Installation Guide for DAIKIN models including: Water Source Heat Pump, Heat Pump, GV27S3AA, GV38S3AA, GV51S3AA, GV61S3AA, GV71S3AA
Continuous airflow is the CFM being circulated with manual fan operation without any additional function occurring. Will occur automatically for first 5 minutes of Part Load Cooling Operation. Will occur automatically after five minutes of Part Load Cooling Operation.
INSTALLATION INSTRUCTIONS
Water Source Heat Pump
Models:
GV27S3AA GV38S3AA GV51S3AA GV61S3AA GV71S3AA
MIS-2615
Earth Loop Fluid Temperatures 25° 110° Ground Water Temperatures 45° 75°
BMC, Inc. Bryan, Ohio 43506
Manual: 2100-666E
Supersedes: 2100-666D
Date:
7-20-21
Page
1 of 37
CONTENTS
Getting Other Informations and Publications .. 3
General Information ............................................... 4 Water Source Nomenclature ................................. 4 Heater Package Nomenclature .............................. 8
Application and Location ...................................... 9 General .............................................................. 9 Shipping Damage ................................................ 9 Application ......................................................... 9 Location ............................................................. 9 Ductwork ............................................................ 9 Filter ................................................................ 10 Condensate Drain .............................................. 12 Piping Access to Unit......................................... 12
Wiring Instructions............................................... 14 General ............................................................ 14 Control Circuit Wiring......................................... 14 Wall Thermostat ................................................ 14 Thermostat Indicators ........................................ 14 Emergency Heat Mode ....................................... 14
Ground Loop (Earth Coupled Water Loop Applications)........ 16
Circulation System Design .................................. 16 Start Up Procedure for Ground Loop System ........ 17
Ground Water (Well System Applications) ....... 19 Water Connections ............................................. 19 Well Pump Sizing .............................................. 19 Start Up Procedure for Ground Water System ....... 21 Water Corrosion ................................................. 21 Remedies of Water Problems .............................. 22 Lake and Pond Installations................................ 22
Sequence of Operation ......................................... 24 Blower.............................................................. 24 Part Load Cooling .............................................. 24 Full Load Cooling .............................................. 24 Part Load Heating (No Electric Heat)................... 24 Full Load Heating (No Electric Heat) ................... 24 Supplementary Electric Heat .............................. 24 Emergency Heat Mode ....................................... 24 Geothermal Logic Control ................................... 24 High Pressure Switch......................................... 25 Low Pressure Switch .......................................... 25 Flow Switch ...................................................... 25 Evaporator Condensation Overflow ....................... 25 Under and Over Voltage Protection ...................... 25 Intelligent Reset................................................ 25 Alarm Output .................................................... 25 Pressure Service Ports........................................ 25 System Start Up ................................................ 25 Quick Reference Troubleshooting Chart................ 30
Service ..................................................................... 31 Service Hints .................................................... 31 Unbrazing System Components........................... 31 Compressor Solenoid ......................................... 31 Troubleshooting GE Endura Pro Series Motors ...... 32
Accessories ............................................................. 34 Add-On GVDM-26 Pump Module Kit.................... 34 General ............................................................ 34 Installation ....................................................... 34
Ground Source Heat Pump Performance Report ......................................... 35
Wiring Diagram................................................ 37
Figures Figure 1 Figure 2
Figure 3 Figure 4
Figure 5 Figure 6 Figure 7
Figure 8
Figure 9
Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15
Unit Dimensions ............................... 7 Field Conversion to Left-Hand Return ........................................... 10 Filter Rack GV Models .................. 12 Condensate Drain and Piping Access to Unit ................................ 13 Thermostat Wiring........................... 15 Circulation System Design ............... 16 Temperature and Pressure Measurement .................................. 17 Performance Model DORFC-1 Flow Center .................................... 18 Performance Model DORFC-2 Flow Center .................................... 18 Water Connection Components ......... 20 Cleaning Water Coil ......................... 22 Lake and Pond Installation .............. 23 Component Location ....................... 26 Control Panel.................................. 26 Refrigerant Flow Diagrams ............... 27
Manual 2100-666E Page 2 of 37
Figure 16A Pressure Tables................................. 28 Figure 16B Pressure Tables............................... 29 Figure 17 Motor Connections .......................... 32 Figure 18 Motor Connections .......................... 33 Figure 19 Typical Pump Kit Connection
to Unit ........................................... 34
Tables Table 1 Table 2 Table 3 Table 4 Table 5
Table 6 Table 7 Table 8A
Table 8B Table 9
Indoor Blower Performance ................ 4 Flow Rates for Various Fluids ............. 5 Specifications................................... 5 Water Coil Pressure Drop ................... 6 Electrical Specifications Optional Field-Installed Heater Packages ......... 8 Air Filter Table................................ 11 Control Circuit Wiring ...................... 14 Wall Thermostat.............................. 14 Minimum Required Flow Rates for Ground Water Installations .......... 19 Constant Flow Valves....................... 19 Solenoid Coil Resistance ................. 31
GETTING OTHER INFORMATION AND PUBLICATIONS
These publications can help with installing the heat pump. They can usually be found at the local library or purchased directly from the publisher. Be sure to consult the 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 2100-666E
Page
3 of 37
GENERAL INFORMATION
WATER SOURCE PRODUCT LINE NOMENCLATURE
G
V
38
S
3
A
A
C
Ground Source
Vertical
Revision Level
Black E-Coated Air Coil
Electrical 230/208V 1-Phase
C = Copper Water Coil (Closed Loop)
N = Cupronickel (Open Loop)
Step Capacity
38 = Nominal heating capacity in thousands @ 50° water - Full Load Nominal cooling capacity in thousands @ 77° brine - Full Load
MODEL
GV27S3 GV38S3 GV51S3 GV61S3 GV71S3
Motor HP
Rated ESP
1/3 0.15 1/2 0.15 1/2 0.20 3/4 0.20 3/4 0.25
TABLE 1 Indoor Blower Performance (Rated CFM)
MAX ESP
Speed #1
Continuous
Airflow
Speed #2
Mild Weather Operation in 1st Stage Cooling Mode (5-Min.)
Speed #3
Part Load Operation
Airflow
0.50
500
650
800
0.50
650
725
900
0.50
750
925
1150
0.50
800
1050
1300
0.50
875
1150
1450
Speed #4
-10% Full Load
Airflow (Optional)
900
1175
1350
1450
1575
Speed #5
Full Load Airflow and Electric Heat
Mode
1000
1300
1500
1600
1750
Motor will automatically step through the various airflows with thermostatic control. ESP = External Static Pressure (inches of water) Maximum allowable duct static Continuous airflow is the CFM being circulated with manual fan operation without any additional function occurring. Will occur automatically for first 5 minutes of Part Load Cooling Operation. Will occur automatically after five minutes of Part Load Cooling Operation. This is a field option for noisy installations to de-rate Full Load airflow (requires change in control panel). Will occur automatically with control signal input (will not be defeated for electric heat operation).
Manual 2100-666E Page 4 of 37
TABLE 2A Rated Flow Rates for Various Fluids
Various Fluids
Flow rate required GPM fresh water Flow rate required GPM 15% Sodium Chloride Flow rate required GPM 25% GS4
GV27S 7 7 7
GV38S 9 9 9
MODELS GV51S
12 12 12
Rated Flow
Fresh Water Optional Pump-N-Dump Flow Rates
TABLE 2B Optional Ground Water Flow Rates
GV27S 5
GV38S 6
MODELS GV51S
7
GV61S 15 15 15
GV61S 9
GV71S 16 16 16
GV71S 10
TABLE 3 Specifications
MODEL
GV27S3AA*
Electrical Rating (60HZ/1PH)
230/208-1
Operating Voltage Range
253-197
Minimum Circuit Ampacity
19
+Field Wire Size
#12
Delay Fuse Max. or Ckt. Bkr.
30
COMPRESSOR
Volts
230/208
Rated Load Amps 230/208
7.5/8.6
Branch Ckt. Selection Current
11.7
Lock Rotor Amps 230/208
58.3/58.3
BLOWER MOTOR AND EVAPORATOR
Blower Motor - HP/Speed/Type
1/3 / 5 / ECM
Blower Motor - Amps
1.5 / 1.6
Face Area Sq. Ft./Row/Fins Per Inch 3.16 / 4 / 11
GV38S3AA* 230/208-1 253-197
24 #10 40
230/208 12.0/13.65
15.3 83/83
1/2 / 5 / ECM 2.5 / 2.95
3.16 / 4 / 11
GV51S3AA* 230/208-1 253-197
32 #8 50
230/208 15.8/17.6
21.2 104/104
1/2 / 5 / ECM 2.8 / 3.0
5.33 / 3 / 11
GV61S3AA* 230/208-1 253-197
40 #6 60
230/208 21.9/24.2
27.2 152.9/152.9
3/4 / 5 / ECM 3.8 / 4.1
5.33 / 4 / 11
GV71S3AA* 230/208-1 253-197
44 #6 70
230/208 26.3/28.9
29.7 179.2/179.2
3/4 / 5 / ECM 4.1 / 4.2
5.33 / 5 / 10
+75°C copper wire
* C - for copper / N for Cupronickel water coil Heat pump only. Optional field-installed heaters are separate circuit.
Manual 2100-666E
Page
5 of 37
Model
GPM 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
TABLE 4 Water Coil Pressure Drop
GV27S3
PSID Ft. Hd.
0.1
0.23
0.5
1.15
1.2
2.77
1.7
3.92
2.3
5.31
3.1
7.15
4.1
9.46
GV38S3 / GV51S3 PSID Ft. Hd.
0.9 1.4 2.3 3.2 4.1 5.1 6.1 7.1 8.2 9.4 10.6
2.08 3.23 5.31 7.38 9.46 11.77 14.07 16.38 18.92 21.69 24.45
GV61S3 PSID Ft. Hd.
2
4.61
2.5
5.77
3.2
7.38
3.9
9.00
4.7
10.84
5.5
12.69
6.4
14.76
7.3
16.84
8.1
18.69
9
20.76
9.9
22.84
GV71S3 PSID Ft. Hd.
2
4.61
2.4
5.54
2.8
6.46
3.4
7.84
3.9
9.00
4.5
10.38
5.2
12.00
5.9
13.61
6.7
15.46
7.4
17.07
8.4
19.38
Manual 2100-666E Page 6 of 37
FIGURE 1 Unit Dimensions
Units
Supply
Return
Width Depth Height
Duct Flange Width Height
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
Y
GV27-38S3 27-5/8 26
48 13-7/8 13-7/8 18 22-3/4 6-7/8 2-7/16 1-1/2 45-1/4 31-5/8 1-5/8 2-1/4 3-1/4 29-1/16 25-13/16 8-3/16 19-1/2 15-1/2 2-1/16 7-3/8 23-1/8 25-7/16 1-1/4
GV51-71S3 32-5/8 27 55-5/8 17-7/8 17-7/8 23-1/2 29-7/8 7 2-7/16 1-1/2 52-7/8 32-1/4 1-5/8 2-1/2 3-1/2 29-3/4 26-13/16 8-1/16 19-5/16 15-5/16 2-1/16 9-7/8 25-5/8 30-7/16 1-5/16
F
TOP VIEW
LEFT SIDE VIEW
G C
SEE NOTE A
S T R
WATER CONNECTIONS
CONDENSATE DRAIN LOCATION
M
N
O K
L P Q
FRONT VIEW
A
D
H
RIGHT SIDE VIEW
J
OPTIONAL HEATER PACKAGE ELECTRICAL ENTRANCE
LOW VOLTAGE ENTRANCE
FLOW CENTER ELECTRICAL ENTRANCE
UNIT ELECTRICAL ENTRANCE
B E SUPPLY AIR
SEE NOTE A
SEE NOTE A
WATER CONNECTIONS
I
RETURN AIR FILTER RACK
G C
S T R
LOW
VOLTAGE
ENTRANCE
Y
DOMESTIC HOT WATER HEAT EXCHANGER WATER CONNECTIONS
CONDENSATE DRAIN LOCATION
REFRIGERANT
HIGH-SIDE
SERVICE PORT
R
REFRIGERANT
LOW-SIDE SERVICE PORT
NOTE A: PANELS ARE REVERSIBLE ALONG WITH CONTROL PANELS FOR HEAT PUMP AND ELECTRIC HEATER PACKAGE FOR BEST INSTALLATION POSITION.
CONDENSATE DRAIN LOCATION
BACK VIEW
U V
W X
Y
MIS-2616 A
Manual 2100-666E
Page
7 of 37
HEATER PACKAGE NOMENCLATURE
EH
3
GSV
A
Electric Heater
3 = 3 Ton 5 = 5 Ton
Modification Code
Ground Source Vertical
A
14
C
Circuit Breaker Nominal KW
240/208-1-60
TABLE 5 Electrical Specifications Optional Field-Installed Heater Packages
For Use with
Models
GV27S3AA GV38S3AA
Heater Package Model No.
Heater Package Volts/Phase 60 HZ
EH3GSVA-A05C 240/208-1
EH3GSVA-A09C 240/208-1
EH3GSVA-A14C 240/208-1
Heater Amps, KW and Capacity @ 240 Volts
AMPS 18.8 37.5 56.3
KW BTU 4.5 15,345 9.0 30,690 13.5 46,035
Heater Amps, KW and Capacity @ 208 Volts
AMPS KW BTU
Minimum Circuit
Ampacity
Maximum Circuit Breaker
Field Wire Size+
16.3 3.38 11,525
23.5
25
10
32.5 6.75 23,018
46.9
50
8
48.7 10.13 34,543
70.4
80
4
GV51S3AA GV61S3AA GV71S3AA
EH5GSVA-A09C EH5GSVA-A14C EH5GSVA-A18C
240/208-1 240/208-1 240/208-1
37.5 56.3 75.0
9.0 30,690 13.5 46,035 18.0 61,380
32.5 48.7 64.9
6.75 23,018 10.13 34,543 13.5 46,035
46.9 70.4 98.3
50
8
80
4
100
3
+ Based on 75F copper wire. All wiring must conform to National Electrical Code (latest edition) and all local codes.
Manual 2100-666E Page 8 of 37
APPLICATION AND LOCATION
GENERAL
Units are shipped completely assembled and internally wired, requiring only duct connections, thermostat wiring, 230/208 volt AC power wiring and water piping. The equipment covered in this manual is to be installed by trained, experienced service and installation technicians.
These instructions and any instructions packaged with any separate equipment required to make up the entire heat pump system should be carefully read before beginning the installation. Note particularly any tags and/or labels attached to the equipment.
While these instructions are intended as a general recommended guide, they do not in any way supersede any national and/or local codes. Authorities having jurisdiction should be consulted before the installation is made.
SHIPPING DAMAGE
Upon receipt of the equipment, the carton should be checked for external signs of shipping damage. If damage is found, the receiving party must contact the last carrier immediately, preferably in writing, requesting inspection by the carrier's agent.
APPLICATION
Capacity of the unit for a proposed installation should be based on heat loss calculations made in accordance with methods of the Air Conditioning Contractors of America. The air duct system should be sized and installed in accordance with Standards of the National Fire Protection Association for the Installation of Air Conditioning and Venting systems of Other than Residence Type NFPA No. 90A and Residence Type Warm Air Heating and Air Conditioning Systems NFPA No. 90B.
LOCATION
The unit may be installed in a basement, closet or utility room provided adequate service access is ensured. The unit is shipped from the factory as a right-hand return and requires access clearance of 2' minimum to the access panels on this side of the unit. If unit is to be field converted to left-hand return the opposite side will require access clearance of 2' minimum.
Unit may be field converted to left-hand return by removing two (2) screws that secure the control panel cover, removing four (4) screws that hold the control panel in place, laying the control panel down, sliding it under the blower and re-securing the control panel on
the opposite side of the unit (see Figure 2 on page 10). The two access doors from the right-hand return can be transferred to the left-hand return side and the one left-hand panel can be transferred to the right-hand side.
Unit casing suitable for 0" clearance with 1" duct clearance for at least the first 3' of duct. These units are not approved for outdoor installation and therefore must be installed inside the structure being conditioned. Do not locate in areas subject to freezing in the winter or subject to sweating in the summer.
Before setting the unit, consider ease of piping, drain and electrical connections for the unit. Also, for units which will be used with a field-installed heat recovery unit, consider the proximity of the unit to the water heater or storage tank. Place the unit on a solid base, preferably concrete, to minimize undesirable noise and vibration. DO NOT elevate the base pan on rubber or cork vibration eliminator pads as this will permit the unit base to act like a drum, transmitting objectionable noise.
DUCTWORK
If the unit is to be installed in a closet or utility room which does not have a floor drain, a secondary drain pan under the entire unit is highly recommended.
DO NOT install the unit in such a way that a direct path exists between any return grille and the unit. Rather, insure that the air entering the return grille will make at least one turn before entering the unit or coil. This will reduce possible objectionable compressor and air noise from entering the occupied space.
Design the ductwork according to methods given by the Air Conditioning Contractors of America. When duct runs through unconditioned spaces, it should be insulated with vapor barrier. It is recommended that flexible connections be used to connect the ductwork to the unit in order to keep the noise transmission to a minimum.
WARNING
Failure to provide the 1" clearance between the supply duct and a combustible surface for the first 3' of duct can result in a fire.
Manual 2100-666E
Page
9 of 37
FIGURE 2 Field Conversion to Left-Hand Return
2
1
3
Panel removed for clarity. Does not need removed to change control panel location.
1. Remove control panel fill plate. 2. Remove two screws securing control panel to unit. 3. Pass control panel through blower section rotating 180°. 4. Re-secure control panel on opposite side in same manner
as originally attached. 5. Move double doors to control panel side of unit.
MIS-2617
FILTER
This unit must not be operated without a filter. It comes equipped with 2" disposable filters, which should be checked often and replaced if dirty. Insufficient airflow due to undersized duct systems or dirty filters can result in nuisance tripping of the high or low pressure controls. Refer to Table 1 on page 4 for correct airflow and static pressure requirements.
NOTE: The filter rack is installed on the unit as shipped for right-hand return. If left-hand return is required, remove the filter access door and screws holding the filter rack to the unit (slide downward from underneath unit top). Invert the filter rack 180° to move filter
Manual 2100-666E Page 10 of 37
access door to the other side of the unit, and reverse the previous steps (see Figure 3).
NOTE: The duct attachment flanges will need to be bent up using duck bill pliers or similar device, as the unit is shipped with them collapsed.
Air Filters
Model
GV27S GV38S
GV51S GV61S GV71S
Filter Size 20" x 25" x 2" 16" x 25" x 2"
Quantity 1 2
Front of Unit
FIGURE 3 Filter Rack GV Models
Left-hand access filter rack installed.
Filter rack channel on GV51S3, 61S3,
7iFdinn1oislfteSteaas3rcllntredoaodroctykelno-sieccnheansadtotioanttlnnonl.eeebdleeodlnrootcGtoaaVttbei5oed1n.rS.oL1tea,6at1evSde.1in,7Lf1eaSacv1toery Remove all screws holding filter rack frame to unit. Rotate filter rack frame 180°
Manual 2100-666E
Page
Filter rack shipped for right-hand access from factory.
DDrarawwininggsshhoowwssdduuaall aaiirr ffiilltteerr models GmVo5d1eSls3G, 6V15S1S31, ,7611SS13,.71GSV12. 7S3, 38S3 hGavVe27oSnl1y,3o8nSe1ahiravfielteorn.ly one air filter.
To convert filter rack to left-hand access first remove filter rack door and filters.
MIS-2618 A
11 of 37
CONDENSATE DRAIN
Drain lines must be installed according to local plumbing codes. It is not recommended that any condensate drain line be connected to a sewer main.
Determine where the drain line will run and then select one of four locations for the condensate to exit the unit casing (see Figure 4). There are knockouts in the unit casing that can be selected for the condensate exit. Internal of the unit, there is a clear flexible hose with a termination fitting installed. When installed properly, this hose will create a trap internal of the unit and will remain serviceable if the drain system requires cleaning or service. Supplied in the parts bag of the unit is a 3/4" PVC male adaptor that will secure the internal drain components to the sheet metal casing at the location selected.
NOTE: This drain line will contain cold water and must be insulated to avoid droplets of water from condensing on the pipe and dripping on finished floors or the ceiling below the unit.
PIPING ACCESS TO UNIT
Water piping to and from the unit enters the unit cabinet on either side of the unit. The connection directly at the unit is a special double O-ring fitting with a retainer nut that secures it in place. (It is the same style fitting used for the flow center connection on ground loop applications.) Enter in and out either side of the unit in any combination as the installation dictates. One side has both connections closed off with a double O-ring plug seal with retaining caps. One or both of these can be transferred to the opposite side, depending upon installation requirements.
NOTE: All double O-ring fittings require "hand tightening only". Do not use wrench or pliers as retainer nut can be damaged with excessive force.
NOTE: Apply petroleum jelly to O-rings to prevent damage and aid in insertion.
Various fittings are available to connect to the unit with various materials and methods. These methods include 1" barbed fittings (straight and 90°), 1" MPT (straight and 90°), and 1-1/4" hot fusion fitting (straight only) (see Figure 4).
Manual 2100-666E Page 12 of 37
FIGURE 4 Condensate Drain and Piping Access to Unit
Water in connection Water out connection
Condensate drain access (4) locations
Desuperheater Pump module connections 1/2" I.D. copper stub
MIS-2619 A
SUCTION SERVICE CONNECTION
DISCHARGE SERVICE CONNECTION
Manual 2100-666E
Page
13 of 37
WIRING INSTRUCTIONS
GENERAL
All wiring must be installed in accordance with the National Electrical Code and local codes. In Canada, all wiring must be installed in accordance with the Canadian Electrical Code and in accordance with the regulations of the authorities having jurisdiction. Power supply voltage must conform to the voltage shown on the unit serial plate. A wiring diagram of the unit is attached to the inside of the electrical cover. The power supply shall be sized and fused according to the specifications supplied. A ground lug is supplied in the control compartment for equipment ground.
The unit rating plate lists a maximum circuit breaker or fuse that is to be used with the equipment. The correct size must be used for proper circuit protection and also to assure that there will be no nuisance tripping due to the momentary high starting current of the compressor motor.
CONTROL CIRCUIT WIRING
The minimum control circuit wiring gauge needed to ensure proper operation of all controls in the unit will depend on two factors.
1. The rated VA of the control circuit transformer.
2. The maximum total distance of the control circuit wiring.
Table 6 should be used to determine proper gauge of control circuit wiring required.
TABLE 6 Control Circuit Wiring
Rated VA of Control Circuit Transformer
Transformer Secondary FLA
@ 24V
Maximum Total Distance of Control Circuit Wiring in Feet
20 gauge 45
18 gauge 60
50
2.1
16 gauge 100
14 gauge 160
12 gauge 250
Example:
1. Control circuit transformer rated at 50 VA
2. Maximum total distance of control circuit wiring 85'
Per Table 6, minimum of 16 gauge wire should be used in the control circuit wiring.
WALL THERMOSTAT
The following thermostat should be used as indicated, depending on the application.
TABLE 7 Wall Thermostat
Thermostat
8403-060 (1120-445)
Predominant Features
3 stage Cool; 3 stage Heat Programmable/Non-Programmable Electronic HP or Conventional Auto or Manual changeover
THERMOSTAT INDICATORS
8403-060 (1120-445) Temperature/Humidity Control:
In heating or cooling, the display may be black and light gray, or backlit in blue depending on configuration. In the event of a system malfunction such as a loss of charge or high head pressure, the heat pump control board will issue a signal to the thermostat causing the screen to be backlit in RED and the display to read "Service Needed". If this occurs, the control will continue to function, but adjustments will not be able to be made until the problem is corrected and the fault device is reset.
EMERGENCY HEAT MODE
The operator of the equipment must manually place the system switch in this mode. This is done when there is a known problem with the unit.
When the 8403-060 (1120-445) Temperature/ Humidity Control is placed in the Emergency Heat mode, the display will be backlit in RED to indicate that service is needed. The display will remain backlit in red until the mode is switched out of Emergency Heat.
Manual 2100-666E Page 14 of 37
FIGURE 5 Thermostat Wiring
GROUND LOOP APPLICATIONS (when utilized with a flow center)
8403-060 (1120-445) (See notes 1 & 2 below)
C
R
G Y1 Y2 O W2 W1/E L
A D/YO
Unit 24V terminal strip C
R
G Y1 Y2 O W
E
L
A
GROUND WATER APPLICATIONS (when installed with recommended motorized valve with end switch)
8403-060 (1120-445) (See notes 1 & 2 below)
C
R
G Y1 Y2 O W2 W1/E L
A D/YO
Unit 24V terminal strip C
R G Y1 Y2 O W E
L
A
C W/Y ES ES
Bard part # 8603-033 Motorized valve with end switch (part of Bard GVGWK-1 Ground Water Kit)
GROUND WATER APPLICATIONS (when installed with standard 2-wire solenoid valve)
8403-060 (1120-445) (See notes 1 & 2 below)
C
R
G Y1 Y2 O W2 W1/E L
A D/YO
Unit 24V terminal strip C
R G Y1 Y2 O W E
L
A
Bard part #8603-006 Solenoid valve
1. Will need to be programmed for multi-stage heat pump 2. Will need to be configured to energize reversing valve for cooling mode 3. All wiring field supplied low voltage
MIS-2620 E
Manual 2100-666E
Page
15 of 37
GROUND LOOP (EARTH COUPLED WATER LOOP APPLICATIONS)
NOTE: Unit shipped from factory with 60 PSIG low pressure switch wired into control circuit and must be rewired to 45 PSIG low pressure switch for ground loop applications. This unit is designed to work on earth coupled water loop systems, however, these systems operate at entering water (without antifreeze) temperature with pressures well below the pressures normally experienced in water well systems.
CIRCULATION SYSTEM DESIGN
Equipment room piping design is based on years of experience with earth coupled heat pump systems. The design eliminates most causes of system failure.
The heat pump itself is rarely the cause. Most problems occur because designers and installers forget that a ground loop "earth coupled" heat pump system is NOT like a household plumbing system.
Most household water systems have more than enough water pressure either from the well pump of the municipal water system to overcome the pressure
of head loss in 1/2" or 3/4" household plumbing. A closed loop earth coupled heat pump system, however, is separated from the pressure of the household supply and relies on a small, low wattage pump to circulate the water and antifreeze solution through the earth coupling, heat pump and equipment room components.
The small circulator keeps the operating costs of the system to a minimum. However, the performance of the circulator MUST be closely matched with the pressure of head loss of the entire system in order to provide the required flow through the heat pump. Insufficient flow through the heat exchanger is one of the most common causes of system failure. Proper system piping design and circulator selection will eliminate this problem.
The equipment supplier may provide a worksheet to simplify heat loss calculations and circulator selection. Refer to "Circulating Pump Worksheet" section.
FIGURE 6 Circulation System Design
PIPE TO GROUND LOOP
PIPE FROM GROUND LOOP
PUMP MODULE
WATER IN WATER OUT
HOSE CLAMPS 1" FLEXIBLE HOSE
Manual 2100-666E Page 16 of 37
STRAIGHT BARBED BRASS ADAPTERS
NOTE: APPLY PETROLEUM JELLY TO O-RINGS TO PREVENT DAMAGE AND AID IN INSERTION.
OPTIONAL VISUAL FLOW METER NOTE: IF USED SUPPORT WITH A FIELD-FABRICATED WALL BRACKET
MIS-2621 B
START UP PROCEDURE FOR GROUND LOOP SYSTEM
1. Be sure main power to the unit is OFF at disconnect.
2. Set thermostat system switch to OFF and fan switch to AUTO.
3. Move main power disconnect to ON. Except as required for safety while servicing, DO NOT OPEN THE UNIT DISCONNECT SWITCH.
4. Check system airflow for obstructions.
A. Move thermostat fan switch to ON. Blower runs.
B. Be sure all registers and grilles are open.
C. Move thermostat fan switch to AUTO. Blower should stop.
5. Flush, fill and pressurize the closed loop system as outlined.
6. Fully open the manual inlet and outlet valves. Start the loop pump module circulator(s) and check for proper operation. If circulator(s) are not operating, turn off power and diagnose the problem.
7. Check fluid flow using a direct reading flow meter or a single water pressure gauge; measure the pressure drop at the pressure/temperature plugs across the water coil. Compare the measurement with flow versus pressure drop table to determine the actual flow rate. If the flow rate is too low,
recheck the selection of the loop pump module model for sufficient capacity. If the module selection is correct, there is probably trapped air or a restriction in the piping circuit.
8. Start the unit in cooling mode by moving the thermostat switch to cool. Fan should be set for AUTO.
9. Check the system refrigerant pressures against the cooling refrigerant pressure table in the installation manual for rated water flow and entering water temperatures. If the refrigerant pressures do not match, check for airflow problem then refrigeration system problem.
10. Switch the unit to the heating mode by moving the thermostat switch to heat. Fan should be set for AUTO.
11. Check the refrigerant system pressures against the heating refrigerant pressure table in installation manual. Once again, if they do not match, check for airflow problems and then refrigeration system problems.
NOTE: If a charge problem is determined (high or low):
A. Check for possible refrigerant leaks.
B. Recover all remaining refrigerant from unit and repair leak.
C. Evacuate unit down to 29" of vacuum.
D. Recharge the unit with refrigerant by weight. This is the only way to ensure a proper charge.
Thermometer
FIGURE 7 Temperature and Pressure Measurement
Dial face pressure guage with guage adaptor
NOTE: Slide retaining cap back to expose double o-rings. Apply petroleum jelly to o-rings to prevent damage and aid in insertion
50 60 70
40
80
30
90
20
100
10
110
0
12 0
Retaining cap, hand tighten only
Barbed 90° adapter
PePte/'Ts test plug Test plug cap
MIS-2622 A
Manual 2100-666E
Page
17 of 37
FIGURE 8 Performance Model DORFC-1 Flow Center
FIGURE 9 Performance Model DORFC-2 Flow Center
Manual 2100-666E Page 18 of 37
GROUND WATER (WELL SYSTEM APPLICATIONS)
NOTE: It is highly recommended on ground water systems (pump & dump) that a cupronickel coaxial coil is utilized on the source side of the system. Not doing so may void the product warranty due to aggressive/ corrosive/highly oxygenated water attacking a copper coaxial water coil.
NOTE: Unit shipped from factory with 60 PSIG low pressure switch wired into control circuit for open loop applications.
WATER CONNECTIONS
It is very important that an adequate supply of clean, non-corrosive water at the proper pressure be provided before the installation is made. Insufficient water, in the heating mode for example, will cause the low pressure switch to trip, shutting down the heat pump. In assessing the capacity of the water system, it is advisable that the complete water system be evaluated to prevent possible lack of water or water pressure at various household fixtures whenever the heat pump turns on. All plumbing to and from the unit is to be installed in accordance with local plumbing codes. The use of plastic pipe, where permissible, is recommended to prevent electrolytic corrosion of the water pipe. Because of the relatively cold temperatures encountered with well water, it is strongly recommended that the water lines connecting the unit be insulated to prevent water droplets from condensing on the pipe surface.
Refer to piping shown in Figure 10 on page 20. Slow open/close with End Switch (2), 24V, provides on/ off control of the water flow to the unit. Refer to the wiring diagram for correct hookup of the valve solenoid coil.
Constant Flow Valve (3) provides correct flow of water to the unit regardless of variations in water pressure. Observe the water flow direction indicated by the arrow on the side of the valve body. Table 8A shows the allowable flow range for each model and Table 8B shows the constant flow valve part numbers.
Strainer (8) installed upstream of water coil inlet to collect foreign material which would clog the flow valve orifice.
Figure 10 shows the use of shutoff valves (4) and (5) on the in and out water lines to permit isolation of the unit from the plumbing system should future service work require this. Globe valves should not be used as shutoff valves because of the excessive pressure drop inherent in the valve design. Instead use gate or ball valves as shutoffs to minimize pressure drop.
TABLE 8A Minimum Required Flow Rates for
Ground Water Installations
GV27S3 GV38S3 GV51S3 GV61S3 GV71S3
Flow rate
required GPM 5
fresh water
(7)
(Rated)
6
7
9
10
(9)
(12) (15) (16)
TABLE 8B Constant Flow Valves
Part No.
CFV-5 CFV-6 CFV-7 CFV-9 CFV-10 CFV-11 CFV-12 CFV-15 CFV-16
Min. Available Pressure PSIG 15* 15* 15* 15* 15* 15* 15* 15* 15*
Flow Rate GPM
5 6 7 9 10 11 12 15 16
* The pressure drop through the constant flow valve will vary depending on the available pressure ahead of the valve. Unless minimum of 15 psig is available immediately ahead of the valve, no water will flow.
Hose bib (6) and (7) and tees should be included to permit acid cleaning the refrigerant-to-water coil should such cleaning be required. See WATER CORROSION on page 21.
Hose bib (1) provides access to the system to check water flow through the constant flow valve to insure adequate water flow through the unit. A water meter is used to check the water flow rate.
WELL PUMP SIZING
Strictly speaking, sizing the well pump is the responsibility of the well drilling contractor. It is important, however, that the HVAC contractor be familiar with the factors that determine what size pump will be required. Rule of thumb estimates will invariably lead to under or oversized well pumps. Undersizing the pump will result in inadequate water to the whole plumbing system, but with especially bad results to the heat pump--NO HEAT/NO COOL calls
Manual 2100-666E
Page
19 of 37
will result. Oversized pumps will short cycle and could cause premature pump motor or switch failures.
The well pump must be capable of supplying enough water and at an adequate pressure to meet competing demands of water fixtures. The well pump must be sized in such a way that three requirements are met:
1. Adequate flow rate in GPM.
2. Adequate pressure at the fixture.
3. Able to meet the above from the depth of the wellfeet of lift.
The pressure requirements put on the pump are directly affected by the diameter of pipe being used, as well as, by the water flow rate through the pipe. The worksheet included should guarantee that the well pump has enough capacity. It should also ensure that the piping is not undersized, which would create too much pressure due to friction loss. High pressure losses due to undersized pipe will reduce efficiency and require larger pumps and could also create water noise problems.
FIGURE 10 Water Connection Components
8
7
6
5 4
See page 19 for descriptions for these reference numbers
3 2
1
Manual 2100-666E Page 20 of 37
MIS-2623 A
START UP PROCEDURE FOR GROUND WATER SYSTEM
1. Be sure main power to the unit is OFF at disconnect.
2. Set thermostat system switch to OFF and fan switch to AUTO.
3. Move main power disconnect to ON. Except as required for safety while servicing, DO NOT OPEN THE UNIT DISCONNECT SWITCH.
4. Check system airflow for obstructions.
A. Move thermostat fan switch to ON. Blower runs.
B. Be sure all registers and grilles are open.
C. Move thermostat fan switch to AUTO. Blower should stop.
5. Fully open the manual inlet and outlet valves.
6. Check water flow:
A. Connect a water flow meter to the drain cock between the constant flow valve and the solenoid valve. Run a hose from the flow meter to a drain or sink. Open the drain cock.
B. Check the water flow rate through constant flow valve to be sure it is the same as the unit is rated for. (Example: 5 GPM for a GV27S3.)
C. When water flow is okay, close drain cock and remove the water flow meter. The unit is now ready to start.
7. Start the unit in cooling mode by moving thermostat switch to cool. Fan should be set for AUTO. Check to see the solenoid valve opened.
8. Check the system refrigerant pressures against the cooling refrigerant pressure table in the installation manual for rated water flow and entering water temperatures. If the refrigerant pressures do not match, check for airflow problem that refrigeration system problem.
9. Switch the unit to the heat mode by moving thermostat switch to heat. Fan should be set for AUTO. Check to see the solenoid valve opened again.
10. Check the refrigerant system pressures against the heating refrigerant pressure table in installation manual. Once again, if they do not match, check for airflow problems and then refrigeration system problems.
NOTE: If a charge problem is determined (high or low):
A. Check for possible refrigerant loss.
B. Discharge all remaining refrigerant from unit.
C. Evacuate unit down to 29" of vacuum.
D. Recharge the unit with refrigerant by weight. This is the only way to ensure proper charge.
WATER CORROSION
Two concerns will immediately come to light when considering a water source heat pump, whether for ground water or for a ground loop application: Will there be enough water? And, how will the water quality affect the system?
Water quantity is an important consideration and one which is easily determined. The well driller must perform a pump down test on the well according to methods described by the National Well Water Association. This test, if performed correctly, will provide information on the rate of flow and on the capacity of the well. It is important to consider the overall capacity of the well when thinking about a water source heat pump because the heat pump may be required to run for extended periods of time.
The second concern, about water quality, is equally important. Generally speaking, if the water is not offensive for drinking purposes, it should pose no problem for the heat pump. The well driller or local water softening company can perform tests which will determine the chemical properties of the well water.
Water quality problems will show up in the heat pump in one or more of the following ways:
1. Decrease in water flow through the unit.
2. Decreased heat transfer of the water coil (entering to leaving water temperature difference is less).
There are four main water quality problems associated with ground water:
1. Biological Growth. This is the growth of microscopic organisms in the water and will show up as a slimy deposit throughout the water system. Shock treatment of the well is usually required and this is best left up to the well driller. The treatment consists of injecting chlorine into the well casing and flushing the system until all growth is removed.
2. Suspended Particles in the Water. Filtering will usually remove most suspended particles (fine sand, small gravel) from the water. The problem with suspended particles in the water is that it will erode metal parts, pumps, heat transfer coils, etc. So long as the filter is cleaned and periodically maintained, suspended particles should pose no serious problem. Consult with the well driller.
3. Corrosion of Metal. Corrosion of metal parts results from either highly corrosive water (acid water, generally not the case with ground water) of galvanic reaction between dissimilar metals in the presence of water. By using plastic plumbing or dielectric unions, galvanic reaction is eliminated. The use of corrosion resistant materials such as the Cupronickel coil) through the water system will reduce corrosion problems significantly.
Manual 2100-666E
Page
21 of 37
4. Scale Formation. Of all the water problems, the formation of scale by ground water is by far the most common. Usually this scale is due to the formation of calcium carbonate but magnesium carbonate or calcium sulfate may also be present. Carbon dioxide gas (CO2), the carbonate of calcium and magnesium carbonate, is very soluble in water. It will remain dissolved in the water until some outside factor upsets the balance. This outside influence may be a large change in water temperature or pressure. When this happens, enough carbon dioxide gas combines with dissolved calcium or magnesium in the water and falls out of solution until a new balance is reached. The change in temperature that this heat pump produces is usually not high enough to cause the dissolved gas to fall out of solution. Likewise, if pressure drops are kept to a reasonable level, no precipitation of carbon dioxide should occur.
REMEDIES OF WATER PROBLEMS
Water Treatment
Water treatment can usually be economically justified for water loop systems. However, because of the large amounts of water involved with a ground water system, water treatment is generally too expensive.
Acid Cleaning the Water Coil or Heat Pump Recovery Unit
If scaling of the coil is strongly suspected, the coil can be cleaned up with a solution of phosphoric acid (food grade acid). Follow the manufacturer's directions for mixing, use, etc. The acid solution can be introduced into the heat pump coil through hose bib A (see Figure 11). Be sure the isolation valves are closed to prevent contamination of the rest of the system by the coil. The acid should be pumped from a bucket into the hose bib and returned to the bucket through the other hose bib B. Follow the manufacturer's directions for the product used as to how long the solution is to be circulated, but it is usually circulated for a period of several hours.
LAKE AND POND INSTALLATIONS
Lakes and ponds can provide a low cost source of water for heating and cooling with a ground water heat pump. Direct usage of the water without some filtration is not recommended as algae and turbid water can foul the water to refrigerant heat exchanger. Instead, there have been very good results using a dry well dug next to the water line or edge. Normal procedure in installing a dry well is to backhoe a 15' to 20' hole adjacent to the body of water (set backhoe as close to the water's edge as possible). Once excavated, a perforated plastic casing should be installed with gravel backfill placed around the casing. The gravel bed should provide adequate filtration of the water to allow good performance of the ground water heat pump.
The following is a list of recommendations to follow when installing this type of system:
A. A lake or pond should be at least 1 acre (40,000 square feet) in surface area for each 50,000 BTUs of ground water heat pump capacity or have two times the cubic feet size of the dwelling to be heated (includes basement if heated).
B. The average water depth should be at least 4' and there should be an area where the water depth is at least 12' to 15' deep.
FIGURE 11 Cleaning Water Coil
Hose Bib (A) Pump
Hose Bib (B) Isolation Valve
MIS-2624 A
C. If possible, use a submersible pump suspended in the dry well casing. Jet pumps and other types of suction pumps normally consume more electrical energy than similarly sized submersible pumps. Pipe the unit the same as a water well system.
D. Size the pump to provide necessary GPM for the ground water heat pump. A 12 GPM or greater water flow rate is required on all models when used on this type system.
Manual 2100-666E Page 22 of 37
E. A pressure tank should be installed in dwelling to be heated adjacent to the ground water heat pump. A pressure switch should be installed at the tank for pump control.
F. All plumbing should be carefully sized to compensate for friction losses, etc., particularly if the pond or lake is over 200' from the dwelling to be heated or cooled.
G. Keep all water lines below low water level and below the frost line.
H. Most installers use 4" field tile (rigid plastic or corrugated) for water return to the lake or pond.
I. The drain line discharge should be located at least 100' from the dry well location.
J. The drain line should be installed with a slope of 2" per 10' of run to provide complete drainage of the line when the ground water heat pump is not operating. This gradient should also help prevent freezing of the discharge where the pipe terminates above the frost line.
K. Locate the discharge high enough above high water level so the water will not back up and freeze inside the drain pipe.
L. Where the local conditions prevent the use of a gravity drainage system to a lake or pond, run standard plastic piping out into the pond below the frost and low water level.
WARNING
Thin ice may result in the vicinity of the discharge line.
For complete information on water well systems and lake and pond applications, refer to manual from the distributor.
FIGURE 12 Lake and Pond Installation
WELL CAP
LAKE
12'
to
or
15'
POND
GRAVEL FILL WATER LEVEL
ELECTRICAL LINE
PITLESS ADAPTER TO PRESSURE TANK
WATER SUPPLY LINE
DROP PIPE
15' to 20' DEEP
PERFORATED PLASTIC CASING
SUBMERSIBLE PUMP
Manual 2100-666E
Page
23 of 37
SEQUENCE OF OPERATION
BLOWER
Blower functions are all automatic through the thermostat control. (See Table 1 for the specific airflows on each speed.) Motor control inputs are all 24 VAC with line power to motor being continuous.
On a call for "G" from the thermostat (call for manual fan), speed tap #1 on the blower motor is energized.
On a call for "Y1" from the thermostat (heating or cooling), speed tap #2 of the blower motor is energized immediately. Simultaneously, the "Y1" tap of the blower control board is also energized, and following 5 minutes, the blower control will power speed tap #3 of the blower motor.
On a call for "Y2" operation from the thermostat (heating or cooling), speed tap #5 will be energized through the blower control board. The exception is a jumper pin connection on the blower control board. It comes from the factory by default jumpering pins #4 and #5 together to run the blower at nominal rated full load airflow. If this is too noisy, this jumper can be removed from pins #4/#5 to allow the full load airflow to be reduced by 10% (see unit wiring diagram).
On any call for "W" (electric heat operation) from the thermostat, speed tap #5 is always energized. (It is not affected by the #4/#5 jumper on the blower control board.)
PART LOAD COOLING
When thermostat system switch is placed in COOL, it completes a circuit from "R" to "O", energizing the reversing valve solenoid. On a call for cooling, the thermostat completes a circuit from "R" to "Y1", which energizes the compressor contactor and blower motor on speed tap #2 initially, then speed tap #3 after 5 minutes (see BLOWER above).
FULL LOAD COOLING
The system should already be in part load cooling operation prior to full load cooling being energized. Additionally, the thermostat completes a circuit from "R" to "Y2". This sends a signal to both the staging solenoid on the side of the compressor and energizes either tap #5 or tap #4 of the blower motor (see BLOWER above).
PART LOAD HEATING (No Electric Heat)
When thermostat system switch is placed in HEAT, the reversing valve solenoid is no longer energized. On a call for part load heating, the thermostat completes a circuit from "R" to "Y1", which energizes the compressor contactor and blower motor on speed tap #2 initially, then speed tap #3 after 5 minutes (see BLOWER above).
Manual 2100-666E Page 24 of 37
FULL LOAD HEATING (No Electric Heat)
The system should already be in part load heating operation prior to full load heating being energized. Additionally, the thermostat completes a circuit from "R" to "Y2". This sends a signal to both the staging solenoid on the side of the compressor and energizes either tap #5 or tap #4 of the blower motor (see BLOWER above).
SUPPLEMENTARY ELECTRIC HEAT
The system should already be in full load heating operation (above). The thermostat completes a circuit from "R" to "W2", which energizes up to 9 KW of electric heat (depending on heater package installed). 9 KW of electric heat is the limit when operating with the heat pump and is controlled through the emergency heat relay.
EMERGENCY HEAT MODE
When thermostat system switch is placed in EMERGENCY HEAT MODE and the thermostat calls for heat, it completes a circuit from "R" to "E" and from "R" to "W2". This will energize the heater package for all available KW per the installed heater package. (The call from "R" to "E" locks out compressor operation.) The blower motor is automatically energized with this function and will run on speed #5 (see BLOWER above).
GEOTHERMAL LOGIC CONTROL
If the controller operates in normal mode, the green Status LED blinks. This indicates that 24 volt power is applied to the board and the controller is running in normal operation.
On initial power up and call for compressor operation, a 5-minute delay + a random start delay of 0 to 60-second is applied. After the random delay, the compressor relay is energized (terminals CC and CCG). When the "Y" input opens, the compressor deenergizes.
NOTE: The time delay + random start can be disabled by removing the Test jumper on the Geothermal Logic Control Board. However, this is NOT recommended. This is only intended to be a function for factory run-in processes.
Water Solenoid When "Y" signal is sent to Geothermal Logic Control, the water solenoid output "A" terminal will energize 10 seconds prior to "CC" output that starts compressor.
NOTE: The 10-second time delay between the energization of the "A" terminal and the "CC" terminal can be disabled by removing the WSD jumper on the Geothermal Logic Control Board.
Anti-Short Cycle Timer After compressor shutdown or power disruption, a 5-minute timer is applied and prevents the compressor from operating.
HIGH PRESSURE SWITCH
(Terminals HP1 and HP2) Circuit will be proved as "closed" prior to energizing "A" or "CC" terminals. If pressure switch opens, compressor will go into soft lockout mode and compressor operation will be terminated; green fault light illuminated. Logic control will then go through 5-minute delay on break + random start sequence. If no fault found on next run cycle, compressor will continue operation. If fault reoccurs, hard lockout occurs, and fault signal is sent to "L" terminal.
LOW PRESSURE SWITCH
(Terminals LP1 and LP2) Circuit will be proved as "closed" prior to energizing "A" or "CC" terminals. The conditions of the LP terminals will then be ignored for the first 90 seconds after a demand for compressor operation. Following this 90-second period, if pressure switch opens, compressor will go into soft lockout mode and compressor operation will be terminated; orange fault light illuminated. The control board will then go through a 5-minute delay on break + random start sequence. If no fault found on next run cycle, compressor will continue operation. If fault reoccurs, hard lockout occurs, and fault signal is sent to "L" terminal.
FLOW SWITCH
(Terminals FS and FS2) Circuit will be proved as "closed" prior to energizing "CC" terminal. If flow switch opens, compressor will go into soft lockout mode and compressor operation will be terminated; red fault light illuminated. Logic control will then go through 5-minute delay on break + random start sequence. If no fault found on next run cycle, compressor will continue operation. If fault reoccurs, hard lockout occurs and fault signal is sent to "L" terminal.
NOTE: Jumper wire is factory installed.
EVAPORATOR CONDENSATE OVERFLOW
(Terminals CO and CO2) This input operates when the water level in the evaporator pan rises and completes a signal across the terminals of the terminal block located in the indoor coil drain pan; yellow fault light illuminates. If fault clears, the logic control will go through 5-minute delay + random start. If fault reoccurs, or didn't clear the first time after 30 seconds, the control will go into hard lockout, and will energize the "L" output signal.
UNDER AND OVER VOLTAGE PROTECTION
When an under or over voltage condition exists, the controller locks out the unit. When condition clears, the controller automatically releases the unit to normal operation and the compressor restarts after the random start and anti-short cycle timings are met. The under and
over voltage protection starts at plus or minus 20% from nominal voltage and returns to operation at plus or minus 10% from nominal voltage. All four (4) LED fault lights will flash when an under or over voltage condition occurs.
NOTE: The over voltage protection can be disabled by removing the O/V jumper on the Geothermal Logic Control Board.
INTELLIGENT RESET
The Geothermal Logic Control has an intelligent reset feature after a safety control is activated. The controller locks out the unit for 5 minutes; at the end of this period, the controller checks to verify that all faults have been cleared. If faults have been cleared, the controller restarts the unit. If a second fault occurs, the controller will lock out the unit until the unit is manually reset by breaking "Y" signal from thermostat. The last fault will be kept in memory after a full lockout; this is only cleared by cycling the power.
ALARM OUTPUT
The "L" terminal has 24 volts applied when a hard lockout occurs. This can be used to drive a fault light or a low voltage relay.
PRESSURE SERVICE PORTS
High and low pressure service ports are installed on all units so that the system operating pressures can be observed. Pressure tables can be found later in the manual covering all models. It is imperative to match the correct pressure table to the unit by model number.
SYSTEM START UP
Step 1 Close disconnect switch(es) and set the thermostat to cool and the temperature to the highest setting.
Step 2 Check for proper airflow across the indoor coil.
Step 3 Connect the service gauges and allow the unit to run for at least 10 minutes or until pressures are stable. Check pressures to the system pressure table attached to the unit service panel.
Step 4 Fill out Ground Source Heat Pump Performance Report.
"WSD" JUMPER
"TEST" JUMPER
"O/V" JUMPER
Manual 2100-666E
Page
25 of 37
FIGURE 13 Component Location
LOW PRESSURE SWITCHES SUCTION SERVICE PORT DISCHARGE SERVICE PORT DESUPERHEAT COIL
EXPANSION VALVE
HIGH VOLTAGE IN
FLOW CENTER POWER
WATER COIL
COMPRESSOR HIGH PRESSURE SWITCH REVERSING VALVE
MIS-2625
TERMINAL BLOCK
GROUND BLOCK
CIRCUIT BREAKER
FIGURE 14 Control Panel
TRANSFORMER
GEOTHERMAL LOGIC CONTROL MODULE
RELAY
E. HEAT PLUG
TERMINAL STRIP
COMPRESSOR CONTACTOR
Manual 2100-666E Page 26 of 37
COMPRESSOR CAPACITOR
MIS-3858
BLOWER CONTROL
FIGURE 15 Refrigerant Flow Diagrams
Manual 2100-666E
Page
27 of 37
Manual 2100-666E Page 28 of 37
Model GV27S3 GV38S3
Return Air Temperature
75° DB 62° WB
80° DB 67° WB
85° DB 72° WB
75° DB 62° WB
80° DB 67° WB
85° DB 72° WB
Pressure
Low Side High Side
Low Side High Side
Low Side High Side
Low Side High Side
Low Side High Side
Low Side High Side
30°F
111 135
119 138
128 143
101 145
108 149
116 154
Model
Return Air Pressure
Temperature
5°F
GV27S3
70° DB
Low Side High Side
- -
GV38S3
70° DB
Low Side 52 High Side 215
35°F
115 150 123 153 132 159 104 160 112 164 120 170
10°F
49 265 58 228
40°F
118 165 126 169 135 175 108 175 115 179 124 185
15°F
58 274 64 241
45°F
121 180 130 184 139 191 111 189 119 194 128 201
20°F
66 282 70 255
FIGURE 16A Pressure Tables
50°F
124 195 133 200 143 206 115 204 123 209 132 216
25°F
75 291 75 268
FULL LOAD COOLING -- Fluid Temperature Entering Water Coil °F
55°F 60°F 65°F 70°F 75°F 80°F 85°F
128
131
134
137
138
139
140
210
224
239
254
275
296
317
137
140
144
147
148
149
150
215
230
246
261
282
304
325
147
151
154
158
159
160
161
222
238
254
270
292
314
336
118
121
125
128
129
131
132
218
233
248
262
283
304
324
126
130
133
137
139
140
142
224
239
254
269
290
311
333
136
139
143
147
149
151
152
232
247
263
278
300
322
344
FULL LOAD HEATING -- Fluid Temperature Entering Water Coil °F
30°F 35°F 40°F 45°F 50°F 55°F 60°F
83
92
100
109
117
125
134
299
308
316
325
333
343
353
81
87
93
98
104
112
121
281
294
308
321
334
343
352
90°F
141 338 151 346 162 358 134 345 143 354 154 366
65°F
142 363 129 361
95°F
142 358
152 368
163 381
135 365
145 375
155 388
100°F
143 379
153 389
164 403
137 386
146 396
157 410
105°F
144 400
154 410
166 425
138 407
148 417
159 432
110°F
145 421
155 432
167 447
139 427
149 438
160 454
70°F
150 373
137 370
75°F
158 383
145 379
80°F
167 393
154 388
85°F
175 403
162 397
Model GV27S3 GV38S3
Return Air Temperature
75° DB 62° WB
80° DB 67° WB
85° DB 72° WB
75° DB 62° WB
80° DB 67° WB
85° DB 72° WB
Pressure
Low Side High Side
Low Side High Side
Low Side High Side
Low Side High Side
Low Side High Side
Low Side High Side
30°F
104 114
111 117
119 121
104 126
111 129
119 134
Model
Return Air Pressure
Temperature
5°F
GV27S3
70° DB
Low Side High Side
- -
GV38S3
70° DB
Low Side 47 High Side 254
35°F
109 130 116 133 125 138 108 140 115 144 124 149
10°F
50 258 54 261
40°F
113 146 121 149 130 154 112 155 120 159 129 164
15°F
59 265 62 269
45°F
118 161 126 165 136 171 116 169 124 174 133 180
20°F
68 273 69 276
50°F
123 177 132 182 141 188 120 184 129 189 138 195
25°F
77 280 77 284
PART LOAD COOLING -- Fluid Temperature Entering Water Coil °F
55°F 60°F 65°F 70°F 75°F 80°F 85°F
128
133
137
142
143
144
145
193
208
224
240
260
280
301
137
142
147
152
153
154
155
198
214
230
246
267
288
309
147
152
158
163
164
166
167
205
221
238
255
276
298
319
124
128
132
137
138
139
140
198
213
227
242
262
282
302
133
137
142
146
147
149
150
203
218
233
248
269
289
310
143
148
152
157
158
160
161
210
226
241
257
278
299
321
PART LOAD HEATING -- Fluid Temperature Entering Water Coil °F
30°F 35°F 40°F 45°F 50°F 55°F 60°F
86
95
104
113
122
131
140
287
294
302
309
316
325
334
84
92
99
107
114
123
131
291
299
306
314
321
329
337
90°F
146 321 156 329 168 341 141 322 151 331 163 342
65°F
149 342 140 345
95°F
147 341
157 350
169 362
143 343
153 351
164 364
100°F
148 362
158 371
170 384
144 363
154 372
166 385
105°F
149 382
159 392
171 406
145 383
155 393
167 406
110°F
150 402
160 413
172 427
146 403
157 413
168 428
70°F
158 351
148 353
75°F
167 360
157 361
80°F
176 369
165 369
85°F
185 377
174 377
FIGURE 16B Pressure Tables
Model
Return Air
Temp.
Pressure
FULL LOAD COOLING -- Fluid Temperature Entering Water Coil °F 30°F 35°F 40°F 45°F 50°F 55°F 60°F 65°F 70°F 75°F 80°F 85°F 90°F 95°F 100°F 105°F 110°F
75° DB Low Side 104 106 109 112 115 117 120 123 125 127 128 129 130 132 133 134 135 62° WB High Side 141 157 173 189 205 221 236 252 268 289 309 330 351 371 392 413 433
GV51S3
80° DB 67° WB
Low Side High Side
111 145
114 161
117 178
120 194
123 210
125 226
128 243
131 259
134 275
135 296
137 317
138 339
139 360
141 381
142 402
143 423
145 444
85° DB Low Side 119 122 126 129 132 135 138 141 144 145 147 148 150 151 153 154 156 72° WB High Side 150 167 184 201 217 234 251 268 285 307 328 350 372 394 416 438 460
75° DB Low Side 108 110 112 114 116 118 120 122 123 125 126 127 128 130 131 132 133 62° WB High Side 143 160 176 192 208 224 241 257 273 293 314 334 354 375 395 415 436
GV61S3
80° DB 67° WB
Low Side High Side
116 147
118 164
120 180
122 197
124 214
126 230
128 247
130 263
132 280
133 301
135 322
136 343
137 363
139 384
140 405
141 426
143 447
85° DB Low Side 125 127 129 131 133 135 138 140 142 143 145 146 148 149 151 152 153 72° WB High Side 152 169 187 204 221 238 255 273 290 311 333 354 376 398 419 441 462
75° DB Low Side 110 111 112 113 115 116 117 118 119 119 119 120 120 120 121 121 121 62° WB High Side 175 186 197 209 220 231 243 254 265 286 307 328 348 369 390 411 432
GV71S3
80° DB 67° WB
Low Side High Side
118 179
119 191
120 202
121 214
123 226
124 237
125 249
126 260
127 272
127 293
128 315
128 336
128 357
129 379
129 400
129 421
130 443
85° DB Low Side 127 128 129 130 132 133 134 135 137 137 137 138 138 138 139 139 139 72° WB High Side 185 197 209 221 233 245 257 269 282 304 326 348 370 392 414 436 458
Model
Return Air
Temp.
Pressure
FULL LOAD HEATING -- Fluid Temperature Entering Water Coil °F 5°F 10°F 15°F 20°F 25°F 30°F 35°F 40°F 45°F 50°F 55°F 60°F 65°F 70°F 75°F
80°F
85°F
GV51S3
70° DB
Low Side High Side
- -
- -
50 58 65 73 81 89 96 104 113 123 132 141 150 291 300 308 317 326 335 343 352 363 374 385 396 407
160 418
169 429
GV61S3
70° DB
Low Side High Side
- -
45 53 61 69 77 85 93 101 109 118 127 136 145 154 283 294 305 315 326 337 348 358 369 382 395 408 421 434
163 447
172 460
GV71S3
70° DB
Low Side High Side
- -
45 52 59 66 73 80 87 94 101 111 121 131 141 151 268 278 287 297 306 316 325 335 344 355 366 376 387 398
161 409
171 419
Model
Return Air
Temp.
Pressure
PART LOAD COOLING -- Fluid Temperature Entering Water Coil °F 30°F 35°F 40°F 45°F 50°F 55°F 60°F 65°F 70°F 75°F 80°F 85°F 90°F 95°F 100°F 105°F 110°F
75° DB Low Side 106 109 112 115 119 122 125 129 132 133 135 136 137 139 140 142 143 62° WB High Side 127 142 157 172 187 202 217 233 248 268 288 308 328 348 369 389 409
GV51S3
80° DB 67° WB
Low Side High Side
113 130
117 146
120 161
124 177
127 192
131 208
134 223
138 239
141 254
143 275
144 295
146 316
147 337
149 357
150 378
152 399
153 419
85° DB Low Side 121 125 129 133 137 140 144 148 152 153 155 156 158 160 161 163 164 72° WB High Side 135 151 167 183 199 215 231 247 263 284 306 327 348 370 391 413 434
75° DB Low Side 108 111 114 117 120 123 126 129 132 133 134 135 136 137 138 139 141 62° WB High Side 136 150 165 179 194 209 223 238 253 273 293 312 332 352 372 392 412
GV61S3
80° DB 67° WB
Low Side High Side
115 139
118 154
122 169
125 184
128 199
131 214
135 229
138 244
141 259
142 280
143 300
145 321
146 341
147 362
148 382
149 403
150 423
85° DB Low Side 124 127 131 134 138 141 145 148 152 153 154 155 157 158 159 160 162 72° WB High Side 144 159 175 190 206 221 237 253 268 289 311 332 353 374 395 417 438
75° DB Low Side 108 111 113 115 117 119 121 123 125 127 128 129 130 132 133 134 135 62° WB High Side 139 153 167 181 195 209 223 237 251 271 291 312 332 352 372 393 413
GV71S3
80° DB 67° WB
Low Side High Side
116 143
118 157
121 172
123 186
125 200
127 214
130 229
132 243
134 257
135 278
137 299
138 320
139 340
141 361
142 382
143 403
145 424
85° DB Low Side 125 127 130 132 134 137 139 142 144 145 147 148 150 151 153 154 156 72° WB High Side 148 163 178 192 207 222 236 251 266 288 309 331 352 374 395 417 438
Model
Return Air
Temp.
Pressure
PART LOAD HEATING -- Fluid Temperature Entering Water Coil °F 5°F 10°F 15°F 20°F 25°F 30°F 35°F 40°F 45°F 50°F 55°F 60°F 65°F 70°F 75°F
80°F
85°F
GV51S3
70° DB
Low Side High Side
- -
49 57 65 73 81 89 97 105 113 123 132 142 151 161 264 273 281 290 298 307 315 324 332 342 351 361 370 380
170 389
180 399
GV61S3
70° DB
Low Side High Side
- -
49 58 66 75 83 92 100 109 117 126 135 144 153 162 261 271 281 291 301 311 321 331 341 351 362 372 382 392
171 403
180 413
GV71S3
70° DB
Low Side High Side
- -
47 55 64 72 80 88 97 105 113 123 132 142 151 161 258 267 277 286 295 304 314 323 332 341 351 360 369 378
170 388
180 397
LOW SIDE PRESSURE +/- 2 PSIG HIGH SIDE PRESSURE +/- 5 PSIG Tables based upon rated CFM (airflow) across the evaporator coil. If incorrect charge suspected (more than +2 psig suction, +5 psig liquid), it is recommended refrigerant charge be reclaimed, system evacuated and charged to serial plate quantity.
Manual 2100-666E
Page
29 of 37
Compressor Will Not Run No Power at Contactor Compressor Will Not Run Power at Contactor Compressor "Hums" But Will Not Start Compressor Cycles on Overload Thermostat Check Light Lite-Lockout Relay Compressor Off on High Pressure Control Compressor Off on Low Pressure Control Compressor Noisy
Head Pressure Too High
Head Pressure Too Low
Suction Pressure Too High
Suction Pressure Too Low
I.D. Blower Will Not Start
I.D. Coil Frosting or Icing
High Compressor Amps
Excessive Water Usage Compressor Runs Continuously No Cooling Liquid Refrigerant Flooding Back To Compressor Compressor Runs Continuously No Heating Reversing Valve Does Not Shift Liquid Refrigerant Flooding Back To Compressor Aux. Heat on I.D. Blower Off
Excessive Operation Costs
Ice in Water Coil
Heating Cycle
Cooling Cycle
Heating or Cooling Cycles
Power Failure Blown Fuse or Tripped Breaker Faulty Wiring Loose Terminals Low Voltage Defective Contacts in Contactor Compressor Overload Potential Relay Run Capacitor Start Capacitor Faulty Wiring Loose Terminals Control Transformer Low Voltage Thermostat Contactor Coil Pressure Controls (High or Low) Indoor Blower Relay Discharge Line Hitting Inside of Shell Bearings Defective Seized Valve Defective Motor Wingings Defective Refrigerant Charge Low Refrigerant Overcharge High Head Pressure Low Head Pressure High Suction Pressure Low Suction Pressure Non-Condensables Unequalized Pressures Solenoid Valve Stuck Closed (Htg) Solenoid Valve Stuck Closed (Clg) Solenoid Valve Stuck Open (Htg or Clg) Leaking Defective Valve or Coil Plugged or Restricted Metering Device (Htg) Scaled or Plugged Coil (Htg) Scaled or Plugged Coil (CLg) Water Volume Low (Htg) Water Volume Low (Clg) Low Water Temperature (Htg) Plugged or Restricted Metering Device (Clg) Fins Dirty or Plugged Motor Winding Defective Air Volume Low Air Filters Dirty Undersized or Restricted Ductwork
Auxillary Heat Upstream of Coil
Manual 2100-666E Page 30 of 37
Denotes common cause Denotes occasional cause
Heat Gen.
and Coil
Water Coil
Solenoid Valve
Refrigerant System
Compressor
Control Circuit
Line Voltage
INDOOR SECTION Indoor Blower Motor
Water Rev.
AUX.
WATER COIL SECTION
POWER SUPPLY
QUICK REFERENCE TROUBLESHOOTING CHART FOR WATER TO AIR HEAT PUMP
SERVICE
SERVICE HINTS
1. Caution owner to maintain clean air filters at all times and to not needlessly close off supply and return air registers. This reduces airflow through the system, which shortens equipment service life as well as increasing operating costs.
2. Check all power fuses or circuit breakers to be sure that they are the correct rating.
UNBRAZING SYSTEM COMPONENTS
If the refrigerant charge is removed from a scroll equipped unit by bleeding the high side only, it is sometimes possible for the scrolls to seal, preventing pressure equalization through the compressor. This may leave low side shell and suction line tubing pressurized. If the brazing torch is then applied to the low side while the low side shell and suction line contains pressure, the pressurized refrigerant and oil mixture could ignite when it escapes and contacts the brazing flame. To prevent this occurrence, it is important to check both the high and low side with manifold gauges before unbrazing.
This unit is equipped with an ECM motor. It is important that the blower motor plugs are not plugged in or unplugged while the power is on. Failure to remove power prior to unplugging or plugging in the motor could result in motor failure.
WARNING
Both the high and low side of the scroll compressor must be checked with manifold gauges before unbrazing system components. Failure to do so could cause pressurized refrigerant and oil mixture to ignite if it escapes and contacts the brazing flame causing property damage, bodily harm or death.
CAUTION
Do not plug in or unplug blower motor connectors while the power is on. Failure to do so may result in motor failure.
COMPRESSOR SOLENOID
(See Sequence of Operation on pages 24 and 25 for function.) A nominal 24-volt direct current coil activates the internal compressor solenoid. The input control circuit voltage must be 18 to 28 volt ac. The coil power requirement is 20 VA. The external electrical connection is made with a molded plug assembly. This plug contains a full wave rectifier to supply direct current to the unloader coil.
Compressor Solenoid Test Procedure If it is suspected that the unloader is not working, the following methods may be used to verify operation.
1. Operate the system and measure compressor amperage. Cycle the compressor solenoid on and off at 10-second intervals. The compressor amperage should go up or down at least 25%.
2. If Step 1 does not give the expected results, shut unit off. Apply 18 to 28 volt ac to the solenoid molded plug leads and listen for a click as the solenoid pulls in. Remove power and listen for another click as the solenoid returns to its original position.
3. If clicks can't be heard, shut off power, remove the control circuit molded plug from the compressor and measure the solenoid coil resistance (see Table 9).
TABLE 9 Solenoid Coil Resistance
Compressor Model ZPS***K4 ZPS***K5 ZPS***K6
Solenoid Ohms 33.6
350 or 1640 1640
4. Next, check the molded plug.
Voltage check: Apply control voltage to the plug wires (18 to 28 volt ac). The measured dc voltage at the female connectors in the plug should be around 15 to 27 vdc.
Resistance check: Measure the resistance from the end of one molded plug lead to either of the two female connectors in the plug. One of the connectors should read close to 0 ohms, while the other should read infinity. Repeat with other wire. The same female connector as before should read zero, while the other connector again reads infinity. Reverse polarity on the ohmmeter leads and repeat. The female connector that read infinity previously should now read close to 0 ohms.
Replace plug if either of these test methods does not show the desired results.
Manual 2100-666E
Page
31 of 37
TROUBLESHOOTING GE ENDURA PRO SERIES ECM MOTORS
If the Motor Is Running
1. It is normal for the motor to rock back and forth on start up. Do not replace the motor if this is the only problem identified.
2. If the system is excessively noisy, does not appear to change speeds in response to a demand (Heat, Cool, Other) or is having symptoms during the cycle such as tripping limit or freezing coil, check the following:
A. Wait for programmed delays to time out.
B. Ensure that the motors control inputs are wired as shown in the factory-supplied wiring diagram to ensure motor is getting proper control signals and sequencing.
C. Remove the filter and check that all dampers, registers and grilles are open and free flowing. If removing the filters corrects the problem, clean or replace with a less restrictive filter. Also check and clean the blower wheel or coil as necessary.
D. Check the external static pressure (total of both supply and return) to ensure it is within
the range as listed on the unit serial plate. If higher than allowed, additional duct work is needed.
E. If the motor does not shut off at the end of the cycle, wait for any programmed delays to time out (no more than 90 seconds). Also make sure that there is no call for "Continuous Fan" on the "G" terminal.
F. If the above diagnostics do not solve the problem, confirm the voltage checks in the next section below, then continue with the "Model Endura Pro Communication Diagnostics".
If the Motor Is Not Running
1. Check for proper high voltage and ground at the (L/L1) (G) (N/L2) connections at the motor (see Figure 17). Correct any voltage issues before proceeding to the next step. The Endura Pro motor is voltage specific. Only the correct voltage should be applied to the proper motor. Input voltage within plus or minus 10% of the nominal 230 VAC is acceptable.
2. If the motor has proper high voltage and ground at the (L/L1) (G) (N/L2) connections, then continue with the "Model Endura Pro Communication Diagnostics".
FIGURE 17 Motor Connections
230VAC LINE2
GROUND
230VAC LINE1
L2 LINE EARTH POWER GROUND
L1 LINE POWER
NOTE: MOTOR IS CONSTANTLY POWERED BY LINE VOLTAGE
Manual 2100-666E Page 32 of 37
Model Endura Pro Communication Diagnostics
The Endura Pro motor is communicated through 24 VAC low voltage (Thermostat Control Circuit Wiring).
1. Start with unit wiring diagram to confirm proper connections and voltage (see Figure 18).
2. Initiate a demand from the thermostat and check the voltage between the common and the appropriate motor terminal (1-5). ("G" input is typically on terminal #1, but refer to wiring diagram!)
A. If the low voltage communication is not present, check the demand from the thermostat. Also check the output terminal and wire(s) from the terminal strip or control relay(s) to the motor.
B. If the motor has proper high voltage as identified above (Motor not Running #1), and proper low voltage to a programmed terminal, and is not operating, the motor is failed, and will require replacement.
FIGURE 18 Motor Connections
24VAC Common
24VAC "R" Signal through thermostat output.
24VAC Common
24VAC "R" Signal through thermostat output.
Manual 2100-666E
Page
33 of 37
ACCESSORIES
ADD-ON GVDM-26 PUMP MODULE KIT
NOTE: This section applies only if a GVDM-26 pump module is added. Refer to GVDM-26 instructions for complete installation details.
GENERAL
This high efficiency water source heat pump series was designed with a refrigerant to water heat exchanger commonly know as a desuperheater coil factoryinstalled for ease in installing optional GVDM-26 pump module kit. The addition of this optional kit allows for heat recovery for hot water heating when connected to a home water heater. The amount of annual hot water supplied and thus additional energy cost savings will depend on the amount of hot water usage and the number of hours the heat pump operates. This pump kit is suitable for potable water.
INSTALLATION
1. Follow all local, state and national codes applicable to the installation of the pump module kit.
2. Follow the installation instructions received with the GVDM-26 pump module kit.
3. Connect the water lines between the unit, pump module kit and the water heater.
4. Pump power is 115V-60Hz 1-phase. A 6' 3-prong cord is supplied. Pump control is accomplished by 18 gauge 3-wire connection (field supplied) from pump module to the GV heat pump 24V terminal strip.
NOTE: The GVDM-26 pump module can be installed on adjacent surface or nearer to hot water storage tank if that better facilitates the plumbing or electrical connection.
FIGURE 19 Typical Pump Kit Connection to Unit
FILTER ASSEMBLY
Manual 2100-666E Page 34 of 37
DESUPERHEATER PUMP MODULE
ATTACH TO UNIT USING PROVIDED SCREWS
INLET AND OUTLET TUBES SUPPLIED WITH PUMP MODULE
MIS-2647 B
Ground Source Heat Pump Performance Report
Date: ____________________
Technician: __________________________________________
Company Reporting: ________________________ Contact Phone: ____________________________
Owner's Name: ____________________________ Owner's Address: ___________________________
1. Model/Serial Numbers: (For 3-Pc. Geo-Trio system, include coil/compressor/blower information)
Model Number(s): ______________________________________________________________
Serial Number(s): _______________________________________________________________
2. Accessory Information:
Thermostat Mfgr. _____________________ Model/Part Number: ___________________ Flow-Center* Mfgr. _____________________ Model/Part Number: ___________________
*if applicable
3. Open-Loop Water Source Information: Where/how is water discharged ___________________________________________________
4. Closed-Loop Water Source Information:
Horizontal Trenches
Horizontally Bored
Vertical
Pond/Lake
Other (Describe) ________________________________________________________________
Type of Antifreeze________________ % of Antifreeze __________ Freezepoint °F _________
Piping Material ____________ Diameter of Loop Pipe ______ Diameter of Header Pipe _____ Length of Loops ________ Pressurized/Non-Pressurized Flow Center _____________________
If Horz. Trench: Loops per trench ____ L x W x D of trenches ___________________________
Total Number of Trenches ________ Total Number of Loops _______
If Horz. Bored: Avg. Depth of Bores ________ Grout was used (Y/N) ___________
Total Number of Bores ___________ Total Number of Loops ___________
If Vert. Bored: Depth of Bores __________ Grout was used (Y/N) ____________
Total Number of Bores ___________ Total Number of Loops ____________
If Pond/Lake: Approx. Acreage of Pond/Lake _______________ Depth of Loops __________
Style of Loops: (coils, mats, Lake Plates) ____________ Total Number of Loops _____
General Notes: ________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________
Manual 2100-666E
Page
35 of 37
The following information is needed to verify performance of the system.
Note: Before testing, disable desuperheater, auxiliary electric heat, and any ventilation equipment that may allow outdoor air into the system. Measurements should be taken after a minimum 10 min. run time to ensure "steady-state" of operation. Temperature and pressure measurements should be taken with a single thermometer and pressure gauge to eliminate discrepancies between multiple devices.
Fluid Data:
1st Stg. Cool 2nd Stg. Cool 1st Stg. Heat 2nd Stg. Heat
5. Entering Fluid Temperature °F __________ __________ __________ __________
6. Leaving Fluid Temperature °F
7. Entering Fluid Pressure psi 8. Leaving Fluid Pressure psi 9. Pressure Drop through coil (psi)
__________ __________ __________ __________
__________ __________ __________ __________
__________ __________ __________ __________
__________ __________ __________ __________
Using the specific model number and pressure drop, refer to Water Coil Pressure Drop Chart on page 6 to find gallons-per-minute flow through water coil.
10. GPM through coil
__________ __________ __________ __________
Air Data: 11. Dry Bulb Return Air Temp °F 12. Wet Bulb Return Air Temp °F 13. Dry Bulb Supply Temperature °F 14. Wet Bulb Supply Air Temp °F 15. Return Static Pressure "WC 16. Supply Static Pressure "WC
1st Stg. Cool __________ __________ __________ __________ __________ __________
2nd Stg. Cool __________ __________ __________ __________ __________ __________
1st Stg. Heat __________ __________ __________ __________ __________ __________
2nd Stg. Heat __________ __________ __________ __________ __________ __________
Refrigerant Data:
1st Stg. Cool 2nd Stg. Cool 1st Stg. Heat 2nd Stg. Heat
17. Head Pressure psi
__________ __________ __________ __________
18. Suction Pressure psi
__________ __________ __________ __________
19. Liquid Line Temperature °F
__________ __________ __________ __________
Note: Liquid line temperature should be measure directly before metering device.
20. Suction Line Temperature °F
__________ __________ __________ __________
Note: Suction line temperature should be measured approximately 6" from compressor.
Calculate the subcooling from line #17 and Line #19 (Typically 10°F to 30°F)
21. Coil Subcooling °F
__________ __________ __________ __________
Calculate the superheat from line #18 and Line #20 (Typically 6°F to 12°F)
22. Coil Superheat °F
__________ __________ __________ __________
Electrical Data:_
1st Stg. Cool 2nd Stg. Cool 1st Stg. Heat 2nd Stg. Heat
23. Voltage at Load Side of Contactor __________ __________ __________ __________
Note: Voltage must be within 197VAC to 253VAC (for 208V/230V), 414VAC to 506VAC (for 460V)
24. Amperage Draw of Compressor __________ __________ __________ __________
25. Amperage Draw of Blower Motor __________ __________ __________ __________ Note: consult Electrical Table on page 5 to compare against typical run load amps.
Manual 2100-666E Page 36 of 37
3 pin plug for Heater Package 12 3 2 1
CCG CC
A C R Y1 L O
High Pressure Switch
Compressor R
Red Red
Red
2
Black
Transformer 7
9
SC
Blue Blue
Low Pressure Switch (Water) 36
36
240V 208V COM
8
7
STATUS
High Speed Solenoid
230V water circulating pump(s) connected for direct control from compressor contactor
Low Pressure Switch (Anti-freeze)
Yellow Yellow
1 FLOW SWITCH
208/230-60-1
Red Black Yellow
L1
38 Red
L2
37 Black
Terminal Block 2
36 Ground
Lug 23
4
Circuit Breakers
PUSH
3
Red
45
PUSH
3
Black
44
Contactor 22
L2
T2
L1
T1
35
27
Black/White
36
Red
Black
Black
Red
42
Black
CO CO2
R
25
C 26
Red/White 26 Black/White
Brown Blue
Blue Blue Red Red Blue Blue
19 Capacitor
Model GV27S GV38S GV51S GV61S GV71S
Capacitor 35/370 40/370 30/370 40/440 40/440
Brown 28 Purple Yellow/Red
28 39 Orange
Yellow/Red
27
Black/White
41
36
44 FLOW CENTER
RELAY
18
4
6
Black Brown/White
Black/White
1
3
7
9
Red
43
A
B
40
4 3 2 1 36 4 pin plug for Indoor Blower Motor
28
54321 5 pin plug for Indoor Blower Motor
GEOTHERMAL LOGIC CONTROL
FS1 6
FS2
WSD
TEST O/V
Blue Blue
LP2
5
LP1
HP2
4
46
Yellow Orange Yellow/Red
HP1
R2 R1 C2 C1
Black/White
Yellow/Brown
34
Black/White 25
3
1 31
Red/Yellow
Emergency Heat Relay
11
65
Yellow 28
4
12 25
2
28
40
Brown
12
Blue/Black
12
Purple 30
Blue/Black
Purple 3
Gray Gray Brown/White
Reversing Valve
Blue/White Blue/White
Cond. cverflow Sensor
29 29
Orange 28 Yellow 28
Black/White 12 15
Low Voltage Term. Strip
Class 2
G
C
Y1
C
Y2
A
28
30
Blower Control 17
Pink Black/White Red/White Black/White
O
R
Blue/Black 12
12 W
Red/Yellow
E
31
L
14
26
25 27
1
For antifreeze applications change low pressure switch to yellow leads on compressor control module "LPC" terminals
2 For 208V operation move this wire to 208V transformer tap
3 For -10% airflow in stage #2 operation move this jumper off of 4-5
4 H.P.S = Green fault light illuminated when fault indicated.
5 L.P.S = Orange fault light illuminated when fault indicated.
6 F.S. = Red fault light illumninated when fault indicated.
7 COND. = Yellow fault light illuminated when fault indicated. 8 Status = Green Status LED will blink in normal operation.
! WARNING
USE COPPER CONDUCTORS ONLY SUITABLE FOR AT LEAST
75° C.
! DANGER
*ELECTRICAL SHOCK HAZARD *DISCONNECT POWER BEFORE SERVICING.
99
Wire Identification for Bard use only.
numbers
Factory Field Optional High Voltage
Low Voltage
4105-106 D
Manual 2100-666E
Page
37 of 37
Adobe PDF Library 15.0