Installation, Operation and Maintenace Manual GeoLogix® HTS Series Split System, Two Stage, 2-5 Tons Heat Controller, LLC. • 1900 Wellworth Ave. • Jackson, MI 49203 • (517)787-2100 • www.heatcontroller.
Installation, Operation & Maintenance HTS SERIES SPLIT SYSTEM Heat Controller, LLC Table of Contents Model Nomenclature . . . . . . . . . . . . . . . . . . . . 3 Electrical - Line Voltage . . . . . . . . . . . . . . . . . 23 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Electrical - Low Voltage Wiring . . . . . . . . . . . . 24 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Low Water Temperature Cutout Selection . . . 24 Pre-Installation . . . . . .
HTS SERIES SPLIT SYSTEM Installation, Operation & Maintenance Heat Controller, LLC Model Nomenclature : for Indoor Split Series 1 2 3 4 5 6 7 8 HT S 024 C 1 9 10 D 0 11 12 13 14 1 N N N SERIES HT = Heat Controller Two Stage SUPPLY AIR FLOW & MOTOR CONFIGURATION N = NOT APPLICABLE CONFIGURATION S = SPLIT RETURN AIR FLOW CONFIGURATION UNIT SIZE N = NOT APPLICABLE 024 036 048 060 HEAT EXCHANGER OPTIONS REVISION LEVEL C = Current Revision Effective 7-1-13 Standard Copper Cupro-Nick
Installation, Operation & Maintenance HTS SERIES SPLIT SYSTEM Heat Controller, LLC Safety Safety WARNING! Warnings, cautions and notices appear throughout this manual. Read these items carefully before attempting any installation, service or troubleshooting of the equipment. 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.
Installation, Operation & Maintenance HTS SERIES SPLIT SYSTEM Heat Controller, LLC General Information 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. 6. Locate and verify any hot water generator (HWG) or other accessory kit located in the compressor section.
Installation, Operation & Maintenance HTS SERIES SPLIT SYSTEM Heat Controller, LLC Equipment Selection NOTICE! AHRI matched systems are required for warranty and applicable federal tax credits. Indoor Coil Selection - HTS GeoLogix® HCI split system heat pumps are rated in the AHRI directory with a specific indoor coil match. GeoLogix® (HTS) models are rated with Heat Controller WDG Series air handlers and MWG Series coils as shown in Table 1a.
Installation, Operation & Maintenance HTS SERIES SPLIT SYSTEM Heat Controller, LLC Equipment Selection 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 airflow 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.
Installation, Operation & Maintenance HTS SERIES SPLIT SYSTEM Heat Controller, LLC Installation 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.
Installation, Operation & Maintenance HTS SERIES SPLIT SYSTEM Heat Controller, LLC Installation Figure 2: HTS Installation External Flow Controller Mounting The Flow Controller can be mounted beside the unit as shown in Figure 4. Review the Flow Controller installation manual for more details. The female locking ring is threaded onto the pipe threads which holds the male pipe end against the rubber gasket, and seals the joint.
Installation, Operation & Maintenance HTS SERIES SPLIT SYSTEM Heat Controller, LLC Ground-Loop Heat Pump Applications Earth loop temperatures can range between 25 and 110°F [-4 to 43°C]. Flow rates between 2.25 and 3 gpm per ton [2.41 to 3.23 l/m per kW] of cooling capacity is recommended in these applications. Pressures will be higher in the winter months than during the cooling season. This fluctuation is normal and should be considered when charging the system initially.
HTS SERIES SPLIT SYSTEM Installation, Operation & Maintenance Heat Controller, LLC Ground-Loop Heat Pump Applications Table 2: Approximate Fluid Volume (U.S. gal. [L]) per 100’ of Pipe Figure 4: Loop Connection (Indoor Compressor Section) Fluid Volume (gal [liters] per 100’ [30 meters] Pipe) Pipe Size Volume (gal) [liters] 1” 4.1 [15.3] Copper 1.25” 6.4 [23.8] 2.5” 9.2 [34.3] 1” 3.9 [14.6] 3/4” IPS SDR11 2.8 [10.4] 1” IPS SDR11 4.5 [16.7] Rubber Hose Polyethylene 1.25” IPS SDR11 8.
Installation, Operation & Maintenance HTS SERIES SPLIT SYSTEM Heat Controller, LLC Ground-Water Heat Pump Applications -Compressor Section Only Open Loop - Ground Water Systems (“Indoor” Compressor Section Only) The “outdoor” version of the compressor section may not be used with open loop systems due to potential freezing of water piping. Typical open loop piping is shown in Figure 9. Shut off valves should be included for ease of servicing.
HTS SERIES SPLIT SYSTEM Installation, Operation & Maintenance Heat Controller, LLC Ground-Water Heat Pump Applications To manually open the internal modulating motorized water valve in HTS024 - 048 push down on the handle to unlock it. Then rotate the handle to the open position as shown in Figure 9a. This fully opens the valve for flushing. Once flushing is complete, return the valve handle to its normally closed position. Water Coil Low Temperature Limit Setting For all open loop systems the 30°F [-1.
HTS SERIES SPLIT SYSTEM Installation, Operation & Maintenance Heat Controller, LLC Water Quality Standards Table 4: 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.
HTS SERIES SPLIT SYSTEM Installation, Operation & Maintenance Heat Controller, LLC Refrigeration Installation When passing refrigerant lines through a wall, seal opening with silicon-based caulk. Avoid direct contact with water pipes, duct work, floor joists, wall studs, floors or other structural components that could transmit compressor vibration. Do not suspend refrigerant tubing from joists with rigid straps. Do not attach line set to the wall.
HTS SERIES SPLIT SYSTEM Installation, Operation & Maintenance Heat Controller, LLC Refrigeration Installation Figure 10: Braze Instructions Figure 11: Air Coil Connection Bulb (Must be Installed and Insulated) Equalizer Line TXV (‘IN’ toward compressor section) Vapor Fully Insulated Suction Line Suction Line FP2 Sensor TXV has internal check valve Liquid Line Fully Insulated Liquid Line Add-On Heat Pump Applications Nitrogen Braze The HWG Series indoor coil should be located in the supply side
Installation, Operation & Maintenance HTS SERIES SPLIT SYSTEM Heat Controller, LLC Refrigeration Installation Figure 12: Typical Split/Air Handler Installation (Indoor Compressor Section) Power Disconnects WDG Series TXV ‘IN’ toward Compressor Section Insulated Line Sets PVC Condensate with vented trap Indoor Compressor Section Low Voltage Air pad or extruded polystyrene Figure 13: Typical Split/Add-on Coil Fossil Fuel Furnace Installation (Indoor Compressor Section) TXV ‘IN’ toward Compressor Se
Installation, Operation & Maintenance HTS SERIES SPLIT SYSTEM Heat Controller, LLC Refrigeration Installation Evacuation Of The Lineset And Coil Charging The System The line set and coil must be evacuated to at least 500 microns to remove any moisture and noncondensables. Evacuate the system through both service ports in the shipping position (full CW in - see table 5) to prevent false readings on the gauge because of pressure drop through service ports.
Installation, Operation & Maintenance HTS SERIES SPLIT SYSTEM Heat Controller, LLC Refrigeration Installation Turn service valves full out CCW (see Table 5) and then turn back in one-half turn to open service ports. Add the required refrigerant so that the total charge calculated for the unit and line set is now in the system. Open the service valve fully counter clockwise so that the stem will backseat and prevent leakage through the schrader port while it is not in use.
HTS SERIES SPLIT SYSTEM Installation, Operation & Maintenance Heat Controller, LLC Hot Water Generator The HWG (Hot Water Generator) or desuperheater option provides considerable operating cost savings by utilizing excess heat energy from the heat pump to help satisfy domestic hot water requirements. The HWG is active throughout the year, providing virtually free hot water when the heat pump operates in the cooling mode or hot water at the COP of the heat pump during operation in the heating mode.
Installation, Operation & Maintenance HTS SERIES SPLIT SYSTEM Heat Controller, LLC Hot Water Generator Figure 20: Anti-Scald Valve Piping Connections ANTI-SCALD COLD WATER VALVE PIPING SUPPLY CONNECTIONS CHECK VALVE Installation The HWG is controlled by two sensors and the DXM2 microprocessor control. One sensor is located on the compressor discharge line to sense the discharge refrigerant temperature.
Installation, Operation & Maintenance HTS SERIES SPLIT SYSTEM Heat Controller, LLC Hot Water Generator Table 6: HWG Water Piping Sizes and Length HWG Water Piping 1. Using at least 1/2” [12.7mm] I.D. copper, route and install the water piping and valves as shown in Figures 15 or 16. Install an approved anti-scald valve if the 150°F HWG setpoint is or will be selected. An appropriate method must be employed to purge air from the HWG piping.
HTS SERIES SPLIT SYSTEM Installation, Operation & Maintenance Heat Controller, LLC Electrical - Line Voltage All final electrical connections must be made with a length of flexible conduit to minimize vibration and sound transmission to the building. 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.
HTS SERIES SPLIT SYSTEM Installation, Operation & Maintenance Heat Controller, LLC Electrical - Low Voltage Accessory Connections Figure 22: HTS Low Voltage Field Wiring A terminal paralleling the compressor contactor coil has been provided on the DXM2 control. Terminal “A” is designed to control accessory devices. Note: This terminal should be used only with 24 Volt signals and not line voltage. Terminal “A” is energized with the compressor contactor.
Installation, Operation & Maintenance HTS SERIES SPLIT SYSTEM Heat Controller, LLC Electrical - Thermostat Wiring Thermostat Installation Figure 24: Communicating Thermostat Connection to DXM2 Control The thermostat should be located on an interior wall in a larger room, away from supply duct drafts. DO NOT locate the thermostat in areas subject to sunlight, drafts or on external walls.
Installation, Operation & Maintenance HTS SERIES SPLIT SYSTEM Heat Controller, LLC DXM2 Controls DXM2 Control DXM2 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.
HTS SERIES SPLIT SYSTEM Installation, Operation & Maintenance Heat Controller, LLC Figure 26a: DXM2 Layout and Connections Service tool Communicating connection stat connection C Gnd B- A+ 24V P4 N.O. Com Y2 Conventional stat connection N.C. N.O.
Installation, Operation & Maintenance HTS SERIES SPLIT SYSTEM Heat Controller, LLC Indoor Split HTS024-060 Wiring Diagram 208-230-/60/1 DXM2 28
HTS SERIES SPLIT SYSTEM Installation, Operation & Maintenance Heat Controller, LLC Unit Commissioning And Operating Conditions Operating Limits Environment – Units are designed for indoor installation only. Never install units in areas subject to freezing or where humidity levels could cause cabinet condensation (such as unconditioned spaces subject to 100% outside air). Power Supply – Voltage utilization shall comply with AHRI standard 110.
Installation, Operation & Maintenance HTS SERIES SPLIT SYSTEM Heat Controller, LLC Unit Start-Up and Operating Conditions 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 set properly (LT1 - JW3). Miscellaneous: Note any questionable aspects of the installation.
Installation, Operation & Maintenance HTS SERIES SPLIT SYSTEM Heat Controller, LLC Unit Start-Up Procedure d. Check the elevation and cleanliness of the condensate lines. Dripping may be a sign of a blocked line. Check that the condensate trap is filled to provide a water seal. e. Turn thermostat to “OFF” position. A hissing noise indicates proper functioning of the reversing valve.
Installation, Operation & Maintenance HTS SERIES SPLIT SYSTEM Unit Start-Up and Operating Conditions solutions), where TD is the temperature difference between the entering and leaving water, and GPM is the flow rate in U.S. GPM determined by comparing the unit heat exchanger pressure drop to Table 12. If performance during any mode appears abnormal, refer to the DXM2 section or troubleshooting section of this manual. NOTE: To obtain maximum performance, the air coil should be cleaned before start-up.
HTS SERIES SPLIT SYSTEM Installation, Operation & Maintenance Heat Controller, LLC Unit Operating Conditions Table 12: Two-Stage R-410A Compressor Section Coax Water Pressure Drop Model 024 026 038 036 048 049 064 060 GPM 2.3 3.0 3.4 4.5 6.0 3.0 4.5 6.0 6.8 9.0 4.5 6.0 6.8 9.0 12.0 6.0 7.5 9.0 11.3 12.0 15.0 Table 13: Water Temperature Change Through Heat Exchanger Pressure Drop (psi) 30°F 0.7 1.1 1.3 2.0 3.1 0.7 1.1 1.3 2.0 3.1 0.7 1.1 1.3 2.0 3.1 0.9 1.7 2.5 3.7 4.1 6.1 50°F 0.4 0.7 0.9 1.4 2.
HTS SERIES SPLIT SYSTEM Installation, Operation & Maintenance Heat Controller, LLC Unit Operating Conditions Table 14c: Size 048 HTS Two-Stage R-410A Typical Unit Operating Pressures and Temperatures Entering Water Temp °F Water Flow GPM Full Load Cooling - without HWG active Suction Pressure PSIG Discharge Pressure PSIG Superheat Subcooling Full Load Heating - without HWG active Air Temp Drop °F DB Water Temp Rise °F Suction Pressure PSIG Discharge Pressure PSIG Superheat Subcooling Water Te
Installation, Operation & Maintenance HTS SERIES SPLIT SYSTEM Heat Controller, LLC Preventive Maintenance Water Coil Maintenance Condensate Drain (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.
Installation, Operation & Maintenance HTS SERIES SPLIT SYSTEM Heat Controller, LLC Basic Troubleshooting Information General Troubleshooting Sensor: Nominal resistance at various temperatures Basic DXM2 board troubleshooting in general is best summarized as simply verifying inputs and outputs. After this process has been verified, confidence in board operation is confirmed and the trouble must be else where.
Installation, Operation & Maintenance HTS SERIES SPLIT SYSTEM Heat Controller, LLC Advanced Troubleshooting and Configuration Information Unit Size, Blower Type, and Loop Type. The Heat Pump Family, Unit Size, and Blower Type are needed to properly operate any particular unit configuration, especially those with ECM blowers.
Installation, Operation & Maintenance HTS SERIES SPLIT SYSTEM Heat Controller, LLC Advanced Troubleshooting and Configuration Information Fault I/O Conditions – This option displays the status of the DXM2 physical and communicated inputs and the relay outputs when the lockout occurred. Service Mode The Service Mode provides the installer with several functions for troubleshooting, including Manual Operation, Control Diagnostics, Control Configuration, and Fault History.
HTS SERIES SPLIT SYSTEM Installation, Operation & Maintenance Heat Controller, LLC DXM2 Process Flow Chart WARNING! WARNING! HAZARDOUS VOLTAGE! DISCONNECT ALL ELECTRIC POWER INCLUDING REMOTE DISCONNECTS BEFORE SERVICING. Failure to disconnect power before servicing can cause severe personal injury or death.
Installation, Operation & Maintenance HTS SERIES SPLIT SYSTEM Heat Controller, LLC 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 Low Temperature Htg Clg Possible Cause X Green status LED off X Reduced or no water flow in cooling X Water t emperature out of range in Bring water temp within design parameters cooling X Reduced or no air flow in heating Check for dirty air filter and clea
Installation, Operation & Maintenance HTS SERIES SPLIT SYSTEM Heat Controller, LLC Functional Troubleshooting Fault IFC Fault Code 13 Internal Flow Controller Fault Htg Clg Possible Cause X X Solution No pump output signal Check DC voltage between A02 and GND - should be between 0.5 and 10 VDC with pump active Low pump voltage Check line voltage to the pump No pump feedback signal Check DC voltage between T1 and GND.
Installation, Operation & Maintenance HTS SERIES SPLIT SYSTEM Heat Controller, LLC Performance Troubleshooting Symptom Htg Clg Possible Cause X X Rduced or no air flow in heating X Insufficient Capacity/ Not Cooling or Heating Properly 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 o
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Revision History Date Page # 5 July, 13 3, 15, 23, 26, 33, 34 5 July, 13 All Description Info Updated to Rev. C Heat Controller Inc Changed to Heat Controller LLC R AI BR I HE AT P U M P S A TO NE WATER TO IFIED TO ARI A RT S C CE NG WITH LYI MP O IR MANUFACT UR ER Design, material, performance data and components subject to change without notice. IS ST AND 3 ARD 1 -1 R O 25 6 1900 Wellworth Ave., Jackson MI 49203 • Ph. 517-787-2100 • www.heatcontroller.
