MARS Geothermal WSHP HRC Console Series Installation and Operation Manual
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INSTALLATION, OPERATION
MAINTENANCE
HRC Series
Commercial Console
Water-Source Heat Pumps
60Hz
Heat Controller • 1900 Wellworth Ave. • Jackson, MI 49203 • (517)787-2100 • www.heatcontroller.com
Installation, Operation, Maintenance HRC SeRieS Heat Controller
Table of Contents
Model Nomenclature: Console (HRC) Series (60Hz) ...................................3
General Information ................................................................................... 4-5
Unit Physical Data .........................................................................................6
Installation ................................................................................................. 7-8
Piping Connections - HRC Size 06-15 ..........................................................9
Piping Connections - HRC Size 18.........................................................10-11
Water-Loop Heat Pump Applications ...........................................................12
Ground-Loop Heat Pump Applications ........................................................13
Ground-Water Heat Pump Applications ................................................. 14-15
Water Quality Standards .............................................................................16
Electrical - Line Voltage ......................................................................... 17-18
Electrical - Low Voltage ......................................................................... 19-20
HRC Series Wiring Diagram Matrix .............................................................21
CXM Controls ..............................................................................................22
DXM Controls ........................................................................................ 23-24
Safety Features - CXM/DXM Controls................................................... 25-26
Unit Commissioning and Operating Conditions ...........................................27
Piping System Cleaning and Flushing .........................................................28
Unit and System Checkout Procedure ........................................................29
Unit Start-Up Procedure ..............................................................................30
Unit Operating Conditions ..................................................................... 31-32
Start-Up Log Sheet ......................................................................................33
Preventive Maintenance ..............................................................................34
Functional Troubleshooting .........................................................................35
Preventive Maintenance ..............................................................................36
Performance Troubleshooting .....................................................................37
Revision History............................................................................Back Cover
2
Heat Controller HRC SeRieS Installation, Operation, Maintenance
Model Nomenclature: (HRC) Series (60Hz)
3
Installation, Operation, Maintenance HRC SeRieS Heat Controller
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 hazard-related.
� WARNING!
�
WARNING! The EarthPure ® Application and Service Manual should be read and understood before attempting to service refrigerant circuits with HFC-410A.
� WARNING!
�
WARNING! To avoid the release of refrigerant into the atmosphere, the refrigerant circuit of this unit must be serviced only by technicians who meet local, state, and federal proficiency requirements.
� WARNING!
�
WARNING! The installation of water-source heat pumps 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.
� 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.
4
Heat Controller HRC SeRieS Installation, Operation, Maintenance
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 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.
Storage - Equipment should be stored in its original packaging in a clean, dry area. Store units in an upright position at all times. Stack units a maximum of 3 units high.
Unit Protection - Cover units on the job site with either the original packaging or an equivalent protective covering. Cap the open ends of pipes stored on the job site. In areas where painting, plastering, and/or spraying has not been completed, all due precautions must be taken to avoid physical damage to the units and contamination by foreign material. Physical damage and contamination may prevent proper start-up and may result in costly equipment clean-up.
Examine all pipes, fittings, and valves before installing any of the system components. Remove any dirt or debris found in or on these components.
Pre-Installation - Installation, Operation, and
Maintenance instructions are provided with each unit. Horizontal equipment is designed for installation above false ceiling or in a ceiling plenum. Other unit configurations are typically installed in a mechanical room. The installation site chosen should include adequate service clearance around the unit. Before unit start-up, read all manuals and become familiar with the unit and its operation. Thoroughly check the system before operation. Make sure wall behind the unit is flat and smooth.
Prepare units for installation as follows:
1. Compare the electrical data on the unit nameplate with ordering and shipping information to verify that the correct unit has been shipped.
2. Keep the cabinet covered with the original packaging until installation is complete and all plastering, painting, etc. is finished.
3. Verify refrigerant tubing is free of kinks or dents and that it does not touch other unit components.
4. Inspect all electrical connections. Connections must be clean and tight at the terminals.
� 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.
5
Installation, Operation, Maintenance HRC SeRieS Heat Controller
Unit Physical Data
(HRC) Series (60Hz)
Model
Compressor (1 Each)
Factory Charge HFC-410A (oz) [kg]
Blower Wheel
Blower Wheel Size (dia x w) -
(in) [mm] - Qty 2
Water Connection Size
O.D. Sweat (in) [mm]
Optional FPT Fittings (in)
Optional MPT Fittings (in)
Coax Volume
Volume US Gal
[Liters]
Condensate Connection Size
I.D. Vinyl Hose (In) [mm]
Air Coil Size
09
28 [0.794]
.09
[.34]
12
1/2 [12.7]
1/2
1/2
.09
[.34]
15
29 [0.822] 33 [0.907]
5.25 x 6.25 [133 x 159]
.23
[.87]
5/8 [15.9]
Dimensions (h x w) - (in) [mm]
8 x 26
[203 x 660]
10 x 26
[254 x 660]
Filter Size
Bottom Return (in) [mm]
Front Return (In) [mm]
Cabinet Size
Bottom Return (Std. 5” Base)
(W x H x D) - (In) [mm]
Front Return (No Subbase)
(W x H x D) - (In) [mm]
Cabinet Size
Weight - Operating, (lbs) [kg]
Weight - Packaged, (lbs) [kg]
1 - 10 x 30 x 1 [254 x 762 x 25]
1 - 7 x 29.5 x 1/8 [178 x 749 x 3.2]
48 x 26 x 12 [1219 x 660 x 305]
48 x 21 x 12 [1219 x 533 x 305]
175 [79]
185 [83.9]
180 [82]
190 [86]
* Data not available at time of publication.
All units have rubber grommet compressor mountings and TXV expansion devices.
190 [86.2]
200 [90.8]
18
39 [1.105]
3/4 [19.1]
3/4
3/4
.26
[.98]
10 x 32
[254 x 812]
1 - 10 x 36 x 1 [254 x 914 x 25]
1 - 7 x 35.5 x 1/8 [178 x 902 x 3.2]
54 x 26 x 12 [1372 x 660 x 305]
54 x 21 x 12 [1372 x 533 x 305]
220 [99.8]
232 [105.2]
Unit Maximum Water Working Pressure
Options Max Pressure PSIG [kPa]
Base Unit
Internal Secondary Pump (ISP)
Internal Motorized Water Valve (MWV)
500 [3,445]
145 [999]
300 [2,068]
Internal Auto Flow Valve 500 [3,445]
Use the lowest maximum pressure rating when multiple options are combined.
Optional Factory Installed Auto Flow Regulator GPM [LPS]
Model 2.25 GPM/Ton 3 GPM/Ton
9 2.0 [.126] 2.5 [.158]
12
15
2.5 [.158]
3.0 [.189]
3.0 [.189]
3.5 [.221]
18 3.5 [.221] 4.0 [.252]
Use the lowest maximum pressure rating when multiple options are combined.
6
Heat Controller HRC SeRieS Installation, Operation, Maintenance
Installation
The installation of Console Water-Source Heat Pumps and all associated components, parts and accessories that 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.
Note: An Installation Checklist is provided in this manual. Complete this checklist after all installation procedures are completed. A periodic maintenance checklist provided in the Maintenance section outlines recommended maintenance schedules. A
Start-Up Inspection Log is also included at the end of this manual to encourage thorough unit checkout at initial start-up. These checklists are not a substitute for the detailed information found in the Installation section of this manual.
1. Console units are typically installed along an outside wall of the room. Provide adequate space in front of the unit for service and maintenance. Locate the Console Unit so that it provides adequate air circulation throughout the room.
2. Unpack the Console Unit from the shipping carton.
Remove the front cabinet by lifting up and away from the backplate. Protect the cabinet from damage during installation by returning it to its original packaging until required.
3. Using a carpenter's square and a level, ensure the unit is level. Shim the unit if necessary to assure proper installation.
4. Select the proper fasteners to connect the backplate securely to the wall.
5. Fasten the backplate onto the wall through the screw holes located in the back flange. Secure the subbase in place.
6. Make all necessary electrical connections as described in the Electrical Wiring section of this manual. Consult the wiring diagram to ensure proper hook-up.
7. Connect the final piping as described in the Supply and Return Piping and Condensate Piping section of the manual. Install shut-off valves, piping and/or hoses and other accessories as specified.
8. Before making the final water connections, flush the system as described in the Start Up section of this manual. After flushing the system, connect piping and hoses to the proper supply, return and condensate connections of the unit.
Note: When necessary, use adapters to connect hoses.
9. Install any other system components as required following manufacturer's instructions.
10. After Start-up, reinstall the front cabinet by carefully lowering the front cabinet over the chassis onto the backplate.
Supply and Return Hoses - Optional pressure-rated hose assemblies 300 psi [2067 kPa] are available for use with Heat Controller Console Units. Use the following guidelines when installing supply and return hose assemblies.
1. Install supply and return hoses fitted with swivel-joint fittings at one end to prevent the hose from twisting.
2. Use adapters to secure the hose assembly to the unit and the riser.
3. Do not allow the hose to twist during installation.
Twisting may damage the hose wall or the interior rubber compound.
4. Use pipe joint compound sparingly on the pipe threads of the fitting adapters.
5. Prevent sealant from reaching the flared surfaces of the joint.
6. Do not use pipe joint compound when teflon thread tape is pre-applied to hose assemblies or when flared-end connections are used.
7. Maximum torque which may be applied to brass fittings is 30 ft-lbs [41 N-m]. When a torque wrench is not used, tighten brass fittings finger-tight plus one quarter turn.
8. Tighten steel fittings as necessary.
9. Shut-off/balancing valves, flow indicators, and drain tees in the supply runout and return at each floor to aid in loop balancing and servicing.
� CAUTION!
�
CAUTION! Poor or inadequate installation may result in noisy unit operation or unattractive installation.
7
Installation, Operation, Maintenance HRC SeRieS Heat Controller
Installation
� CAUTION!
�
CAUTION! Loop Fluids should be of good quality with no more than 0.50 ppm of chlorides w/copper heat exchangers
(125 ppm w/ Cupro-nickel) to prevent corrosion and should also be filtered to a maximum 800 micron [0.8mm particle size to prevent erosion of the heat exchangers.
Condensate Piping - Unit is supplied with condensate drain hose, 5/8 inch [16mm] I.D. flexible plastic nonpressure-rated, protruding from piping side of unit.
Connect this hose to building drain. Avoid making kinks in hose to ensure an unobstructed flow of condensate from the unit to the drain. DO NOT twist, pull hose out, or push excess hose into unit. If hose will not connect to your building drain several options include, relocate end of building drain, add to or cut hose, use hard plastic or copper elbow fittings for tight radii (put inside hose). Keep hose positioned within or over subbase area so hose does not interfere with front cabinet. Cabinet should not push or reroute hose. Clamp all joints watertight. Check for leaks.
If the building drain connection is parallel with floor, the height can be up to 1-1/2 inches [38mm] above the subbase for proper pitch and correct drainage. Up to 5 inches [127mm] above the subbase is allowable, but drainage will be slower. When the drain connection is 2-1/2 to 5 inches [64 to 127mm] above, the hose inside the unit will act as a trap. Heights of more than 5 inches [127mm] above the subbase are NOT allowable
(condensate overflow may occur). If the unit has a disconnect option, drain locations are limited. See unit configuration pages for details.
Field installation of a trap or vent is not required unless specified by local codes. Console units are designed in a blow-through configuration. The condensate drain pan is located on the outlet side of the blower so that the pressure in the drain pan is higher than atmospheric pressures.
When drain connection is completed check for proper drainage and leaks. Correct if necessary.
If trap is used, check and clean often. See Preventive
Maintenance Instructions.
Internally the drain hose is clamped to drain pan and pitched correctly. Horizontal runs of condensate hose should be pitched downward 1/4 inch minimum for every foot [10mm per 46cm] of hose. Avoid low points because dirt collects in these areas and may cause blockage. If blocked the condensate level in drain pan increases.
When the level gets too high, the Console unit has sensor switch that will shut unit off. Overflow may still occur.
8
Heat Controller HRC SeRieS Installation, Operation, Maintenance
Piping Connections - HRC Size 06-15
1.62 (41)
1.62 (41)
2.00
2.00
(51)
Optional
Motorized
Out
In Out
In
Optional
Autoflow
Water Connections
5/8Ó (15.9) OD
Copper, 1/2Ó FPT, or
1/2Ó MPT
*
11.25 (286)
*
11.25 (286)
2.25
2.25
(57)
Blower Access Panel
Blower Access Panel
Compressor
Access
Panel
8.00 Min
8.00 Min
(203)
Optional
Motorized
1.75 (44)
1.75 (44)
Right Hand Configuration
Water Out
Water Out
Water In
1.84
1.84
(47)
5/8" (15.9) ID
Vinyl Hose
Right Hand Configuration
Water Connections
Water Connections
5/8" (15.9)
1/2" MPT
1/2" MPT Optional Fused
Optional Fused
Disconnect Box
Also Available in Non-Fused
Also Available in Non-Fused
Optional Disconnect
Optional Disconnect
Only Box (All Configurations)
Optional
Optional
Valve
Optional
Motorized
Water Valve
5/8Ó (15.9) OD
Copper, 1/2Ó FPT, or 1/2Ó MPT
Water Connections
1/2" FPT or
1/2" MPT
1/2" FPT or
1/2" MPT
Disconnect Box
(mounted to cabinet not chassis) not chassis)
2.25
(57)
2.25
(57)
Condensate
Condensate
5/8" (15.9) ID
Vinyl Hose
2.72
(96)
2.72
(96)
*
11.25 (286)
*
11.25 (286)
2.25
(57)
2.25
(57)
2.00
(51)
2.00
(51)
8.00 Min
(203)
8.00 Min
(203)
1.50 (38)
Left Hand Configuration
Notes:
*
Dimension reduced by fitting if selected
Notes:
*
Dimension reduced by fitting if selected
1.50 (38)
Left Hand Configuration
� CAUTION!
�
CAUTION! Corrosive system water requires corrosion resistant fittings and hoses, and may require water treatment.
�
CAUTION!
�
CAUTION!
�
CAUTION!
�
CAUTION!
ÊÊCorrosiveÊsystemÊwaterÊrequiresÊcorrosionÊ
9
� CAUTION!
�
CAUTION! Piping must comply with all applicable codes.
�
CAUTION!
�
CAUTION!Ê
�
CAUTION!
�
CAUTION!Ê PipingÊmustÊcomplyÊwithÊallÊapplicableÊcodes.
treatment.
20.50
(521)
Installation, Operation, Maintenance HRC SeRieS Heat Controller
Piping Connections - HRC Size 18
Blower Deck
40.98
(1040)
Blower Access Panel
Optional
Autoflow
Valve
Optional
Motorized
Water Valve
Water Connections
5/8" (15.9AA)
OD Copper,
1/2" FPT or
1/2" MPT
Optional
Disconnect Box
(mounted to cabinet not chassis)
1.62 (41)
2.00
(51)
Optional
Motorized
Water Valve
Out
In
Optional Flow
Regulator
Control Box
Compressor
Access
Panel
Water Out
Water In
Water Connections
5/8Ó (15.9) OD
Copper, 1/2Ó FPT, or
1/2Ó MPT
*
11.25 (286)
8.00 Min
(203)
1.75 (44)
2.25
(57)
1.84
(47)
Condensate
Vinyl Hose
Right Hand Configuration
Water Out
Water In
Water Connections
5/8Ó (15.9) OD
Copper, 1/2Ó FPT, or 1/2Ó MPT
Optional
Autoflow
Valve
Optional
Motorized
Water Valve
Water Connections
5/8" (15.9)
OD Copper,
1/2" FPT or
1/2" MPT
Optional Fused
Disconnect Box
(mounted to cabinet not chassis)
Also Available in Non-Fused
Optional Disconnect
Only Box (All Configurations)
1.50 (38) 2.25
(57)
2.00
(51)
*
11.25 (286)
8.00 Min
(203)
2.25
(57)
Condensate
5/8" (15.9) ID
Vinyl Hose 2.72
(96)
Left Hand Configuration
Notes:
*
Dimension reduced by fitting if selected
� CAUTION!
�
CAUTION! Corrosive system water requires corrosion resistant fittings and hoses, and may require water treatment.
�
CAUTION!
�
CAUTION!
ÊÊCorrosiveÊsystemÊwaterÊrequiresÊcorrosionÊ
� CAUTION!
�
CAUTION! Piping must comply with all applicable codes.
�
CAUTION!
�
CAUTION!Ê PipingÊmustÊcomplyÊwithÊallÊapplicableÊcodes.
10 treatment.
Heat Controller HRC SeRieS Installation, Operation, Maintenance
Piping Connections
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. Refer to Table 1. Do not exceed the minimum bend radius for the hose selected. 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.
Insulation is not required on loop water piping except where the piping runs through unheated areas, outside the building or when the loop water temperature is below the minimum expected dew point of the pipe ambient conditions. Insulation is required if loop water temperature drops below the dew point (insulation is required for ground loop applications in most climates).
Pipe joint compound is not necessary when Teflon ® thread 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 external pipe threads of the fitting adapters. Prevent sealant from reaching the flared surfaces of the joint.
� WARNING!
�
WARNING! Polyolester Oil, commonly known as POE oil, is a synthetic oil used in many refrigeration systems including those with HFC-410A refrigerant. POE oil, if it ever comes in contact with PVC or CPVC piping, may cause failure of the PVC/CPVC. PVC/CPVC piping should never be used as supply or return water piping with water source heat pump products containing HFC-410A as system failures and property damage may result.
� CAUTION!
�
CAUTION! Do not bend or kink supply lines or hoses.
Table 1: Metal Hose Minimum Bend Radii
Hose Diameter
1/2" [12.7mm]
3/4" [19.1mm]
1" [25.4mm]
1-1/4" [31.8mm]
Minimum Bend Radii
2-1/2" [6.4cm]
4" [10.2cm]
5-1/2" [14cm]
6-3/4" [17.1cm]
NOTICE! Do not allow hoses to rest against structural building components. Compressor vibration may be transmitted through the hoses to the structure, causing unnecessary noise complaints.
Figure 2: Supply/Return Hose Kit
Rib Crimped
Swivel
Brass
Fitting
Note: When antifreeze is used in the loop, insure that it is compatible with the Teflon tape or pipe joint compound that is applied.
MPT
Length
(0.6m Length Standard)
MPT
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.
Rib Crimped
Swivel
Brass
Fitting
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.
MPT
Length
(2 ft [0.6m] Length Standard)
MPT
Reborde Acanalado
Accesorio
Giratorio de Bronce
Accesorio de Bronce
Refer to Figure 2 for an illustration of a typical supply/ return hose kit. Adapters secure hose assemblies to the unit and risers. Install hose assemblies properly and check regularly to avoid system failure and reduced service life.
11
MPT
Longitud
(Long. Estándar de 2 pies)
MPT
Installation, Operation, Maintenance HRC SeRieS Heat Controller
Water-Loop Heat Pump Applications
Commercial Water Loop Applications - Commercial systems typically include a number of units connected 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 (extended range units required). Metal to plastic threaded joints should never be used due to their tendency to leak over time.
Teflon tape thread sealant is recommended to minimize internal fouling of the heat exchanger. Do not over tighten 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 unit and the piping system.
Depending upon selection, hose kits may include shut off valves, P/T plugs for performance measurement, high pressure stainless steel braided hose, “Y” type strainer with blow down valve, and/or “J” type swivel connection.
Balancing valves and an external low pressure drop solenoid valve for use in variable speed pumping systems may also be included in the hose kit.
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” in this manual). The flow rate is usually set between 2.25 and 3.5 gpm per ton [2.9 and 4.5 l/m per kW] of cooling capacity.
Heat Controller recommends 3 gpm per ton [3.9 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.
Water loop heat pump (cooling tower/boiler) systems typically utilize a common loop, maintained between 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 antifreeze is selected, the LT1 jumper (JW3) should be clipped to select the low temperature
(antifreeze 10.0°F [-12.2°C]) setpoint and avoid nuisance faults (see “Low Water Temperature Cutout Selection” in this manual). Note: Low water temperature operation requires extended range equipment.
Table 2: Antifreeze Percentages by Volume
Type
Methanol - 100% USP food grade
Propylene Glycol
Minimum Temperature for Freeze Protection
10ºF [-12.2ºC] 15ºF [-9.4ºC] 20ºF [6.7ºC] 25ºF [-3.9ºC]
25%
38%
21%
30%
16%
22%
10%
15%
12
Heat Controller HRC SeRieS Installation, Operation, Maintenance
Ground-Loop Heat Pump Applications
� CAUTION!
�
CAUTION! The following instructions represent industry accepted installation practices for closed loop earth coupled heat pump systems. Instructions are provided to assist the contractor in installing trouble free ground loops. These instructions are recommendations only. State/provincial and local codes MUST be followed and installation MUST conform to ALL applicable codes. It is the responsibility of the installing contractor to determine and comply with ALL applicable codes and regulations.
� CAUTION!
�
CAUTION! Ground loop applications require extended range equipment and optional refrigerant/water circuit insulation.
Antifreeze If any liquid fluid or piping is exposed to unconditioned ambient below 42°F (5.5 C), antifreeze must be added. If the liquid fluid entering the heat pump is 50°F (10°C) or below, calculate the leaving heat pump temperature (shown in submittal on performance data selection notes section). Using the lowest temperature leaving the heat pump, must protect system 15°F (8°C) lower. IE: if temperature leaving the heat pump is 35°F subtract 15°F = 20°F protection required, if Methanol is used the system would require 16% mix by volume.
Antifreeze is available in alcohol and glycols, contact local sales office for the best type for your system and area. Following must be considered safety, thermal performance, corrosiveness, local codes, stability, convenience, and cost.
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.
All alcohols should be premixed and pumped from a reservoir outside of the building when possible or introduced under the water level to prevent fumes.
Calculate the total volume of fluid in the piping system.
Then use the percentage by volume shown in table
2 for the amount of antifreeze needed. Antifreeze concentration should be checked from a well mixed sample using a hydrometer to measure specific gravity.
Piping Installation - 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.
Low Water Temperature Cutout Setting - CXM Control
When antifreeze is selected, the LT1 jumper (JW3) should be clipped to select the low temperature
(antifreeze 10.0°F [-12.2°C]) setpoint and avoid nuisance faults (see “Low Water Temperature Cutout Selection” in this manual). Note: Low water temperature operation requires extended range equipment.
Earth loop temperatures can range between 25 and
110°F [-4 to 43°C]. Flow rates between 2.25 and 3 gpm per ton [2.41 to 3.23 l/m per kW] of cooling capacity is recommended in these applications.
Test individual horizontal loop circuits before backfilling.
Test vertical U-bends and pond loop assemblies prior to installation. Pressures of at least 100 psi [689 kPa] should be used when testing. Do not exceed the pipe pressure rating. Test entire system when all loops are assembled.
Flushing the Earth Loop - Upon completion of system installation and testing, flush the system to remove all foreign objects and purge to remove all air.
13
Installation, Operation, Maintenance HRC SeRieS Heat Controller
Ground-Water Heat Pump Applications
Open Loop - Ground Water Systems - 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. Supply and return water piping materials should be limited to copper, PE, or similar material. PVC or CPVC should never be used as they are incompatible with the POE oils used in HFC-410A products and piping system failure and property damage may result.
� WARNING!
Shut off valves
�
WARNING! Polyolester Oil, commonly known as POE oil, is a synthetic oil used in many refrigeration systems including those with HFC-410A refrigerant. POE oil, if it ever comes in contact with PVC or CPVC piping, may cause failure of the PVC/CPVC. PVC/CPVC piping should never be used as supply or return water piping with water source heat pump products containing HFC-410A as system failures and property damage may result.
Water quantity should be plentiful and of good quality.
Consult table 2 for water quality guidelines. The unit can be ordered with either a copper or cupro-nickel water heat exchanger. Consult Table 2 for recommendations.
Copper is recommended for closed loop systems and open loop ground water systems that are not high in mineral content or corrosiveness. In conditions anticipating heavy scale formation or in brackish water, a cupro-nickel heat exchanger is recommended. In ground water situations where scaling could be heavy or where biological growth such as iron bacteria will be present, an open loop system is not recommended. Heat exchanger coils may over time lose heat exchange capabilities due to build up of mineral deposits. Heat exchangers must only be serviced by a qualified technician, as acid and special pumping equipment is required. Desuperheater coils can likewise become scaled and possibly plugged. In areas with extremely hard water, the owner should be informed that the heat exchanger may require occasional acid flushing.
In some cases, the desuperheater option should not be recommended due to hard water conditions and additional maintenance required.
Water Quality Standards - Table 2 should be consulted for water quality requirements. Scaling potential should be assessed using the pH/Calcium hardness method. If the pH <7.5 and the calcium hardness is less than 100 ppm, scaling potential is low. If this method yields numbers out of range of those listed, the Ryznar Stability and
Langelier Saturation indecies should be calculated. Use the appropriate scaling surface temperature for the application,
150°F [66°C] for direct use (well water/open loop) and
DHW (desuperheater); 90°F [32°F] for indirect use. A monitoring plan should be implemented in these probable scaling situations. Other water quality issues such as iron fouling, corrosion prevention and erosion and clogging should be referenced in Table 2.
Expansion Tank and Pump Use a closed, bladder-type expansion tank to minimize mineral formation due to air exposure. The expansion tank should be sized to provide at least one minute continuous run time of the pump using its drawdown capacity rating to 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.
Water Control Valve - 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..
14
Heat Controller HRC SeRieS Installation, Operation, Maintenance
Ground-Water Heat Pump Applications
Flow Regulation - Flow regulation can be accomplished by two methods. One method of flow regulation involves simply adjusting the ball valve or water control valve on the discharge line. Measure the pressure drop through the unit heat exchanger, and determine flow rate. 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.
Notice! Ground-water applications for commercial buildings with more than 2-3 units should include a plate frame heat-exchanger to isolate the heat pumps from the ground-water and confine heat exchanger cleanings to one location and lessen maintenance. Direct use of ground-water may increase the frequency of heat pump maintenance and may shorten life expectancy.
Water Coil Low Temperature Limit Setting - For all open loop systems the 30°F [-1.1°C] LT1 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.
15
Installation, Operation, Maintenance HRC SeRieS Heat Controller
Water Quality Standards
Table 2: 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
All
6.0 - 7.5
If >7.5 minimize steel pipe use.
Langelier
Saturation Index
All
-0.5 to +0.5
If <-0.5 minimize steel pipe use. Based upon 66°C HWG and
Direct well, 29°C Indirect Well HX
Iron Fouling
Iron Fe 2+ (Ferrous)
(Bacterial Iron potential)
All
-
If Fe 2+
<0.2 ppm (Ferrous)
(ferrous)>0.2 ppm with pH 6 - 8, O2<5 ppm check for iron bacteria.
Iron Fouling All
<0.5 ppm of Oxygen
Above this level deposition will occur.
Corrosion Prevention pH All
6 - 8.5
Monitor/treat as needed
-
6 - 8.5
Minimize steel pipe below 7 and no open tanks with pH <8
Hydrogen Sulfide (H2S) All
<0.5 ppm
At H2S>0.2 ppm, avoid use of copper and copper nickel piping or HX's.
Rotten egg smell appears at 0.5 ppm level.
Copper alloy (bronze or brass) cast components are OK to <0.5 ppm.
Ammonia ion as hydroxide, chloride, nitrate and sulfate compounds All
-
<0.5 ppm
Maximum
Chloride Levels
Erosion and Clogging
Copper
Cupronickel
304 SS
316 SS
Titanium
-
-
-
-
-
Maximum Allowable at maximum water temperature.
10 ° C
<20ppm
<150 ppm
<400 ppm
<1000 ppm
>1000 ppm
24 ° C
NR
NR
<250 ppm
<550 ppm
>550 ppm
38 C
NR
NR
<150 ppm
< 375 ppm
>375 ppm
Particulate Size and
Erosion
All
<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.
The Heat Controller Water Quality Table provides water quality requirements for Heat Controller coaxial heat exchangers. The water should be evaluated by an independent testing facility comparing to this Table and when properties are outside of these 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 and any other components damaged by a leak.
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.
Rev.: 5/6/2014 S
16
Heat Controller HRC SeRieS Installation, Operation, Maintenance
Electrical - Line Voltage
� WARNING!
�
WARNING! To avoid possible injury or death due to electrical shock, open the power supply disconnect switch and secure it in an open position during installation.
� CAUTION!
�
CAUTION!
Use only copper conductors for field installed electrical wiring. Unit terminals are not designed to accept other types of conductors.
Electrical - Line Voltage - All field installed wiring, including electrical ground, must comply with the National
Electrical Code as well as all applicable local codes.
Refer to the unit electrical data for fuse sizes. Consult wiring diagram for field connections that must be made by the installing (or electrical) contractor. All final electrical connections must be made with a length of flexible conduit to minimize vibration and sound transmission to the building.
General Line Voltage Wiring - Be sure the available power is the same voltage and phase shown on the unit serial plate. Line and low voltage wiring must be done in accordance with local codes or the National Electric Code, whichever is applicable.
Power Connection - Line voltage connection is made by connecting the incoming line voltage wires to the “L” side of the contactor. Consult Tables 4 through 5 for correct fuse size.
Transformer - All commercial dual voltage units are factory wired for 208/60/1. If supply voltage is 230/60/1, installer must rewire transformer. See wire diagram for connections.
Table 4: HRC Electrical Data (60Hz)
HRC09
HRC12
HRC15
HRC18
E
G
E
G
E
A
G
E
A
G
Voltage
Min/Max
Voltage
115/60/1 104-126
208-230/60/1 197-254
265/60/1 239-292
115/60/1 104-126
208-230/60/1 197-254
265/60/1 239-292
208-230/60/1 197-254
265/60/1 239-292
208-230/60/1 197-254
265/60/1 239-292
Compressor
1
1
1
1
1
QTY RLA LRA
1 8.0
46.5
1
1
4.5
23.0
5.0
19.0
1
1
9.5
50.0
4.7
25.0
4.2
22.0
5.6
30.0
4.7
28.5
6.8
38.0
6.2
29.0
Fan
Motor
FLA
0.5
0.4
0.4
0.5
0.6
0.4
0.8
0.6
0.7
0.6
Total
Unit
FLA
8.5
4.9
5.4
10.0
5.3
4.6
6.4
5.3
7.5
6.8
Standard Unit
5.7
7.8
6.5
9.2
8.4
Min
Circuit
Amps
10.5
6.0
6.7
12.4
6.5
Max
Fuse/
HACR
20
15
15
20
15
15
15
15
15
15
With Secondary Pump
5.4
7.2
6.2
8.3
7.6
Total
Unit
FLA
8.8
5.3
6.2
11.5
5.7
Min
Circuit
Amps
11.3
6.4
7.5
13.8
7.3
6.5
8.6
7.3
10.0
9.2
15
15
15
15
15
Max
Fuse/
HACR
20
15
15
20
15
17
Installation, Operation, Maintenance HRC SeRieS Heat Controller
Figure 3: Typical Field Installed Wiring
A
Field Supplied
Disconnect Switch
Heat Pump
B
Room Thermostat
� WARNING!
�
WARNING! To avoid possible injury or death due to electrical shock, open the power supply disconnect switch and secure it in an open position during installation.
� CAUTION!
�
CAUTION!
Use only copper conductors for field installed electrical wiring. Unit terminals are not designed to accept other types of conductors.
A= Two power wires on single-phase units: three power wires on three-phase units. B= 1 heat /1 cool /manual or Auto Change-over remote 24V thermostat. Note: All customer-supplied wiring to be copper only and must conform to NEC and local electrical codes. Wiring shown with dashed lines must be field-supplied and field-installed.
"B" only required with systems employing remote mounted thermostats.
Figure 4: LT1 Limit Setting
Low Water Temperature Cutout Setting - CXM Control
When antifreeze is selected, the LT1 jumper (JW3) should be clipped to select the low temperature
(antifreeze 10.0°F [-12.2°C]) setpoint and avoid nuisance faults (see “Low Water Temperature Cutout Selection” in this manual). Note: Low water temperature operation requires extended range equipment.
CXM PCB
LT1
LT2
JW3-LT1 jumper should be clipped for low temperature operation
LT1
LT1
LT2
LT2
18
Heat Controller HRC SeRieS Installation, Operation, Maintenance
Electrical - Low Voltage
Unit-Mounted Control Models include digital display unit-mounted auto changeover (ACO) control. (see Fig. 5).
Figure 5: ACO Thermostat
To Change Mode - push mode button to toggle through heat, cool, auto, off. Stop where desired.
To Adjust Setpoint - push up arrow for temperature increase or down arrow for temperature decrease. Stop where desired.
To Select Fan Operation/Speed - push fan button to toggle through fan on low, fan on hi, fan auto lo, and fan auto hi. Stop where desired. ON is continuous and Auto cycles fan with compressor.
To Configure Thermostat - for temperature reading in
Fahrenheit or Celsius and backlight on/off.
Temperature reading - Press and hold mode button for 3-5 seconds.
Screen will flash U1 with ºF or ºC below. Press and release mode button ºF or ºC will flash. Use down arrow to change to ºC. Use up arrow to change to ºF.
Press fan button to escape.
Backlight - Press and hold mode button for 3-5 seconds.
Screen will flash U1 press up arrow and screen will change to U2 flashing. Press and release mode button and on will flash. To turn off push down arrow, push up arrow to get back to on.
Press fan button to escape.
Thermostat has advanced features to be changed by qualified installer only (do not use code 99- to restore factory default settings, reset each code if needed.)
To enter advanced mode push and hold fan button for
10-15 seconds. Use mode and arrow buttons to make selections.
Code 02 is sensor selection : rS is remote (default) DO
NOT CHANGE.
Code 07 is delay: off - timeguard enabled (default); on- timeguard disabled. DO NOT CHANGE.
Code 11 is deadband between auto heat and cool: 1 through 10 for ºF or ºC ( 5 default).
Code 15 is auto or manual: On is auto (default); of is manual.
Code 21 is keypad lock: user has full access (default); 1 only access to setpoints; cd entire keypad is locked.
Code 26 is minimum cooling setpoint: 55ºF to 90ºF (60ºF default).
[12 ºC to 32 ºC (50 ºC default)]
Code 27 is maximum heating setpoint: 50ºF to 90ºF (85ºF default).
[10 ºC to 32 ºC (29 ºC default)]
Figure 6: Display
Mode
Fan
heat actual temp set at
Setting
ºF
keypad lock
19
Installation, Operation, Maintenance HRC SeRieS Heat Controller
Optional Wall-Mounted Thermostat
HRC WSHP units (Model digit 8 is C, D, F, or K) are built with standard internal thermostat that has automatic changeover (ACO) configuration. No external, fieldinstalled low-voltage wiring is required.
When desired, the unit can be furnished with a 24-volt control circuit which is field-wired to a Heat Controllersupplied accessory remote thermostat.
Low-voltage wiring between the unit and the wall thermostat must comply with all applicable electrical codes
(i.e., NEC and local codes), and be completed before the unit is installed.
Figure 7: Typical Remote Thermostat Wiring
Connection to CXM Control
Thermostat
Compressor
Reversing Valve
Fan
24Vac Hot
24Vac Common
Fault LED
Y
R
C
O
G
L
CXM
Y
R
C
O
G
AL1
Table 6: Recommended Thermostat Wire Sizes
Wire Size
18-Gauge
16-Gauge
14-Gauge
Maximum Wire Length*
75 feet [22m]
125 feet [38m]
200 feet [60 m]
*Length = Physical distance from thermostat to unit.
Thermostat Installation The thermostat should be located on an interior wall in a larger room, away from supply air drafts. DO NOT locate the thermostat in areas subject to sunlight, drafts or on external walls. The wire access hole behind the thermostat may in certain cases need to be sealed to prevent erroneous temperature measurement. Position the thermostat back plate against the wall so that it appears level and so the thermostat wires protrude through the middle of the back plate. Mark the position of the back plate mounting holes and drill holes with a 3/16” (5mm) bit. Install supplied anchors and secure plate to the wall. Thermostat wire must be 18 AWG wire.
Wire the appropriate thermostat as shown in Figure 7 to the low voltage terminal strip on the CXM or DXM control board. Practically any heat pump thermostat will work with
Heat Controller units, provided it has the correct number of heating and cooling stages.
Note: If ATA11U03 is used must jumper G and G2
Figure 7a: Wiring for multiple units to be controlled from 1 thermostat
Thermostat
CS
DXM
Unit
1
CS
DXM
Unit
2-6
Connect thermostat to Unit 1 then jumper Com 1 (S to S and C to C) up to 6 units with twisted pair.
Zone integrity must be maintained to efficiently control units or groups of units. Unless zones of control are considered and accounted for, adjacent units may operate in heating and cooling modes simultaneously, to prevent units with
DXM can be wired per figure 7A.
20
Heat Controller HRC SeRieS Installation, Operation, Maintenance
HRC Series Wiring Diagram Matrix
Diagrams can be located online for 60 Hz go to www.heatcontroller.com
Model
HRC09 -
HRC18
Refrigerant
R410A
R410A
R410A
R410A
R410A
R410A
R410A
R410A
Wiring Diagram
Part Number
96B0099N52
96B0099N53
96B0099N54
96B0099N55
96B0100N52
96B0100N53
96B0100N54
96B0100N55
Electrical
115/60/1,
208-230/60/1,
265/60/1
115/60/1,
208-230/60/1,
265/60/1
CXM
DXM
Control
ACO/MCO
REM
LON
MPC
ACO/MCO
REM
LON
MPC
Agency
ETL
ETL
ETL
ETL
ETL
ETL
ETL
ETL
21
Installation, Operation, Maintenance HRC SeRieS Heat Controller
CXM Controls
CXM Control - For detailed control information, see CXM
Application, Operation and Maintenance (AOM) manual
(part # 97B0003N12).
Field Selectable Inputs - Test mode: Test mode allows the service technician to check the operation of the control in a timely manner. At board, momentarily shorting the test terminals or externally, momentarily push test button
(See Fig 10), 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 or holding button 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-
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).
Not Clipped = 30°F [-1°C]. Clipped = 10°F [-12°C].
Air coil low temperature limit setting: Jumper 2 (JW2-LT2
Low Temp) provides field selection of temperature limit setting for LT2 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 switch 2: Stage 2 Selection - provides selection of whether compressor has an “on” delay. If set to stage
2, the compressor will have a 3 second delay before energizing. Also, if set for stage 2, the alarm relay will
NOT cycle during test mode.
On = Stage 1. Off = Stage 2
DIP switch 3: Not Used.
DIP switch 4 : DDC Output at EH2 - provides selection for
DDC operation. If set to “DDC Output at EH2,” the EH2 terminal will continuously output the last fault code of the controller. If set to “EH2 normal,” EH2 will operate as standard electric heat output.
On = EH2 Normal. Off = DDC Output at EH2.
Note: Some CXM controls only have a 2 position DIP switch package. If this is the case, this option can be selected by clipping the jumper which is in position 4 of
SW1.
Jumper not clipped = EH2 Normal. Jumper clipped =
DDC Output at EH2.
DIP switch 5: Factory Setting - Normal position is “On.”
Do not change selection unless instructed to do so by the factory.
-Slow Flash = 1 flash every 2 seconds
-Fast Flash = 2 flashes every 1 second
Table 7a: LED And Alarm Relay Operations
Description of Operation LED Alarm
Normal Mode
Normal Mode w/UPS Warning
CXM is non-functional
Fault Retry
Lockout
Over/Under Voltage Shutdown
ON
ON
OFF
Slow Flash
Fast Flash
Slow Flash
Test Mode - No Fault in Memory Flashing Code 1
Test Mode - HP Fault in Memory Flashing Code 2
Test Mode - LP Fault in Memory Flashing Code 3
Test Mode - LT1 Fault in Memory Flashing Code 4
Test Mode - LT2 Fault in Memory Flashing Code 5
Test Mode - CO Fault in Memory Flashing Code 6
Test Mode - Over/Under
Shutdown in Memory
Flashing Code 7
Test Mode - UPS in Memory Flashing Code 8
Test Mode - Swapped Thermistor Flashing Code 9
Open
Cycle (Closed 5 seconds,
Open 25 seconds)
Open
Open
Closed
Open (Closed after 15
Minutes)
Cycling Code 1
Cycling Code 2
Cycling Code 3
Cycling Code 4
Cycling Code 5
Cycling Code 6
Cycling Code 7
Cycling Code 8
Cycling Code 9
DIP Switches - Note: In the following field configuration options, DIP switches should only be changed when power is removed from the CXM control.
-Flash code 2 = 2 quick flashes, 10 second pause, 2 quick flashes, 10 second pause, etc.
-On pulse 1/3 second; off pulse 1/3 second
DIP switch 1: Unit Performance Sentinel Disable provides field selection to disable the UPS feature.
On = Enabled. Off = Disabled.
22
Heat Controller HRC SeRieS Installation, Operation, Maintenance
DXM Controls
DXM Control For detailed control information, see DXM
AOM (part #97B0003N13), Lon controller AOM (part
#97B0013N01) or MPC AOM (part # 97B0031N01).
Table 7b: DXM LED And Alarm Relay Operations
Normal mode
Normal mode with UPS
DXM is non-functional
Fault Retry
Lockout
Test Mode
Night Setback
ESD
Invalid T-stat Inputs
Status LED
(green)
On
On
Off
Slow Flash
Fast Flash
-
Flashing Code 2
Flashing Code 3
Flashing Code 4
Test LED
(yellow)
-
-
Off
-
-
On
-
-
-
Fault LED
(red)
Off
Flashing Code 8
Off
Flashing fault code
Flashing fault code
-
-
-
-
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).
Alarm Relay
Open
Not Clipped = 30°F [-1°C]. Clipped = 10°F
[-12°C].
Air coil low temperature limit setting: Jumper 2
(JW2-LT2 Low Temp) provides field selection
Cycle (closed 5 sec, open 25 sec)
Open
Open
Closed
-
-
-
of temperature limit setting for LT2 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 Heat Controller technical services.
Not Clipped = 30°F [-1°C]. Clipped = 10°F
[-12°C].
HP Fault
LP Fault
LT1 Fault
LT2 Fault
CO Fault
Over/Under Voltages
Slow Flash
Slow Flash
Slow Flash
Slow Flash
Slow Flash
Slow Flash
-
-
-
-
-
-
-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.
-On pulse 1/3 second; off pulse 1/3 second
Flashing Code 2
Flashing Code 3
Flashing Code 4
Flashing Code 5
Flashing Code 6
Flashing Code 7
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 DXM 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.
Open
Open
Open
Open
Open
Open (closed after 15 minutes)
Alarm relay setting: Jumper 4 (JW4-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).
Low pressure normally open: Jumper 1 (JW1-LP norm open) provides field selection for low pressure input to be normally closed or normally open.
Not Clipped = LP normally closed. Clipped = LP normally open.
DIP Switches - Note: In the following field configuration options, DIP switches should only be changed when power is removed from the DXM control.
Retry mode:
Field Configuration Options Note: In the following field configuration options, jumper wires should be clipped ONLY when power is removed from the DXM control.
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.
DIP Package #1 (S1) - DIP Package #1 has 8 switches and provides the following setup selections:
1.1 - Unit Performance Sentinel (UPS) disable: DIP
Switch 1.1 provides field selection to disable the UPS feature.
On = Enabled. Off = Disabled.
1.2 Compressor relay staging operation: DIP 1.2 provides selection of compressor relay staging operation.
The compressor relay can be selected to turn on with a stage 1 or stage 2 call from the thermostat.
This is used with dual stage units (2 compressors where 2 DXM controls are being used) or with master/ slave applications. In master/slave applications, each compressor and fan will stage according to its appropriate
DIP 1.2 setting. If set to stage 2, the compressor will have a 3 second on-delay before energizing during a Stage 2 demand. Also, if set for stage 2, the alarm relay will NOT cycle during test mode.
23
Installation, Operation, Maintenance HRC SeRieS Heat Controller
On = Stage 1. Off = Stage 2.
1.3 - Thermostat type (heat pump or heat/cool): DIP 1.3 provides selection of thermostat type. Heat pump or heat/cool thermostats can be selected. When in heat/ cool mode, Y1 is the input call for cooling stage 1; Y2 is the input call for cooling stage 2; W1 is the input call for heating stage 1; and O/W2 is the input call for heating stage 2. In heat pump mode, Y1 is the input call for compressor stage 1; Y2 is the input call for compressor stage 2; W1 is the input call for heating stage 3 or emergency heat; and O/W2 is the input call for reversing valve (heating or cooling, depending upon DIP 1.4).
On = Heat Pump. Off = Heat/Cool.
1.4 Thermostat type (O/B): DIP 1.4 provides selection of thermostat type for reversing valve activation. Heat pump thermostats with “O” output (reversing valve energized for cooling) or “B” output (reversing valve energized for heating) can be selected with DIP 1.4.
On = HP stat with “O” output for cooling. Off = HP stat with “B” output for heating.
1.5 Dehumidification mode: DIP 1.5 provides selection of normal or dehumidification fan mode. In dehumidification mode, the fan speed relay will remain off during cooling stage 2. In normal mode, the fan speed relay will turn on during cooling stage 2.
On = Normal fan mode. Off = Dehumidification mode.
1.6 DDC output at EH2: DIP 1.6 provides selection for
DDC operation. If set to “DDC Output at EH2,” the EH2 terminal will continuously output the last fault code of the controller. If set to “EH2 normal,” EH2 will operate as standard electric heat output.
On = EH2 Normal. Off = DDC Output at EH2.
1.7 Boilerless operation: DIP 1.7 provides selection of boilerless operation. In boilerless mode, the compressor is only used for heating when LT1 is above the temperature specified by the setting of DIP 1.8. Below
DIP 1.8 setting, the compressor is not used and the control goes into emergency heat mode, staging on EH1 and EH2 to provide heating.
On = normal. Off = Boilerless operation.
1.8 Boilerless changeover temperature: DIP 1.8 provides selection of boilerless changeover temperature setpoint. Note that the LT1 thermistor is sensing refrigerant temperature between the coaxial heat exchanger and the expansion device (TXV). Therefore, the 50°F [10°C] setting is not 50°F [10°C] water, but approximately 60°F [16°C] EWT.
On = 50°F [10°C]. Off = 40°F [16°C].
DIP Package #2 (S2) DIP Package #2 has 8 switches and provides the following setup selections:
2.1 Accessory1 relay personality: DIP 2.1 provides selection of ACC1 relay personality (relay operation/ characteristics). See table 5c for description of functionality.
2.2 - Accessory1 relay personality: DIP 2.2 provides selection of ACC 1 relay personality (relay operation/ characteristics). See table 5c for description of functionality.
2.3 Accessory1 relay personality: DIP 2.3 provides selection of ACC 1 relay options. See table 5c for description of functionality.
2.4 - Accessory2 relay personality: DIP 2.4 provides selection of ACC 2 relay personality (relay operation/ characteristics). See table5c for description of functionality.
2.5 Accessory2 relay personality: DIP 2.5 provides selection of ACC 2 relay personality (relay operation/ characteristics). See table 5c for description of functionality.
2.6 Accessory2 relay personality: DIP 2.6 provides selection of ACC 2 relay options. See table 5c for description of functionality.
Table 7c: Accessory DIP Switch Settings
DIP 2.1
DIP 2.2
DIP 2.3
On On On
Off On On
On
On
Off
Off
On
Off
On
Off
Off
Off On Off
DIP 2.4
DIP 2.5
DIP 2.6
On On On
Off
On
On
On
Off
On
On
On
Off
All other DIP combinations are invalid
ACC1 Relay Option
Cycle with fan
Digital NSB
Water Valve - slow opening
OAD
Reheat Option - Humidistat
Reheat Option - Dehumidistat
ACC2 Relay Option
Cycle with compressor
Digital NSB
Water Valve - slow opening
OAD
24
Heat Controller HRC SeRieS Installation, Operation, Maintenance
Safety Features - CXM/DXM Controls
Safety Features – CXM/DXM Control - 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 (DXM board) or by going into test mode (CXM board). Note: LT1/LT2 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. If DXM is configured for heat pump thermostat type (DIP 1.3), emergency heat will become active if O/
W2 is energized.
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 120 seconds of a compressor run cycle.
25
Low pressure lockout code = 3
Water coil low temperature (LT1): The LT1 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 LT1 fault.
The LT1 input is bypassed for the initial 120 seconds of a compressor run cycle. LT1 is set at the factory for one try.
Therefore, the control will go into lockout mode once the
LT1 fault has occurred.
LT1 lockout code = 4
Air coil low temperature (LT2): The LT2 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 LT2 fault.
The LT2 input is bypassed for the initial 60 seconds of a compressor run cycle. LT2 is set at the factory for one try.
Therefore, the control will go into lockout mode once the
LT2 fault has occurred.
LT2 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 self-resetting safety. If the voltage comes back within range for at least 0.5 seconds, normal operation is restored. This is not considered a fault or lockout. If the CXM/DXM 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,
LT2 is greater than 125°F [52°C] for 30 continuous seconds, or: b. In cooling mode with compressor energized, LT1 is greater than 125°F [52°C] for 30 continuous seconds, or: c. In cooling mode with compressor energized,
LT2 is less than 40°F [4.5°C] for 30 continuous seconds.
Installation, Operation, Maintenance HRC SeRieS Heat Controller
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 LT1/LT2 thermistors: During test mode, the control monitors to see if the LT1 and LT2 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
LT1 sensor is colder than the LT2 sensor, or: b. The compressor is on in the heating mode and the LT2 sensor is colder than the LT1 sensor.
Swapped LT1/LT2 thermistor code = 9.
ESD (DXM only): The ESD (Emergency Shut Down) mode can be enabled from an external common signal to terminal ESD to shut down the unit. The green status light will flash code 3 when the unit is in ESD mode.
ESD mode = code 3 (green “status” LED)
CXM/DXM 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.
CXM/DXM 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).
The green status LED and red fault LED on the DXM board advise the technician of the current status of the
DXM control. The status LED will indicate the current mode that the DXM control is in. The fault LED will
ALWAYS flash a code representing the LAST fault in memory. If there is no fault in memory, the fault LED will flash Code 1. The yellow test LED will turn on when in test mode. CAUTION: Do not restart units without inspection and remedy of faulting condition. Damage may occur.
26
Heat Controller HRC SeRieS Installation, Operation, Maintenance
Unit Commissioning and 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.
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 indicates the maximum and minimum ranges of the unit. Operation and performance is primarily dependent upon return air temperature, airflow, water temperature, water flow rate and ambient air temperature. This water to air 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.
Table 9: Water Temperature Change Through Heat
Exchanger
The commissioning table indicates air and water
Table 8: Building Commissioning
For more specific unit performance reference the product catalog, the submittal data sheets or contact your supplier for assistance.
This is used in the TRW IOM-option for open loop is deleted
BUILDING COMMISSIONING
ALL HRC MODELS
AMBIENT MIN - MAX DB
RETURN AIR MIN DB/WB
RETURN AIR MAX DB/WB
STANDARD UNIT ENTERING
WATER MIN* - MAX
EXTENDED RANGE UNIT** EN-
TERING WATER MIN* - MAX
Cooling ° F [ ° C] Heating ° F [ ° C]
45-110 [7-43] 40-85 [4.5-29]
60/45 [16/7] 40 [4.5]
110/83 [43/28] 80 [27]
40-120 [4.5-49]
30-120 [-1-49]
60-90 [16-43]
20-90 [-6.7-32]
*- Requires optional insulation package when operating below the dew point
**- Requires antifreeze, optional insulation package and jumper clipped.
Table 8A: Unit Operating Limits
UNIT OPERATING LIMITS
All HRC Models
Cooling ° F [ ° C] Heating ° F [ ° C]
50-100 [10-38] 50-85 [10-29] AMBIENT MIN - MAX DB
RETURN AIR MIN DB/WB
RETURN AIR MAX DB/WB
65/60 [18/15.5]
95/75 [35/24]
50 [10]
80 [27]
STANDARD UNIT ENTERING
WATER MIN* - MAX
EXTENDED RANGE UNIT** EN-
TERING WATER MIN* - MAX
50-120 [10-49]
30-120 [-1-49]
60-90 [16-43]
20-90 [-6.7-32]
*- Requires optional insulation package when operating below the dew point
**- Requires antifreeze, optional insulation package and jumper clipped.
27
Installation, Operation, Maintenance HRC SeRieS Heat Controller
Piping System Cleaning and Flushing
Piping System Cleaning and Flushing - Cleaning and flushing 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. Ensure that 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 water. DO
NOT allow system to overflow. Bleed all air from the system. Pressurize and check the system for leaks and repair as appropriate.
4. Verify that all strainers are in place (Heat Controller recommends a strainer with a #20 stainless steel wire mesh). Start the pumps, and systematically check each vent to ensure that all air is bled from the system.
5. Verify that make-up water is available. Adjust make-up water as required 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 86°F [30°C]. Open 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 approved cleaning agent). Reset the boiler to raise the loop temperature to 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 the 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 in the range of pH 6.0 - 8.5 (see table
3). Add chemicals, as appropriate to maintain neutral pH 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!
�
CAUTION! To avoid possible damage to a plastic (PVC) piping system, do not allow temperatures to exceed 110ºF (43ºC).
Note: The manufacturer 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. The manufacturer 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.
DO NOT use “Stop Leak” or similar chemical agent in this system. Addition of chemicals of this type to the loop water will foul the heat exchanger and inhibit unit operation.
28
Heat Controller HRC SeRieS Installation, Operation, Maintenance
Unit and System Checkout Procedure
WARNING! Polyolester Oil, commonly known as POE oil, is a synthetic oil used in many refrigeration systems including those with HFC-410A refrigerant. POE oil, if it ever comes in contact with PVC or CPVC piping, may cause failure of the PVC/CPVC. PVC/CPVC piping should never be used as supply or return water piping with water source heat pump products containing HFC-410A as system failures and property damage may result.
BEFORE POWERING SYSTEM, please check the following:
� WARNING!
�
UNIT CHECKOUT
� Balancing/shutoff valves: Insure that all isolation valves are open and water control valves are wired.
� Line voltage and wiring: Verify that voltage is within an acceptable range for the unit and wiring and fuses/ breakers are properly sized. Verify that low voltage wiring is complete.
� Unit control transformer: Insure that transformer has the properly selected voltage tap. Commercial 208-
230V units are factory wired for 208V operation unless specified otherwise.
� Entering water and air: Insure that entering water and air temperatures are within operating limits of Table 8.
� Low water temperature cutout: Verify that low water temperature cut-out on the CXM/DXM control is properly set.
� Unit fan: Manually rotate fan to verify free rotation and insure that blower wheel is secured to the motor shaft.
Be sure to remove any shipping supports if needed.
DO NOT oil motors upon start-up. Fan motors are pre-oiled at the factory. Check unit fan speed selection and compare to design requirements.
� Condensate line: Verify that condensate line is open and properly pitched toward drain.
� Water flow balancing: Record inlet and outlet water temperatures for each heat pump upon startup. This check can eliminate nuisance trip outs and high velocity water flow that could erode heat exchangers.
� Unit air coil and filters: Insure that filter is clean and accessible. Clean air coil of all manufacturing oils.
� Unit controls: Verify that CXM or DXM field selection options are properly set.
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 hoses are connected end to end when flushing to insure that debris bypasses the unit heat exchanger, water valves and other components. Water used in the system must be potable quality initially and clean of dirt, piping slag, and strong chemical cleaning agents. Verify that all air is purged from the system. Air in the system can cause poor operation or system corrosion.
� Cooling tower/boiler: Check equipment for proper set points and operation.
� Standby pumps: Verify that the standby pump is properly installed and in operating condition.
� System controls: Verify that system controls function and operate in the proper sequence.
� Low water temperature cutout: Verify that low water temperature cut-out controls are provided for the outdoor portion of the loop. Otherwise, operating problems may occur.
� System control center: Verify that the control center and alarm panel have appropriate set points and are operating as designed.
� Miscellaneous: Note any questionable aspects of the installation.
� CAUTION!
�
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.
� CAUTION!
�
CAUTION! To avoid equipment damage, DO NOT leave system filled in a building without heat during the winter unless antifreeze is added to the water loop. Heat exchangers never fully drain by themselves and will freeze unless winterized with antifreeze.
NOTICE! Failure to remove shipping brackets from spring-mounted compressors will cause excessive noise, and could cause component failure due to added vibration.
29
Installation, Operation, Maintenance HRC SeRieS Heat Controller
Unit Start-Up Procedure
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 positions. Turn on the line power to all heat pumps.
4. Room temperature should be within the minimummaximum ranges of table 8. During start-up checks, loop water temperature entering the heat pump should be between 60°F [16°C] and 95°F [35°C].
5. Two factors determine the operating limits of Heat
Controller 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.
b. Check for cool air delivery at the unit grille within a few minutes after the unit has begun to operate.
Note: Units have a five minute time delay in the control circuit that can be eliminated on the CXM/
DXM control board as shown below in Figure 8. See controls description for details.
c. 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.
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.
e. 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].
f. Turn thermostat to “OFF” position. A hissing noise indicates proper functioning of the reversing valve.
6. Allow five (5) minutes between tests for pressure to equalize before beginning heating test.
a. Adjust the thermostat to the lowest setting.
Place the thermostat mode switch in the “HEAT” position.
b. Slowly raise the thermostat to a higher temperature until the compressor activates.
c. Check for warm air delivery within a few minutes after the unit has begun to operate.
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.
e. Check air temperature rise across the air coil when compressor is operating. Air temperature rise should be between 20°F and 30°F [11°C and 17°C]. f. Check for vibration, noise, and water leaks.
7. If unit fails to operate, perform troubleshooting analysis (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.
Note: If performance during any mode appears abnormal, refer to the CXM/DXM section or troubleshooting section of this manual. To obtain maximum performance, the air coil should be cleaned before start-up. A 10% solution of dishwasher detergent and water is recommended.
� WARNING �
WARNING! When the disconnect switch is closed, high voltage is present in some areas of the electrical panel.
Exercise caution when working with energized equipment.
� CAUTION!
�
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.
Figure 8: Test Mode Pins
LT1
LT2
Short test pins together to enter
Test Mode and speed-up timing and delays for 20 minutes.
LT1
LT1
LT2
LT2
30
Heat Controller HRC SeRieS Installation, Operation, Maintenance
Unit Operating Conditions
NOTE: Table 10 includes the following notes:
• Airflow is at nominal (rated) conditions;
• Entering air is based upon 70°F [21°C] DB in heating and 80/67°F [27/19°C] in cooling;
• Subcooling is based upon head pressure at compressor service port;
• Cooling air and water values can vary greatly with changes in humidity level.
Table: 10 HRC Series Typical Operating Pressures and Temperatures (60 Hz I-P Units)
HRC09
Entering
Water
Temp °F
Water
Flow
GPM/
Ton
30
1.4
2
2.75
50
70
90
110
1.4
2
2.75
1.4
2
2.75
1.4
2
2.75
1.4
2
2.75
Suction
Pressure
PSIG
Full Load Cooling - without HWG Active
Discharge
Pressure
PSIG
Superheat
Subcooling
Water
Temp
Drop °F
126-136
126-136
126-136
132-142
132-142
132-142
138-148
138-148
137-147
142-152
142-152
142-152
150-160
150-160
150-160
161-181
146-166
131-151
215-235
200-220
185-205
278-298
263-283
248-268
365-385
351-371
337-357
439-459
439-459
439-459
17-22
17-22
17-22
10-15
10-15
10-15
8-13
8-13
8-13
8-13
8-13
8-13
7-12
7-12
7-12
8-13
7-12
6-11
8-13
7-12
6-11
9-14
8-13
7-12
9-14
8-13
7-12
9-14
8-13
7-12
19.8-21.8
14.9-16.9
9.9-11.9
18.8-20.8
14.4-16.1
9.4-11.4
17.7-19.7
13.1-15.1
8.5-10.5
16-18
12-14
8-10
14.2-16.2
10.6-12.6
6.9-8.9
Air Temp
Rise °F
DB
19-25
19-25
19-25
18-24
18-24
18-24
17-23
17-23
17-23
21-27
21-27
21-27
20-26
20-26
20-26
Suction
Pressure
PSIG
Full Load Heating - without HWG Active
Discharge
Pressure
PSIG
Superheat
Subcooling
Water
Temp
Drop °F
74-84
77-87
79-89
104-114
106-116
108-118
127-137
132-142
138-148
164-174
165-175
167-177
278-298
280-300
283-303
309-329
312-332
315-335
332-352
340-360
341-367
372-392
375-395
379-399
10-15
11-16
13-18
17-22
18-23
19-24
6-11
6-11
6-11
8-12
8-12
8-12
10-15
10-15
10-15
13-18
13-18
13-18
4-9
4-9
3-8
7-12
7-12
7-12
6.1-8.1
4.5-6.5
2.8-4.8
9.6-11.6
7-9
4.5-6.5
12-14
9-10
6.1-8.1
14.5-16.5
11.2-13.2
7.9-9.9
Air
Temp
Rise °F
DB
18-24
18-24
19-25
24-30
24-30
25-31
29-35
29-35
30-36
35-41
35-41
36-42
HRC12
Entering
Water
Temp °F
Water
Flow
GPM/
Ton
30
1.75
2.6
3.5
50
70
90
110
1.75
2.6
3.5
1.75
2.6
3.5
1.75
2.6
3.5
1.75
2.6
3.5
Suction
Pressure
PSIG
Full Load Cooling - without HWG Active
Discharge
Pressure
PSIG
Superheat
Subcooling
Water
Temp
Drop °F
Air Temp
Rise °F
DB
Suction
Pressure
PSIG
Full Load Heating - without HWG Active
Discharge
Pressure
PSIG
Superheat
Subcooling
Water
Temp
Drop °F
98-108
98-108
99-109
118-128
118-128
118-128
132-142
132-142
132-142
138-148
138-148
138-148
145-155
145-155
145-155
140-160
135-155
127-148
215-235
200-220
185-205
300-320
263-282
245-265
366-386
353-373
340-360
453-473
442-462
431-451
11-16
11-16
12-17
9-14
9-14
9-14
9-14
9-14
9-14
36-41
36-41
36-41
22-27
22-27
22-27
12-17
10-15
7-12
11-16
9-14
6-11
9-14
7-12
5-10
14-19
12-17
10-15
14-19
12-17
10-15
17.1-19.1
12.5-14.5
7.9-9.9
18.1-20.1
13.1-15.1
8.1-10.1
17-19
12.6-14.6
8.2-10.2
15.8-17.8
14.9-16.9
14-16
14.7-16.7
10.8-12.8
6.8-8.8
19-25
19-25
19-25
18-24
18-24
18-24
16-22
16-22
17-23
19-25
19-25
19-25
20-26
20-26
19-25
72-82
85-95
78-88
100-110
98-108
95-105
115-125
112-122
110-120
122-132
123-133
124-134
301-321
304-324
308-328
337-357
334-354
332-352
361-381
360-380
356-376
376-396
378-398
380-400
19-24
20-25
21-26
34-39
36-41
38-43
9-14
9-14
9-14
10-15
10-15
11-16
18-23
18-23
18-23
22-27
22-27
23-28
12-17
12-17
12-17
15-20
15-20
15-20
6.5-8.5
4.7-6.7
2.9-4.9
9.5-11.5
6.6-8.6
3.8-5.8
11.1-13.1
8-10
4.8-6.8
12.1-14.1
9-11
5.8-7.8
Air
Temp
Rise °F
DB
21-27
21-27
22-28
26-32
26-32
26-32
29-35
29-35
29-35
32-38
32-38
32-38
31
42
C L I M AT E M A S T E R W AT E R - S O U R C E H E AT P U M P S
Installation, Operation, Maintenance HRC SeRieS Heat Controller
C o n s o l e s
R e v. : 1 2 D e c , 2 0 0 8 B
Unit Operating Conditions
Unit Operating Conditions
Entering
Water
Temp °F
30
50
70
90
110
2.1
3.15
4.2
2.1
3.15
4.2
2.1
3.15
4.2
Water
Flow
GPM/ton
2.1
3.15
4.2
2.1
3.15
4.2
Suction
Pressure
PSIG
Full Load Cooling - without HWG active
Discharge
Pressure
PSIG
Superheat
Subcooling
Water
Temp Drop
°F
Air Temp
Rise °F DB
98-108
98-108
99-109
118-128
118-128
118-128
132-142
132-142
132-142
138-148
138-148
138-148
145-155
145-155
145-155
140-160
135-155
127-148
215-235
200-220
185-205
300-320
263-282
245-265
366-386
353-373
340-360
453-473
442-462
431-451
36-41
36-41
36-41
22-27
22-27
22-27
11-16
11-16
12-17
9-14
9-14
9-14
9-14
9-14
9-14
14-19
12-17
10-15
14-19
12-17
10-15
12-17
10-15
7-12
11-16
9-14
6-11
9-14
7-12
5-10
17.1-19.1
12.5-14.5
7.9-9.9
18.1-20.1
13.1-15.1
8.1-10.1
17-19
12.6-14.6
8.2-10.2
15.8-17.8
14.9-16.9
14-16
14.7-16.7
10.8-12.8
6.8-8.8
19-25
19-25
19-25
20-26
20-26
19-25
19-25
19-25
19-25
18-24
18-24
18-24
16-22
16-22
17-23
Suction
Pressure
PSIG
Full Load Heating - without HWG active
Discharge
Pressure
PSIG
Superheat
Subcooling
Water
Temp Drop
°F
Air Temp
Rise °F DB
74-84
77-87
79-89
104-114
106-116
108-118
127-137
132-142
138-148
164-174
165-175
167-177
278-298
280-300
283-303
309-329
312-332
315-335
332-352
340-360
347-367
372-392
375-395
379-399
10-15
11-16
13-18
17-22
18-23
19-24
6-11
6-11
6-11
8-12
8-12
8-12
10-15
10-15
10-15
13-18
13-18
13-18
4-9
4-9
3-8
7-12
7-12
7-12
6.1-8.1
4.5-6.5
2.8-4.8
9.6-11.6
7-9
4.5-6.5
12-14
9-10
6.1-8.1
14.5-16.5
11.2-13.2
7.9-9.9
18-24
18-24
19-25
24-30
24-30
25-31
29-35
29-35
30-36
35-41
35-41
36-42
Entering
Water
Temp °F
30
50
70
90
110
Water
Flow
GPM/ton
2.5
3.75
5
2.5
3.75
5
2.5
3.75
5
2.5
3.75
5
2.5
3.75
5
Suction
Pressure
PSIG
Full Load Cooling - without HWG active
Discharge
Pressure
PSIG
Superheat
Subcooling
Water
Temp Drop
°F
Air Temp
Rise °F DB
98-108
98-108
99-109
118-128
118-128
118-128
132-142
132-142
132-142
138-148
138-148
138-148
145-155
145-155
145-155
140-160
135-155
127-148
215-235
200-220
185-205
300-320
263-282
245-265
366-386
353-373
340-360
453-473
442-462
431-451
36-41
36-41
36-41
22-27
22-27
22-27
11-16
11-16
12-17
9-14
9-14
9-14
9-14
9-14
9-14
14-19
12-17
10-15
14-19
12-17
10-15
12-17
10-15
7-12
11-16
9-14
6-11
9-14
7-12
5-10
17.1-19.1
12.5-14.5
7.9-9.9
18.1-20.1
13.1-15.1
8.1-10.1
17-19
12.6-14.6
8.2-10.2
15.8-17.8
14.9-16.9
14-16
14.7-16.7
10.8-12.8
6.8-8.8
19-25
19-25
19-25
20-26
20-26
19-25
19-25
19-25
19-25
18-24
18-24
18-24
16-22
16-22
17-23
Suction
Pressure
PSIG
Full Load Heating - without HWG active
Discharge
Pressure
PSIG
Superheat
Subcooling
Water
Temp Drop
°F
Air Temp
Rise °F DB
74-84
77-87
79-89
104-114
106-116
108-118
127-137
132-142
138-148
164-174
165-175
167-177
278-298
280-300
283-303
309-329
312-332
315-335
332-352
340-360
347-367
372-392
375-395
379-399
6-11
6-11
6-11
8-12
8-12
8-12
10-15
11-16
13-18
17-22
18-23
19-24
4-9
4-9
3-8
7-12
7-12
7-12
10-15
10-15
10-15
13-18
13-18
13-18
6.1-8.1
4.5-6.5
2.8-4.8
9.6-11.6
7-9
4.5-6.5
12-14
9-10
6.1-8.1
14.5-16.5
11.2-13.2
7.9-9.9
18-24
18-24
19-25
24-30
24-30
25-31
29-35
29-35
30-36
35-41
35-41
36-42
1.1
1.6
1.5
2.3
3
1.9
2.8
1.6
2.6
2.1
4.5
6.8
1.5
3
Pressure Drop, PSI
50°F
1.2
2.2
1.0
2.0
1.8
3.8
5.8
1
2.3
1.5
3.5
4.9
0.9
2
0.9
1.9
1.3
3
4.5
0.8
1.7
PD Added for
Motorized Water Valve
0.3
0.6
0.3
0.6
0.5
1.2
2.2
1.2
0.7
1.7
C l i m a t e M a s t e r Wa t e r- S o u r c e H e a t i n g a n d C o o l i n g S y s t e m s
32
Heat Controller HRC SeRieS Installation, Operation, Maintenance
Start-Up Log Sheet
Installer:
Complete unit and system checkout and follow unit start-up procedures in the IOM. Use this form to record unit information, temperatures and pressures during start-up. Keep this form for future reference.
Job Name:
Model Number:
Unit Location in Building:
Date: Sales Order No:
Street Address:
Serial Number:
In order to minimize troubleshooting and costly system failures, complete the following checks and data entries before the system is put into full operation.
Temperatures: F or C
Pressures: PSIG or kPa
Return-Air Temperature
Supply-Air Temperature
Temperature Differential
Entering Fluid Temperature
Leaving Fluid Temperature
Temperature Differential
Water Coil Heat Exchanger
(Water Pressure IN)
Cooling Mode
DB
DB
Water Coil Heat Exchanger
(Water Pressure OUT)
Pressure Differential
Flow Rate GPM (l/s)
Compressor
Amps
Volts
Discharge Line Temperature
Motor
Amps
Volts
Allow unit to run 15 minutes in each mode before taking data.
Do not connect gauge lines
Antifreeze: _____ %
Type __________________
Heating Mode
WB
WB
DB
DB
33
Installation, Operation, Maintenance HRC SeRieS Heat Controller
Preventive Maintenance
Water 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 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].
Condensate Drain 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.
Compressor Conduct annual amperage checks to insure that amp draw is no more than 10% greater than indicated on the serial plate data.
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 water coil can be checked regularly. Dirty installations are typically the result of deterioration of iron or galvanized piping or components in the system. Open cooling towers requiring heavy chemical treatment and mineral buildup through water use can also contribute to higher maintenance. Should periodic coil cleaning be necessary, use standard coil cleaning procedures, which are compatible with both the heat exchanger material and copper water lines. Generally, the more water flowing through the unit, the less chance for scaling. However, flow rates over 3 gpm per ton (3.9 l/m per kW) can produce water (or debris) velocities that can erode the heat exchanger wall and ultimately produce leaks.
Filters necessary. Units should never be operated without a filter.
Filters must be clean to obtain maximum performance. Filters should be inspected every month under normal operating conditions and be replaced when
Fan Motors - 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 insure amp draw is no more than 10% greater than indicated on serial plate data.
Air Coil - The air coil must be cleaned to obtain maximum performance. Check once a year under normal operating conditions and, if dirty, brush or vacuum clean.
Care must be taken not to damage the aluminum fins while cleaning. CAUTION: Fin edges are sharp.
Cabinet Do not allow water to stay in contact with the cabinet for long periods of time to prevent corrosion of the cabinet sheet metal. The cabinet can be cleaned using a mild detergent.
Refrigerant System To maintain sealed circuit integrity, do not install service gauges unless unit operation appears abnormal. Reference the operating charts for pressures and temperatures. Verify that air and water flow rates are at proper levels before servicing the refrigerant circuit.
Washable, high efficiency, electrostatic filters, when dirty, can exhibit a very high pressure drop for the fan motor and reduce air flow, resulting in poor performance. It is especially important to provide consistent washing of these filters (in the opposite direction of the normal air flow) once per month using a high pressure wash similar to those found at self-serve car washes.
34
Heat Controller HRC SeRieS Installation, Operation, Maintenance
Functional Troubleshooting
Fault
Main power problems
HP Fault
Code 2
High Pressure
LP/LOC Fault
Code 3
Low Pressure / Loss of Charge
LT1 Fault
Code 4
Water coil low temperature limit
LT2 Fault
Code 5
Air coil low temperature limit
Condensate Fault
Code 6
Over/Under
Voltage Code 7
(Auto resetting)
Unit Performance Sentinel
Code 8
Swapped Thermistor
Code 9
No Fault Code Shown
Unit Short Cycles
Only Fan Runs
Only Compressor Runs
Unit Doesn’t Operate in Cooling
Htg Clg Possible Cause
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X x
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X Green Status LED Off
X Reduced or no water flow in cooling
X Water Temperature out of range in cooling
X
Reduced or no air flow in heating
Air temperature out of range in heating
X Overcharged with refrigerant
X Bad HP Switch
X Insufficient charge
Compressor pump down at start-up
Reduced or no water flow in heating
Inadequate antifreeze level
Improper temperature limit setting (30°F vs
10°F [-1°C vs -2°C])
Water Temperature out of range
X Bad thermistor
X Reduced or no air flow in cooling
X Air Temperature out of range
X
Improper temperature limit setting (30°F vs
10°F [-1°C vs -12°C])
X Bad thermistor
X Blocked drain
X Improper trap
X Poor drainage
X Moisture on sensor
X Plugged air filter
X Restricted Return Air Flow
Under Voltage
X Over Voltage
X
Heating mode LT2>125°F [52°C]
Cooling Mode LT1>125°F [52°C] OR LT2<
40ºF [4ºC])
X LT1 and LT2 swapped
X No compressor operation
X Compressor overload
X Control board
X Dirty air filter
X Unit in "test mode"
X Unit selection
X Compressor overload
X Thermostat position
X Unit locked out
X Compressor Overload
X Thermostat wiring
X Thermostat wiring
X
Fan motor relay
X
X Fan motor
X Thermostat wiring
X Reversing valve
X Thermostat setup
X Thermostat wiring
X Thermostat wiring
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 CXM/DXM'
Check primary/secondary voltage on transformer.
Check pump operation or valve operation/setting.
Check water flow adjust to proper flow rate.
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.
Too high of external static. Check static vs blower table.
Bring return air temp within design parameters.
Check superheat/subcooling vs typical operating condition table.
Check switch continuity and operation. Replace.
Check for refrigerant leaks
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.
Clip JW3 jumper for antifreeze (10°F [-12°C]) use.
Bring water temp within design parameters.
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.
Too much cold vent air? Bring entering air temp within design parameters.
Normal airside applications will require 30°F [-1°C] only.
Check temp and impedance correlation per chart.
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.
Poor venting. Check vent location.
Check for moisture shorting to air coil.
Replace air filter.
Find and eliminate restriction. Increase return duct and/or grille size.
Check power supply and 24VAC voltage before and during operation.
Check power supply wire size.
Check compressor starting. Need hard start kit?
Check 24VAC and unit transformer tap for correct power supply voltage.
Check power supply voltage and 24VAC before and during operation.
Check 24VAC and unit transformer tap for correct power supply voltage.
Check for poor air flow or overcharged unit.
Check for poor water flow, or air flow.
Reverse position of thermistors
See "Only Fan Operates".
Check and replace if necessary.
Reset power and check operation.
Check and clean air filter.
Reset power or wait 20 minutes for auto exit.
Unit may be oversized for space. Check sizing for actual load of space.
Check and replace if necessary
Ensure thermostat set for heating or cooling operation.
Check for lockout codes. Reset power.
Check compressor overload. Replace if necessary.
Check thermostat wiring at heat pump. Jumper Y and R for compressor operation in test mode.
Check G wiring at heat pump. Jumper G and R for fan operation
Jumper G and R for fan operation. Check for Line voltage across BR contacts.
Check fan power enable relay operation (if present).
Check for line voltage at motor. Check capacitor.
Check thermostat wiring at heat pump. Jumper Y and R for compressor operation in test mode
Set for cooling demand and check 24VAC on RV coil and at CXM/DXM board.
If RV is stuck, run high pressure up by reducing water flow and while operating engage and disengage RV coil voltage to push valve.
Check for ‘O’ RV setup not ‘B’.
Check O wiring at heat pump. Jumper O and R for RV coil ‘click’.
Put thermostat in cooling mode. Check 24 VAC on O (check between C and
O); check for 24 VAC on W (check between W and C). There should be voltage on O, but not on W. If voltage is present on W, thermostat may be bad or wired incorrectly.
35
Installation, Operation, Maintenance HRC SeRieS Heat Controller
Performance Troubleshooting
Performance Troubleshooting Htg Clg Possible Cause
X X Dirty filter
X Reduced or no air flow in heating
Insufficient capacity/ Not cooling or heating
X Reduced or no air flow in cooling
X
X
X
X
X
X
X
X Leaky duct work
X Low refrigerant charge
X Restricted metering device
X Defective reversing valve
X Thermostat improperly located
X Unit undersized
X Scaling in water heat exchanger
X Inlet water too hot or too cold
X Reduced or no air flow in heating
High Head Pressure
Low Suction Pressure
X
X
X
X
X Reduced or no water flow in cooling
X Inlet water too hot
Air temperature out of range in heating
X Scaling in water heat exchanger
X Unit overcharged
X Non-condensables in system
X Restricted metering device.
X Reduced water flow in heating.
X Water temperature out of range.
X Reduced air flow in cooling.
Low Discharge Air Temperature in Heating
X
X
X
High humidity
X Air temperature out of range
X Insufficient charge
Too high of air flow
Poor performance
X Too high of air flow
X Unit oversized
Solution
Replace or clean.
Check for dirty air filter and clean or replace.
Check fan motor operation and airflow restrictions.
Too high of external static. Check static vs. blower table.
Check for dirty air filter and clean or replace.
Check fan motor operation and airflow restrictions.
Too high of external static. Check static vs. blower table.
Check supply and return air temperatures at the unit and at distant duct registers if significantly different, duct leaks are present.
Check superheat and subcooling per chart.
Check superheat and subcooling per chart. Replace.
Perform RV touch test.
Check location and for air drafts behind stat.
Recheck loads & sizing. Check sensible clg. load and heat pump capacity.
Perform scaling check and clean if necessary.
Check load, loop sizing, loop backfill, ground moisture.
Check for dirty air filter and clean or replace.
Check fan motor operation and air flow restrictions.
Too high of external static. Check static vs. blower table.
Check pump operation or valve operation/setting.
Check water flow. Adjust to proper flow rate.
Check load, loop sizing, loop backfill, ground moisture.
Bring return air temperature within design parameters.
Perform scaling check and clean if necessary.
Check superheat and subcooling. Re-weigh in charge.
Vacuum system and re-weigh in charge.
Check superheat and subcooling per chart. Replace.
Check pump operation or water valve operation/setting.
Plugged strainer or filter. Clean or replace.
Check water flow. Adjust to proper flow rate.
Bring water temperature within design parameters.
Check for dirty air filter and clean or replace.
Check fan motor operation and air flow restrictions.
Too high of external static. Check static vs. blower table.
Too much cold vent air? Bring entering air temperature within design parameters.
Check for refrigerant leaks.
Check fan motor speed selection and air flow chart.
See ‘Insufficient Capacity’
Check fan motor speed selection and airflow chart.
Recheck loads & sizing. Check sensible clg load and heat pump capacity.
36
Performance Troubleshooting Htg Clg Possible Cause
X X Dirty filter
X Reduced or no air flow in heating
Insufficient capacity/ Not cooling or heating
X Reduced or no air flow in cooling
X
X
X
X
X
X
X
X Leaky duct work
X Low refrigerant charge
X Restricted metering device
X Defective reversing valve
X Thermostat improperly located
X Unit undersized
X Scaling in water heat exchanger
X Inlet water too hot or too cold
X Reduced or no air flow in heating
High Head Pressure
Low Suction Pressure
X
X
X
X
X Reduced or no water flow in cooling
X Inlet water too hot
Air temperature out of range in heating
X Scaling in water heat exchanger
X Unit overcharged
X Non-condensables in system
X Restricted metering device.
X Reduced water flow in heating.
X Water temperature out of range.
X Reduced air flow in cooling.
Low Discharge Air Temperature in Heating
X
X
X
High humidity
X Air temperature out of range
X Insufficient charge
Too high of air flow
Poor performance
X Too high of air flow
X Unit oversized
Solution
Replace or clean.
Check for dirty air filter and clean or replace.
Check fan motor operation and airflow restrictions.
Too high of external static. Check static vs. blower table.
Check for dirty air filter and clean or replace.
Check fan motor operation and airflow restrictions.
Too high of external static. Check static vs. blower table.
Check supply and return air temperatures at the unit and at distant duct registers if significantly different, duct leaks are present.
Check superheat and subcooling per chart.
Check superheat and subcooling per chart. Replace.
Perform RV touch test.
Check location and for air drafts behind stat.
Recheck loads & sizing. Check sensible clg. load and heat pump capacity.
Perform scaling check and clean if necessary.
Check load, loop sizing, loop backfill, ground moisture.
Check for dirty air filter and clean or replace.
Check fan motor operation and air flow restrictions.
Too high of external static. Check static vs. blower table.
Check pump operation or valve operation/setting.
Check water flow. Adjust to proper flow rate.
Check load, loop sizing, loop backfill, ground moisture.
Bring return air temperature within design parameters.
Perform scaling check and clean if necessary.
Check superheat and subcooling. Re-weigh in charge.
Vacuum system and re-weigh in charge.
Check superheat and subcooling per chart. Replace.
Check pump operation or water valve operation/setting.
Plugged strainer or filter. Clean or replace.
Check water flow. Adjust to proper flow rate.
Bring water temperature within design parameters.
Check for dirty air filter and clean or replace.
Check fan motor operation and air flow restrictions.
Too high of external static. Check static vs. blower table.
Too much cold vent air? Bring entering air temperature within design parameters.
Check for refrigerant leaks.
Check fan motor speed selection and air flow chart.
See ‘Insufficient Capacity’
Check fan motor speed selection and airflow chart.
Recheck loads & sizing. Check sensible clg load and heat pump capacity.
Heat Controller HRC SeRieS Installation, Operation, Maintenance
C u s t o m e :r
Model #:
Complaint:
S e ir a l # :
Troubleshooting Form
Water-to-Air 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 & % :
HEATING POSITION COOLING POSITION
OPERATING MODE: HEATING COOLING
10
AIR
COIL
REFRIG FLOW - HEATING
11
CONDENSER (HEATING)
EVAPORATOR (COOLING)
REFRIG FLOW - COOLING
REVERSING
VALVE
CONDENSER (COOLING)
EVAPORATOR (HEATING)
5 LT2:
HEATING
LIQUID
LINE
EXPANSION
VALVE
FILTER
DRIER
COAX
5 LT1:
COOLING
LIQUID
LINE
6
8
Source
7
9
D e s c ir p it o n
Voltage
Compressor Amps
1
2
2a
2b
3
4
4a
4b
Suction Temp
Suction Press
Saturation Temp
Superheat
Discharge Temp
Discharge Press
Saturation Temp
Subcooling
5 Liquid Line Temp
6 Source Water In Tmp
9
9a
9b
10
7 Source Water Out Tmp
8 Source Water In Pres
11
Source Water Out Pres
Press Drop
Flow Rate
Return Air Temp
Supply Air Temp
Heating Cooling
Temp Diff. =
2 1
SUCTION
3
COMPRESSOR
DISCHARGE
4
N o t e s
Heat of Extraction (Absorption) or Heat of Rejection:
HE or HR =
Fluid Factor: (for Btuh)
500 (Water); 485 (Antifreeze)
Fluid Factor: (for kW)
4.18 (Water); 4.05 (Antifreeze)
Flow Rate x Temp. Diff x Fluid Factor
Superheat = Suction temperature - suction saturation temp. = _________________ (deg F)
Subcooling = Discharge saturation temp. - liquid line temp. = _________________ (deg F)
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.
37
Installation, Operation, Maintenance HRC SeRieS Heat Controller
38
Heat Controller HRC SeRieS Installation, Operation, Maintenance
39
Date:
03-2015
Item:
HRC-IOM Design Guide
Revision History
Action: sent to CLM
3/2015
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