Amabilia Dorfc 1 Users Manual 2100 518(B) (2012 04)
DOUBLE O-RING GEOTHERMAL FLOW CENTERS DORFC-2 2100-518
dorfc1 4bba9a5b-a7ba-4e1e-8923-1bdc93edd28c AMABILIA Vacuum Cleaner DORFC-1 User Guide |
2015-02-05
: Amabilia Amabilia-Dorfc-1-Users-Manual-507499 amabilia-dorfc-1-users-manual-507499 amabilia pdf
Open the PDF directly: View PDF .
Page Count: 30
Download | ![]() |
Open PDF In Browser | View PDF |
INSTALLATION INSTRUCTIONS DOUBLE O-RING GEOTHERMAL FLOW CENTERS Models: DORFC-1 DORFC-2 DORFC-1 DORFC-2 WARNING: After flushing is complete, but prior to pump motor start-up, loosen the large screw in the center of the pump motor(s) to allow air to escape. Once water has seeped out around the screw, re-tighten. Failure to perform this step will likely result in premature pump motor failure! PUMP MOTOR REPLACEMENT: Bard Part #8300-003 (UP26-99F) BMC, Inc. Bryan, Ohio 43506 Manual: 2100-518B Supersedes: 2100-518A File: Volume I, Tab 8 Date: 04-23-12 Manual 2100-518B Page 1 of 30 Contents Getting Other Informations and Publications.......... 3 General Information Flow Center Nomenclature........................................ 4 Application Description................................................................. 4 Safety .................................................................. 4 Danger .................................................................. 4 Warning .................................................................. 4 Caution .................................................................. 4 Notice .................................................................. 4 Flow Center Mounting Instructions Notice .................................................................. 7 Stud Wall .................................................................. 7 Concrete/Masonry Wall.............................................. 7 Side of Unit................................................................ 7 Piping Installation Description............................................................... 10 Actual Photo Images........................................... 10-11 Multiple Unit to Single Loop Connection Description............................................................... 12 Figures Figure 1A Performance Model DORFC-1.................. 5 Figure 1B Performance Model DORFC-2.................. 5 Figure 2 Flow Center Dimensions........................... 6 Figure 3 Pump Horizontal Applications................... 8 Figure 4A Mounting - Studded Wall........................... 9 Figure 4B Mounting - Masonry Wall........................... 9 Figure 5A Flow Center Connection to GV Series.... 12 Figure 5B Flow Center Connection to GT Series.... 13 Figure 5C Flow Center Connection to QW Series... 14 Figure 6 Multiple Unit Connection to Singular....... 15 Figure 7 Electrical Connections............................. 17 Figure 8 Connecting Flush Cart to Flow Center.... 19 Figure 9A Positioning - Flush Loop.......................... 20 Figure 9B Positioning - Flush Loop & Unit............... 20 Figure 9C Positioning - Flush Unit........................... 21 Figure 9D Positioning - Operation............................ 21 Figure 10 Pressure Temperature Ports................... 25 Figure 11 Density Verification - Solution Strength..... 30 Manual 2100-518B Page 2 of 30 Flow Center Wiring Description............................................................... 16 Flushing & Charging General ................................................................ 18 Procedures for Adding Antifreeze............................ 18 Flushing & Filling Earth Loop & Units...................... 22 Flushing Earth Loop Only........................................ 22 Flushing Unit Only.................................................... 23 Flow Center Initial Startup General ................................................................ 24 Procedures for Pressurizing the System.................. 24 Pressure/Temperature Plugs................................... 24 Troubleshooting Troubleshooting Table.............................................. 27 Antifreeze Selection & Use General ................................................................ 28 Methanol ................................................................ 28 Ethanol ................................................................ 28 Propylene Glycol...................................................... 29 Potassium Acetate (GS4)......................................... 29 Antifreeze Verification.............................................. 30 Tables Table 1 Fusion or Barbed Fittings........................ 10 Table 2 Electrical Ratings.................................... 16 Table 3A GV Series Coil Pressure Drop................ 25 Table 3B GT Series Coil Pressure Drop................. 26 Table 3C QW Series Coil Pressure Drop............... 26 Table Troubleshooting...................................... 27 Table 4 Fluid Volume........................................... 29 Table 5 Percentages by Volume.......................... 29 Table 6 Propylene Glycol Specific Gravity........... 30 Table 7 Methanol Specific Gravity....................... 30 Getting Other Information and Publications These publications can help you install the air conditioner or heat pump. You can usually find these at your local library or purchase them directly from the publisher. Be sure to consult current edition of each standard. National Electrical Code........................ANSI/NFPA 70 Standard for the Installation................ ANSI/NFPA 90A of Air Conditioning and Ventilating Systems Standard for Warm Air........................ ANSI/NFPA 90B Heating and Air Conditioning Systems Load Calculation for Residential ....... ACCA Manual J Winter and Summer Air Conditioning Duct Design for Residential...............ACCA Manual D Winter and Summer Air Conditioning and Equipment Selection Closed-Loop/Ground Source Heat Pump.........IGSHPA Systems Installation Guide Grouting Procedures for Ground-Source..........IGSHPA Heat Pump Systems Soil and Rock Classification for.......................IGSHPA the Design of Ground-Coupled Heat Pump Systems Ground Source Installation Standards..............IGSHPA Closed-Loop Geothermal Systems...................IGSHPA – Slinky Installation Guide For more information, contact these publishers: ACCA Air Conditioning Contractors of America 1712 New Hampshire Avenue Washington, DC 20009 Telephone: (202) 483-9370 Fax: (202) 234-4721 ANSI American National Standards Institute 11 West Street, 13th Floor New York, NY 10036 Telephone: (212) 642-4900 Fax: (212) 302-1286 ASHRAE American Society of Heating Refrigerating, and Air Conditioning Engineers, Inc. 1791 Tullie Circle, N.E. Atlanta, GA 30329-2305 Telephone: (404) 636-8400 Fax: (404) 321-5478 NFPA National Fire Protection Association Batterymarch Park P.O. Box 9101 Quincy, MA 02269-9901 Telephone: (800) 344-3555 Fax: (617) 984-7057 IGSHPA International Ground Source Heat Pump Association 490 Cordell South Stillwater, OK 74078-8018 Manual 2100-518B Page 3 of 30 geothermal flow centers nOMENCLATURE DORFC 2 Double O-Ring Flow Center 1 = 1-Pump Version, 208/230V, 60 Hz, 1-phase, 22’ HD @ 16 GPM 2 = 2-Pump Version, 208/230V, 60 Hz, 1-phase, 44’ HD @ 16 GPM fLow center description warning The DORFC Series Flow Centers are a compact, easy to mount polystyrene cabinet that contains 3-way valves and pump(s) with connections for flushing, filling and pumping fluids for geothermal closed loop systems. The proven design is foam insulated to prevent condensation and full flow service valves minimize pressure drop. Indicates a potentially hazardous situation which, if not avoided, will result in death or serious injury. One or two Grundfos pump models UP26-99 are available based upon flow requirements and loop design. Unit and loop connections are designed for double o-ring fittings with several varieties of connections available (fusion, threaded, barbed and sweat). Pump motor(s) are 230VAC, 60 Hz, 1-phase. An attractive light gray polystyrene cabinet (that matches geothermal unit) with black pump(s) provides an aesthetically pleasing enclosure for pump(s) and valves. SAfEty Warnings, cautions and notices appear throughout this Manual. Read these items carefully before attempting any installation, service or troubleshooting of the equipment. danger Indicates an immediate hazardous situation which, if not avoided, will result in death or serious injury. DANGER labels on unit access panels must be observed. Manual 2100-518B Page 4 of 30 caution Indicates a potentially hazardous situation or an unsafe practice which, if not avoided, could result in minor or moderate injury or product or property damage. notice Notification of installation, operation or maintenance information, which is important, but which is not hazardrelated. WARNING Failure to do so could cause property damage, bodily harm or death. caution Failure to do so could cause property damage, bodily harm or death. FLOW CENTER PERFORMANCE flow center performance FIGURE 1A PERFORMANCE MODEL DORFC-1 FLOW CENTER 35 30 20 15 10 5 0 0 5 10 15 20 25 30 35 Flow (GPM) FIGURE 1B PERFORMANCE MODEL DORFC-2 FLOW CENTER 70 60 50 Head (Feet) Head (Feet) 25 40 30 20 10 0 0 5 10 15 20 25 30 35 Flow (GPM) Manual 2100-518A Page 5 of 30 Manual 2100-518B Page 5 of 30 dimensional drawing figure 2 flow center dimensions F G A D H C INCHES CM A 13.5 34.3 B B 10.3 26.2 C 7.5 19.1 D 12.4 31.5 E 2.0 5.1 F 2.6 6.7 G 5.0 12.7 H 4.7 11.4 TYPE DORFC-1 DORFC-2 SHIPPING WEIGHT 26 LBS 31 LBS MIS-2658 Manual 2100-518B Page 6 of 30 flow center mounting caution The following instructions represent industry accepted installation practices for closed-loop earth coupled (ground loop) installations. Instructions are provided to assist the contractor in installing trouble free ground loops. These instructions are recommendations only. State/provincial and local codes MUST be followed and installation MUST conform to ALL applicable codes. It is the responsibility of the installing contractor to determine and comply with ALL applicable codes and regulations. notice Side of unit The Flow Center must be mounted with the pump shaft in the horizontal position. In other words, it should always be mounted in a vertical position (not on its back or mounted to the ceiling). See Figure 3. Mounting on the side of the unit is possible, but not necessarily recommended because it can inhibit serviceability and also lead to vibration of the sheet metal casing. It could also lead to puncturing an internal refrigerant or water pipe. If necessary, however, the flow center can be mounted to the sheet metal casing utilizing four (4) self-drilling screws. (Pay close attention not to puncture internal components.) The pump should be located as close to the unit as possible to limit the length of rubber hose kit or interconnect piping and thus its associated pressure drop. Stud wall Mounting on stud wall with or without drywall can be accomplished by using two (2) lag bolts through the top and bottom center holes directly into the stud. See Figure 4A. concrete/masonry wall Mounting onto a concrete wall can be accomplished typically using four (4) 1/4" diameter tapcon cement screws in the four (4) outer corner mounting holes. See Figure 4B. Manual 2100-518B Page 7 of 30 figure 3 pump horizontal applications OK IMPELLER SHAFT HORIZONTAL OK IMPELLER SHAFT HORIZONTAL NO IMPELLER SHAFT CAN NOT BE VERTICAL MIS-2659 Manual 2100-518B Page 8 of 30 figure 4 mounting FIGURE 4A Studded Wall Mounting 1/4" LAG BOLTS DIRECTLY INTO STUD FIGURE 4B Masonry Wall Mounting 1/4" TAPCON SCREWS MIS-2660 Manual 2100-518B Page 9 of 30 piping installation The Flow Center features Double O-Ring fittings for installation flexibility and ease of installation – maintaining a reliable connection. Table 1 illustrates the connection options available for Flow Centers. Pressure drop in piping systems should be calculated to ensure adequate flow through the unit. All piping should be properly insulated with closed cell insulation of 1/2" wall thickness. Piping insulation should be glued and sealed to prevent condensation using closed cell insulation glue. The swivel connectors on the flow center and at the unit are designed to be hand-tightened only. NOTE: Apply petroleum jelly to O-Rings to prevent damage and aid in insertion. Loop side piping is typically polyethylene piping directly into the flow center. Connection to the flow center can be made with either a fusion or barbed fitting as shown in Table 1. Connection between the flow center and the geothermal heat pump typically would be made using the hose kit (DORLFCK-1), which contains all fittings necessary for connection between the heat pump and the flow center as shown in Figure 5. Other variety of materials may also be used for this connection - such as PE or copper piping. TABLE 1 Description Part Number 1-1/4" PE Fusion X Double O-Ring DORF125-S Double O-Ring Loop Flow Center Kit DORLFCK-1 1" Barb X Double O-Ring (includes {4} hose clamps) DORB1-S-4HC 1" MPT X Double O-Ring DORMP1-S 1" FPT X Double O-Ring DORFP1-S 1" Copper Sweat X Double O-Ring (includes {2} P/T fittings) 1" Hose Barb X Double O-Ring 90° Elbow (includes {4} hose clamps and {2} P/T fittings) DORS1-S DORB1-90-4HC 1" MPT X Double O-Ring, 90° Elbow (includes {2} P/T fittings) DORMP1-90 Quick Connect Cam Lock X Double O-Ring 90° Elbow DORCL1-90 Male Garden Hose Thread X Double O-Ring (1-piece per box) DORGHMT NOTE: All fittings boxed in pairs (2-pieces each) will exception of DORGHMT. 1-1/4" Socket Fusion X Double O-ring 1" Hose Barb X Double O-ring DORF125-S DORB1-S-4HC Manual 2100-518B Page 10 of 30 1" MPT X Double O-ring DORMP1-S piping installation (Continued) 1" Swivel X Double O-ring DORFP1-S Elbow, 1" MPT X Double O-ring with 1/4" Port and Pressure/Temperature Test Plugs DORMP1-90 1" Copper Sweat X Double O-ring with 1/4" FPT Port & Pressure/Temperature Test Plugs DORS1-S Elbow, 1" Hose Barb X Double O-ring with 1/4" Port and Pressure/ Temperature Test Plugs DORB1-90-4HC 1" Cam Lever Male X Double O-ring Garden Hose Male X O-ring (single) Adapter DORCL1-90 DORGHMT NOTES: 1. 2. 3. Apply petroleum jelly to O-Rings to prevent damage and aid in insertion. Use two (2) stainless steel clamps per connection (included quantities of hose clamps with fittings and hose kits are per this recommendation). Adaptors required from 1" MPT, 1" FPT, Copper, etc. provided by others. Manual 2100-518B Page 11 of 30 figure 5A flow center connection to GV Series model PIPE TO GROUND LOOP PIPE FROM GROUND LOOP PUMP MODULE STRAIGHT BARBED BRASS ADAPTERS WATER IN WATER OUT HOSE CLAMPS NOTE: APPLY PETROLEUM JELLY TO O-RINGS TO PREVENT DAMAGE AND AID IN INSERTION. 1" FLEXIBLE HOSE multiple unit to single loop connection In instances where multiple units are connected to a singular loop, our recommendation is to apply a flow center to each individual system with full-port balancing valves installed on each unit. See Figure 6. Manual 2100-518B Page 12 of 30 OPTIONAL VISUAL FLOW METER NOTE: IF USED SUPPORT WITH A FIELD-FABRICATED WALL BRACKET MIS-2621 A figure 5B flow center connection to GT Series model PIPE FROM GOUND LOOP PIPE TO GROUND LOOP PUMP MODULE STRAIGHT BARBED BRASS ADAPTERS OPTIONAL VISUAL FLOW METER NOTE: IF USED SUPPORT WITH A FIELD FABRICATED WALL BRACKET HOSE CLAMPS 1" FLEXIBLE HOSE NOTE: APPLY PETROLEUM JELLY TO O-RINGS TO PREVENT DAMAGE AND AID IN INSERTION WATER OUT WATER IN MIS-2827 A Manual 2100-518B Page 13 of 30 figure 5C flow center connection to QW Series model FLEXIBLE HOSE PUMP MODULE (See Spec Sheet for Model No.) PIPE FROM GROUND LOOP PIPE TO GROUND LOOP NOTE: Apply petroleum jelly to o-rings to prevent damage and aid in insertion WATER OUT MIS-2748 A Manual 2100-518B Page 14 of 30 Manual 2100-518B Page 15 of 30 FIELD SUPPLIED FULL PORT BALL VALVE FOR BALANCING EACH HEAT PUMP FIELD SUPPLIED MUST INCLUDE P/T CHECK VALVE TO PORTS TO VERIFY PREVENT SHORT CYCLING FLOW RATES NOTES: 1. Piping is shown schematically. Actual pipe diameter and layout must be determined before installation. 2. Pressure drop calculation must be made to verify that parallel pumping arrangement provides enough head to deliver design flow rate to each unit when all units are operating. 3. Flow controller should be mounted close enough to unit to maintain short (aprox. 10 ft., 3m) hose kit from Flow Controller to unit. MIS-2664 4. All units must include P/T ports for flow rate measure and balancing. GROUND LOOP figure 6 multiple unit connection to singular ground loop flow center wiring WARNING To avoid possible injury or death due to electrical shock, open the power supply disconnect switch and secure it in an open position during installation. caution Use only copper conductors for field installed electrical wiring. Unit terminals are not designed to accept other types of conductors. Power wiring to the Flow Center should conform to all applicable codes. Figure 7 shows the required wiring between the geothermal heat pump and the flow center. Note: the flow center is only available in 208/230 Volt, 60 Hz, 1-phase. The flow center electrical connection interior of the heat pump control panel is circuit breaker protected (both L1 and L2 power lines). See Table 2 for the electrical requirements. TABLE 2 electrical ratings Manual 2100-518B Page 16 of 30 Model Pump Quantity Volts Amps HP DORFC-1 1 230 1.07 1/6 DORFC-2 2 230 2.14 1/3 figure 7 electrical connections FLOW CENTER ELECTRICAL ENTRANCE FLOW CENTER CONNECTION L1 L2 38 Red 37 Black Circuit Breakers PUSH 3 MIS-2665 PUSH 3 Terminal Block 2 Manual 2100-518B Page 17 of 30 flushing & charging All Flushing of earth loops should be performed using a 1.5 HP or larger pump (as specified by IGSHPA). Flushing can be accomplished using three different methods. The first flushing method applies a one-step installation of the loop, unit and inside piping. The second method allows a Loop Contractor to use flush cart when installing the loop, and at a later date, the dealer can install the unit to the loop using only domestic water to flush the unit. The third procedure shown is used when replacing the pump, coaxial refrigerant to water coil, or unit. The following are step-bystep procedures. Be careful not to rotate the 3-way valves into a position where air can be introduced into the loop. Reflushing will be required if this occurs. Valve position can be verified by looking on the end of the valve stem for the pattern position. Consult the IGSHPA for more complete flushing and antifreeze instructions. Flush in one direction for one hour, deadheading in increments - checking site glass for air pockets. Reverse flow in opposite direction, again for one hour, deadheading in increments - checking site glass for air pockets. The presence of air can be detected by “deadheading” the pump. To deadhead the pump, close off the return to the pump and watch the water level site glass. Once you have no more than 1/2" to 3/4" drop in the site glass, you will have achieved complete air removal. Power flushing can be achieved using the home’s city water supply (or well water) connected to the flush cart. This uses the combined pressure of the flush cart pump and the home’s water system for faster flushing. Manual 2100-518B Page 18 of 30 After flushing is complete, but prior to unit start up, remove the large screw from the center of the flow center pump(s) to allow air to escape (water will drip out). Replace the screw after pump has filled with fluid. For final pressurization, run the unit in heating or cooling for a period of 20 minutes. Following this 20 minute run time, pressurize the loop using the flush cart to 50-75 psig in winter or 40-50 psig in summer. In areas where entering loop temperatures drop below 40°F (5°C) or where piping will be routed through areas subject to freezing, antifreeze is needed to prevent the loop from freezing inside the pipe or heat exchanger. Alcohols and glycols are commonly used as antifreeze, however, you should consult with your distributor for assistance in selecting the antifreeze best suited for your region. Procedures for adding antifreeze 1. Flush cart should be half full of water. 2. Add measured amount of antifreeze through hose below the water level (calculate based upon loop). 3. Add antifreeze to loop side only (see valve position in Figure 9A). 4. Pump and dump (discharge). 5. Turn off pump; close discharge valve. 6. Repeat the procedure to add remaining antifreeze to loop. flushing & charging (Continued) figure 8 connecting flush cart to flow center RETURN SUPPLY MIS-2661 Manual 2100-518B Page 19 of 30 flushing & charging (Continued) figures 9A & 9B flow center valve positioning FLUSH LOOP ONLY FLUSH LOOP & UNIT TOGETHER MIS-2662 Manual 2100-518B Page 20 of 30 flushing & charging (Continued) figures 9C & 9D flow center valve positioning FLUSH UNIT ONLY OPERATION MIS-2663 Manual 2100-518B Page 21 of 30 flushing & charging (continued) flushing & filling earth loop and unit(s) together flushing earth loop only All air and debris must be removed from the earth loop piping system before operation. Flush the loop with a high volume of water at a high velocity (2 fps in all piping in accordance with IGSHPA guidelines). 2. Connect the unit side connections of the flow center together with a jumper hose. 1. Connect the unit and loop to the flow center. 2. Connect the flush cart hoses to the front port of the flow center (see Figure 8). 3. Fill closed loop (outside) evenly with domestic water and discharge the return water by adding water to the flush cart until water returns to the reservoir. The return water should be filtered or discharged to remove debris. 4. Fill the flush cart two-thirds full for initial flushing. 5. Flush the lowest portion of the system first. Depending upon the individual layout, this could be the loop or the unit. (If unit is lowest part of system, set valve position as shown in Figure 9C. If loop is lowest part of system, set flow center valve position as shown in Figure 9A.) 6. Restart the pump. Once you have a steady flow of water on the return side from the system, deadhead the pump by closing the ball valve on the hose returning to the reservoir. This will generate the maximum pressure on the system. While the return ball valve is closed, note the fluid level in the reservoir. If all the air is purged from the system, the level will drop only 1/2" to 3/4" in the flush cart site glass, since water is not compressible. This is the only way to tell if the air is purged from the system. Open valve quickly, wait one minute, then deadhead again. Repeat this process until all air is purged from the system. 7. Reverse the flow direction with the flush cart and repeat Step #6. 8. Repeat Step #6 for the higher elevation side of the system. (If unit is highest part of system, set valve position as shown Figure 9C. If loop is highest part of system, set flow center valve position as shown in Figure 9A.) 9. After flushing both sides of the system, reset flow control valves to flush the entire system. Set valve position as shown in Figure 9B and repeat Step #7. Manual 2100-518B Page 22 of 30 1. Connect loop to flow center. 3. Remove caps and plugs from flow center front access ports. 4. Connect flush cart hoses to access ports. 5. Position valve stems as shown in Figure 9A. 6. Fill the flush cart two-thirds full for initial flushing. 7. Restart the pump. Once you have a steady flow of water on the return side from the system, deadhead the pump by closing the ball valve on the hose returning to the reservoir. This will generate the maximum pressure on the system. While the return ball valve is closed, note the fluid level in the reservoir. If all the air is purged from the system, the level will drop only 1/2" to 3/4" in the flush cart site glass, since water is not compressible. This is the only way to tell if the air is purged from the system. Open valve quickly, wait one minute, then deadhead again. Repeat this process until all air is purged from the system. 8. Reverse the flow direction with the flush cart and repeat Step #7. 9. Rotate the flow center valves to isolate the flush cart from the rest of the system (see Figure 9C). 10. Turn off flush cart pump, relieve pressure on the hoses and remove them. 11. Replace flow center access plugs and caps. 12. Rotate valves back to position as shown in Figure 9B. 13. Remove jumper from unit connection ports. flushing & charging (continued) flushing unit only (Also used when replacing unit, coaxial coil, hose kit or pump) 1. Connect unit to flow center. 2. Rotate 3-way valve to position shown in Figure 9C. 3. Remove access port caps and plugs and connect either flush cart or Bard DORGHMT fitting (service only - not intended for primary flush). 4. Attach garden hose to domestic water supply. 5. Purge air from garden hose before connecting to port in flow center. 6. Attach another length of garden hose to the other port in the flow center, leading to drain. 7. Flush flow center and unit with domestic water until air is removed. 8. Close drain valve on discharge hose and pressurize system to domestic water pressure (approx. 4-75 psig). 9. Remove bleed screw(s) from flow center pump motors to purge air and replace screw(s). 10. Close valve on supply hose to trap pressure in the system. 11. Rotate 3-way valves back to normal operating position (see Figure 9D). 12. Remove water supply hose from flow center and replace access port caps/plugs. Manual 2100-518B Page 23 of 30 flow center initial startup 1. Check to make sure the loop and unit isolation valves are completely open and the flush ports are closed and sealed (see Figure 9D). 2. Geothermal units have two low pressure switches installed. One switch is intended for Ground Water Applications (default factory wired - blue wires), and the second is intended for Ground Loop Applications (yellow wires). Remove the “blue” wires from the LPS terminals of the compressor control module internal of the control panel of the geothermal heat pump and replace with the yellow low pressure switch wires (see unit wiring diagram). 3. Check and record the earth loop pressure (use P/T ports at geothermal heat pump). Loop Pressure_____IN_____OUT 4. Check and record flow rate. FLOW RATE - _____GPM 5. Check performance of unit. (Refer to Geothermal Heat Pump Installation Manual.) procedure for pressurizing the system 1. Once system is completely flushed and antifreeze is added, it can then be pressurized. Perform this by deadheading the pump by closing the return hose ball valve. This will increase the pressure on the loop via the flush cart pump. As the pressure will fluctuate with the seasons (set higher in winter and lower in summer), it is suggested that the initial loop pressure be 50-75 psig in winter and 40-50 psig in summer. If you cannot reach these pressures with the flush cart pump alone, turn on the fresh water feed to the cart while still deadheading the pump. The potable water pressure, along with the pump, will increase the amount of pressure in the loop. 2. Bleed any air from the inside of the pump. This can be done by removing the bleed screw from the center of the pump motor head, allowing a small amount of fluid to drip out. Replace the bleed screw. 3. Rotate the flow center valves to isolate the flush cart from the rest of the system (see Figure 9D). 4. Turn off the flush cart pump, relieve the pressure on the hoses and remove them. 5. Replace flow center access plugs and caps. NOTE: If the flow center is mounted in the horizontal position, the supply hose must be connected to the lower flushing port to allow air to pass out of the upper port during the final flushing. Manual 2100-518B Page 24 of 30 pressure/temperature plugs The pressure/temperature plugs (P/T plugs) supplied with the ground water connectors are provided as a means of measuring flow and temperature (see Figure 10). The waterflow through the unit can be checked by measuring the incoming water pressure at the supply pressure P/T and subtracting the leaving water pressure at the return water P/T plug. Comparing the differential to the pressure drop/ flow chart (Table 3) will determine the flow rate through the heat pump. Example: Model GV51S1 with a measured pressure drop of 5.1 psig is equivalent to 9 GPM flow. GPM rates higher than the required minimum flow rates will not be detrimental to performance. However, insufficient flow can significantly reduce capacity, efficiency and create nuisance trips of safety controls, and possibly damage to components in extreme conditions. NOTE: Pressure/Temperature probes should be lubricated with a water-based lubricant prior to gently pushing the probes into the P/T ports to prevent internal damage. Thermometers, probes and gauges are available for conducting these tests. figure 10 pressure temperature ports Thermometer NOTE: Slide retaining cap back to expose double o-rings. Apply petroleum jelly to o-rings to prevent damage and aid in insertion Dial face pressure guage with guage adaptor 40 50 60 70 Retaining cap, hand tighten only 80 30 90 20 100 10 110 0 120 P/T test plug Pete's Test plug cap Barbed 90° adapter MIS-2622 A TABLE 3A GV Series coil pressure drop Model GV27S1 GPM PSID Ft. Hd. 3 0.1 0.23 4 0.5 5 GV38S1 / GV51S1 PSID Ft. Hd. 1.15 0.9 2.08 1.2 2.77 1.4 3.23 6 1.7 3.92 2.3 5.31 7 2.3 5.31 3.2 8 3.1 7.15 9 4.1 9.46 GV61S1 PSID Ft. Hd. 7.38 2 4.61 4.1 9.46 2.5 5.1 11.77 10 6.1 11 GV71S1 PSID Ft. Hd. 5.77 2 4.61 3.2 7.38 2.4 5.54 14.07 3.9 9.00 2.8 6.46 7.1 16.38 4.7 10.84 3.4 7.84 12 8.2 18.92 5.5 12.69 3.9 9.00 13 9.4 21.69 6.4 14.76 4.5 10.38 14 10.6 24.45 7.3 16.84 5.2 12.00 15 8.1 18.69 5.9 13.61 16 9 20.76 6.7 15.46 17 9.9 22.84 7.4 17.07 8.4 19.38 18 Manual 2100-518B Page 25 of 30 TABLE 3B GT Series coil pressure drop Model GTC48S1 GTC36S1 GPM PSID Ft. Hd. PSID Ft. Hd. 3 0.1 0.23 4 0.5 1.15 0.9 2.08 5 1.2 2.77 1.4 3.23 6 1.7 3.92 2.3 5.31 7 2.3 5.31 3.2 8 3.1 7.15 9 4.1 9.46 GTC60S1 PSID Ft. Hd. 7.38 2 4.61 4.1 9.46 2.5 5.77 5.1 11.77 3.2 7.38 10 6.1 14.07 3.9 9.00 11 7.1 16.38 4.7 10.84 12 8.2 18.92 5.5 12.69 13 9.4 21.69 6.4 14.76 14 10.6 24.45 7.3 16.84 15 8.1 18.69 16 9 20.76 17 9.9 22.84 18 TABLE 3C QW Series coil pressure drop Model GPM PSID Ft. Hd. 3 0.1 0.23 4 0.5 5 QW4S1 PSID Ft. Hd. 1.15 0.9 2.08 1.2 2.77 1.4 3.23 6 1.7 3.92 2.3 5.31 7 2.3 5.31 3.2 8 3.1 7.15 9 4.1 9.46 QW6S1 PSID Ft. Hd. 7.38 2 4.61 4.1 9.46 2.5 5.77 5.1 11.77 3.2 7.38 10 6.1 14.07 3.9 9.00 11 7.1 16.38 4.7 10.84 12 8.2 18.92 5.5 12.69 13 9.4 21.69 6.4 14.76 14 10.6 24.45 7.3 16.84 15 8.1 18.69 16 9 20.76 17 9.9 22.84 18 Manual 2100-518B Page 26 of 30 QW2S1 & QW3S1 troubleshooting Problem Water Drips Out Low Flow / No Flow Noisey Pressure Loss Unit Trips Out on Water Flow (Low Pressure or High Pressure) Possible Causes Checks & Corrections Condensation Insulate piping, check for insulation gaps. Water Leak Inspect/tighten fittings. Power Loss Check power supply from the heat pump. Blown Circuit Breaker Reset circuit breaker for flow center in heat pump control box. Broken or Loose Wires Replace or tighten wires. Pump Shaft Stuck Remove the indication plug and ensure that shaft is rotating. Air Lock Flush loop to eliminate air. Improperly Sized Pump Add pump capacity. Defective Pump Replace. No Positive Pressure Check for leaks, add fluid, flush as required and pressurize. Viscous Solution Change type of antifreeze. Loop Freezing or Frozen Switch thermostat to A/C operation to see if flow improves at warmer temperature. Add antifreeze and measure freeze protection. Kink in Loop Straighten or Replace. Defective Pump Replace. Air in Loop Flush loop again. Vibration Check mounting. Leak Repair. Temperature Change Not a problem; pressure should vary as temperature changes. Pipe Expansion Not a problem; plastic piping relaxing. Low Flow / No Flow See Low Flow / No Flow. Manual 2100-518B Page 27 of 30 ANTIfreeze selection & use Selection of antifreeze solutions for ground loop applications requires consideration of many important factors, which may have long-term implications in regards to performance and system component life. Each area of concern leads to a different antifreeze solution. The fact that there is no “ideal” antifreeze and any choice will require compromises in one area or another. Some of these considering factors include: Safety – The toxicity and flammability of the antifreeze solution. Thermal Performance – The heat transfer and viscosity effects of the antifreeze. Cost – The prices vary widely. Corrosiveness – System materials must be compatible with the antifreeze solution. Stability – Will the solution require periodic change out or maintenance? Convenience – Is the solution readily available and easy to transport and install? Codes – Will the solution meet local/regional/state/ national regulatory standards? It is highly recommended to utilize pre-mixed antifreeze solutions where possible to alleviate many installation problems and extra labor. The following are some general observations about the types of antifreeze materials presently being applied in the geothermal ground loop markets: Manual 2100-518B Page 28 of 30 Methanol – Considered toxic in pure form, good heat transfer, low to mid-price, flammable in concentrations greater than 25%, non-corrosive and low viscosity. Methanol has delivered outstanding performance in ground loop applications for over 20 years. Its only drawbacks are toxicity and flammability. Although methanol enjoys widespread consumer use as windshield washer fluid in even higher concentrations, some local codes may limit its use in ground loops. (Note: Do NOT use automotive windshield washer fluid as antifreeze. Most washer fluids contain chemicals that will cause foaming.) To increase safety, a pre-mixed form should be used on the jobsite to increase the safety factor. Pure methanol can be purchased from any chemical supplier. Ethanol – Good heat transfer (lower than methanol), high price, flammable in concentrations greater than 10%, non-corrosive and low viscosity. Ethanol in pure form is considered non-toxic and shows promise as a geothermal heat transfer fluid. However, the U.S. Bureau of Alcohol, Tobacco & Firearms (ATF) limit its distribution. All nonbeverage ethanol is required to be denatured and rendered unfit to drink. Generally, this is done by adding a small percentage of toxic substances such as methanol, benzene or gasoline as a denaturant. Many of the denaturants are difficult to identify by the casual user, and many are not compatible with polyethylene pipe. Only denatured ethanol can be purchased for commercial use. The use of ethanol is not recommended because of the unknown denaturants included in the solution and their possible toxicity and damage resulting to polyethylene piping systems. Denaturing agents that are petroleum based can damage polyethylene pipe. ANTIfreeze selection & use (continued) Potassium Acetate (GS4) – Non-toxic, good heat transfer, high price, non-corrosive with added inhibitors, low viscosity. Due to its low surface tension, Potassium Acetate has been known to leak through mechanical fittings and certain thread sealants. A variant of the salt family, it can be extremely corrosive when exposed to air. Potassium Acetate is not recommended in ground loop applications due to the leaking and (ultimately) corrosion problems associated with it. Propylene Glycol – Non-toxic, non-corrosive, expensive, hard to handle when cold, poorest heat transfer, has formed “slime-type” coatings inside system piping. Propylene Glycol is acceptable in systems anticipating loop temperatures no colder than 40°F (4.4°C). These systems typically use antifreeze because of low ambient conditions (outside plumbing or cooling tower, etc.). When loop temperatures are below 40°F, the fluid becomes very difficult to pump and heat transfer characteristics suffer greatly. Only food grade propylene glycol is recommended to prevent the corrosion inhibitors from reacting with local water causing “slime-type” coatings inside heat exchangers. If propylene glycol must be used (code requirements), careful consideration of loop Reynolds numbers, pump selection and pressure drop must be considered. Note: Consult with your local distributor if you have questions regarding antifreeze selection and any comments to report about problems or success with any particular methods in your area. TABLE 4 fluid volume Approximate Fluid Volume per 100’ (10 Meters) of Pipe Size Volume (u.s. gallon/100'pipe) Volume (Liters/10 meters) Copper 1" CTS 4.1 15.5 Copper 1-1/4" CTS 6.4 24.2 Copper 1-1/2" CTS 9.2 34.8 Polyethylene 3/4" - IPS SDR 11 3.0 11.4 Polyethylene 1" - IPS SDR 11 4.7 17.8 Polyethylene 1-1/4" - IPS SDR 11 7.5 28.4 Polyethylene 1-1/2" - IPS SDR 11 9.8 37.1 Polyethylene 2" - IPS SDR 11 15.4 58.3 Type TABLE 5 percentages by volume Antifreeze Percentages by Volume Type Minimum Temperature for Freeze Protection 10°F (-12.2°C) 15°F (-9.4°C) 20°F (-6.7°C) 25°F (-3.9°C) Methanol 25% 21% 16% 10% Ethanol * 29% 25% 20% 14% 100% USP Food Grade Propylene Glycol 27% 24% 20% 13% * Must not be denatured with any petroleum based product. Manual 2100-518B Page 29 of 30 WARNING WARNING Always use properly marked vehicles (D.O.T. Always use properly marked vehicles (D.O.T. placards) and clean/suitable/properly marked placards) containers and clean/suitable/properly marked identified for handling flammable identified containers handling flammable antifreeze mixtures. for Post and advise those antifreeze mixtures. Post and those on the jobsite of chemical use advise and potential on the jobsite of chemical use and potential dangers of handling and storage. dangers of handling and storage. antifreeze verification ANTIFREEZE VERIFICATION caution CAUTION Always obtain MSDS (material safety data Always obtain MSDS (material safety data sheets) for all chemicals used in ground loop sheets) for all chemicals used in ground loop applications - including chemicals used as applications - including chemicals used as antifreeze. antifreeze. figure 11 FIGURE 11 density verification DENSITY VERIFICATION for Solution strength for SOLUTION STRENGTH Both Glycol and Alcohol based antifreeze solutions can Both Glycol and Alcohol based antifreeze solutions can be be verified to the specific percentage of volume within the verified to the specific percentage of volume within the ground loop system. One of the easiest ways to check this ground loop system. One of the easiest ways to check this is through use of a Hydrometer to check the specific density is through use of a Hydrometer to check the specific of the ground loop fluid and comparing these to the charts density of the ground loop fluid and comparing these to the supplied by the antifreeze manufacturer (see Figure 11). charts supplied by the antifreeze manufacturer (see Figure Hydrometers can be purchased from your local distributor 11). and are also available through national wholesalers. Hydrometers can be purchased from your local distributor and are also available through national wholesalers. MIS-2666 MIS-2666 TABLE 6 TABLE 7 It is recommended that IGSHPA design and specifications are utilized for Loop Design, Pipe Manifolding and Hot Fusion It is recommended that IGSHPA design and specifications are utilized for Loop Design, Pipe Manifolding and Hot Fusion operations. operations. There are many available software programs available to aid with loop design parameters. Your local loop material or equipment There are many available softwareavailable. programsTechnical availableService to aid with design parameters. local loop supplier may have this technology has loop the capability to assist youYour in this area as material well, but or it is on a equipment may have this technology available. Technical Service has the capability to assist you in this area as well, first come - supplier first serve basis. but it is on a first come - first serve basis. Manual 2100-518B Manual 30 2100-518A Page of 30 Page 30 of 30
Source Exif Data:
File Type : PDF File Type Extension : pdf MIME Type : application/pdf PDF Version : 1.6 Linearized : Yes Create Date : 2012:04:23 15:42:10-04:00 Keywords : DORFC-1, DORFC-2 Modify Date : 2012:04:24 06:39:15-04:00 XMP Toolkit : Adobe XMP Core 4.2.1-c043 52.372728, 2009/01/18-15:08:04 Metadata Date : 2012:04:24 06:39:15-04:00 Creator Tool : Adobe InDesign CS5 (7.0.4) Page Image Page Number : 1, 2 Page Image Format : JPEG, JPEG Page Image Width : 256, 256 Page Image Height : 256, 256 Page Image : (Binary data 7889 bytes, use -b option to extract), (Binary data 8522 bytes, use -b option to extract) Instance ID : uuid:53502309-8a58-4b61-9913-6ff4630d7b9b Document ID : xmp.did:B0FECA777A85E111BA84D80EDC11B88E Original Document ID : xmp.did:B0FECA777A85E111BA84D80EDC11B88E Rendition Class : proof:pdf History Action : created, saved, saved, saved, saved, saved History Instance ID : xmp.iid:B0FECA777A85E111BA84D80EDC11B88E, xmp.iid:B3FECA777A85E111BA84D80EDC11B88E, xmp.iid:B4FECA777A85E111BA84D80EDC11B88E, xmp.iid:B37CD55D7B85E111BA84D80EDC11B88E, xmp.iid:209FB5DE8185E111BA84D80EDC11B88E, xmp.iid:AFAAA9917B8DE111B60984E0877874E5 History When : 2012:04:13 11:08:04-04:00, 2012:04:13 11:11:51-04:00, 2012:04:13 11:11:51-04:00, 2012:04:13 11:27:41-04:00, 2012:04:13 12:01:03-04:00, 2012:04:23 15:41:52-04:00 History Software Agent : Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0, Adobe InDesign 7.0 History Changed : /;/metadata, /metadata, /;/metadata, /;/metadata, /;/metadata Doc Change Count : 449 Format : application/pdf Title : 2100-518(B) (2012 04) Description : I Creator : Subject : DORFC-1 DORFC-2 Producer : Adobe PDF Library 9.9 Trapped : False Page Layout : OneColumn Page Count : 30EXIF Metadata provided by EXIF.tools