Taco iWorX HPU2 User manual

© 2011 Taco Electronic Solutions, Inc. 1
Installation Guide 502-025
HPU2 Water Source Heat Pump Controller
Self-Contained Interoperable Controller Model UCP-1
SUPERSEDES: New EFFECTIVE: April 12, 2011
Plant ID: 001-3982
Table of Contents
HPU2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Purpose of This Guide . . . . . . . . . . . . . . . . . . . . . . . . . 2
Representations and Warranties . . . . . . . . . . . . . . . . . 2
Applicable Documentation . . . . . . . . . . . . . . . . . . . . . . 3
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . 3
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Static Electricity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FCC Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Before Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
About this Document . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspecting the Equipment . . . . . . . . . . . . . . . . . . . . 4
What is Not Included with this Equipment . . . . . . . . 4
Equipment Location . . . . . . . . . . . . . . . . . . . . . . . . . 5
Selecting a Power Source . . . . . . . . . . . . . . . . . . . . 5
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Mounting the Device. . . . . . . . . . . . . . . . . . . . . . . . .5
Routing Cabling to the Device . . . . . . . . . . . . . . . . .6
Grounding the Device. . . . . . . . . . . . . . . . . . . . . . . .7
Wiring Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Connecting Input Devices. . . . . . . . . . . . . . . . . . . . .9
Connecting Output Devices . . . . . . . . . . . . . . . . . .10
Other Connections . . . . . . . . . . . . . . . . . . . . . . . . .10
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Troubleshooting Tips . . . . . . . . . . . . . . . . . . . . . . .13

iWorx® HPU2
2 502-025, Effective: April 12, 2011
© 2011 Taco Electronic Solutions, Inc.
HPU2
The HPU2 heat pump controller is a stand-alone microprocessor-based controller for liquid source heat pump units.
The application includes liquid source heat pump units with two-stage compressor, reversing valve and fan.
Overview
A digital input is provided to monitor equipment status. A two-wire serial interface is provided for the thermostat. The
HPU2 incorporates digital outputs in the form of triacs for fan start/stop, two compressor stages, and a reversing valve.
The controller is based on LONWORKS®networking technology. The controller can be networked to a higher-level control
system for monitoring and control applications.
Features
• Two stage compressor heating/cooling control
• Reversing valve control
• Local backup schedule
• Individual temperature setpoints for occupied/unoccupied heat and cool
•LONWORKS interface to building automation systems
• Equipment status input for additional safety interlocks
• Thermostat with space temperature, setpoint adjust, fan override, occupancy override
• Fan control energized on call for heating or cooling
• Automatic heat/cool changeover
• Global unit enable for main plant synchronization
• Remote sensor capabilities
• Automatic configuration with the LCI
• Real Time Clock
• Alarm/Event reporting
PURPOSE OF THIS GUIDE
The iWorx® HPU2 Installation Guide provides installation information for the HPU2 Controller.
The reader should understand basic HVAC concepts, intelligent environmental control automation, and basic LON-
WORKS networking and communications. This application manual is written for:
• Users who engineer control logic
• Users who set up hardware configuration
• Users who change hardware or control logic
• Technicians and field engineers
REPRESENTATIONS AND WARRANTIES
This Document is subject to change from time to time at the sole discretion of Taco Electronic Solutions, Inc. All
updates to the Document are available at www.taco-hvac.com. When installing this product, it is the reader’s responsi-
bility to ensure that the latest version of the Document is being used.
iWorx® products shall only be used for the applications identified in the product specifications and for no other pur-
poses. For example, iWorx® products are not intended for use to support fire suppression systems, life support sys-
tems, critical care applications, commercial aviation, nuclear facilities or any other applications where product failure
could lead to injury to person, loss of life, or catastrophic property damage and should not be used for such purposes.

iWorx® HPU2
502-025, Effective: April 12, 2011 3
© 2011 Taco Electronic Solutions, Inc.
Taco Electronic Solutions, Inc. will not be responsible for any product or part not installed or operated in conformity with
the Document and instructions or which has been subject to accident, disaster, neglect, misuse, misapplication, inade-
quate operating environment, repair, attempted repair, modification or alteration, or other abuse. For further informa-
tion, please refer to the last page of this Document for the company’s Limited Warranty Statement, which is also issued
with the product or available at www.taco-hvac.com.
APPLICABLE DOCUMENTATION
See the table below for additional documentation that may be applicable to this controller.
INSTALLATION INSTRUCTIONS
Precautions
General
This symbol is intended to alert the user to the presence of important installation and maintenance (servic-
ing) instructions in the literature accompanying the equipment.
WARNING: Electrical shock hazard. Disconnect ALL power sources when installing or servicing this
equipment to prevent electrical shock or equipment damage.
Make all wiring connections in accordance with these instructions and in accordance with pertinent national and local
electrical codes. Use only copper conductors.
Description Audience Purpose
iWorx® HPU2 Application Guide,
Document No. 505-025
– Application Engineers
– Installers
– Service Personnel
– Start-up Technicians
– End user
Provides complete instructions for setting up
and using the iWorx® HPU2 controller.
iWorx® LCI2 Application Guide, Doc-
ument No. 505-002
– Application Engineers
– Installers
– Service Personnel
– Start-up Technicians
– End user
Provides instructions for setting up and using
the iWorx® Local Control Interface.
iWorx® LHP2 Application Guide, Doc-
ument No.505-024
– Application Engineers
– Installers
– Service Personnel
– Start-up Technicians
– End user
These controllers may operate in conjunction
with the HPU2. Application manuals provide
specific application information about these con-
trollers, including sequence of operation and
configuration information.
http://iWorxWizard.taco-hvac.com – Application Engineers
– Wholesalers
– Contractors
An on-line configuration and submittal package
generator based on user input. Automatically
generates bill of materials, sequence of opera-
tions, flow diagrams, wiring diagrams, points
and specifications.
Additional
Documentation
LonWorks FTT-10A Free Topology Transceiver User’s Guide, published by Echelon Corpo-
ration. It provides specifications and user instructions for the FTT-10A Free Topology Trans-
ceiver. See also: www.echelon.com/support/documentation/manuals/transceivers.

iWorx® HPU2
4 502-025, Effective: April 12, 2011
© 2011 Taco Electronic Solutions, Inc.
Static Electricity
Static charges produce voltages that can damage this equipment. Follow these static electricity precautions when han-
dling this equipment.
• Work in a static free area.
• Touch a known, securely grounded object to discharge any charge you may have accumulated.
• Use a wrist strap when handling printed circuit boards. The strap must be secured to earth ground.
Location
Avoid locations where corrosive fumes, excessive moisture, vibration or explosive vapors are present.
Avoid electrical noise interference. Do not install near large contactors, electrical machinery, or welding equipment.
This equipment is suitable for indoor use only. Preferably, or as required by National Electrical Code, the unit is
intended to be installed within an electrical control enclosure. Operate where ambient temperatures do not exceed
140 °F (60 °C) or fall below 32 °F (0 °C) and relative humidity does not exceed 90%, non-condensing.
FCC Compliance
This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of
the FCC rules. These limits are designed to provide reasonable protection against harmful interference. This equip-
ment can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause
harmful interference to radio communications. However, there is no guarantee that interference will not occur in a par-
ticular installation. If this equipment does cause harmful interference to radio or television reception, which can be
determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or
more of the following measures:
• Reorient or relocate the receiving antenna.
• Increase the separation between the equipment and the receiver.
• Connect the equipment to a power source different from that to which the receiver is connected.
• Consult the equipment supplier or an experienced radio/TV technician for help.
You are cautioned that any changes or modifications to this equipment not expressly approved in these instructions
could void your authority to operate this equipment in the United States.
BEFORE INSTALLING
About this Document
The instructions in this manual are for the HPU2 module which supports a liquid source heat pump.
Inspecting the Equipment
Inspect the shipping carton for damage. If damaged, notify the carrier immediately. Inspect the equipment for damage.
Return damaged equipment to the supplier.
What is Not Included with this Equipment
• A power source for the equipment electronics and peripheral devices.
• Tools necessary to install, troubleshoot and service the equipment.
• The screws or DIN rail needed to mount the device.

iWorx® HPU2
502-025, Effective: April 12, 2011 5
© 2011 Taco Electronic Solutions, Inc.
• Peripheral devices, such as sensors, actuators, etc.
• Cabling, cabling raceway, and fittings necessary to connect this equipment to the power source, FTT-10A network
and peripheral devices.
Equipment Location
Abide by all warnings regarding equipment location provided earlier in this document.
Optimally, the equipment should be installed within a secure enclosure.
If the equipment is to be installed outdoors, it must be contained within a protective enclosure. The enclosure must
maintain internal temperature and humidity within the ranges specified for this equipment.
The equipment must be installed within 500 feet of all input peripherals (smoke detectors, sensors, etc.) that will be
connected to the equipment.
Selecting a Power Source
This equipment requires a UL recognized Class 2 external power source (not supplied) to operate. The controller
power input requires a voltage of 24 Volts AC.
To calculate power source current requirements, add the power consumption of all peripheral devices to that of the
controller.
The controller and sensor power supplies can use the same power source. If both are using the same power source,
the loads must have EMF protection. This protection can be integral to the load, or installed in the 24 VAC wiring across
the load’s coil.
To provide necessary RFI and transient protection, the controller’s ground (GND) pin (T40) must be connected to earth
ground or the earth ground of the packaged unit’s enclosure ground. Failure to properly ground the controller may
cause it to exceed FCC limits. Excessive noise could also produce inaccurate sensor data. The power source must be
capable of operating with this connection to ground.
INSTALLATION
Warning: Electrical shock hazard. To prevent electrical shock or equipment damage, disconnect ALL
power sources to controllers and loads before installing or servicing this equipment or modifying any wir-
ing.
Mounting the Device
1.Select a mounting location. Enclosure mounting is recommended.
2.Hold the controller on the panel you wish to mount it on. With a marker or pencil mark the mounting locations on
the panel.
3.Using a small drill bit pre-drill the mounting holes.
4.Using two #6 pan head screws, mount the controller to the panel.
5.Wire the controller (See Routing Cabling to the Device).

iWorx® HPU2
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© 2011 Taco Electronic Solutions, Inc.
Figure 1: Mounting Dimensions
Routing Cabling to the Device
Cabling used to connect the power source and cabling used to connect the FTT-10A network must remain
separated within the control enclosure and wiring conduit.

iWorx® HPU2
502-025, Effective: April 12, 2011 7
© 2011 Taco Electronic Solutions, Inc.
Grounding the Device
The ground terminal (T40) must be securely connected to earth ground. Failure to properly ground this
equipment will result in improper operation. Improper grounding may also increase the risk of electrical
shock and may increase the possibility of interference with radio/TV reception.
For best performance, connect the power supply common terminal (T38) to the same external point as the
ground terminal (T40).
WIRING INFORMATION
WARNING: Terminals 4 and 6 are connected internally on all HPU2 controllers. Disconnect ALL power
sources when installing or servicing this equipment to prevent electrical shock or equipment damage.
Figure 2: HPU2 Wiring Example - Power Sourcing

iWorx® HPU2
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© 2011 Taco Electronic Solutions, Inc.
Figure 3: HPU2 Wiring Example - Power Sinking

iWorx® HPU2
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© 2011 Taco Electronic Solutions, Inc.
Figure 4: HPU2 Wiring Example - Power Isolated
Connecting Input Devices
Thermostat (STAT)
To connect the heat pump thermostat to the unit, attach one wire from the thermostat to STAT (T3) and the other wire to
the adjacent common (T4).

iWorx® HPU2
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Equipment Status (EQS)
To connect the equipment switch to the digital input, attach one wire of the contact to EQS (T5) and the other wire to
the adjacent common (T6). This must be a dry contact, normally open switch which closes when flow is detected. If a
flow proof switch is not installed, the terminals should be connected with a jumper wire.
Space Temperature (ST, optional)
To connect a thermistor (Precon II or Precon III) to the analog input, attach one wire of the sensor to ST (T7) and the
other wire to the adjacent common (T6). The thermistor can be used if no TS300 series thermostat is being used.
Connecting Output Devices
Stage 1 & Stage 2 (S1, S2)
The outputs for the stages must be connected to 24 VAC pilot relays if the load is greater than 1 Amp for each pump. If
the load is less than 1 Amp, connect stage 1 to S1 (T28) and adjacent TC34 (T27), and connect stage 2 to S2 (T26)
and adjacent TC34 (T27)
Reversing Valve (RV)
The output for the reversing valve must be connected to a 24 VAC pilot relays if the load is greater than 1 Amp. If the
load is less than 1 Amp, connect the reversing valve input to RV (T29) and adjacent TC12 (T30).
Fan (FAN)
The output for the fan must be connected to a 24 VAC pilot relay if the load is greater than 1 Amp. If the load is less
than 1 Amp, connect the fan input to FAN (T31) and adjacent TC12 (T30).
Other Connections
Network (LON)
Network wiring must be twisted pair. One network wire must be connected to terminal NETA (T1) and the other network
wire must be connected to terminal NETB (T2). Polarity is not an issue since an FTT-10A network is used for commu-
nications.
Power (PWR)
Connect one output wire from a 24 VAC power supply to PWR (T39) and the other output wire from the power supply to
the adjacent common terminal (T38).
Ground (GND)
Terminal GND (T40) must be connected to earth ground. Failure to properly ground this equipment will
result in improper operation. Improper grounding may also increase the risk of electrical shock, and may
increase the possibility of interference with radio and TV reception.
SPECIFICATIONS
Electrical
Inputs
• Cabling: twisted shielded pair, 18 AWG recommended—500 feet max. (152 meters)
• Resolution: 10 bit

iWorx® HPU2
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© 2011 Taco Electronic Solutions, Inc.
Stat
• iWorx® TS300 Series
Equipment Status
• Dry Contact
• Normally Open
• 5 Volts DC Max
Space Temp (optional)
• Precon Type II or Type III 10K thermistor
Outputs
Stage 1, Stage 2, Reversing Valve, and Fan
•24Volts AC
• 1A @ 50C, 0.5A @ 60C, limited by the Class 2 supply rating
Power
Power Requirements
• 24VAC (20VAC to 28VAC), requires an external Class 2 supply
Power Consumption
• 7.2W with no external loads, maximum limited by the Class 2 supply rating
Recommended Sensor Wire
FTT-10A Network
• Speed: 78KBPS
• Cabling: Maximum node-to-node distance: 1312 feet (400 meters)
• Maximum total distance: 1640 feet (500 meters)
For detailed specifications, refer to the FTT-10A Free-Topology Transceiver User’s Guide published by Echelon Corpo-
ration (www.echelon.com/support/documentation/manuals/transceivers).
Mechanical
Housing
• Dimensions: 5.55” (141mm) high, 6.54” (166 mm) wide, 1.75” deep (44 mm)
• ABS
Weight
• Controller Weight: 0.70 pounds (0.32 kilograms)
• Shipping Weight: 1.0 pounds (0.46 kilograms)
Cable Type Pairs Details Taco Catalog No.
18AWG 1 Stranded Twisted Shielded Pair, Plenum WIR-018
Cable Type Pairs Details Taco Catalog No.
Level 4 22AWG (0.65mm) 1 Unshielded, Plenum, U.L. Type CMP WIR-022

iWorx® HPU2
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Electronics
• Processor: 3150 Neuron 10 MHz
• Flash: 48 Kilobytes
• SRAM: 8 Kilobytes
• Termination: 0.197” (5.0 mm) Pluggable Terminal Blocks, 14-22 AWG
Environmental
• Temperature: 32 °F to 140 °F (0 °C to 60 °C)
• Humidity: 0 to 90%, non-condensing
Agency Listings
• UL Listed for US and Canada, Energy Management Equipment PAZX and PAZX7.
Agency Compliances
• FCC Part 15 Class A
TROUBLESHOOTING
Diagnostic LEDs
The controller has 3 LED indicators. These indicators can aid in troubleshooting equipment operation problems. The
following table lists the functions of the controller’s LEDs in the order they appear from left to right on the unit.
LED Indication
Status – Solid green when running and configured by an LCI (networking)
– Flashing green when running and NOT configured by an LCI (stand-alone)
– Solid red when a fault condition exists (control shut down)
– Blinking Red - the controller has a device failure
– Solid Amber - The controller has not received a LCI ping message in over 10 minutes and is part of a network.
Network – Yellow while the controller is transmitting data onto the FTT-10A network
– Green when there is network activity
– Off when there is no network activity
Service – Illuminated when the service pin is depressed or when a controller gets configured by the LCI.

iWorx® HPU2
Taco Electronic Solutions, Inc. iWorX-ALM2-APP-102 www.taco-hvac.com
Figure 5: HPU2 Controller LEDs
Status Network Service
Troubleshooting Tips
The table below provides solution to some common problems you may encounter.
Problem Solution
Controller is not running and Status
LED is not illuminated.
No power to controller. Verify the voltage on the controller’s power connector (24 VAC).
How do I reset the controller? The controller can be reset by the LCI, or you can cycle power to the controller. Refer to
the LCI documentation for more information on resetting the controller using the LCI.
The fan will not cycle on after the
equipment status input alarm has
been resolved
If the controller was previously in a fan fault condition, the controller must be reset
before proper operation can be restored.
The fan and heat/cool pilot relays will
not come on even though the LCI
indicates it is on.
Ensure that the controller and output pilot relay have been powered with 24 VAC and
the output has been correctly wired to the coil of the pilot relay. Also ensure that the pilot
relay has a 24 VAC coil.
The 10K thermistor reading is at its
maximum or minimum.
The input is either shorted or open.
The Heat or Cool outputs will not
come on even though the space
requires conditioned air.
Is there water flow in the system? Verify the associated CCU2 or LHP2 controller are
operating and the HPU2 is a member of the controller. If there is no CCU2 or LHP2 con-
nected, then the Unit Enable input of the ASM2 must detect water flow (On).
Thermistor readings fluctuate rapidly,
sometimes by several degrees.
The controller is not properly grounded. The controller's ground (GND) pin (T40) must
be connected to earth ground. Also ensure that the controller's digital inputs are dry
contacts and that no voltage is being applied or switched to the inputs.
How do I associate my HPU2 control-
lers with the LHP2?
Use the LHP2's grouping mechanism, specifically Members on the LHP2 HVAC Setup
screen of the LCI. Only HPU2s may be associated with the LHP2.

iWorx® HPU2
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Getting Help
Components within an iWorx® controller, sensor, or power supply cannot be field repaired. If there is a problem with a
unit, follow the steps below before contacting your local TES representative or TES technical service.
1.Make sure controllers, sensors, and power supplies are connected and communicating to desired devices.
2.Record precise hardware setup indicating the following:
Version numbers of application software.
Device and/or firmware version number.
A complete description of difficulties encountered.
Notes:
What is Save for in the Members
screen and when do I press it?
This button stores network information into the LHP2 about the controllers in its group.
Press this button when you have made any changes to the grouping.
What iWorX controllers can be part of
a LHP2's group?
Only HPU2 controllers can be part of the LHP2's group and demand cooling or heating
from it.
Under what conditions does the
HPU2 require a reset for normal
operation.
There is one condition that requires a reset:
– Equipment failure
Problem Solution

iWorx® HPU2
502-025, Effective: April 12, 2011 15
© 2011 Taco Electronic Solutions, Inc.

iWorx® HPU2
Printed in the USA iWorx® and iView® are registered trademarks of Taco Electronic Solutions, Inc.
© 2011 Taco Electronic Solutions, Inc. LON, LONWORKS, & LONMARK are trademarks of Echelon Corporation
CONTROLS MADE EASY®
Taco Electronic Solutions, Inc., 1160 Cranston Street, Cranston, RI 02920
Telephone: [phone] FAX: [phone].
Taco (Canada), Ltd., 8450 Lawson Road, Unit #3, Milton, Ontario L9T 0J8.
Telephone: [phone]. FAX: [phone].
Taco Electronic Solutions, Inc. is a subsidiary of Taco, Inc.
Visit our web site at: http://www.taco-hvac.com
Taco Electronic Solutions, Inc. (TES) will repair
or replace without charge (at the company's
option) any product or part which is proven
defective under normal use within one (1) year
from the date of start-up or one (1) year and six
(6) months from date of shipment (whichever
occurs first).
In order to obtain service under this warranty, it
is the responsibility of the purchaser to
promptly notify the local TES stocking distribu-
tor or TES in writing and promptly deliver the
subject product or part, delivery prepaid, to the
stocking distributor. For assistance on war-
ranty returns, the purchaser may either contact
the local TES stocking distributor or TES. If the
subject product or part contains no defect as
covered in this warranty, the purchaser will be
billed for parts and labor charges in effect at
time of factory examination and repair.
Any TES product or part not installed or oper-
ated in conformity with TES instructions or
which has been subject to accident, disaster,
neglect, misuse, misapplication, inadequate
operating environment, repair, attempted
repair, modification or alteration, or other
abuse, will not be covered by this warranty.
TES products are not intended for use to sup-
port fire suppression systems, life support sys-
tems, critical care applications, commercial
aviation, nuclear facilities or any other applica-
tions where product failure could lead to injury
to person, loss of life, or catastrophic property
damage and should not be sold for such pur-
poses.
If in doubt as to whether a particular product is
suitable for use with a TES product or part, or
for any application restrictions, consult the
applicable TES instruction sheets or in the U.S.
contact TES at 401-942-8000 and in Canada
contact Taco (Canada) Limited at 905-564-
9422.
TES reserves the right to provide replacement
products and parts which are substantially simi-
lar in design and functionally equivalent to the
defective product or part. TES reserves the
right to make changes in details of design, con-
struction, or arrangement of materials of its
products without notification.
TES OFFERS THIS WARRANTY IN LIEU OF
ALL OTHER EXPRESS WARRANTIES. ANY
WARRANTY IMPLIED BY LAW INCLUDING
WARRANTIES OF MERCHANTABILITY OR
FITNESS IS IN EFFECT ONLY FOR THE
DURATION OF THE EXPRESS WARRANTY
SET FORTH IN THE FIRST PARAGRAPH
ABOVE.
THE ABOVE WARRANTIES ARE IN LIEU OF
ALL OTHER WARRANTIES, EXPRESS OR
STATUTORY, OR ANY OTHER WARRANTY
OBLIGATION ON THE PART OF TES.
TES WILL NOT BE LIABLE FOR ANY SPE-
CIAL, INCIDENTAL, INDIRECT OR CONSE-
QUENTIAL DAMAGES RESULTING FROM
THE USE OF ITS PRODUCTS OR ANY INCI-
DENTAL COSTS OF REMOVING OR
REPLACING DEFECTIVE PRODUCTS.
This warranty gives the purchaser specific
rights, and the purchaser may have other rights
which vary from state to state. Some states do
not allow limitations on how long an implied
warranty lasts or on the exclusion of incidental
or consequential damages, so these limitations
or exclusions may not apply to you.
LIMITED WARRANTY STATEMENT