Heat Controller HSS Series Guía

Split Products

HSS Series Split System,

11/2to 5 Tons

HTS Series Split System,

Two Stage, 2-5 Tons

Outdoor Split

Geothermal Heat Pumps

Installation, Operation &

Maintenance Instructions

Revision: 23 June, 2008

Model Nomenclature 3

Safety 4

Storage 5

Pre-Installation 5

Equipment Selection 6

Air Coil Match-ups 6-7

Air Handler Selection 8

Installation 9

Water Connections 10-11

Ground Loop Applications 11-13

Open Loop - Ground Water Systems 14-15

Water Quality Standards 16

Refrigeration Installation 17-22

Lineset Information 17

Internal Hot Water Generator 23-24

Hot Water Generator Module 25-26

Electrical - Line Voltage 27-28

Power Wiring 28

Electrical - Low Voltage Wiring 29-31

Low Water Temperature Cutout Selection 31

Water Valve Wiring 31

Thermostat Wiring 31

CXM Controls 32-34

CXM Safety Features 33

Unit Start-Up and Operating Conditions 36

Unit Start-Up

and System Checkout Procedure 37-38

Unit Operating Conditions 39-41

Preventive Maintenance 42

Troubleshooting 43-44

Functional & Performance Troubleshooting 45-46

Refrigerant Circuit Diagram 47

Revision Log 48

Table of Contents

2www.heatcontoller.com

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The Quality Leader in Conditioning Air

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

The Quality Leader in Conditioning Air

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

www.heatcontoller.com

Model Nomenclature: for Indoor Split Series

NOTE: Above model nomenclature is a general reference. Consult individual specication catalogs for detailed information.

Model Nomenclature: for Indoor Split Series

4 5 6 7

HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

4Heat Controller, Inc. Water-Source Heating and Cooling Systems

WARNING! Verify refrigerant type before proceeding.

Units are shipped with R-22 and R-410A refrigerants. The

unit label will indicate which refrigerant is provided. The

EarthPure

Application and Service Manual should be read

and understood before attempting to service refrigerant

circuits with R-410A.

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 prociency requirements.

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!

To avoid equipment damage, DO NOT use

these units as a source of heating or cooling during the

construction process. The mechanical components and

lters will quickly become clogged with construction dirt and

debris, which may cause system damage.

x WARNING! x

x CAUTION! x

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: Notication of installation, operation or

maintenance information, which is important, but which is not

hazard-related.

Safety

The Quality Leader in Conditioning Air

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

www.heatcontoller.com

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. Concealed

damage not discovered during unloading must be reported

to the carrier within 15 days of receipt of shipment. If not led

within 15 days, the freight company can deny the claim without

recourse. Note: It is the responsibility of the purchaser to le

all necessary claims with the carrier. Notify your equipment

supplier of all damage within fteen (15) days of shipment.

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, ttings, 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 congurations are typically installed in a mechanical

room. The installation site chosen should include adequate

service clearance around the unit. Before unit start-up,

read all manuals and become familiar with the unit and its

operation. Thoroughly check the system before operation.

Prepare units for installation as follows:

1. Compare the electrical data on the unit nameplate with

ordering and shipping information to verify that the

correct unit has been shipped.

2. Keep the cabinet covered with the original packaging

until installation is complete and all plastering, painting,

etc. is nished.

3. Verify refrigerant tubing is free of kinks or dents and that

it does not touch other unit components.

4. Inspect all electrical connections. Connections must be

clean and tight at the terminals.

5. Loosen compressor bolts on units equipped with

compressor spring vibration isolation until the compressor

rides freely on the springs. Remove shipping restraints.

REMOVE COMPRESSOR SUPPORT PLATE 1/4”

SHIPPING BOLTS (2 on each side) TO MAXIMIZE

VIBRATION AND SOUND ATTENUATION (R22 indoor

units only).

7. Locate and verify any hot water generator (HWG) or

other accessory kit located in the compressor section.

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

signicantly reduce performance, reliability, and service life.

Always move and store units in an upright position. Tilting

units on their sides may cause equipment damage.

NOTICE! Failure to remove shipping brackets from spring-

mounted compressors will cause excessive noise, and could

cause component failure due to added vibration.

x CAUTION! x

CAUTION! CUT HAZARD - Failure to follow this caution

may result in personal injury. Sheet metal parts may have

sharp edges or burrs. Use care and wear appropriate

protective clothing, safety glasses and gloves when

handling parts and servicing heat pumps.

x CAUTION! x

HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

6Heat Controller, Inc. Water-Source Heating and Cooling Systems

The installation of geothermal heat pump units and all

associated components, parts, and accessories which make

up the installation shall be in accordance with the regulations

of ALL authorities having jurisdiction and MUST conform to

all applicable codes. It is the responsibility of the installing

contractor to determine and comply with ALL applicable

codes and regulations.

General

Proper indoor coil selection is critical to system efficiency.

Using an older-model coil can affect efficiency and may not

provide the customer with rated or advertised EER and COP.

Coil design and technology have dramatically improved

operating efficiency and capacity in the past 20 years.

Homeowners using an older coil are not reaping these cost

savings and comfort benefits. NEVER MATCH AN R-22

INDOOR COIL WITH AN R-410A COMPRESSOR SECTION.

Newer indoor coils have a larger surface area, enhanced fin

design, and grooved tubing. These features provide a larger

area for heat transfer, improving efficiency and expanding

capacity. Typical older coils may only have one-third to one-

half the face area of these redesigned coils.

Equipment Selection

Indoor Coil Selection - HTS GeoMax 2

HCI split system heat pumps are rated in the ARI directory

with a specific indoor coil match. GeoMax 2 (HTS) models

are rated with Carrier/Bryant FV4 or FE4 series variable

speed air handlers as shown in Table 1a. Other brands of

air handlers may attain the same ARI ratings providing that

the specifications meet or exceed those listed in Table 1a

AND Table 1b. An ECM motor and TXV is required. Cap

tubes and fixed orifices are not acceptable. PSC fans may

be used if matched to Table 1b, but will not meet ARI ratings.

If using PSC fan, compressor section must be operated as a

single stage unit (i.e. wired for either 1st stage or 2nd stage).

Without the ability to vary the airflow, supply air temperatures

may not be acceptable if the compressor is allowed to

change stages when used with a PSC fan motor.

Table 1a: GeoMax 2 (HTS) Air Handler Matches for ARI Ratings

Compressor Section 024 036 048 060

Air Handler

Model FV4 003 005 006 006

Refrigerant R-410A

Metering Device TXV (required)

Air Coil

Type

Rows - Fins/in.

Face Area (sq. ft.)

Slope

3 - 14.5

3.46

3 - 14.5

5.93

3 - 14.5

7.42

3 - 14.5

7.42

Cabinet Configuration

Upflow/Downflow/Horizontal (Multipoise)

ECM Settings for

ARI Ratings

(FV4 Fan Coil)

AC/HP size: 036

System Type:

Comfort AC/HP

CFM Adjust: Nom

AC/HP size: 036

System Type:

HP-Effic AC/HP

CFM Adjust: High

AC/HP size: 048

System Type:

Comfort AC/HP

CFM Adjust: High

AC/HP size: 060

System Type:

Comfort AC/HP

CFM Adjust: High

Fan Motor Type - HP ECM - 1/2 ECM - 1/2 ECM - 3/4 ECM - 3/4

The Quality Leader in Conditioning Air

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

www.heatcontoller.com

Table 1b: GeoMax 2 (H

S) Air Handler Characteristics for Brands other than Above Models

Model* Nominal

Tons*

Evaporator

Temp (ºF) CFM Capacity

(MBtuh)**

024 - Part Load 1.5 50 530 19.2 - 22.4

024 - Full Load 2.0 52 880 24.2 - 28.2

036 - Part Load 2.5 51 700 25.2 - 29.2

036 - Full Load 3.0 50 1200 34.5 - 40.1

048 - Part Load 3.5 47 1000 34.3 - 39.9

048 - Full Load 4.0 48 1650 46.3 - 53.8

060 - Full Load 5.0 48 1850 54.5 - 63.3

* Nominal tons are at ARI/ISO 13256-1 GLHP conditions. Two-stage units may be operated in single-stage mode if desired, where smaller

capacity is required. For example, a model 026 may be used as a 1-1/2 ton unit if “locked” into 1st stage operation only. If PSC fan is used,

unit must be “locked” into either 1st or 2nd stage. An ECM fan is required for two-stage operation and for ARI ratings. Size air handler for

“Full Load” if operating in two-stage mode.

**When selecting an air handler based upon the above conditions, choose entering WB temperature of 67ºF. Use evaporator temperature,

CFM and capacity requirements as listed above. The air handler capacity must be at least at the minimum capacity shown in the table in

order for the ARI rating condition to be valid. See Figure 1 for an example selection.

Indoor Coil Selection - For HSS R-22 Units

Geothermal split system heat pumps with R-22 refrigerant are rated in the ARI directory with a “generic” indoor coil match and

PSC fan. Selection of air handlers that attain the published ARI ratings must meet or exceed the specifications listed in Table

2. A TXV is required. Cap tubes and fixed orifices are not

acceptable.

Table 2: R-22 Air Handler Characteristics

Model* Nominal

Tons*

Evaporator

Temp (ºF) CFM Capacity

(MBtuh)**

018 1.5 50 600 18.5 - 21.3

024 2.0 47 800 25.5 - 29.3

030 2.5 49 1000 31.5 - 36.2

036 3.0 48 1200 37.0 - 42.5

042 3.5 45 1400 42.2 - 48.5

048 4.0 46 1600 50.0 - 57.5

060 5.0 45 2000 58.0 - 66.7

* Nominal tons are at ARI/ISO 13256-1 GLHP conditions.

**When selecting an air handler based upon the above conditions, choose entering WB temperature of 67ºF. Use evaporator temperature,

CFM and capacity requirements as listed above. The air handler capacity must be at least at the minimum capacity shown in the table in

order for the ARI rating condition to be valid. See Figure 1 for an example selection.

Equipment Selection

HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

8Heat Controller, Inc. Water-Source Heating and Cooling Systems

Air Handler Selection Example

Figure 1 shows a typical performance table for a heat pump air

handler. Suppose the evaporator temperature required is 50ºF,

the capacity required is 35,000 Btuh and the airow required

is 1,200 CFM. Each evaporator temperature listed in the table

shows three wet bulb temperatures. As recommended in the

table notes above, select the 67ºF WB column. At 1,200 CFM,

the model 003 capacity is 36 MBtuh, which is higher than the

minimum capacity required of 35,000 Btuh. In this example,

model 003 would be the appropriate match.

Figure 1: Selecting Air Handler

Equipment Selection

Utilizing the Existing Air Handler or Coil (R22 units only)

It is recommended that a new coil or air handler be installed

with any geothermal split system compressor section due to the

low initial cost of the additional equipment versus the reliability

and benet of new technology, increased reliability and

warranty. However, if the existing air handler must be used (R22

systems only), the following conditions apply:

• If the existing coil currently uses an orice, the orice must be

removed and replaced with a TXV. If the coil utilizes capillary

tubes, it will not operate properly with the geothermal split

system and should be replaced.

• If life expectancy of indoor coil (and associated components

- fan, cabinet, etc.) is less than 7-10 years, indoor section

should be replaced.

The Quality Leader in Conditioning Air

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

www.heatcontoller.com

Installation

NOTICE! Failure to remove shipping

brackets from spring-mounted compressors

will cause excessive noise, and could cause

component failure due to added vibration.

The installation of water source heat pump units and all

associated components, parts and accessories which make

up the installation shall be in accordance with the regulations

of ALL authorities having jurisdiction and MUST conform to

all applicable codes. It is the responsibility of the installing

contractor to determine and comply with ALL applicable

codes and regulations.

Removing Existing Condensing Unit (Where Applicable)

1. Pump down condensing unit. Close the liquid line service

valve of existing condensing unit and start compressor

to pump refrigerant back into compressor section. Then,

close suction service valve while compressor is still

running to trap refrigerant in outdoor section. Immediately

kill power to the condensing unit.

2. Disconnect power and low voltage and remove old

condensing unit. Cut or unbraze line set from unit.

Remove condensing unit.

3. If condensing unit is not operational or will not pump

down, refrigerant should be recovered using appropriate

equipment.

4. Replace line set, especially if upgrading system from

R-22 to R-410A refrigerant. If line set cannot be replaced,

it must be thoroughly flushed before installing new

compressor section. R-410A compressors use POE

oil instead of mineral oil (R-22 systems). Mineral oil is

not compatible with POE oil, and could cause system

damage if not completely flushed from the line set.

“Indoor” Compressor Section Location

Both “indoor” and “outdoor” versions of the geothermal split

system compressor section are available. “Indoor” version

is not designed for outdoor installation. Locate the unit in

an INDOOR area that allows enough space for service

personnel to perform typical maintenance or repairs without

removing unit. Units are typically installed in a mechanical

room or closet. Never install units in areas subject to freezing

or where humidity levels could cause cabinet condensation

(such as unconditioned spaces subject to 100% outside air).

Consideration should be given to access for easy removal

of service access panels. Provide sufficient room to make

water, electrical, and line set connections.

Any access panel screws that would be difficult to remove

after the unit is installed should be removed prior to setting the

unit. Refer to Figure 2 for an illustration of a typical installation.

Refer to “Physical Dimensions” section for dimensional data.

Conform to the following guidelines when selecting unit

location:

Install the unit on a piece of rubber, neoprene or other

mounting pad material for sound isolation. The pad should

be at least 3/8” [10mm] to 1/2” [13mm] in thickness. Extend

the pad beyond all four edges of the unit.

2. Provide adequate clearance for maintenance and

service. Do not block access panels with piping, conduit

or other materials.

3. Provide access for servicing the compressor and coils

without removing the unit.

4. Provide an unobstructed path to the unit within the closet

or mechanical room. Space should be sufficient to allow

removal of the unit, if necessary.

In limited side access installations, pre-removal of the

control box side mounting screws will allow control box

removal for future servicing (R22 units only).

6. Provide access to water valves and fittings and

screwdriver access to the unit side panels and all

electrical connections.

Air Handler Installation

This manual specifically addresses the compressor section

of the system. Air handler location and installation should be

according to the instructions provided with the air handling

unit.

HEAT CONTROLLER, INC. WATER-SOURCE HEAT PUMPS

Residential Split - 60Hz R22 &R410A

Rev.: 5 June, 2008

10 Heat Controller, Inc. Water-Source Heating and Cooling Systems

Installation

Figure 2: HTS/HSS Installation

External Flow Controller Mounting

The Flow Controller can be mounted beside the unit

as shown in Figure 7. Review the Flow Controller

installation manual for more details.

Gas k et

Swiv e lNut

Stain le ss s te e l

snap ring

Brass Adaptor

Hand Tighten

Only !

Do Not

Overtighten !

Figure 4: Water Connections (Indoor Compressor Section)

Water Connections-Residential (Distributor) Models

Residential models utilize swivel piping ttings for

water connections that are rated for 450 psi (3101 kPa)

operating pressure. The connections have a rubber

gasket seal similar to a garden hose gasket, which when

mated to the ush end of most 1” threaded male pipe

ttings provides a leak-free seal without the need for

thread sealing tape or joint compound. Insure that the

rubber seal is in the swivel connector prior to attempting

any connection (rubber seals are shipped attached to the

swivel connector). DO NOT OVER TIGHTEN or leaks may

occur.

The female locking ring is threaded onto the pipe threads

which holds the male pipe end against the rubber gasket,

and seals the joint. HAND TIGHTEN ONLY! DO NOT

OVERTIGHTEN!

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