ClimateMaster AHWG Guide

AHWG Remote Mount
Hot Water
Generator Module
for TEP Series
Outdoor Split Unit
Installation, Operation &
Maintenance Instructions
97B0072N05
Revised: March 12, 2019
Table of Contents
Model Nomenclature Example 3
Description and Installation Examples 4
Water Quality Requirements 5
Installation and Operating Instructions 6-9
Wiring and Electrical Data 10
Wire Diagrams 11-14
Warranty 15
Revision History 16

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3
Remote HWG
Revised: March 12, 2019
climatemaster.com
Model Nomenclature:for Remote
HotWater Generator
AHWG 1
1 2 3 4 5
Accessory
AHWG = Accessory Remote
Hot Water Generator
Size
B
6
Revision
A
7
S
89
Future
Voltage
S
1 = Standard
B = Current Revision
SS = Standard
A = 115/60/1
G = 208-230/60/1

Remote HWG
Revised: March 12, 2019
4Geothermal Heat Pump Systems
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100 - 110°
F
[38 - 43°C
Cold Inlet from
Domestic supply
Shut-off
Valve #4
Shut-off
Valve #3
Shut Off
Valve #2
Shut-off
Valve #1
Insulated water lines - 5/8” OD, 50 ft maximum (one way)
[16mm OD, 15 meters maximum]
Upper element to 130°F [54°C]
(or owner preference)
Cold Inlet
Hot Outlet to
house
Powered
Water Heater
Cold Inlet from
Domestic supply
Hot Outlet
Unpowered
Water Heater
Field Supplied 3/4” brass nipple and “T”
Lower element to 120°F [49°C]
Shut-off
Valve #1
Shut-off
Valve #4
Shut-off
Valve #3
Shut Off
Valve #2
Figure 1: Typical HWG Installation (Outdoor Compressor
Section)
Figure 2: HWG Double Tank Installation (Outdoor Com-
pressor Section)
HotWater Generator Module For
Outdoor Compressor Section
General Information
The HWG Module consists of an all-copper, vented double-
wall heat exchanger and a water-cooled bronze water
circulating pump. The pump is controlled by DXM2 control.
Power for the pump is provided from a remote 115 or 230
vac power source.
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 may be 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. Actual HWG water heating capacities are provided in
the appropriate heat pump performance data.
The temperature set point of the HWG is field selectable on
the DXM2 to 125°F or 150°F . The 150°F set point allows
more heat storage from the HWG. For example, consider
the amount of heat that can be generated by the HWG when
using the 125°F set point, versus the amount of heat that can
be generated by the HWG when using the 150°F set point.
In a typical 50 gallon two-element electric water heater
the lower element should be turned down to 100°F, or the
lowest setting, to get the most from the HWG. The tank will
eventually stratify so that the lower 80% of the tank, or 40
gallons, becomes 100°F (controlled by the lower element).
The upper 20% of the tank, or 10 gallons, will be maintained
at 125°F (controlled by the upper element).
Using a 125°F set point, the HWG can heat the lower 40
gallons of water from 100°F to 125°F, providing up to 8,330
btu’s of heat. Using the 150°F set point, the HWG can heat
the same 40 gallons of water from 100°F to 150°F and the
remaining 10 gallons of water from 125°F to 150°F, providing
a total of up to 18,743 btu’s of heat, or more than twice as
much heat as when using the 125°F set point.
This example ignored standby losses of the tank. When
those losses are considered the savings are even greater.
Electric water heaters are recommended. If a gas, propane,
or oil water heater is used, a second preheat tank must be
installed (Figure 2). If the electric water heater has only a
single center element, the dual tank system is recommended
to insure a usable entering water temperature for the HWG.
Typically a single tank of at least 52 gallons (235 liters) is used
to limit installation costs and space. However, a dual tank, as
shown in Figure 2, is the most efficient system, providing the
maximum storage and temperate source water to the HWG.
It is always advisable to use water softening equipment on
domestic water systems to reduce the scaling potential and
lengthen equipment life. In extreme water conditions, it may
be necessary to avoid the use of the HWG option since the
potential cost of frequent maintenance may offset or exceed
any savings. Consult water quality requirements table for
scaling potential.

5
Remote HWG
Revised: March 12, 2019
climatemaster.com
Water Quality
Parameter HX Material Closed Recirculating Open Loop and Recirculating Well
Scaling Potential - Primary Measurement
pH/Calcium Hardness All -pH < 7.5 and Ca Hardness <100ppm
Method
Index Limits for Probable Scaling Situations - (Operation outside these limits is not recommended)
Ryznar All - 6.0 - 7.5
Stability Index If >7.5 minimize steel pipe use.
Langelier All --0.5 to +0.5
Saturation Index 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) All -<0.2 ppm (Ferrous)
(Bacterial Iron potential) If Fe2+ (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 6 - 8.5
Monitor/treat as
needed 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
Maximum Allowable at maximum water temperature.
Chloride Levels
10$C24$C38
C
Copper
Cupronickel -<20ppm NR NR
-<150 ppm NR NR
304 SS-<400 ppm <250 ppm <150 ppm
316 SS-<1000 ppm <550 ppm < 375 ppm
Titanium ->1000 ppm >550 ppm >375 ppm
Erosion and Clogging
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.
Notes:
• NR - Application not recommended.
• "-" No design Maximum.
• Closed Recirculating system is identified by a closed pressurized piping system.
• Recirculating open wells should observe the open recirculating design considerations.
Above the given limits, scaling is likely to occur. Scaling indexes should be calculated using the limits below
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.
The ClimateMaster Water Quality Table provides water quality requirements for ClimateMaster 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.
Water Quality Requirements

Remote HWG
Revised: March 12, 2019
6Geothermal Heat Pump Systems
HotWater Generator Module Refrigeration Installation
For Outdoor Compressor Section Only
 WARNING! 
 CAUTION! 
 CAUTION! 
WARNING! The HWG module is an appliance that operates
in conjunction with the heat pump system, the hot water
system and the electrical system. Installation should only be
performed by skilled technicians with appropriate training
and experience. The installation must be in compliance with
local codes and ordinances. Local plumbing and electrical
building codes take precedence over instructions contained
herein. The Manufacturer accepts no liability for equipment
damaged and/or personal injury arising from improper
installation of the HWG module.
CAUTION! The HWG module must be installed in an area
that is not subject to freezing temperatures.
NOTICE! Make sure the compressor discharge line
is connected to the “Hot Gas In” stub on the Heat
Recovery Unit.
CAUTION! Locate Refrigerant lines to avoid accidental
damage by lawnmowers or children.
Wiring
Refer to Figures 7-8 in this document for Remote HWG Wir-
ing.
Location/Mounting
The HWG module should be mounted as close to the heat
pump outdoor section as possible, in order to minimize
the length of refrigerant run. Indoor mounting is preferred,
where practical, to reduce the likelihood of freezing ambient
temperature. It is recommended that the HWG module be
mounted above the system compressor in order to promote
proper oil movement and drain-down. This means that the
HWG module can be wall mounted in any orientation
except for stubs up. Mounting should be accomplished
by fastening the HWG module cabinet to the wall or other
selected vertical surface. Mounting holes are provided at
the rear of the unit. Any fastener suitable for supporting a 12
pound [5.4] vertical load is acceptable.
The HWG, water piping and hot water tank should be
located where the ambient temperature does not fall below
50 °F [10°C]. Keep water piping lengths at a minimum. DO
NOT use a one-way length greater than 50 ft. (one way) [15
m]. See Table 2 for maximum water piping lengths.
All installations must be in accordance with local codes. The
installer is responsible for knowing the local requirements,
and for performing the installation accordingly
SPECIAL NOTE: The selected mounting location and
orientation must allow the circulator pump to be positioned
with the motor shaft horizontal. DO NOT install the Heat
Recovery Unit flat on its back.
Refrigerant Line Installation
Before starting the installation into the refrigerant circuit,
inspect and note the condition and performance of the heat
pump. Disconnect power to the heat pump outdoor unit. Any
system deficiencies must be corrected prior to installing the
HWG module. Addition of the unit will not correct system
problems. Record the suction and discharge pressures and
compressor amperage draw. These will be used for compari-
son with system operation after the refrigerant line instal-
lation is complete and before the water line installation is
performed.
Install the Add-On HWG Kit
Locate the HWG as close to the water heater as possible.
Install the lineset to the desuperheater valves in the outdoor
compressor section and the refrigerant line connections on
the HWG. Maximum length should be 30 feet one way. Evac-
uate the lineset to 500 microns through the hot gas valves in
the outdoor unit. Open the HWG valves in the compressor
section up fully (and close the desuperheater bypass valve).
See Figures 3a through 3d. Check the lineset for leaks. Verify
that lineset tubing is completely insulated with a minimum
1/2” thick closed cell and painted to prevent deterioration
of the insulation due to ultra violet light and weather. Make
the connections with high temperature solder or brazing rod.
The recommended refrigerant line size is dependent on the
one way distance between the Heat Recovery Unit and the
compressor; and the size of the system. Use Table 8 as a
guideline.

7
Remote HWG
Revised: March 12, 2019
climatemaster.com
HotWater Generator Module Refrigeration Installation
Outdoor Compressor Section Only
Fully Insulated
Lines to the HWG
Refr to
HWG
Refr from
HWG
Figure 4: HWG Service Valves
Figure 3d: HWG Bypass Valve
Valve Open
(HWG Bypassed) Valve Closed
(HWG Activated)
Figure 3b: Remote HWG Module
Capacity Line Set Size
1/2” OD 5/8” OD 3/4” OD
2 Ton Up to 16 ft.
[4.9m] Up to 30 ft. [9.1m] N/A
3 Ton Up to 9 ft.
[2.7m] Up to 25 ft. [7.6m] Up to 30 ft. [9.1m]
4 Ton Up to 5 ft.
[1.5m] Up to 13 ft. [4.0m] Up to 30 ft. [9.1m]
5 Ton N/A Up to 9 ft.
[2.7m] Up to 25 ft. [7.6m]
HWG
Line Valves
HWG
Bypass
Valve
Refr
to HWG
Refr from
HWG
Pump
Relay
Circulator
HWG
Water Out
HWG
Refr Out
HWG
Refr In
High Voltage
HWG
Water In
Table 1: HWG Refrigerant Line SizingFigure 3a: Outdoor Compressor Section HWG Installation

Remote HWG
Revised: March 12, 2019
8Geothermal Heat Pump Systems
HotWater Generator
 WARNING! 
 WARNING! 
C
H
M
WATER HEATER
CHECK VALVE
8” MAX
HOT WATER
TO HOUSE
ANTI-SCALD
VALVE
ANTI-SCALD
VALVE PIPING
CONNECTIONS
COLD WATER
SUPPLY
Anti-Scald
Valve Piping
Connections
Alarm
Relay
Comp
Relay
24Vdc
EH1
EH2
P6
Off On
JW3
A
OVR
ESD
C
R
NSB
AL2
JW1
Acc1
Relay
Acc2
Relay
H
COM1
NC1
NO1
COM2
NC2
NO2
P3
CO
RV
RV
LT1
LT1
LT2
LT2
LP
LP
HP
HP
P7
Status
Fault
R
RCC
CCG
CO
S1
S2
1
12
1
4
e
sUyrotcaF
Micro
U1
Off On
P2
COH
COM
AO2
P11
Gnd T1
P10
T2 T2 T3 T3 T4 T4 T5
P9
T5 T6 T6
A0-1 A0-2
Off On
S3
RV
Relay
CCH
Relay
Gnd
NC
1 2 3 4
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
Hot Water
Generator
Settings
Figure 5: Hot Water Generator Settings
Installation
The HWG is controlled by two sensors and the DXM2 micro-
processor control. One sensor is located on the compressor
discharge line to sense the discharge refrigerant tempera-
ture. The other sensor is located on the HWG heat exchang-
er’s “Water In” line to sense the potable water temperature.
The DXM2 microprocessor control monitors the refrigerant
and water temperatures to determine when to operate
the HWG. The HWG will operate any time the refrigerant
temperature is sufficiently above the water temperature.
Once the HWG has satisfied the water heating demand
during a heat pump run cycle, the controller will cycle the
pump at regular Intervals to determine if an additional HWG
cycle can be utilized.
When the control is powered and the HWG pump output is
active for water temperature sampling or HWG operation,
the DXM2 status LED will slowly flash (On 1 second, Off1
second).
If the control has detected a HWG fault, the DXM2 status
LED will flash a numeric fault code as follows:
High Water Temperature (>160ºF) 5 flashes
Hot Water Sensor Fault 6 flashes
Compressor Discharge Sensor Fault 6 flashes
Fault code flashes have a duration of 0.3 seconds with
a 10 second pause between fault codes. For example, a
“Compressor Discharge sensor fault” will be six flashes 0.3
seconds long, then a 10 second pause, then six flashes
again, etc.
Hot Water Generator settings are determined by DIP
switches 3-2, 3-3, and 3-4.
DIP 3-2 controls the HWG Test Mode. It provides for forced
operation of the HWG output, activating the HWG pump for
up to five minutes. ON = HWG test mode, OFF = normal
HWG operation. The control will revert to standard operation
after five minutes regardless of switch position.
DIP 3-3 determines HWG set point temperature. It provides
for selection of the HWG operating set point. ON = 150°F
(66°C), OFF = 125°F (52°C).
DIP 3-4 is for the HWG status. It provides HWG operation
control. ON = HWG mode enabled, OFF = HWG mode
disabled. Units are shipped from the factory with this switch
in the OFF position.
WARNING! USING A 150°F SETPOINT ON THE
HWG WILL RESULT IN WATER TEMPERATURES
SUFFICIENT TO CAUSE SEVERE PHYSICAL INJURY
IN THE FORM OF SCALDING OR BURNS, EVEN WHEN
THE HOT WATER TANK TEMPERATURE SETTING
IS VISIBLY SET BELOW 150°F. THE 150°F HWG
SETPOINT MUST ONLY BE USED ON SYSTEMS THAT
EMPLOY AN APPROVED ANTI-SCALD VALVE (PART
NUMBER AVAS4) AT THE HOT WATER STORAGE
TANK WITH SUCH VALVE PROPERLY SET TO
CONTROL WATER TEMPERATURES DISTRIBUTED
TO ALL HOT WATER OUTLETS AT A TEMPERATURE
LEVEL THAT PREVENTS SCALDING OR BURNS!
WARNING! UNDER NO CIRCUMSTANCES SHOULD
THE SENSORS BE DISCONNECTED OR REMOVED.
FULL LOAD CONDITIONS CAN DRIVE HOT
WATER TANK TEMPERATURES FAR ABOVE SAFE
TEMPERATURE LEVELS IF SENSORS DISCONNECTED
OR REMOVED.

9
Remote HWG
Revised: March 12, 2019
climatemaster.com
HotWater Generator Module - DomesticWater Installation
Table 2: HWG Water Piping Size and Length
Unit
Nominal
Tonnage
Nominal
HWG Flow
(gpm)
1/2" Copper
(max length*) 3/4" Copper (max length*)
1.5 0.6 50 -
2.0 0.8 50 -
2.5 1.0 50 -
3.0 1.2 50 -
3.5 1.4 50 -
4.0 1.6 45 50
5.0 2.0 25 50
6.0 2.4 10 50
*Maximum length is equivalent length (in feet) one way of type L
copper.
 CAUTION! 
CAUTION! Use only copper piping for HWG piping due to
the potential of high water temperatures for water that has
been in the HWG heat exchanger during periods of no-flow
conditions (HWG pump not energized). Piping other than
copper may rupture due to high water temperature and
potable water pressure.
Warning! The HWG pump Is fully wired from the
factory. Use extreme caution when working around
the microprocessor control as it contains line voltage
connections that presents a shock hazard that can
cause severe injury or death!
The heat pump, water piping, pump, and hot water tank
should be located where the ambient temperature does
not fall below 50°F [10°C]. Keep water piping lengths at a
minimum. DO NOT use a one way length greater than 50 ft.
(one way) [15 m]. See Table 2 for recommended piping sizes
and maximum lengths.
All installations must be in accordance with local codes. The
installer is responsible for knowing the local requirements,
and for performing the installation accordingly. DO NOT
energize the pump until “water tank refill” section, below is
completed. Powering the pump before all installation steps
are completed may damage the pump.
Water Tank Preparation
1. Turn offpower or fuel supply to the hot water tank.
2. Connect a hose to the drain valve on the water tank.
3. Shut offthe cold water supply to the water tank.
4. Open the drain valve and open the pressure relief valve
or a hot water faucet to drain tank.
5. When using an existing tank, it should be flushed with
cold water after it is drained until the water leaving the
drain hose is clear and free of sediment.
6. Close all valves and remove the drain hose.
7. Install HWG water piping.
HWG Water Piping
1. Using at least 5/8” [16mm] O.D. copper, route and install
the water piping and valves as shown in Figures 1 or 2.
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.
This may be accomplished by flushing water through the
HWG (as In Figures 1 and 2) or by Installing an air vent at
the high point of the HWG piping system.
2. Insulate all HWG water piping with no less than 3/8”
[10mm] wall closed cell insulation.
3. Open both shut offvalves and make sure the tank drain
valve is closed.
Water Tank Refill
1. Close valve #4. Ensure that the HWG valves (valves #2
and #3) are open. Open the cold water supply (valve #1)
to fill the tank through the HWG piping. This will purge air
from the HWG piping.
2. Open a hot water faucet to vent air from the system until
water flows from faucet; turn offfaucet. Open valve #4.
3.
Depress the hot water tank pressure relief valve handle to
ensure that there is no air remaining in the tank.
4. Inspect all work for leaks.
5. Before restoring power or fuel supply to the water heater,
adjust the temperature setting on the tank thermostat(s)
to insure maximum utilization of the heat available from
the refrigeration system and conserve the most energy.
On tanks with both upper and lower elements and
thermostats, the lower element should be turned down
to 100°F [38°C] or the lowest setting; the upper element
should be adjusted to 120-130°F [49-54°C]. Depending
upon the specific needs of the customer, you may want
to adjust the upper element differently. On tanks with a
single thermostat, a preheat tank should be used (Fig 2).
6. Replace access cover(s) and restore power or
fuel supply.
Initial Start-Up
1. Make sure all valves in the HWG water circuit are fully
open.
2. Turn the heat pump power and remote HWG power “off”
and switch dip switch DIP 3.4 on the HWG controller to
the “off” (enabled) position to activate the HWG.
3. The HWG pump should not run if the compressor is not
running.
4. The temperature difference between the water entering
and leaving the HWG should be approximately 5-10 °F
[3-6 °C].
5. Allow the unit to operate for 20 to 30 minutes insure that
it is functioning properly.
6. Always turn dip switch DIP 3.4 on the HWG controller to
the “on” (disabled) position to deactivate the HWG when
servicing the outdoor compressor section.

Remote HWG
Revised: March 12, 2019
10 Geothermal Heat Pump Systems
Electrical -Wiring
 WARNING!  CAUTION! 
HWG
Module Voltage Pump FLA Total FLA Min
Circuit
Amps
Min Wire
Size
AHWG1AASS 115/60/1 0.52 0.52 1.20 14 ga.
AHWG1AGSS 208/230/60/1 0.40 0.40 0.90 14 ga.
Table 3: HWG Module Electrical Data
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! Use only copper conductors for field installed
electrical wiring. Unit terminals are not designed to accept
other types of conductors.
208-230 Volt Operation
Verify transformer tap with air handler wiring diagram to
insure that the transformer tap is set to the correct voltage,
208V or 230V.
HWG Module Wiring - For “Outdoor” Compressor
Section
The HWG module should be wired to a 115 vac power supply
as shown in figure 7. A safety disconnect should be installed
at the HWG module as required by code to allow servicing of
the module. DO NOT energize the pump until all HWG piping
is completed and air is purged from the water piping to avoid
running the pump “dry”.
See Figures 7-8 for 115 and 230V wire diagrams.

11
Remote HWG
Revised: March 12, 2019
climatemaster.com
 WARNING!  CAUTION! 
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! Use only copper conductors for field installed
electrical wiring. Unit terminals are not designed to accept
other types of conductors.
Outdoor Split (TEP) DXM2Wiring Diagram
with Internal Flow Controller - 96B0005N65
Figure 6

Remote HWG
Revised: March 12, 2019
12 Geothermal Heat Pump Systems
Outdoor Split (TEP) DXM2Wiring Diagram
with Internal Flow Controller - 96B0005N65

13
Remote HWG
Revised: March 12, 2019
climatemaster.com
115V HotWater GeneratorWiring Diagram - 96BN0141N11
Figure 7
TEP

Remote HWG
Revised: March 12, 2019
14 Geothermal Heat Pump Systems
230V HotWater GeneratorWiring Diagram - 96BN0141N12
Figure 8
TEP

15
Remote HWG
Revised: March 12, 2019
climatemaster.com
Warranty
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Remote HWG
Revised: March 12, 2019
16 Geothermal Heat Pump Systems
Revision History
97B0072N05
ClimateMaster works continually to improve its products. As a result, the design and specifications of each product at the time for order may be
changed without notice and may not be as described herein. Please contact ClimateMaster’s Customer Service Department at 1-405-745-6000
for specific information on the current design and specifications. Statements and other information contained herein are not express warranties
and do not form the basis of any bargain between the parties, but are merely ClimateMaster’s opinion or commendation of its products.
© ClimateMaster, Inc. 2009
*97B0072N05*
Revised: March 12, 2019
7300 S.W. 44th Street
Oklahoma City, OK 73179
Phone: [phone]
Fax: [phone]
climatemaster.com
Date Page # Description
12 March, 2019 5 Added Water Quality Table
10 Feb, 2016 16 Updated certification logos
15 July 2014 10-13 Updated Wiring Diagrams
17 Dec. 2012 All First Published