Nordic - Model WH Series - High-Temperature Heat Pump - Brochure

02 JAN 2014 Page 1 001200MAN-05 Maritime Geothermal Ltd. P.O. Box 2555 Petitcodiac, N.B. E4Z 6H4 Ph. (506) 756-8135 R-Series Slim Design Two-Stage R410a Model Sizes 25-80 Email: info@nordicghp.com Web: www.nordicghp.com Document Number: 001200MAN-05 ECO 000212 DATE : 02 JAN 2014 Liquid to Air Geothermal Heat Pumps Installation and Service Manual Page 2 001200MAN-05 02 JAN 2014 SAFETY PRECAUTIONS WARNING: Ensure all access panels are in place and properly secured before applying power to the unit. Failure to do so may cause risk of electrical shock. WARNING: Before performing service or maintenance on the heat pump system, ensure all power sources are DISCONNECTED. Electrical shock can cause serious personal injury or death. WARNING: Heat pump systems contain refrigerant under high pressure and as such can be hazardous to work on. Only qualified service personnel should install, repair, or service the heat pump. CAUTION: Safety glasses and work gloves should be worn at all times whenever a heat pump is serviced. A fire extinguisher and proper ventilation should be present whenever brazing is performed. CAUTION: Venting refrigerant to atmosphere is illegal. A proper refrigerant recovery system must be employed whenever repairs require removal of refrigerant from the heat pump. Series: R = Active Cooling Liquid to Air MODEL NOMENCLATURE Nominal Size: 25 = 2 Ton 45 = 3 Ton 55 = 4 Ton 65 = 5 Ton 75 = 6 Ton 80 = 6 Ton Single Stage Functions: H = Heating AC = Active Cooling W = Domestic Hot Water Refrigerant: P = R410a Voltage Code: 1 = 230-1-60 VAC 2 = 208-3-60 VAC 6 = 220-1-50 VAC 7 = 380-3-50 VAC Outdoor Loop Exchanger: C = Copper Z = Cupro-Nickel (CuNi) Air Coil: S = Standard Fan Type: D = Direct Drive Fan Motor: E = ECM (Variable Speed) Fan Return Orientation: L = Left Return R = Right Return Fan Outlet Orientation: D = Down flow F = Field Configurable Revision: 01, 02 etc. R—65—HACW—P—1T—C—SDERF—xx Compressor Stages*: S = 1 Stage T = 2 Stage * 2 stage unless unavailable due to voltage code, refer to the Electrical Tables. 02 JAN 2014 Page 3 001200MAN-05 APPLICATION TABLE SIZE FUNCTION REFRIGERANT VOLTAGE COMPRESSOR STAGES* OUTDOOR COIL FAN/CASE REVISIONS 25 HACW P 1 T C Z SDELF SDERF 09 2 T 09 6 T 09 7 T 09 45 HACW P 1 T C Z SDELF SDERF 09 2 T 09 6 S 09 7 T 09 55 HACW P 1 T C Z SDELF SDERF 09 2 T 09 6 S 09 7 T 09 65 HACW P 1 T C Z SDELF SDERF 09 2 T 09 6 S 09 7 T 09 75 HACW P 1 T C Z SDELF SDERF 09 2 T 09 6 S 09 7 T 09 80 HACW P 1 S C Z SDELF SDERF 09 2 S 09 7 S 09 This manual applies only to the models and revisions listed in this table * T = Two Stage, S = Single Stage Maritime Geothermal Ltd. has a continuous improvement policy and reserves the right to modify specification data at any time without prior notice . Page 4 001200MAN-05 02 JAN 2014 TABLES, DIAGRAMS & DRAWINGS: ……..……...………….……………………………………………………………… PAGE 5 INSTALLATION INFORMATION: …………………...………….……………………………………………………………… PAGE 6 Unit description: …………………………………………………………………………………………………..…... Page 6 Unpacking the unit: …………………………………………………………………………………………………... Page 6 Optimum Placement: …………………………………………………………………………………………………. Page 6 Electrical Connections: ……………………………………………………………………………………………… Page 6 Control Transformer : ……..…………………...…………………………………………………………………… Page 6 Circulator Pump Module Wiring (Ground Loop Only): …………………………………………………………. Page 6 Thermostat Requirements: ………………………………………………………………………………………….. Page 7 Fan Motor: ……………………………………………………………………………………………………………… Page 7 Fan Return Orientation: ………………………...…………………………………………………………………… Page 7 Fan Outlet Orientation : ………………………...…………………………………………………………………… Page 7 Safety Controls: ………………………………………………………………………………………………………. Page 7 Domestic Hot Water Connections (HACW only): …………………..…………………………………………… Page 8 SIZING AND DUCTWORK: ………………...…………………………………………………………………………………… PAGE 11 Heat Pump Sizing: ……………………………………………………………………………………………………. Page 11 Duct Systems - General: …………………………………………………………………………………………….. Page 11 Duct Systems - Grill Layout: ………………………………………………………………………………………… Page 11 Thermostat Location: ………………………………………………………………………………………………… Page 12 Plenum Heater (Optional): …………………………………………………………………………………………… Page 12 Condensate Drain: …………………………………………………………………………………………………….. Page 12 Duct Sizing Guide: ……………………………………………………………………………………………………. Page 14 GROUND WATER SYSTEM INFORMATION: ………………………………………………………………………………… PAGE 15 General Requirements: ………………….…………………………………………………………………………… Page 15 Plumbing the Heat Pump: ……………………………………………………………………………………………. Page 15 Pipe Insulation: ………………………………………………………………………………………………………… Page 15 Water Discharge Methods: …………………………………………………………………………………………… Page 15 GROUND LOOP SYSTEM INFORMATION: ………………………………………………………………………………….. PAGE 18 Circulator Pump Module: ……………………………………………………………………………………………. Page 18 Flushing & Purging the Ground Loop: ……………………………………………………………………………. Page 18 Adding Antifreeze Solution: ………………………………………………………………………………………… Page 19 Initial Pressurization: ………………………………………………………………………………………………… Page 19 Pipe Insulation: ……………………………………………………………………………………………………….. Page 19 STARTUP PROCEDURE: ………………………………………………………………………………………………………. Page 21 Pre-start Inspection: …………………………………………………………………………………………………. Page 21 Unit Startup: …………..………………………………………………………………………………………………. Page 22 Startup Record: ……………….………………………………………………………………………………………. Page 23 GENERAL MAINTENANCE: ……………...…………………….……………………………………………………………… PAGE 24 TROUBLESHOOTING GUIDE: ………………………………….……………………………………………………………… PAGE 25 Repair Procedures: …………………………………………………………………………………………………… Page 34 MODEL SPECIFIC INFORMATION: …………………..………………………………………………………………………. PAGE 35 Refrigerant Charge Chart: …………………………………………………………………………………………… Page 35 Shipping Information: …………………………………………………………………………………………...…… Page 35 Standard Capacity Ratings: …………..……………………………………………………………………………. Page 35 Capacity Ratings: ………..………………..…………………………………………………………………………. Page 37 Electrical Tables: ……………………………………………………………………………………………………… Page 43 Electrical Diagrams: ………………………..………………………………………………………………………… Page 45 Refrigeration Circuit Diagrams: ……………………………………………………………………………………. Page 49 Case Details: ………………………….…..…………………………………………………………………………… Page 51 APPENDIX A: Control Board Specifications: ……………………………………………………………………………… PAGE 57 APPENDIX B: ECM Fan Airflow Tables: ……………………………………………………………………………………. PAGE 58 WARRANTY INFORMATION: ………………………………………………………………………………………………….. PAGE 60 Table of Contents 02 JAN 2014 Page 5 001200MAN-05 Tables, Diagrams and Drawings TABLES Table 1 - Power Supply Connections (Heat Pump): ……………...………………………………...…..…….... Page 6 Table 2 - Power Supply Connections (Optional Plenum Heater): ………..……………………...…..…….... Page 6 Table 3 - Control Signal Description: …….………………………………………………………………..…….... Page 7 Table 4 - Airflow Selections: ………………………………………………………………………………………... Page 7 Table 5 - Control Board Fault Codes: ……...……………………………………………………………………... Page 8 Table 6 - Heat Pump Size vs. Heated Area for Ground Loop Systems: …..………………………………... Page 11 Table 7 - Heat Pump Size vs. Heated Area for Ground Water Systems: ….………………………………... Page 11 Table 8 - Heat Pump Size vs. Hot Air Grills: …..………………………………….……………………………... Page 12 Table 9 - Plenum Heater Sizing: …..………………………………………………..……………………………... Page 12 Table 10 - Duct Sizing Guide: …………………………………………………...………………………………... Page 14 Table 11 - Required Flow and Air Tank Sizing: …..……………………………………………….……………... Page 15 Table 12 - Antifreeze Percentages by Volume: ………………………………..………………………………... Page 19 Table 13 - Volume of Fluid per 100ft. Of Pipe: …..………………………………….…………………………... Page 19 Table 14 - Refrigerant Charge Chart: …..………………………..………………….….………………………... Page 35 Table 15 - Shipping Information: ………...………………………..………………….….………………………... Page 35 Table 16 - Standard Capacity Ratings - Ground Loop Heating 60Hz: …………..…………………………... Page 35 Table 17 - Standard Capacity Ratings - Ground Water Heating 60Hz: …………….………………………... Page 35 Table 18 - Standard Capacity Ratings - Ground Loop Cooling 60Hz: …….…….…………………………... Page 36 Table 19 - Standard Capacity Ratings - Ground Water Cooling 60Hz: …..…….………….………………... Page 36 Table 20 - Heat Pump Electrical Information (208/230-1-60): …..…………………….……..………………... Page 43 Table 21 - Heat Pump Electrical Information (208-3-60): …..…………………….….………………………... Page 43 Table 22 - Heat Pump Electrical Information (460-3-60): …..…………………….….………………………... Page 43 Table 23 - Heat Pump Electrical Information (220-1-50): …..…………………….….………………………... Page 43 Table 24 - Heat Pump Electrical Information (380-3-50): …..…………………….….………………………... Page 44 Table 25 - Plenum Heater Electrical Information (208/230-1-60): ……………….….………………………... Page 44 DIAGRAMS Diagram A - Typical P/T (Pete’s) Plug & Thermometer Stem: …….……………………….…………..…….. Page 18 Diagram B - Typical Purge Cart: …………………………………………………………………………………… Page 18 Case Details - Left Return - Size 25 to 75: ……..…………….…………...………………………………….….. Page 51 Case Details - Right Return - Size 25 to 75: ……..………….…………...………………………………….….. Page 53 Case Details - Left Return - Size 80: ……..…………….…………...…………..…………………………….….. Page 55 Case Details - Right Return - Size 80: ……..………….…………...….…………..………………………….….. Page 56 DRAWINGS 001827CDG - Typical Thermostat Connections: ………………………………………….…………………….. Page 9 000970PDG - Single Unit Connection to DHW Pre-Heat Tank (Brass FPT): ……………………………….. Page 10 001201CDG - Typical Duct and Condensate Connections (Modular Case): ………………………………. Page 13 000907CDG - Typical Ground Water Installation for Size 25-75 Heat Pumps (Brass FPT): …………….. Page 16 000619INF - Ground Water Disposal Methods: ………………………………………………………………… Page 17 000906CDG - Geo-Flo Circulator Pump Module Installation (Brass FPT): ………………………………… Page 20 001754SCH-01 - R-25-75-HAC*-P-1*-*-*DE** Schematic Diagram: …………….…………..…………..…… Page 45 001755ELB-01 - R-25-75-HAC*-P-1*-*-*DE** Electrical Box Diagram: ….…………..………………..……… Page 46 001135SCH-03 - R-**-HAC*-P-1*-*-*DE** Schematic Diagram: …………….…….…………..…………..…… Page 47 001136ELB-03 - R-**-HAC*-P-1*-*-*DE** Electrical Box Diagram: …………………..………………..……… Page 48 001207RCD - R(H)-Series Refrigeration Circuit Diagram—Heating Mode: …….…………………………… Page 49 001208RCD - R(H)-Series Refrigeration Circuit Diagram—Cooling Mode: …….…………………………… Page 50 Page 6 001200MAN-05 02 JAN 2014 UNIT DESCRIPTION The R-Series unit is a high efficiency two-stage geother-mal heat pump. Two-stage units offer longer runtimes and few-er cycles resulting in higher efficiency and a higher comfort lev-el. The heat pump contains environmentally friendly R410a refrigerant. An electrically commutated (ECM) fan with several speed options is standard. The motor has a soft start function for im-proved efficiency and reduced wear. The unit has several key features that are described in the specifications document for the particular heat pump. Please request a copy if desired or visit www.nordicghp.com UNPACKING THE UNIT When the heat pump reaches its destination it should be unpacked to determine if any damage has occurred during shipment. Any visible damage should be noted on the carrier's freight bill and a suitable claim filed at once. The heat pump is well constructed and every effort has been made to ensure that it will arrive intact, however it is in the customer's best interest to examine the unit thoroughly when it arrives. OPTIMUM PLACEMENT For liquid to air units, to achieve the greatest efficiency, the heat pump should be centrally located in the home with respect to the conditioned space. This design provides the utmost in economy and comfort and usually can be accomplished in harmony with the design of the home. A heating system cannot be expected to produce an even warmth throughout the household when it is located at one end of the structure and the warm air is transmitted with uninsulated metal ductwork. If possible the access panels should remain clear of obstruction for a distance of two feet to facilitate servicing and general maintenance. Raising the heat pump off the floor a few inches is generally a good practice since this will prevent rusting of the bottom panel of the unit. We recommend that the heat pump be placed on a piece of 2'' thick styrofoam. The styrofoam will smooth out any irregularities in the cement floor and deaden any compressor noise emitted from the bottom of the cabinet. The heat pumps come equipped with an air-filter rack which can be installed with the removable end (where the filter is in-serted) on either side to facilitate changing the filter. ELECTRICAL CONNECTIONS The heat pump has a concentric 1.093” / 0.875” knockout for power supply connection to the electrical box, as well as one for connection to the circulator pump module for ground loop applications. There are two 1/2” openings with plastic grom-mets (grommet hole is 3/8”) in the upper section of the electrical box, one for the thermostat connections, and one for the option-al plenum heater connections. A schematic diagram (SCH) and electrical box layout diagram (ELB) can be found inside the electrical box cover of the unit as well as in the Model Specific section of this manual. The Electrical Tables in the Model Specific section and the ELB diagram contain information about the size of wire for the connections, as well as the recommended breaker size for both the heat pump and optional plenum heater. Connections are as per TABLE 1 and TABLE 2. NOTE: There are two separate power supplies, one for the heat pump and a second one for the plenum heater if in-stalled, each must have its supply wires and breaker. NOTE: A properly qualified electrician should be retained to make the connections to the heat pump and associated controls. The connections to the heat pump MUST CON-FORM TO LOCAL CODES. CONTROL TRANSFORMER The low voltage controls are powered by a 75VA class II transformer. The transformer has a resettable breaker on the secondary side for circuit protection. Should the breaker trip, locate and correct the problem and then reset the breaker by pressing in on it. IMPORTANT NOTE: For 208/230VAC-1-60 units, if connect-ing to 208VAC power supply move the red wire connected to the 240 terminal of the transformer to the 208 terminal of the transformer. CIRCULATOR PUMP MODULE WIRING (GROUND LOOP ONLY) The heat pump has provisions for connecting the circulator pump module so that the pumps will be turned on whenever the compressor operates. Connect the circulator pump module to the appropriate two terminals of the terminal strip marked OUTDOOR CIRCULATORS in the heat pump, as per the volt-age of the circulator pump module. Ensure that the total current draw does not exceed the value indicated on the label in the heat pump electrical box. Refer to the electrical box drawing on the electrical box cover for more information. Installation Information TABLE 1 - Power Supply Connections (Heat Pump) Line Description Voltages L1 Line 1 All L2 Line 2 All L3 Line 3 208-3-60, 460-3-60, 380-3-50 N** Neutral 208/230-1-60, 208-3-60, 380-3-50 ** Only required if connecting 115VAC circulators to the heat pump for 208/230-1-60 and 208-3-60 models, the heat pump itself does not require a neutral. Required for 380-3-50 models. TABLE 2 - Power Supply Connections (Optional Plenum heater) Line Description Voltages L1 Line 1 208/230-1-60, 208-3-60 L2 Line 2 208/230-1-60, 208-3-60 Contact factory for three phase plenum heater requirements. 02 JAN 2014 Page 7 001200MAN-05 THERMOSTAT REQUIREMENTS The R-Series model requires a three-stage heating and two stage cooling heat pump configurable thermostat for two-stage models. The stages are S1 = Stage 1 compressor, S2 = Stage 2 compressor and S3 = electric auxiliary (heating only). One can be purchased with the unit, or other heat pump thermo-stats with the same number of stages can be used. The electri-cal box diagram on the electrical box cover provides a descrip-tion of the signal connections as in TABLE 3. Refer to DRAW-ING 001827CDG for a diagram of the connections between the thermostat and the heat pump. NOTE: Some models are not available in two-stage at the pre-sent time, models numbers with a T in the Compressor Stages designator are two-stage, models with an S are single stage (verify the model number against pages 2 and 3 of this manual, or refer to the Electrical Tables near the end of this manual to determine if the model is two stage or one stage). The Y2 sig-nal is not used for these units, and they only require a 2 stage heat 1 stage cool thermostat. The stages are S1 = Compressor and S2 = electric auxiliary (heating only). If the selected thermo-stat has more stages than this, configure it for 2 and 1. FAN MOTOR The unit is equipped with a direct drive ECM fan motor for maximum efficiency. The motor features a soft start which fur-ther improves efficiency by eliminating inrush current and pro-vides a smooth, quiet ramp up to speed . The motor will main-tain the programmed air flow up to the maximum external static value. Refer to the APPENDIX B: ECM Fan Airflow Tables. The air flow can be set to four different levels by changing the position on the Air Flow board located in the electrical box. The four levels are indicated in TABLE 4. The actual air flow values can be found in APPENDIX B. Units are shipped with the MED position selected for nomi-nal air flow. The air flow can be further reduced by 15% by making a dry contact across AR1 and AR2 on the terminal strip. This can be used for applications that have multiple zones, or retrofits with undersized ductwork, to help reduce air flow noise in the ductwork. It is recommended that airflow reduction only be used with the High or Max air flow setting. Care should be taken to ensure that the unit does not trip a safety control in heating or cooling mode if the 15% reduction is used in conjunc-tion with the MED or LOW air flow setting. FAN RETURN ORIENTATION The R-Series heat pump can be ordered as a left or right hand return from the factory. This must be specified at time of order as the physical construction of the two configurations is different. Refer to the CASE DETAILS section of this manual or the specification documents for physical dimensions of the units. FAN OUTLET ORIENTATION The R-Series heat pumps have a field configurable fan. It’s default location from the factory is in the top of the unit, providing a “ninety” in the airflow. It can easily be placed in the side of the unit for straight through airflow. To switch the location of the fan outlet follow these simple steps: 1. Turn the power of to the unit. 2. Remove the screw that holds the side access panel in place and remove the access panel by pulling up on the handle and then outward from the bottom. 3. Disconnect the two wire harnesses and ground wire from the fan motor. 4. Repeat step 2 for the access panel with the fan mounted in it. Set the assembly on the floor. 5. Disconnect the plenum heater extension from the fan housing and from the access panel. 6. Mount the fan housing directly to the access panel. 7. Install the fan/panel in the new location and secure with the screw. 8. Reconnect both harnesses and ground wire. 9. Install the remaining access panel and secure with the remaining screw. SAFETY CONTROLS The heat pump has two built in safety controls which are designed to protect the unit from situations which could damage it should the operation of the refrigeration circuit fall outside the allowable operating range. A. Low Pressure Control The low pressure control monitors the compressor suction pressure and will shut the compressor down if the refrigerant evaporating pressure becomes too low, risking the danger of freezing conditions in the evaporator. There are (3) main reasons why this control would activate in response to the operating conditions of the unit while operat-ing in heating mode: 1. Low or no Outdoor loop flow. 2. Low Outdoor loop entering liquid temperature. 3. Dirty or fouled Outdoor loop heat exchanger. TABLE 4 - Airflow Selections Position Airflow LOW -6% MED Nominal HIGH +6% MAX +12% TABLE 3 - Control Signal Description Signal Description C 24VAC Common (Ground) G Fan low speed (for air circulation) Y1 Heat Pump Stage 1 RH 24VAC Hot L Fault (24VAC when fault condition) W2 Heat Pump Stage 3 (auxiliary heat) / Emergency Heat O Cooling Mode (reversing valve) Y2 Heat Pump Stage 2 (Not used for single stage units) AR1 Airflow Reduction* AR2 Airflow Reduction* C(I) Plenum Heater dry contact (Connect to C or I in plenum heater) 1 Plenum Heater dry contact. (Connect to 1 and 2 in plenum heater) * Connect AR1 to AR2 with a dry contact to reduce the air-flow by 15%. Refer to the Fan Motor sub-section for more information. Page 8 001200MAN-05 02 JAN 2014 B. High Pressure Control The high pressure safety control monitors the compressor discharge pressure and will shut the compressor down if the condensing pressure becomes too high. There are (3) main reasons why this control would activate in response to the operating conditions of the unit while operat-ing in heating mode: 1. Low or no airflow. 2. High return air temperature. 3. Dirty air coil due to poor filter maintenance. The unit contains a control board that monitors the safety controls and operates the compressor accordingly. Refer to APPENDIX A for control board specifications. The low pressure control is connected to LP1 and LP2. The high pressure control is connected to HP1 and HP2. The control board also has provisions for a flow switch. The flow switch is unused from the factory and a jumper wire is placed across the FLOW SWITCH terminals. If a flow switch is desired, the jumper can be removed and the two leads from the flow switch can be connected to the FLOW SWITCH terminals on the safety board. The flow switch is ignored for 5 seconds on compressor startup to allow time for flow to be established. The high and low pressure controls are monitored at all times. The compressor will not be able to start if either of them has a fault. The control board has an on-board LED and a FAULT pin with a 24VAC output, which is routed to the L terminal of the thermostat terminal strip. An external indicator or relay can be connected across L and C on the terminal strip if external sig-naling is desired. Should a fault condition occur, the LED will flash the code of the fault condition while the safety control in question is open. The codes are shown in TABLE 5. The con-trol board will lock out the compressor for five minutes when a fault occurs. The control board will then restart the compressor if the fault has been cleared. Should a second fault condition occur within a 60 minute period the control board will go into permanent lockout mode and energize the FAULT pin. The LED will flash the fault code until the control board is reset by powering down the unit. WARNING: If the control board enters permanent lockout mode there is a serious problem with the system and it must be rectified if the unit is to maintain good service. WARNING: REPEATED RESETS OF A LOW PRES-SURE LOCKOUT COULD CAUSE THE HEAT EX-CHANGER TO FREEZE AND RUPTURE, DESTROYING THE HEAT PUMP AND VOIDING THE WARRANTY. DOMESTIC HOT WATER CONNECTIONS (HACW only) The port connections for the DHW circuit are 1/2” brass FPT fittings. They are marked as DHW IN and DHW OUT A typical piping diagram for a pre-heat tank configuration can be found in DRAWING 000970PDG at the end of this sec-tion. Be sure to note the position of the check valve and the direction of water flow. Other configurations are possible, and there may be multiple units tied together in larger buildings. WARNING: USE ONLY COPPER LINES TO CONNECT THE DESUPERHEATER. TEMPERA-TURES COULD REACH 200F SHOULD THE DHW CUTOUT SWITCH FAIL, POTENTIALLY RUPTURING PEX PIPING. Ensure the tank is filled with water and under pressure before activating the heat pump. Slightly loosen the boiler drain on the DHW Out pipe to allow air to escape from the system before the unit is started. This step will make certain that the domestic hot water circulator in the unit is flooded with water when it is started. CAUTION: the domestic hot water pump is water lu-bricated; damage will occur to the pump if it is run dry for even a short period of time. Connect the brown wire with the blue insulated terminal to L1 of the compressor contactor. Ensure the power is off when connecting the wire. The DHW loop may have to be purged of air several times before good circulation is obtained. A temperature difference between the DHW In and DHW Out can be felt by hand when the circulator pump is operating properly. For the pre-heat tank setup, the final tank should be set to 140°F(60°C), unless local code requires a higher setting. The pre-heat tank does not require electric elements. This setup takes full advantage of the desuperheater as it is the sole heat provider to the pre-heat tank. The desuperheater remains active during the compressor runtime until the pre-heat tank has been completely heated by the desuperheater alone. This setup is more energy efficient than a single tank setup. CAUTION: If two (2) shut-off valves are located on the domestic hot water ines as shown in the diagram, a pressure relief valve must be installed to prevent possible damage to the domestic hot water circulator pump should both valves be closed. TABLE 5 - Control Board Fault Codes Fault LED Flashes High Pressure 1 Low Pressure 2 Flow 3 02 JAN 2014 Page 9 001200MAN-05 Page 10 001200MAN-05 02 JAN 2014 02 JAN 2014 Page 11 001200MAN-05 heat pump are greatly reduced. Once the total heat loss has been calculated, the unit can be sized using the performance tables (from the specifications document) in conjunction with the minimum expected entering liquid temperature of the ground loop (well water temperature for ground water system). The heat pump output must be able to match the total heat loss at the selected entering water tempera-ture in order to provide a comfortable environment with minimal auxiliary heat. DUCT SYSTEMS - GENERAL Ductwork layout for a heat pump will differ from traditional hot air furnace design in the number of leads and size of main trunks required. Air temperature leaving the heat pump is normally 95º -105ºF (35-40ºC), much cooler than that of a conventional warm air furnace. To compensate for this, larger volumes of lower temperature air must be moved and consequently duct sizing must be able to accommodate the greater air flow without creating a high static pressure or high velocity at the floor diffusers. A duct system capable of supplying the required air flow is of utmost importance. Maritime Geothermal Ltd. recommends that the static pressure be kept below 0.2 inches of water total. In some instances the number of floor diffusers will actually double when compared to the number that would be used for a hot air oil-fired furnace. Refer to TABLE 10 at the end of this section. 1. Generally allow 100 cfm for each floor grill. 2. All leads to the grills should be 6'' in diameter (28sq.in. each). 3. The main hot air trunks should be at least 75% of the square surface area of leads being fed at any given point. 4. Return air grills should have a minimum of the same total square surface area as the total of the supply grills. 5. The square surface area of the return trunks should equal the square surface area of the grills being handled at any given point along the trunk. It is VERY IMPORTANT that all turns in both the supply trunks and the return trunks be made with TURNING RADII. Air act like a fluid and, just like water, pressure drop is increased when air is forced to change direction rapidly around a sharp or irregular corner. It is recommended that flexible collars be used to connect the main trunks to the heat pump. This helps prevent any vibrations from travelling down the ductwork. If a plenum heater is in-stalled, the collar should be at least 12” away from the heater elements. The first 5-10 feet of the main supply trunks should be insulat-ed with acoustical duct insulation to further inhibit any noise from the unit from travelling down the ductwork. If a plenum heater is installed, insulation should not be placed within 12” of the heater elements. DRAWING 001201CDG shows a typical installation. HEAT PUMP SIZING TABLE 6 depicts a rough guideline as to the size of home each heat pump size can handle for ground loop installations. TABLE 7 depicts a rough guideline as to the size of home each heat pump size can handle for ground water installations. THE TABLES ABOVE ARE FOR INFORMATION ONLY, THEY SHOULD NOT BE USED TO SELECT A UNIT SIZE. They simply show on average what size unit is required for a typical two-level home (main level and below grade basement) with R-20 walls, R-40 ceiling and average size and number of windows. The Heated Area is the area of the main level, The tables account for a basement the same size as the heated ar-ea. MARITME GEOTHERMAL LTD. HIGHLY RECOMMENDS THAT A PROPER HEAT LOSS/GAIN ANALYSIS BE PER-FORMEDE BY A PROFESSIONAL INSTALLER WITH CSA APPROVED SOFTWARE BEFORE SELECTING THE SIZE OF UNIT REQUIRED FOR THE APPLICATION. For heating dominant areas, we recommend sizing the unit to 100% of the heating design load for maximum long term efficiency with minimal supplementary heat. The unit should be in-stalled as per CSA 448.2-02. For ground loop applications, the ground exchanger should be designed using suitable software with a multi-year analysis. There are many factors to consider when sizing the heat pump. Some of these factors include the number of levels, the size of the windows, the orientation of the home, attached gar-age, bonus rooms, walk-in basement, coldest outdoor tempera-ture, etc. The heat loss program will take all of these factors into consideration in its calculations. An undersized installation will not be as efficient as it will require excessive relatively ex-pensive supplemental heat to maintain a comfortable tempera-ture in the home, and the cost savings of having a geothermal TABLE 6 - Heat Pump Size vs. Heated Area for a Ground Loop System Model Sq.ft. Sq.m. 25 800 75 45 1,400 130 55 2,000 185 65 2,600 240 75 3,100 290 80 3,500 325 TABLE 7 - Heat Pump Size vs. Heated Area for a Ground Water System Model Sq.ft. Sq.m. 25 1,000 95 45 1,800 165 55 2,500 230 65 3,200 295 75 3,800 355 80 4,200 390 Sizing and Ductwork Page 12 001200MAN-05 02 JAN 2014 DUCT SYSTEMS - GRILL LAYOUT Most forced air heating systems in homes have the floor grills placed around the perimeter of the room to be heated. Supply grills should be placed under a window when possible to help prevent condensation on the window. As mentioned in the pre-vious sub-section, supply grill leads should be 6'' in diameter (28 sq.in. each) to allow 100cfm of air flow. In a typical new construction, there should be one supply grill for every 100sq.ft. of area in the room. When rooms require more than one grill, they should be placed in a manner that pro-motes even heat distribution, such as one at each end of the room. It is always a good idea to place a damper in each grill supply or place adjustable grills so that any imbalances in the heat distribution can be corrected. The total number of supply grills available is based on the heat pump nominal airflow. TABLE 8 shows the number of grills available per heat pump size. Return grills should be mounted on the floor. At minimum they should be the same size as the supply grill, it is highly recommended that they be 25% to 50% larger than the total supply. They should be placed opposite the supply grills when possible to ensure distribution across the room. For rooms re-quiring more than one supply grill, it may be possible to use one larger return grill if it can be centrally positioned opposite of the supply grills, however it is preferred to have one return for each supply to maximize heat distribution across the room. THERMOSTAT LOCATION Most homes are a single zone with one thermostat. The ther-mostat should be centrally located within the home, typically on the main floor. It should be placed away from any supply grills, and should not be positioned directly above a return grill. Most installations have the thermostat located in a hallway, or in the inner wall of the living room. It should be noted that most homes do not have any supply ducts in the hallway. This can lead to a temperature lag at the thermostat if there is very little air movement in the hallway, causing the home to be warmer than indicated by the thermostat. PLENUM HEATER (OPTIONAL) For installations that do not already have a backup heat source such as electric baseboard, wood stove, propane etc, it is recommended that a plenum heater be installed. This pro-vides two functions. The first function of the plenum heater is to act as an auxiliary heat source. As such it will provide additional heat on extremely cold days if the heat pump is unable to bring the home tempera-ture up quickly enough, eliminating any discomfort to the home-owner. TABLE 8 - Heat Pump Size vs. Hot Air Grills Model Size (tons) # of Grills (@100cfm) 25 2 8 45 3 12 55 4 15 65 5 19 80 6 24 75 6 21 The second function of the plenum heater is to provide emer-gency heat should a problem occur that causes the heat pump to be locked out. This can be engaged by setting the thermostat to emergency heat, allowing the plenum heater to function while preventing the heat pump from operating. Should the heat pump fail while the home is vacant, the auxiliary function of the thermostat will maintain the temperature setting of the thermo-stat. INSTALLATION—Fan outlet at top of unit: The heat pump comes equipped with an internal mounting location for the ple-num heater. Remove the screws from the cover plate, remove the cover plate and place the plenum heater in the hole. Secure it in place with the cover plate screws. Use the indicated knock-outs on the heat pump case for electrical connections. When installation is complete, check the appropriate box of the label on the unit door to indicate which size heater was installed. INSTALLATION—Fan outlet at side of unit: The plenum heater should be installed in the supply duct in a manner that allows all of the airflow to pass through it to prevent any hot spots in the heater elements. Ensure that the plenum heater is mounted in an approved position as per its instructions. Only two control wires are needed to connect the plenum heater to the heat pump terminal strip. Refer to the label on the plenum heater or the electrical box diagram on the inside of the electrical box cover of the compressor unit for details on the connections. The plenum heater requires its own separate power sup-ply. TABLE 9 shows the recommended size plenum heater, as well as the wire size and breaker size needed to provide power to the plenum heater. Refer to the Electrical Tables for electri-cal connection information. CONDENSATE DRAIN The unit comes equipped with a 3/4” PVC socket fitting (female) labeled “Condensate Drain”. This drain allows the con-densate which forms during the air-conditioning cycle to be re-moved from the unit. The drain should be connected as per local codes. During high humidity weather, there could be as much as 25 gallons of water formed per day. Care should be taken in the spring to ensure that this pipe is not plugged with dust that has collected during the winter caus-ing the condensate to overflow into the bottom of the heat pump and onto the floor. The condensate drain is internally trapped; however, proper venting is required external to the heat pump. Refer to local codes to ensure the installa-tion is done properly. DRAWING 001201CDG shows a typical installation. TABLE 9 - Plenum Heater Sizing Heat Pump Plenum Heater Sizes (kW) Model Size Recommended Available 25 7 5 55 10 7 15 65 15 10 20 75 - 80 20 15 45 10 7 02 JAN 2014 Page 13 001200MAN-05 Page 14 001200MAN-05 02 JAN 2014 Airflow (CFM) Diameter (in) Rectangular Equivalents (in) Return Air Diameter (in) Airflow (L/s) 37 5 2.25 x 10 3 x 8 3.5 x 6 4 x 5.5 5 x 5 ` 5 17 63 5 2.25 x 10 3 x 8 3.5 x 6 4 x 5.5 5 x 5 6 30 100 6 3.25 x 10 4 x 8 5 x 6 5.5 x 5.5 6 x 6 7 47 152 7 3.25 x 14 4 x 11 5 x 8.5 6 x 7 6.5 x 6.5 8 72 212 8 4 x 15 5 x 12 6 x 10 7 x 8 8 x 8 9 100 226 8 4 x 15 5 x 12 6 x 10 7 x 8 8 x 8 10 107 277 9 5 x 15 6 x 12 7 x 10 8 x 9 8.5 x 8.5 10 131 304 9 5 x 15 6 x 12 7 x 10 8 x 9 8.5 x 8.5 12 143 393 10 6 x 15 7 x 13 8 x 11 9 x 10 9.5 x 9.5 12 185 411 12 7 x 18 8 x 16 9 x 14 10 x 12 11 x 11 12 194 655 12 7 x 18 8 x 16 9 x 14 10 x 12 11 x 11 14 309 680 14 8 x 22 9 x 19 10 x 17 11 x 15 12 x 14 13 x 13 14 321 995 14 8 x 22 9 x 19 10 x 17 11 x 15 12 x 14 13 x 13 16 470 1325 16 8 x 30 10 x 22 12 x 18 14 x 16 15 x 15 18 625 1450 16 8 x 30 10 x 22 12 x 18 14 x 16 15 x 15 20 684 1750 18 8 x 40 10 x 30 12 x 24 14 x 20 16 x 17 16.5 x 16.5 20 826 2000 18 8 x 40 10 x 30 12 x 24 14 x 20 16 x 17 16.5 x 16.5 22 944 2250 20 10 x 38 12 x 30 14 x 26 16 x 22 18 x 19 18.5 x 18.5 22 1062 2600 20 10 x 38 12 x 30 14 x 26 16 x 22 18 x 19 18.5 x 18.5 24 1227 2900 22 12 x 36 14 x 30 16 x 26 18 x 23 20 x 20 24 1369 3400 22 12 x 36 14 x 30 16 x 26 18 x 23 20 x 20 26 1605 3600 24 14 x 38 16 x 32 18 x 28 20 x 25 22 x 22 26 1699 4300 24 14 x 38 16 x 32 18 x 28 20 x 25 22 x 22 28 2029 5250 26 16 x 38 18 x 32 20 x 30 22 x 24 24 x 24 30 2478 6125 28 18 x 38 20 x 34 22 x 30 24 x 28 26 x 26 32 2891 6500 28 18 x 38 20 x 34 22 x 30 24 x 28 26 x 26 34 3068 7250 30 20 x 40 22 x 38 24 x 32 26 x 30 28 x 28 34 3422 7800 30 20 x 40 22 x 38 24 x 32 26 x 30 28 x 28 36 3681 8500 32 22 x 40 24 x 38 26 x 34 28 x 32 30 x 30 36 4012 9200 32 22 x 40 24 x 38 26 x 34 28 x 32 30 x 30 38 4342 9800 34 24 x 42 25 x 40 26 x 38 28 x 34 30 x 32 31 x 31 38 4625 10900 34 24 x 42 25 x 40 26 x 38 28 x 34 30 x 32 31 x 31 40 5144 28 x 40 30 x 36 32 x 34 33 x 33 30 x 42 32 x 38 34 x 36 35 x 35 30 x 45 34 x 40 36 x 38 37 x 37 TABLE 10 - Duct Sizing Guide (external static of 0.20”H2O) Minimum Duct Area (sq.in) 20 20 28 38 50 50 64 64 79 113 113 154 154 201 201 254 254 314 314 380 380 452 452 531 616 616 707 707 804 804 908 908 02 JAN 2014 Page 15 001200MAN-05 Water flow to the heat pump can be controlled very accurately by the installation of a reverse action refrigeration pressure valve in the discharge line of the unit. Another more common method of regulating the flow is by the use of a DOLE Valve. This valve will automatically control the amount of water flowing through it by varying the diameter of a flexible rubber orifice through which the water passes. This minimizes the water usage of the unit and also prevents exces-sively low discharge pressure when in cooling mode. Dole valves can be noisy, it is recommended that they be installed outside if possible. Optionally a water flow meter can be installed in the dis-charge line so that the exact amount of water flowing can be determined at a glance. It should be placed between the Out-door OUT (Supply OUT) pipe of the heat pump and the water valve. With Proper flow, there should be 5-7°F (3-4°C) delta T be-tween the IN and OUT water temperatures of the heat pump when operating in the heating mode. All water line valves on both the supply and discharge lines should be either BALL or GATE valves. GLOBE valves have a higher pressure drop, meaning more pumping power to maintain the required flow to the heat pump. PIPE INSULATION All ground water piping to and from the Outdoor Loop ports on the heat pump should be insulated with 3/8” closed cell pipe insulation, to prevent condensation and dripping onto floors or walls. WATER DISCHARGE METHODS Water disposal methods vary from area to area. However, some consideration should be made to prevent the cooled discharge water from immediately coming in contact with the supply source. Attempting to return the water to the source well will eventually cool the water so much that the heat pump will shut off on its low pressure safety control. Acceptable methods for disposing of the waste water are listed below. The waste water is clean, the heat pump has no effect other than reducing the temperature of the water. Refer to drawing 000907INF for typical disposal method diagrams. • Second well (return well) • Percolation (Drain, ditch, leaching field) • Pond, river or stream. ENSURE SELECTED METHOD CONFORMS TO LOCAL CODES. GENERAL REQUIREMENTS 1. The temperature of the well water should be a minimum of 39°F (4°C), and should normally be 45+°F (7°C) 2. The well system must be able to supply the required water flow as listed under the Total Flow column in TABLE 11. PLUMBING THE HEAT PUMP The port connections for the Outdoor Loop are 1” brass FPT fittings They are marked as OUTDOOR IN and OUT. Plumbing lines, both IN (supply) and OUT (discharge), must be of adequate size to handle the water flow necessary for the heat pump. A 1” copper or plastic line should be run to the Out-door IN (Supply IN) pipe of the heat pump. Similarly, a 1”' line should be run from the Outdoor OUT (Supply Out) pipe to the method of disposal. P/T plugs should be installed at each port. See Diagram A in the Ground Loop section for a description of P/T plugs. The water valve should be installed in the OUT (discharge) line. Refer to drawing 000907CDG at the end of this section for the recommended setup. Placing the water valve in the discharge line ensures that the heat exchanger in-side the heat pump remains full of water when the unit is not running. Unions or some other form of disconnect should be used so that the coaxial heat exchanger may be accessed should it required cleaning. The heat pump has an electrical connector for the water valve just inside the case. After the water valve is installed, run the valve harness into the case through the hole provided. Remove the jumper plug from the Valve Connector and connect the har-ness in its place. Ideally there will be water flow available in excess of the requirement of the heat pump. In such a situation the proper pump can be selected to maintain a pressure of 30 to 40 psig. on the lines when the heat pump is operating. However in some cases a well can supply a heat pump only if the minimum requirement for water is used. TABLE 11 - Required Flow and Air Tank Sizing Heat Pump Model Size Heat Pump Flow* USGPM (L/s) Home Flow USGPM (L/s) Total Flow USGPM (L/s) Minimum Air Bladder Tank** USgal (L) 25 7.0 (0.44) 4 (0.25) 11 (0.69) 22 (83) 45 10.0 (0.63) 4 (0.25) 14(0.88) 28 (106) 55 12.0 (0.76) 4 (0.25) 16(1.01) 32 (121) 65 14.0 (0.88) 4 (0.25) 18(1.14) 36 (136) 75 16.0 (1.01) 4 (0.25) 20 (1.26) 40 (151) 80 17.0 (1.07) 4 (0.25) 21(1.32) 42 (159) * These are minimum water requirements based on an entering water temperature of 46° F. **Based on two-minute well pump run time. Use next size larger tank if there is not a match for the value indicated. A larger tank may be used if a longer run time is desired. Ground Water System Information Page 16 001200MAN-05 02 JAN 2014 When snow comes it will usually cover the entire process much like a small spring. It is recommended that the pipe be below the frost line when possible for maximum freeze protec-tion. When discharging into a river or stream, or above the surface of a pond, the same guidelines should be followed as described in the paragraph above for the percolation method. When discharging the waste water below the surface of a pond, the discharge pipe should be placed below the frost line to prevent the pipe from freezing. As opposed to the percola-tion method, water will remain in the end of the pipe. It is rec-ommended that the surface of the pond be lower than the instal-lation location of the heat pump where practical. This reduces the back pressure generated by the weight of the water in the pond. A return well should be a minimum of 80 ft. from the supply well for residential applications. The water returned to the well will not necessarily be pumped into the same aquifer, depend-ing on underground conditions. The return well must be able to supply at least the same quantity of water as the amount you wish to recharge into it. If the static level (level when not being pumped) of a well is high (10 to 20 ft. from the surface) it may be necessary to place a well cap on the well to keep the return water from flowing out the top of the well. This cap is commonly required since a certain amount of pressure is needed to force the return water back down the well if the static level is high. Water discharged by percolation will generally soak into the ground within a distance of 50 to 100 ft. If suitable care is taken to ensure that the drain pipe runs downhill and the end of the pipe is protected by a bale of hay or spruce bows etc. the end of the pipe will not freeze as the pipe will empty out when the heat pump shuts off and the water valve closes. 02 JAN 2014 Page 17 001200MAN-05 Page 18 001200MAN-05 02 JAN 2014 Once the ground loop has been pressure tested and the header pipes have been connected to the circulator pump module, the heat pump can be connected to the circulator pump module. The port connections for the Outdoor Loop are 1” brass FPT fittings. They are marked as OUTDOOR IN and OUT. CIRCULATOR PUMP MODULE Maritime Geothermal Ltd. has compact pump modules with built in three way valves to facilitate filling and purging the ground loop. Refer to drawing 000906CDG at the end of this section. Alternatively, Grundfoss® Model UPS 26-99 or Taco® Model 0011 pumps or other brands with similar pumping capability may be used. The single pump module will typically handle systems up to 3 tons (model sizes 25, 35, and 45); the two pump module will typically handle 4 to 6 ton systems (model sizes 55, 65, 75, 80). This is based on a typical parallel system with one circuit per ton. Maritime Geothermal recommends calculating the total pressure drop of the ground loop (including headers, indoor piping and heat pump exchanger drop) based on the antifreeze type and concentration at the desired minimum loop temperature. A pump module that can deliver the flow required for the unit at the calculated total pressure drop should be selected. Refer to the Model Specific Information section for unit flow requirements. Loop pressure drops can be calculated using software such as those mentioned in the Horizontal Ground loops section, or can be calculated in a spreadsheet using the pipe manufacturer’s pressure drop tables for pipe diameter and fittings. The circulator pump module must be connected to the heat pump Outdoor Loop ports with a lineset suitable for the flow required with minimum pressure drop. 1” rubber or plastic lines should be used. The installation of P/T plugs (pressure / temperature, pronounced “Pete’s plugs” ) is recommended on both the entering and leaving lines at the heat pump (see Diagram A). The P/T plug will allow the installer or homeowner to check water flow through the loop by measuring the pressure difference through the heat exchanger and comparing it to that listed in the Model Specific Information section, or the specifications document. Optional fittings with P/T ports are available for the circulator pump modules sold by Maritime Geothermal Ltd.. FLUSHING & PURGING THE GROUND LOOP Once the groundloop has been installed and all connections are completed between the heat pump, circulator pump module and ground loop, the entire ground loop system should be pressure tested with air to 100 PSIG to make sure there are no leaks on any of the inside fittings. Soap all joints and observe that the pressure remains constant for 1 hour. When satisfied that all connections are leak free, release the air pressure and connect a purge cart (see Diagram B ) to the flushing access ports at the pump module (refer to drawing 000906CDG). A temporary flushing system can alternately be constructed using a 45 gal. barrel and a pump with sufficient volume and head capability to circulate fluid at a velocity of at least 2 ft./min. through all parts of the loop. Adjust the circulator pump module valves to connect the purge cart to the ground loop. Begin pumping water through the ground loop, ensuring that the intake of the pump stays submerged at all times by continuously adding water. Water flowing back from the return line should be directed below the water level in the barrel or flush tank to prevent air being mixed with the outgoing water. DIAGRAM A - Typical P/T (Pete’s) Plug & Thermometer Stems DIAGRAM B - Typical Purge Cart Ground Loop System Information 02 JAN 2014 Page 19 001200MAN-05 Once the lines have been filled and no more air bubbles are appearing in the line, adjust the circulator pump module valves to circulate water through the heat pump using the same technique as described above. When all air is removed reverse the flow of water through the lines by interchanging the flush cart lines and purge again. You will be able to visibly tell when all air is removed. ADDING ANTIFREEZE SOLUTION In most mid and northern areas of the US and in all of Canada it is necessary to condition the loop fluid by the addition of some type of antifreeze solution so that it will not freeze during operation in the winter months. This antifreeze is required because the loop fluid will normally reach a low entering temperature of 28°F to 32°F (-2°C to 0°C) and refrigerant temperatures inside the heat pump’s heat exchanger may be as low as 20°F (11°C) cooler. See TABLE 12 for details of freeze protection provided by different concentrations. WARNING: Add enough antifreeze to allow for a temperature 20°F (11°C) lower than the expected lowest loop fluid temperature entering the heat pump. Insufficient antifreeze concentration could cause the heat exchanger to freeze and rupture, voiding the warranty. Although many different antifreeze solutions have been employed in geothermal systems, the alcohols such as methanol or ethanol have the most desirable characteristics for groundloop applications. The overall heat transfer characteristics of these fluids remain high although care must be taken when handling pure alcohols since they are extremely flammable. Once mixed in a typical 25% by volume ratio with water the solution is not flammable. In situations where alcohols are not allowed as a loop fluid due to local regulations then propylene glycol is a non-toxic alternative which can be substituted . Propylene glycol should only be used in cases where alcohols are not permitted since the heat transfer characteristics are less desirable and it becomes more viscous at low temperatures, increasing pumping power. The volume of fluid that your loop system holds can be closely estimated by totaling the number of ft. of each size pipe in the system and referencing TABLE 13 the for approximate volume per 100 ft. When the volume of the loop has been calculated and the appropriate amount of antifreeze is ready for addition by referencing TABLE 12 , drain the equivalent amount of water from the flush cart or mixing barrel and replace it with the antifreeze. When using alcohols, be sure to inject below the water line to reduce initial volatility of the pure antifreeze. If the loop is large it may be necessary to refill the tank with antifreeze several times to get all the antifreeze into the loop. Pump the loop for 5 to 10 minutes longer to ensure the remaining fluid has been well mixed. INITIAL PRESSURIZATION At this point open all valves in the flow circuit and slowly close off the supply and return flush cart valves in a manner that leaves about 20-30 psig. on the system. If an air bladder expansion tank is used it should be charged to the above pressure before actual water pressure is put on the system . Systems without an expansion tank will experience greater fluctuations in pressure between the heating and cooling seasons, causing pressure gauges to have different values as the loop temperature changes. This fluctuation is normal since expansion and contraction of the loop fluid must be handled by the elasticity of the plastic loop. • Pressurize the loop to a static pressure of 45 psig. when installing a system in the fall going into the heating season. • Pressurize the loop to a static pressure of 25 psig. when installing a system in the spring or summer going into the cooling season. After operating the heat pump for a period of time, any residual air in the system should be bled off and the static pressure should be verified and adjusted if necessary. Add additional water / antifreeze mix with the purge cart to bring the pressure back to the original setting if required. PIPE INSULATION All ground loop piping inside the structure (between the structure entry point and the heat pump) should be insulated with 3/8” thick closed cell pipe insulation to prevent condensation and dripping onto floors or walls. TABLE 13 - Volume of fluid per 100 ft. of pipe Volume /100ft. Type of Pipe Diameter Igal USgal L Copper 1” 3.4 4.1 15.5 1-1/4” 5.3 6.4 24.2 1-1/2” 7.7 9.2 34.8 Rubber Hose 1” 3.2 3.9 14.8 Polyethylene 3/4” IPS SDR11 2.3 2.8 10.6 1” IPS SDR11 3.7 4.5 17.0 1-1/4” IPS SDR11 6.7 8.0 30.3 1-1/2” IPS SDR11 9.1 10.9 41.3 2” IPS SDR11 15.0 18.0 68.1 Other Item Volumes Heat Exchanger Average 1.2 1.5 5.7 Purge Cart Tank See cart manual TBD TABLE 12 - Antifreeze Percentages BY VOLUME Protection to: 10°F 15°F 20°F 25°F Methanol 25% 21% 16% 10% Propylene Glycol 38% 30% 22% 15% Protection to: 10°F 15°F 20°F 25°F Methanol 16.8% 13.6% 10% 6.3% Propylene Glycol 30% 23.5% 18.3% 12.9% BY WEIGHT Page 20 001200MAN-05 02 JAN 2014 02 JAN 2014 Page 21 001200MAN-05 The following steps describe how to perform the startup procedure of the geothermal heat pump. The R-Series Two-Stage R410a Startup Record located in this manual is used in conjunction with this startup procedure to pro-vide a detailed record of the installation. A completed copy should be left on site, a copy kept on file by the installer and a copy should be sent to Maritime Geothermal Ltd. Check the boxes or fill in the data as each step is completed. For data boxes, circle the appropriate units. Fill in the top section of all three copies, or one copy if photocopies can be made after the startup has been completed. PRE-START INSPECTION Ductwork: 1. Verify that all ductwork has been completed and is firmly attached to the unit. Verify that any dampers or diverters are properly set for operation of the heat pump. 2. Verify that all registers are open and clear of any objects that would restrict the airflow. 3. Verify that a new air filter is installed and the cover is secured. 4. Verify the condensate drain is connected, properly vented and free of debris. 5. If a plenum heater has been installed, verify that it is securely fastened to the ductwork. Outdoor Loop (Ground Loop): 1. Verify that all shutoff valves are fully open and there are no restrictions in the piping from the heat pump to the ground loop, and that full flow is available to the heat pump. 2. Verify that the entire system has been flooded and all the air has been purged as much as possible. Further purging may be required after the system has been operating for a while. 3. Verify that the loop contains the proper mix of antifreeze for the intended application. Record the type of antifreeze and the mixture value on the startup sheet; circle % Vol. or % Weight. 4. Record the static loop pressure on the startup sheet. Outdoor Loop (Ground Water): 1. Verify there are no leaks in the connections to the unit. Verify the water valve is installed and properly oriented in the return line. 2. Verify that there is flow control in the return line. Domestic Hot Water (if equipped): 1. Verify that all shutoff valves are fully open and there are no restrictions in the piping from the heat pump to the domestic hot water tank. 2. Verify that the entire system has been flooded and all the air has been purged as much as possible. Further purging may be required after the system has been operating for a while. 3. Verify that the brown wire with the insulated terminal is disconnected in the electrical box. Refer to the schematic diagram for more information. Electrical: 1. Ensure the power to the unit is off. Ensure the power to the plenum heater is off if equipped. 2. Verify all high voltage connections. Ensure that there are no stray wire strands, all connections are tight and the ground wire is connected tightly to the ground connector for the heat pump and plenum heater. 3. Record the fuse / circuit breaker size and wire gauge for the heat pump. Record the fuse / circuit breaker size, wire gauge and size of the plenum heater if installed. 4. Verify that the control connections to the thermostat and plenum heater (if installed) are properly connected and all control signals are off, so that the unit will not start up when the power is turned on. 5. Ensure all access panels except the lower one that provides access to the electrical box are in place. Startup Procedure Page 22 001200MAN-05 02 JAN 2014 UNIT STARTUP The unit is now ready to be started. The steps below outline the procedure for starting the unit and verifying proper operation of the unit. It is recommended that safety glasses be worn during the following procedures. Preparation: 1. Remove the caps from the service ports and connect a refrigeration manifold set to the unit. 2. Turn the power on to the heat pump and set the thermostat to OFF. Set up the thermostat as per the instructions provided with it so that it will function properly with the heat pump system (set for heat pump, not for heating and cooling). The O signal should be set to active in cooling mode. 3. Measure the following voltages on the compressor contactor and record them on the startup sheet: L1-L2, L2-L3, L1-L3. Heating Mode: 1. Set the thermostat to heating mode and adjust the setpoint to activate Stage 1 and Stage 2. The fan should slowly ramp up to speed after the time delay of the thermostat expires (if applicable) and the compressor will start (allow 30-60 seconds for the water valve to open for ground water systems) 2. Check the refrigeration gauges. The suction and discharge pressures will depend on the loop temperatures, but they should be about 90-110PSIG and 260-360PSIG respectively for a typical start-up. 3. Monitoring the refrigeration gauges while the unit runs. Record the following after 10 minutes of runtime: 1. Suction pressure 2. Discharge pressure 3. Duct Return temperature (poke a small hole in the flex collar and insert probe in airstream) 4. Duct Supply temperature (poke a small hole in the flex collar and insert probe in airstream) 5. Duct Delta T (should be between 22-32°F, 12-18°C) 6. Outdoor Loop In (Supply In) temperature 7. Outdoor Loop Out (Supply Out) temperature 8. Outdoor Delta T (should be between 5-8°F, 3-4°C) 9. Outdoor flow (if available) 10. Compressor L1(C) current (black wire, place meter between electrical box and compressor) 4. Adjust the thermostat setpoint to the desired room temperature and let the unit run through a cycle. Record the setpoint, Suction, and discharge pressures when the unit shuts off. 5. For units with a desuperheater, turn the power off to the unit. Connect the brown wire with the blue insulated terminal to the compressor contactor as shown in the electrical box diagram. Turn the DHW Switch in the unit post on. Turn the power to the unit on. 6. Remove the electrical cover from the plenum heater. Place a current clamp meter around one of the supply wires. Turn on the power to the plenum heater. Adjust the thermostat setpoint to 85°F (29°C). Verify that the current draw increase as each stage is activated. (10kW has 2 stages, 15kW has 3 stages and 20kW has 4 stages). 7. Verify the DHW IN and DHW OUT temperatures (if applicable) by hand (caution: pipes get hot). If the DHW OUT line does not become hotter than the DHW IN line the circulator is air locked. Bleed the air from the system and check the temperature differential again to ensure there is flow from the circulator. Cooling Mode: 1. Set the thermostat to cooling mode and adjust the setpoint to activate Stage 1 and Stage 2. 2. Monitoring the refrigeration gauges while the unit runs. Record the following after 10 minutes of runtime: 1. Suction pressure 2. Discharge pressure 3. Duct Return temperature 4. Duct Supply Out temperature 5. Duct Delta T 6. Outdoor Loop In (Supply In) temperature 7. Outdoor Loop Out (Supply Out) temperature 8. Outdoor Delta T 3. Adjust the thermostat setpoint to the desired room temperature if possible, otherwise set it just low enough to allow the unit to run (ie 1°F (0.5°C) less than room temperature) and let the unit run through a cycle. Record the thermostat setpoint, suction pressure and discharge pressure when the unit shuts off. Final Inspection: 1. Turn the power off to the unit (and plenum heater if installed) and remove all test equipment. 2. Install the electrical box cover and the access panel on the heat pump. Install the service port caps securely to prevent refrigerant loss. Install the electrical cover on the plenum heater if applicable. 3. Do a final check for leaks in the ground water / ground loop system and ensure the area is clean. 4. Turn the power on to the unit and the plenum heater if installed. Set the thermostat to the final settings. Startup Record: 1. The installer shall sign and date the Startup Record and have the homeowner sign as well. The installer shall leave the Startup Record with the homeowner, retain a copy for filing and send a copy to Maritime Geothermal Ltd. for warranty registration. 02 JAN 2014 Page 23 001200MAN-05 Startup Record —R-Series Size 25-80 Two-Stage R410a Installation Site Startup Date Installer City Company Province Model Country Serial # Check boxes unless asked to record data. Circle data units. PRE-START INSPECTION Ductwork Ductwork is completed, dampers/ diverters are adjusted Registers are open and clear of objects Air filter and end cap are installed Condensate Drain is connected, properly vented and free of debris Plenum heater is securely fastened (if applicable) Ground Loop System All shut-off valve are open (full flow available) Loop is full and purged of air Antifreeze type Antifreeze concentration % Volume % Weight Loop static pressure PSI kPa Ground Water Water Valve installed in return line System Flow control installed in return line Domestic Hot All shut-off valves are open Water Lines are full and purged Desuperheater pump wire is disconnected Electrical High voltage connections are correct and securely fastened Circuit breaker (or fuse) size and wire gauge for Heat Pump A Ga. Circuit breaker (or fuse) size, wire gauge, and Plenum Heater size A Ga. kW Low voltage connections are correct and securely fastened STARTUP DATA Preparation Voltage across L1 and L2, L1 and L3, L2 and L3 VAC Heating Mode Suction Pressure / Discharge Pressure psig kPa (10 minutes) Duct Return, Duct Supply, and Delta T In Out °F °C Outdoor In (Supply In), Outdoor Out (Supply Out), and Delta T In Out °F °C Outdoor Flow Igpm USgpm L/s Compressor L1 (black wire) current A Domestic Hot Water functioning Thermostat setpoint, suction and discharge pressures at cycle end °F °C psig kPa Cooling Mode Suction Pressure / Discharge Pressure psig kPa (10 minutes) Duct Return, Indoor Out, and Delta T In Out °F °C Outdoor In (Supply In), Outdoor Out (Supply Out), and Delta T In Out °F °C Thermostat setpoint, suction and discharge pressures at cycle end °F °C psig kPa Homeowner Name Homeowner Phone # Date: Installer Signature: Homeowner Signature: A total of three copies are required, one for the homeowner, one for the installer and on to be sent to Maritime Geothermal Ltd. Page 24 001200MAN-05 02 JAN 2014 GENERAL MAINTENANCE SCHEDULE Item Interval Procedure Air Filter 6 months Inspect for dirt. Replace if necessary. Contactor 1 year Inspect for pitted or burned points. Replace if necessary. Condensate Drain 1 year Inspect for clogs. Remove and clean if necessary. Heat exchanger As required* Clean as per HEAT EXHCANGER FLUSING PROCEDURE below. *Generally not required for closed loop systems. Whenever system performance is reduced for open loop. COAXIAL HEAT EXCHANGER FLUSHING PROCEDURE—GROUNDWATER STEP 1 Isolate the heat exchanger by closing the valves in the IN and OUT ports to the heat exchanger. STEP 2 Blow out the heat exchanger into a clean 5 gallon bucket using compressed air. STEP 3 If a purge cart is not available, use a 5 gallon plastic bucket, a circulator and some plastic piping to create a makeshift pump system. Connect a the inlet and outlet to the heat exchanger ports.* STEP 4 Place 2 gallons of RYDLYME in the purge cart (or bucket). Circulate the fluid through the heat exchanger for at least 2 hours (3 recommended). STEP 5 Disconnect the purge system dispose of the solution. RYDLYME is non-toxic and biodegradable and as such can be poured down a drain. *Depending on the plumbing, there should be either unions or boiler drains for to access the heat exchanger. STEP 6 Connect fresh water and a drain to the heat exchanger ports and flush the exchanger for several minutes. STEP 7 Return the plumbing to its original configuration and open the IN and OUT valves. Operate the system and check for improved performance. COAXIAL HEAT EXCHANGER FLUSHING PROCEDURE—GROUND LOOP STEP 1 Isolate the heat exchanger by placing the pump module valves in the exchanger flushing position. STEP 2 Connect a compressed air and a drain pipe to the pump module purge ports and blow the anti-freeze solu-tion into a clean 5 gallon bucket. STEP 3 Connect a purge cart to the pump module purge ports. STEP 4 Place 2 gallons of RYDLYME in the purge cart. Circulate the fluid through the heat exchanger for at least 2 hours (3 recommended). STEP 5 Disconnect the purge cart and dispose of the solution. RYDLYME is non-toxic and biodegradable and as such can be poured down a drain. Clean the purge cart thoroughly. *Depending on the plumbing, there should be either unions or boiler drains for to access the heat exchanger. STEP 6 Connect fresh water and a drain to the pump module purge ports and flush the exchanger for several minutes. STEP 7 Blow the heat exchanger out with compressed air as per STEP 2 and dump the water down a drain. STEP 8 Connect the purge cart to the pump module purge ports. Re-fill and purge the heat exchanger with as per standard procedures (the anti-freeze from STEP 2 can be re-used). STEP 9 Disconnect the purge cart and set the pump module valves back to the original positions. STEP 10 Operate the system and check for improved performance. General Maintenance 02 JAN 2014 Page 25 001200MAN-05 POWER SUPPLY TROUBLESHOOTING Fault Possible Cause Verification Recommended Action No power to the heat pump Disconnect switch open (if installed) Verify disconnect switch is in the ON position. Determine why the disconnect switch was opened, if all is OK close the switch. Fuse blown / Breaker Tripped. At heat pump disconnect box, voltmeter shows 230VAC on the line side but not on the load side. Reset breaker or replace fuse with proper size and type. (Time-delay type “D”) No display on thermostat. Transformer breaker tripped. Breaker on transformer is sticking out. Push breaker back in. If it trips again locate cause of short circuit and correct. Faulty wiring between heat pump and thermo-stat. 24VAC is not present across C and R(RH) of the thermostat. Correct the wiring. Faulty Thermostat. 24VAC is present across C and R(RH) of the thermostat but ther-mostat has no display. Replace thermostat. Faulty transformer Transformer breaker is not tripped, 230VAC is present across L1 and L3 of the compres-sor contactor but 24VAC is not present across RH and C of the terminal strip. Replace transformer. The following steps are for troubleshooting the geothermal heat pump. If the problem is with the domestic hot water or the plenum heater, proceed to those sections at the end of the troubleshooting guide. Repair procedures and reference refriger-ation circuit diagrams can be found at the end of the troubleshooting guide. STEP 1: Verify that the display is present on the thermostat. If it is not, proceed to POWER SUPPLY TROUBLE SHOOTING, otherwise proceed to STEP 2. STEP 2: Remove the door and electrical box cover and check to see if there is a fault code on the control board. If there is, record the fault code. Turn the power off, wait 10 seconds and turn the power back on. Set the thermostat to call for heating or cooling depending on the season. STEP 3: If a 24VAC signal does not appear across Y1 and C of the terminal strip within 6 minutes, proceed to the THERMOSTAT TROUBLESHOOTING section, otherwise proceed to STEP 4. STEP 4: If a fault code appears once a signal is present at Y1 and the compressor does not attempt to start, proceed to the FAULT CODE TROUBLESHOOTING section, otherwise proceed to STEP 5. STEP 5: If no fault codes appear and the compressor does not attempt to start, attempts to start but cannot, starts hard, or starts but does not sound normal, proceed to the COMPRESSOR TROUBLESHOOTING section, otherwise proceed to STEP 6. STEP 6: If the compressor starts and sounds normal, this means the compressor is OK and the problem lies elsewhere. Proceed to the OPERATION TROUBLESHOOTING section. NOTE: To speed up the troubleshooting process, the Test Jumper on the safety board can be placed to the YES position to change the anti-short cycle timer to 5 seconds. Be sure to set it back to NO when servicing is complete. Troubleshooting Guide Page 26 001200MAN-05 02 JAN 2014 FAULT CODE TROUBLESHOOTING Fault Possible Cause Verification Recommended Action Fault Code 1 (High Pressure Control) Faulty High Pressure Con-trol (open). * Must be a signal present on Y1 for this test. *HP pressures must be at static levels. Verify if there is 24VAC across HP1 on the control board and C of the ter-minal strip, as well as HP2 and C. Replace high pressure control if voltage is present on HP1 but not on HP2. Faulty control board. 24VAC is present across HP1 and C1, and HP2 and C, but no voltage is present across CC on the control board and C. Replace control board. Fault Code 2 (Low Pressure Control) Faulty Low pressure con-trol (open). * Must be a signal present on Y1 for this test. *HP pressures must be at static levels. Verify if there is 24VAC across LP1 on the control board and C of the ter-minal strip, as well as LP2 and C. Replace high pressure control if voltage is present on LP1 but not on LP1. Faulty control board. 24VAC is present across LP1 and C, and LP2 and C, but no voltage is present across CC on the control board and C. Replace control board. Unit out of refrigerant. Check static refrigeration pressure of the unit for a very low value. Locate the leak and repair it. Spray nine, a sniffer and dye are common methods of locating a leak. Fault Code 3 (Flow Switch) Flow switch jumper re-moved or faulty. Verify jumper is in place between pins marked FLOW SWITCH. Place a jumper if missing. Flow switch faulty. (Only if installed) Verify 24VAC is present between each flow switch pin on the control board and the C terminal of the ter-minal strip while there is flow through the unit. Replace flow switch if signal is not present at both terminals on the control board. Faulty control board. 24VAC is present across each FLOW SWITCH terminal and C, but not voltage is present across CC on the control board and C. Replace control board. THERMOSTAT TROUBLESHOOTING Fault Possible Cause Verification Recommended Action No Y1 signal to heat pump (after 6 minutes) Incorrect thermostat set-up. Thermostat does not indicate a call for heat. No 24VAC signal present across C and Stage 1 of the thermo-stat Correct the setup. Faulty thermostat to heat pump wiring. 24VAC signal present across Stage 1 and C of the thermostat but not present across Y1 and C of the ter-minal strip. Correct or replace wiring Faulty thermostat. No 24VAC between Stage 1 and C of the thermostat when a call is indi-cated on the thermostat. Replace thermostat. 02 JAN 2014 Page 27 001200MAN-05 COMPRESSOR TROUBLESHOOTING Fault Possible Cause Verification Recommended Action Compressor will not start Faulty control board. Measuring from C on the terminal strip, verify there is voltage at Y, HP1, HP2, LP1, LP2, and both flow pins but no voltage present at CC. Replace control board. Faulty run capacitor. (Single phase only) Check value with capacitance meter. Should match label on capacitor. Compressor will hum while trying to start and then trip its overload. Replace if faulty. Loose or faulty wiring. Check all compressor wiring, includ-ing inside compressor electrical box. Fix any loose connections. Re-place any damaged wires. Faulty compressor contactor. Voltage on line side with contactor held closed, but no voltage on one or both terminals on the load side. Points pitted or burned. Or, 24VAC across coil but contactor will not engage. Replace contactor. Thermal overload on compressor tripped. Ohmmeter shows reading when placed across R and S terminals and infinity between C & R or C & S. A valid resistance reading is present again after the compressor has cooled down. Proceed to Operation Trouble-shooting to determine the cause of the thermal overload trip. Burned out motor (open winding) Remove wires from compressor. Ohmmeter shows infinite resistance between any two terminals Note: Be sure compressor overload has had a chance to reset. If compressor is hot this may take several hours. Replace the compressor. Burned out motor (shorted windings) Remove wires from compressor. Resistance between any two termi-nals is below the specified value. Replace the compressor. Motor shorted to ground. Remove wires from compressor. Check for infinite resistance be-tween each terminal and ground. If any terminal to ground is not infinite replace the compressor. Seized compressor due to locked or damaged mechanism. Compressor attempts to start but trips its internal overload after a few seconds. (Run capacitor already verified) Attempt to “rock” compressor free. If normal operation cannot be established, replace compressor. Compressor starts hard Start capacitor faulty. (Single phase only) Check with capacitance meter. Check for black residue around blowout hole on top of capacitor. Replace if faulty. Remove black residue in electrical box if any. Potential Relay faulty. (Single phase only) Replace with new one and verify compressor starts properly. Replace if faulty. Compressor is “tight” due to damaged mechanism Compressor attempts to start but trips its internal overload after a few seconds. Run capacitor has been verified already. Attempt to “rock” compressor free. If normal operation cannot be es-tablished, replace compressor. Compressor Stage 2 will not activate Faulty Stage 2 module Verify if 24VAC is present across Y2 and C of the terminal strip. Replace module if signal is pre-sent. Check wiring if signal is not present. Page 28 001200MAN-05 02 JAN 2014 OPERATION TROUBLESHOOTING - HEATING MODE Fault Possible Cause Verification Recommended Action High Discharge Pressure Air Flow See Fan Troubleshooting section Correct the problem. TXV adjusted too far closed. Verify superheat. It should be be-tween 8-12°F (3-6°C). Superheat will be high if TXV is closed too far. Adjust TXV to obtain 8-12°F (3-6°C) superheat. TXV stuck almost closed or partially blocked by for-eign object. Adjusting the TXV does not affect the superheat or the suction pressure. Adjust the TXV all the way in and out a few times to loosen it. Re-place TXV if this does not work. Filter-drier plugged Feel each end of the filter- drier, it should be the same temperature. If there is a temperature difference then it is plugged. Also causes low suc-tion pressure. Replace filter-drier. Unit is overcharged. (Only possible if unit has been opened in the field and incorrectly charged). High sub-cooling, low delta T across air coil. Remove 1/2lb of refrigerant at a time and verify that the discharge pressure reduces. Low Suction Pressure Low or no Outdoor liquid flow Delta T across the Outdoor Loop ports should be between 5-7°F (3-4°C), or compare pressure drop to the tables for the unit. Determine the cause of the flow restriction and correct it. Verify pumps are working and sized correctly for ground loop systems. Verify well pump and water valve is working for ground water sys-tems. Entering liquid tempera-ture too cold. Measure the entering liquid tempera-ture. Most likely caused by under-sized ground loop. Increase the size of the ground loop. Dirty or fouled coaxial heat exchanger. (typically for ground water, unlikely for ground loop) Disconnect the water lines and check the inside of the pipes for scale deposits. Have a qualified service techni-cian backflush the coaxial ex-changer. Return air too cold Measure return air temperature. Should be above 60°F (15°C). Restrict air flow temporarily until room comes up to temperature. TXV stuck almost closed or partially blocked by for-eign object. Adjusting the TXV does not affect the superheat or the suction pressure. TXV may be frosting up. Adjust the TXV all the way in and out a few times to loosen it. Re-place TXV if this does not work. Low refrigerant charge. Entering liquid temperature, flow and entering air temperature are good but suction is low. Check static refrigera-tion pressure of the unit for a very low value. Locate the leak and repair it. Spray nine, a sniffer and dye are common methods of locating a leak. Faulty compressor, not pumping. Pressures change only slightly from static values when compressor is started. Replace compressor. 02 JAN 2014 Page 29 001200MAN-05 OPERATION TROUBLESHOOTING - COOLING MODE Fault Possible Cause Verification Recommended Action Heating instead of cooling Thermostat not set up properly. Verify that there is 24VAC across O/B/W1 and C of the terminal strip when calling for cooling. Correct thermostat setup. Change to a different thermostat. Faulty reversing valve so-lenoid coil. Verify solenoid by removing it from the shaft while the unit is running. There should be a loud “whoosh” sound when it is removed. Replace solenoid if faulty. Faulty reversing valve. A click can be heard when the coil is energized but the unit continues to heat instead of cool. Replace reversing valve. High Discharge pressure Low or no Outdoor liquid flow Delta T across the Outdoor Loop ports should be between 8-12°F (4-7°C), or compare pressure drop to the tables for the unit. Determine the cause of the flow restriction and correct it. Verify pumps are working for ground loop systems. Verify well pump and water valve is working for ground water systems. Entering liquid tempera-ture too warm. Most likely caused by undersized ground loop. Verify the ground loop sizing. In-crease the size of the ground loop if undersized. Dirty or fouled coaxial heat exchanger. (typically for ground water, unlikely for ground loop) Disconnect the water lines and check the inside of the pipes for scale deposits. Have a qualified service technician backflush the coaxial exchanger. OPERATION TROUBLESHOOTING - HEATING MODE Fault Possible Cause Verification Recommended Action High Suction Pressure (may appear to not be pumping) Leaking reversing valve. Reversing valve is the same temper-ature on both ends of body, com-mon suction line is warm, compres-sor is running hot. Replace reversing valve. Compressor frosting up See Low Suction Pressure in this section. TXV frosting up TXV stuck almost closed or partially blocked by for-eign object. Adjusting the TXV does not affect the superheat or the suction pres-sure. Attempt to adjust the TXV all the way out and all the way in a few times to loosen it. Replace TXV if this does not work. Random high pressure trip (does not occur while on site) Faulty compressor contac-tor. Points pitted or burned. Contactor sometimes sticks causing the com-pressor to run without the fan, trip-ping the high pressure control. Replace contactor. Intermittent fan. See Fan Troubleshooting section. Correct the problem. TXV stuck open. Adjusting the TXV does not affect the superheat or the suction pres-sure. Low super heat and discharge pressure. Adjust the TXV all the way in and out a few times to loosen it. Replace TXV if this does not work. TXV adjusted too far open. Verify superheat. It should be be-tween 8-12°F (3-6°C). Superheat will be low if TXV is open too far. Adjust TXV to obtain 8-12°F (3-6°C) superheat. Page 30 001200MAN-05 02 JAN 2014 OPERATION TROUBLESHOOTING - COOLING MODE Fault Possible Cause Verification Recommended Action High Discharge pressure Air Flow See Fan Troubleshooting section. Note: low airflow will cause the air coil to ice up once the suction drops below 90PSIG. Correct the problem. TXV stuck almost closed or partially blocked by for-eign object. Adjusting the TXV does not affect the superheat or the suction pres-sure. TXV may be frosting up. Adjust the TXV all the way in and out a few times to loosen it. Re-place TXV if this does not work. Low or no refrigerant charge. Entering air temperature and air-flow are good but suction is low. Check static refrigeration pressure of unit for very low value. Locate the leak and repair it. Spray nine, a sniffer and dye are common methods of locating a leak. Compressor frosting up See Low Suction Pressure in this section. TXV frosting up TXV stuck almost closed or partially blocked by for-eign object. Adjusting the TXV does not affect the superheat or the suction pres-sure. Adjust the TXV all the way in and out a few times to loosen it. Replace TXV if this does not work. Random Low Pressure trip (does not occur while there) Faulty compressor contactor. Points pitted or burned. Contactor sometimes sticks causing the com-pressor to run without the fan, trip-ping the low pressure control. Replace contactor. Intermittent fan. See Fan Troubleshooting section. Correct the problem. Unit is overcharged. (Only possible if unit has been opened in the field and incorrectly charged). High sub-cooling, low delta T across water coil. Remove 1/2lb of refrigerant at a time and verify that the discharge pressure reduces. Low Suction Pressure High Suction Pressure (may appear to not be pumping) TXV adjusted too far open. Verify superheat. It should be be-tween 8-12°F (3-6°C). Superheat will be low if TXV is open too far. Adjust TXV to obtain 8-12°F (3-6°C) superheat. Faulty compressor, not pumping. Pressures change only slightly from static values when compressor is started. Replace compressor. TXV stuck open. Adjusting the TXV does not affect the superheat or the suction pres-sure. Low super heat and dis-charge pressure. Adjust the TXV all the way in and out a few times to loosen it. Replace TXV if this does not work. Leaking reversing valve. Reversing valve is the same tem-perature on both ends of body, common suction line is warm, com-pressor is running hot. Replace reversing valve. 02 JAN 2014 Page 31 001200MAN-05 FAN TROUBLESHOOTING Fault Possible Cause Verification Recommended Action Low Airflow Dirty air filter Inspect. Replace. Poor Ductwork Measure delta T between supply and return ducts at the unit, it in heating mode, it should not be above 30°F(17°C). The ECM fan will provide proper airflow up to 0.5 inH2o for 1/2HP motors and 0.7 inH2o for 1HP motors. The ductwork is poorly designed or greatly undersized if the fan motor cannot provide the required airflow. Air flow selected on Tap Board is too low. Check selection on Air Flow Tap Board. Select a higher setting. Air flow reduction is ena-bled. AR1 and AR2 are connected with a dry contact. Air flow reduction may not be fea-sible with poor ductwork, and/or lower Air Flow selections. In-crease settings until unit operates properly. Fan operating on wrong Stage speed Fan Control Signal Har-ness is loose. Verify that the connector is properly inserted into the fan motor. Gently tug on each wire to verify it is properly inserted into the connector. Repair any loose connections. Faulty Control Signal Har-ness or faulty motor head. Ensure signal is present on terminal strip. Measure 24VAC between White (pin 3) and the following at the fan con-trol signal harness (insert probes in connector where wire is inserted, do not unplug the connector): Circulation = Grey (pin 15) Stage 1 = Yellow (pin 6) Stage 2=Yellow/Black (pin14) Stage 3 = Violet (pin 2) If proper signal isn’t present, re-place Fan Control Signal Har-ness. If proper signal is present, replace fan motor head. Fan not operat-ing or operating intermittently Fan Control Signal Har-ness and/or Fan Power Harness is loose. Verify that the connector is properly inserted into the fan motor. Gently tug on each wire to verify it is properly inserted into the connector. Repair any loose connections. Faulty Control Signal Har-ness or faulty motor head. Ensure signal is present on terminal strip. Measure 24VAC between White (pin 3) and the following at the fan con-trol signal harness (insert probes in connector where wire is inserted, do not unplug the connector): Circulation = Grey (pin 15) Stage 1 = Yellow (pin 6) Stage 2=Yellow/Black (pin14) Stage 3 = Violet (pin 2) If proper signal isn’t present, re-place Fan Control Signal Har-ness. If proper signal is present, replace fan motor head. Faulty Fan Power Har-ness or faulty motor. Insert the tips of the voltmeter probes into the back of the connect-or at the fan to measure the voltage across the red and black wires, val-ue should be 230VAC Replace Power Harness if 230VAC is not present, replace motor if 230VAC is present Dirty air coil. Inspect. Clean. Page 32 001200MAN-05 02 JAN 2014 PLENUM HEATER TROUBLE SHOOTING Fault Possible Cause Verification Recommended Action No 230VAC across plenum heater L1 and L2 Disconnect switch open. (if installed) Verify disconnect switch is in the ON position. Determine why the disconnect switch was opened, if all is OK close the switch. Fuse blown / Breaker Tripped. At plenum heater disconnect box (if installed), voltmeter shows voltage on the line side but not on the load side. Check if breaker is tripped. Reset breaker or replace fuse at plenum heater disconnect box. Replace fuse with proper size and type. (Time-delay type “D”) Same “Line” to L1 and L2 Measuring L1 to ground and L2 to ground both yield 115VAC, but L1 to L2 yields 0VAC. Correct wiring. No W2 signal at Heat pump termi-nal strip No call for auxiliary or emergency heat from ther-mostat. Verify that the thermostat is indicating that auxiliary or emergency heat should be on. Set thermostat to engage auxilia-ry or emergency heat (note some thermostats require a jumper be-tween auxiliary and emergency. Check the thermostat manual). Faulty thermostat. Thermostat doesn’t indicate a call for auxiliary or emergency when it should. Replace thermostat. Faulty thermostat. Thermostat indicates auxiliary or emergency but no 24VAC signal pre-sent across C and the auxiliary and/or emergency pin at the thermostat. Replace thermostat. Faulty thermostat wiring. 24VAC signal is present across C and the auxiliary and/or emergency pin at the thermostat but no 24VAC signal is present across W2 and C at the heat pump terminal strip. Correct wiring. No 24VAC signal from C to ground at the plenum heater control connector Plenum Heater transform-er is burned out. Voltmeter does not show 24VAC across transformer secondary wind-ing. Replace transformer. Plenum heater control board is faulty. Transformer tested OK in previous step. Replace control board. No 24VAC signal from 1 to ground at the plenum heater control connector Faulty wiring. 24VAC present across C and ground at the plenum heater, but not across ground of the plenum heater and I of the heat pump terminal strip Correct wiring. Faulty wiring. If previous step tested OK, 24VAC is present across ground of the plenum heart and 1 of the heat pump terminal strip, but not across ground of the plenum heater and 1 of the plenum heater. Correct wiring. 02 JAN 2014 Page 33 001200MAN-05 Digital Thermometer Refrigeration Gauges In-line Flowmeter Multimeter - Voltmeter /Amprobe Trouble Shooting Tools The Dole® flow control is a simple, self-cleaning device designed to deliver a constant volume of water from any outlet whether the pressure is 15 psig or as high as 125 psi. The controlling mechanism consists of a flexible orifice that varies its area inversely with pressure so that a constant flow is maintained. Dole flow control Valve PLENUM HEATER TROUBLE SHOOTING Fault Possible Cause Verification Recommended Action No 24VAC signal from 1 to ground at the plenum heater control connector Faulty Plenum Heater Relay in heat pump 24VAC is present across pin 1 and pin 3 of the relay, 24VAC is present from heat pump terminal strip I to plenum heater ground, but not from heat pump terminal strip 1 to plenum heater ground. Replace relay. Fan not operating See Fan Not Operating section Correct problem. Reset thermal overload. Faulty overload Reset thermal overload Replace if faulty. Thermal overload is tripped. DOMESTIC HOT WATER (DHW) TROUBLE SHOOTING Fault Possible Cause Verification Recommended Action Insufficient hot water (Tank Problem) Thermostat on hot water tank set too low. Should be set at 120°F. (140°F if required by local code) Visually inspect the setting. Readjust the setting to 120°F. (140°F if required by local code) Breaker tripped, or fuse blown in electrical supply to hot water tank. Check both line and load sides of fuses. If switch is open determine why. Replace blown fuse or reset breaker. Reset button tripped on hot water tank. Check voltage at elements with multimeter. Push reset button. Circulator pump not operating. Visually inspect the pump to see if shaft is turning. Use an amprobe to measure current draw. Replace if faulty. Blockage or restriction in the water line or hot water heat exchanger. Check water flow and power to pump. Check water lines for obstruction Remove obstruction in water lines. Acid treat the domestic hot water coil. Faulty DHW cutout (failed open). Check contact operation. Should close at 120°F and open at 140°F. Replace DHW cutout if faulty. Heat pump not running enough hours to make sufficient hot water. Note the amount of time the heat pump runs in any given hour. Temporarily turn up the tank thermostats until colder weather creates longer run cycles. Water is too hot. Faulty DHW cutout (failed closed). Check contact operation. Should close at 120°F and open at 140°F. Replace DHW cutout if faulty. Thermostat on hot water tank set too high. Should be set at 120°F. (140°F if required by local code) Visually inspect the setting. Readjust the setting to 120°F.(140°F if required by local code) Insufficient hot water (Heat Pump Problem) Page 34 001200MAN-05 02 JAN 2014 PUMP DOWN PROCEDURE STEP 1 Connect the refrigerant recovery unit to the heat pump service ports via a refrigeration charging manifold and to a recovery tank as per the instructions in the recovery unit manual. If there was a compressor burn out, the refrigerant cannot be reused and must be disposed of according to local codes. STEP 2 All water coil heat exchangers must either have full flow or be completely drained of fluid before recovery begins. Failure to do so can freeze and rupture the heat exchanger, voiding its warranty. (Note that this does not apply to double wall domestic hot water exchangers (desuperheater coils) STEP 3 Ensure all hose connections are properly purged of air. Start the refrigerant recovery as per the instructions in the recovery unit manual. STEP 4 Allow the recovery unit suction pressure to reach a vacuum. Once achieved, close the charging manifold valves. Shut down, purge and disconnect the recovery unit as per the instructions in its manual. Ensure the recovery tank valve is closed before disconnecting the hose to it. STEP 5 Connect a nitrogen tank to the charging manifold and add nitrogen to the heat pump until a positive pres-sure of 5-10PSIG is reached. This prevents air from being sucked into the unit by the vacuum when the hoses are disconnected. STEP 6 The heat pump is now ready for repairs. Always ensure nitrogen is flowing through the system during any soldering procedures to prevent soot buildup inside the pipes. Maritime Geothermal Ltd. recommends re-placing the liquid line filter-drier anytime the refrigeration system has been exposed to the atmosphere. REPAIR PROCEDURES VACUUM AND CHARGING PROCEDURE STEP 1 After completion of repairs and nitrogen pressure testing, the refrigeration circuit is ready for vacuuming. STEP 2 Release the refrigerant circuit pressure and connect the vacuum pump to the charging manifold. Start the vacuum pump and open the charging manifold valves. Vacuum until the vacuum gauge remains at less than 500 microns for at least 1 minute with the vacuum pump valve closed. STEP 3 Close the charging manifold valves then shut off and disconnect the vacuum pump. Place a refrigerant tank with the proper refrigerant on a scale and connect it to the charging manifold. Purge the hose to the tank. STEP 4 Weigh in the appropriate amount of refrigerant through the low pressure (suction) service port. Refer to the label on the unit or the Refrigerant Charge Chart in the MODEL SPECIFIC INFORMATION section for the proper charge amount. STEP 5 If the unit will not accept the entire charge, the remainder can be added through the low pressure service port after the unit has been restarted. REPLACMENT PROCEDURE FOR A COMPRESSOR BURN-OUT STEP 1 Pump down the unit as per the Pump Down Procedure above. Discard the refrigerant according to local codes. STEP 2 Replace the compressor. Replace the liquid line filter-drier. STEP 3 Vacuum the unit until it remains under 500 microns for several minutes with the vacuum pump valve closed. STEP 4 Charge the unit with NEW REFRIGERANT and operate it for continuously for 2 hours. Pump down the unit and replace the filter-drier. Vacuum the unit until