
Load Min/Max
50/110 50/120
60/80 60/90
30/80
60/120
30/80
60/120
Ambient Min/Max 45/110
BUILDING OPERATING
Unit Size
COOLING
036 060/120
39/85
HEATING
036 060/120
50/120 50/120 20/80 20/80 Source Min/Max
Load Min/Max
Ambient Min/Max
50/90 50/90
45/110
60/130
39/85
60/130
22
Installation & Operation WATER-TO-WATER (HWW) SERIES Heat Controller, Inc.
Piping Systems Cleaning & Flushing
Cleaning and flushing of the WLHP piping system is the single most important step to ensure proper start-up and continued efficient operation of the system.
Follow the instructions below to properly clean and flush the system:
1. Verify electrical power to the unit is disconnected.
2. Install the system with the supply hose connected directly to the return riser valve. Use a single length of flexible hose.
3. Open all air vents. Fill the system with the water. DO
NOT allow system to overflow. Bleed all air from the system. Pressurize and check the system for leaks and repair appropriately.
4. Verify all strainers are in place. Start the pumps, and systematically check each vent to ensure all air is bled from the system.
5. Verify make-up water is available. Adjust make-up water appropriately to replace the air which was bled from the system. Check and adjust the water/air level in the expansion tank.
6. Set the boiler to raise the loop temperature to approximately 85°F [29°C]. Open the a drain at the lowest point in the system. Adjust the make-up water replacement rate to equal the rate of bleed.
7. Refill the system and add trisodium phosphate in a proportion of approximately one pound per 150 gallons [1/2 kg per 750 L] of water (or other equivalent
� CAUTION! �
To avoid possible damage to a plastic (PVC) piping system, do not allow temperatures to exceed 110°F [43°C].
approved cleaning agent). Reset the boiler to raise the loop temperature to about 100°F [38°C]. Circulate the solution for a minimum of 8 to 24 hours. At the end of this period, shut off the circulating pump and drain the solution. Repeat system cleaning if desired.
8. When the cleaning process is complete, remove the short-circuited hoses. Reconnect the hoses to the proper supply, and return connections to each of the units. Refill the system and bleed off all air.
9. Test the system pH with litmus paper. The system water should be slightly alkaline (pH 7.5-8.5). Add chemicals, as appropriate, to maintain acidity levels.
10. When the system is successfully cleaned, flushed, refilled and bled, check the main system panels, safety cutouts and alarms. Set the controls to properly maintain loop temperatures.
� CAUTION! �
DO NOT use 'stop leak' or any similar chemical agent in this system. Addition of these chemicals to the loop water will foul the system and inhibit unit operation.
23
Heat Controller, Inc. WATER-TO-WATER (HWW) SERIES
Unit & System Checkout
BEFORE POWERING SYSTEM, please check the following:
� WARNING! �
Verify ALL water controls are open and allow water flow prior to engaging the compressor. Freezing of the coax or water lines can permanently damage the heat pump.
NOTE:
Heat Controller strongly recommends all piping connections, both internal and external to the unit, be pressure tested by an appropriate method prior to any finishing of the interior space or before access to all connections is limited. Test pressure may not exceed the maximum allowable pressure for the unit and all components within the water system.
Heat Controller will not be responsible or liable for damages from water leaks due to inadequate or lack of a pressurized leak test, or damages caused by exceeding the maximum pressure rating during installation.
UNIT CHECKOUT q Balancing/Shutoff Valves: Ensure all isolation valves are open, water control valves wired and open or coax may freeze and burst.
q Line Voltage and Wiring: Ensure Voltage is within an acceptable range for the unit and wiring and fuses/breakers are properly sized. Low voltage wiring is complete.
q Unit Control Transformer: Ensure transformer has properly selected control voltage tap. 208-230V units are factory wired for 208V operation unless specified otherwise.
q Entering Water: Ensure entering water temperatures are within operating limits of Table 6 [Page 25].
q Low Water Temperature Cutout: Verify low water temperature cut-out on CXM is properly set.
q Water Flow Balancing: Verify inlet and outlet water temperatures on both Load and source are recorded for each heat pump upon startup. This check can eliminate nuisance trip outs and high velocity water flows that can erode heat exchangers.
q Unit Controls: Verify CXM field selection options are proper and complete.
SYSTEM CHECKOUT q System Water Temperature: Check load and source water temperature for proper range and also verify heating and cooling setpoints for proper operation.
Installation & Operation q System pH: System water pH is 6 - 8.5. Proper pH promotes longevity of hoses and fittings.
q System Flushing: Verify all hoses are connected end to end when flushing to ensure debris bypasses unit heat exchanger and water valves etc. Water used in the system must be potable quality initially and clean of dirt, piping slag, and strong chemical cleaning agents. Verify all air is purged from the system. Air in the system can cause poor operation or system corrosion.
q Cooling Tower/Boiler: Check equipment for proper setpoints and operation.
q Standby Pumps: Verify the standby pump is properly installed and in operating condition.
q System Controls: Verify system controls function and operate in the proper sequence.
q Low Water Temperature Cutout: Verify low water temperature cut-out controls are provided for the outdoor portion of the loop or operating problems will occur.
q System Control Center: Verify control center and alarm panel for proper setpoints and operation.
q Strainers: Verify 20 mesh (841 micron) [0.84mm] strainers are installed in load and source water piping. Confirm maintenance schedule for strainers.
q Miscellaneous: Note any questionable aspects of the installation.
� WARNING! �
To avoid equipment damage, DO NOT leave system filled in a building without heat during the winter unless antifreeze is added to system water. Condenser coils never fully drain by themselves and will freeze unless winterized with antifreeze.
24
Installation & Operation WATER-TO-WATER (HWW) SERIES
Unit Start Up Procedures
� 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.
Heat Controller, Inc.
Table 5: Water Temperature Change
Through Source Heat Exchanger
Water Flow, gpm [l/m]
For Closed Loop: Ground Source or
Closed Loop Systems at 3 gpm per ton [3.9 l/m per kW]
For Open Loop: Ground Water
Systems at 1.5 gpm per ton
[2.0 l/m per kW]
Rise, Cooling
°F, [°C]
9 - 12
[5 - 6.7]
20 - 26
[11.1 - 14.4]
Drop, Heating
°F, [°C]
4 - 8
[2.2 - 4.4]
10 - 17
[5.6 - 9.4]
1. Adjust all valves to their full open position. Turn on the line power to all heat pump units.
2. Operate each unit in the cooling cycle. Loop water temperature entering the heat pumps should be between 70°F [21°C] and 110° F [43°C].
3. Operate each heat pump in the heating cycle immediately after checking cooling cycle operation. A time delay will prevent the compressor from re-starting for approximately five (5) minutes.
4. Establish a permanent operating record by logging the unit operating conditions at initial start-up for each unit.
5. If a unit fails to operate, conduct the following checks: a. Check the voltage and current. They should comply with the electrical specifications described on the unit nameplate.
b. Look for wiring errors. Check for loose terminal screws where wire connections have been made on both the line and low-voltage terminal boards.
c. Check the supply and return piping. They must be properly connected to the inlet and outlet connections on the unit.
d. If the checks described above fail to reveal the problem and the unit still will not operate, contact a trained service technician to ensure proper diagnosis and repair of the equipment.
Note: Units have a five minute time delay in the control circuit that can be eliminated on the CXM PCB as shown in Figure 9 [Page 20]. See controls description for detailed features of the control.
� WARNING! �
Verify ALL water controls are open and allow water flow prior to engaging the compressor. Freezing of the coax or water lines can permanently damage the heat pump.
25
Heat Controller, Inc. WATER-TO-WATER (HWW) SERIES
Unit Start Up Procedure
Table 6: Coax Water Pressure Drop HWW036-120
Installation & Operation
26
Installation & Operation WATER-TO-WATER (HWW) SERIES
Operating Pressures
TMW036-120 (TMW120 Per Circuit) (60 Hz I-P Units)
Cooling
Source
Entering
Water
Temp °F
Source
Water
Flow
GPM/ton
Load EWT
°F @ 1.5-3.0
GPM/ton
Suction
Pressure
PSIG
Discharge
Pressure
PSIG
Super-heat Sub-cooling
50
80
110
1.5
2.3
3.0
1.5
2.3
3.0
1.5
2.3
3.0
60
70
50
60
70
80
50
70
80
50
70
80
50
60
60
70
50
60
70
80
70
80
50
60
80
50
60
80
50
60
70
50
60
70
138-152
148-161
103-111
118.-129
132-147
140-172
94-110
112-121
121-146
131-151
109-116
128-135
147-154
109-116
99-106
111-122
122-137
126-145
98-105
106-117
114-129
117-135
87-101
91-113
95-124
107-128
104-111
121-132
127-135
153-159
100-112
120-130
131-152
153-164
367-373
377-381
320-325
328-334
336-344
343-353
305-314
313-319
317-329
324-333
483-497
494-511
505-525
459-473
230-234
241-243
251-253
254-258
212-214
218-220
225-227
228-230
199-203
203-207
204-216
212-217
343-348
355-360
466-484
473-495
444-431
449-467
454-474
463-479
9-13
12-20
18-27
9-13
9-13
9-13
9-13
9-14
12-23
8-14
8-14
12-20
19-29
9-13
9-13
9-13
9-14
9-14
9-14
13-21
32-41
12-18
12-18
16-34
33-35
9-14
9-14
11-18
11-18
17-25
26-35
18-23
18-23
24-32
12-18
12-18
12-18
17-23
17-23
17-23
15-20
18-25
18-25
14-21
14-21
14-21
14-21
12-18
15-20
15-20
12-17
12-17
12-17
12-17
14-20
12-18
12-18
12-18
12-18
18-25
18-25
18-25
18-25
18-25
18-25
14-20
14-20
14-20
Water
Temp
Rise °F
Source
20-28
13-18
9-12
19-28
13-18
8-12
18-26
14-17
8-13
Water
Temp
Drop °F
Load
8-16
9-18
9-20
5-11
6-13
7-15
5-11
8-18
9-20
7-14
8-16
8-18
9-20
7-15
6-13
7-15
5-12
6-14
7-15
8-17
9-20
8-16
8-17
9-19
9-20
7-14
7-16
7-15
8-17
8-19
9-20
7-15
8-17
9-19
Heat Controller, Inc.
27
Heat Controller, Inc. WATER-TO-WATER (HWW) SERIES
Operating Pressures
Source
Entering
Water
Temp °F
Source
Water
Flow
GPM/ton
20
50
80
3.0
1.5
2.3
3.0
1.5
2.3
3.0
TMW036-120 (TMW120 Per Circuit) (60 Hz I-P Units)
Heating
Suction
Pressure
PSIG
105-114
108-118
109-129
123-138
130-142
137-147
150-157
111-132
135-147
143-152
145-154
156-163
110-149
135-150
145-166
148-158
95-102
98-106
99-108
102-110
106-114
95-107
101-110
103-112
56-63
58-65
59-66
61-65
64-69
85-95
91-99
92-101
96-103
100-108
Load EWT
°F @ 1.5-3.0
GPM/ton
100
120
60
80
90
100
100
120
60
80
90
100
120
60
80
90
120
60
80
90
60
80
90
100
60
80
90
100
120
60
80
90
100
120
Discharge
Pressure
PSIG
Super-heat Sub-cooling
10-16
10-16
19-44
19-44
13-23
13-23
6-14
6-14
14-26
14-26
10-15
10-15
10-15
14-38
14-38
10-16
6-13
6-13
6-13
6-13
6-13
6-14
6-14
6-14
6-11
6-11
6-11
6-11
6-11
4-14
4-14
4-14
4-14
4-14
399-414
476-524
225-237
314-327
343-357
402-415
493-504
227-239
315-330
344-360
405-418
494-507
227-279
286-332
345-408
405-420
215-228
299-313
329-341
384-401
475-491
215-256
310-326
329-376
199-228
286-297
310-344
360-385
459-510
212-224
290-310
326-338
381-399
474-488
6-15
6-15
6-18
6-18
6-18
6-18
5-14
5-14
6-15
6-15
6-15
7-15
7-15
5-14
5-14
5-14
7-11
7-11
7-11
7-11
7-11
7-15
7-15
7-15
7-11
7-11
7-11
7-11
7-11
6-14
6-14
6-14
6-14
6-14
Water
Temp
Drop °F
Source
2-6
9-16
6-12
5-9
15-21
10-15
7-12
Water
Temp
Rise °F
Load
7-20
6-20
9-21
8-21
8-21
8-21
7-19
6-20
8-20
8-20
8-20
6-18
5-17
8-18
8-19
7-19
7-18
6-18
6-18
6-17
5-17
7-19
7-19
6-19
6-17
6-17
6-17
5-17
4-16
5-14
5-14
4-14
4-14
4-13
Installation & Operation
28
Installation & Operation WATER-TO-WATER (HWW) SERIES
Preventative Maintenance
Heat Exchanger Maintenance –
(Direct Ground Water Applications Only)
If the installation is performed in an area with a known high mineral content (125 P.P.M. or greater) in the water, it is best to establish with the owner a periodic maintenance schedule 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 either the heat exchanger material or copper water lines. Generally, the more water flowing through the unit the less chance for scaling therefore 2.5 gpm per ton
[2.0 l/m per kW] is recommended as a minimum flow.
Heat Exchanger Maintenance –
(All Other Water Loop Applications)
Generally water coil maintenance is not needed however, if the installation is located in a system with a known high dirt or debris content, it is best to establish with the owner a periodic maintenance schedule so the coil can be checked regularly. These dirty installations are a result of the deterioration of iron or galvanized piping or components in the system or open cooling towers requiring heavy chemical treatment and mineral buildup through water use. Should periodic coil cleaning be necessary, use standard coil cleaning procedures which are compatible with both the heat exchanger material and copper water lines. Generally, the more water flowing through the unit, the less chance for scaling, however flow rates over 3 gpm per ton [3.9 l/m per kW] can produce water (or debris) velocities that can erode the heat exchanger wall and ultimately produce leaks.
Clean or replace 20 mesh (841 micron) [0.84mm] strainer/ filters on a timely schedule.
Heat Controller, Inc.
Compressors
Conduct annual amperage checks to ensure amp draw is no more than 10% greater than that indicated by serial plate data.
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 for prevention. The cabinet can be cleaned using a mild detergent.
Refrigerant System
To maintain sealed circuit integrity, do not install service gauges unless unit operation appears abnormal. Reference the operating chart for pressure and temperatures. Verify that air and water flow rates are at proper levels before servicing the refrigerant circuit.
If the refrigerant circuit is opened for any reason, a new liquid line filter-drier must be installed.
29
Heat Controller, Inc. WATER-TO-WATER (HWW) SERIES
Refrigeration Troubleshooting Form
Installation & Operation
C u s t o m e :r
Model #:
Complaint:
S e ir a l # :
Refrigeration Troubleshooting Form
Water-to-Water Units
L o o p T y p e : S t a tr u p D a t e :
A n it rf e e z e T y p e & % :
WATER-TO-WATER UNITS
REFRIGERANT: R-22 R-410A R-407C
OPERATING MODE: HEATING COOLING
REFRIG FLOW - HEATING REFRIG FLOW - COOLING
HEATING POSITION COOLING POSITION
11 13 REVERSING
VALVE
CONDENSER (COOLING)
EVAPORATOR (HEATING)
2 1
Load
10 12
CONDENSER (HTG)
EVAPORATOR (CLG)
*Filter drier not used
for some R-22 units.
**Turn off HWG before
troubleshooting.
D e
Voltage s c ir p it o n
1
2
2a
2b
3
4
Compressor Amps
Suction Temp
Suction Press
Saturation Temp
Superheat
Discharge Temp
Discharge Press
Saturation Temp 4a
4b
5
Subcooling
Liquid Line Temp
6 Source Water In Tmp
7 Source Water Out Tmp
8 Source Water In Pres
9 Source Water Out Pres
9a Press Drop
9b Flow Rate GPM [l/s]
10 Load Water In Temp
11 Load Water Out Temp
12 Load Water In Pres
13 Load Water Out Pres
13a Press Drop
13b Flow Rate GPM [l/s]
5 FP2:
HEATING
LIQUID
LINE
Heating
EXPANSION
VALVE
FILTER
DRIER*
COAX
5 FP1:
COOLING
LIQUID
LINE
6
8
Source
7
9
Cooling
Temp Diff. =
Temp Diff. =
HWG**
N o t e
<--Water-to-Water units only
<--Water-to-Water units only
<--Water-to-Water units only
<--Water-to-Water units only
<--Water-to-Water units only s
SUCTION
3
COMPRESSOR
DISCHARGE
4
Heat of Extraction (Absorption) or Heat of Rejection:
HE or HR =
Flow Rate x Temp. Diff x
Fluid Factor: (for Btuh)
500 (Water); 485 (Antifreeze)
Fluid Factor: (for kW)
4.18 (Water); 4.05 (Antifreeze)
Fluid Factor
30
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