service & installation

Geothermal Troubleshooting

Jeff Hurst

GSHP Unit

• Heat Pump Components

-Compressor

-Refrigerant Reversing Valve

-Fluid Heat Exchanger (Coax)

-Metering Device (TXV)

-Air Heat Exchanger (Air Coil)

- Electrical Controls

Heating Cycle

Suction

Compressor

Discharge

Air

Coil Reversing

Valve

To

DHW Tank

To Loop

Source

COAXExpansion

Device Coax

HWG

Refrigeration Circuit

10/10/28/05vcbrev3

Option

Heat of Extraction/Rejection

• No refrigeration gauges needed

• Verifies equipment performance by measuring amount of heat being rejected and extracted

• Water pressure gauge and digital thermometer needed

• Compare numbers to factory catalog

• Use pressure/temperature (PT) ports at unit

• Use HE / HR worksheet

• Note: Always Disconnect HWG Pump during this checkout

Water Side Performance Check

Unit Performance Verification

Steps in Diagnostic Performance Check

Always Start up new

unit(s) in the Cooling

Mode at the initial

Start Up

Disable HWG Pump


Disable

desuperheater per

manufacturer

recommendations

Always allow the unit to operate approx. 15 minutes (Run Time) before collecting Temperatures and Pressures to allow

“Steady State” conditions to occur with the system


Formula Basics

• Delta T: Temperature Difference between Entering

and Leaving Water -> EWT - LWT = dT

• GPM (dP = Pressure Differential between EWT and

LWT - dP converts to GPM using pressure drop table

for each unit at the correct EWT) -> EWP - LWP =

dP

• Fluid Factor is the ability of a solution to transfer

heat in a certain period of time.

ALWAYS Turn Desuperheater Hot Water Generator off before checking equipment

performance

Q (BTUH) = dT X GPM X Fluid FactorHE and HR

Fluid Factors

Water is 500

Antifreeze is 485

HE/HR= Delta T x GPM x (500 or 485)

Suction

Compressor

Discharge

Air

Coil

HWG

RVExpansion

Device CoaxCoaxFilter

Dryer

FP2

Liquid

°F °F

40 PSI

SAT°F

°F °F

40°F 34°F

45.5 PSI

°F

PSI

12/22/05Rev3vcb

SC =

-

SH =

-

Heating CycleTTV038 Full load Methanol 1250 CFM

°F

SAT°FPSI

Saturated

Liquid Line

FP1

Sensor

Water Side Unit Performance

• HE = ______ X ______ X ______

• HE = ______BTU’s

• Specification is______BTU’s

ALWAYS Turn Desuperheater (Hot Water Generator) off before checking

unit performance

HE = dT X GPM X Fluid Factor

Suction

Compressor

Discharge

Air

Coil

HWG

RVExpansion


Dryer

FP2

Liquid

°F °F

40 PSI

SAT°F

°F °F

40°F 34°F

45.5 PSI

°F

PSI

12/22/05Rev3vcb

SC =

-

SH =

-


°F

SAT°FPSI

Saturated

Liquid Line

FP1

Sensor ?

?

Use hand out

Water Side Unit Performance Check

• HE = 6 X ______ X _______

• HE = _______BTU’s

• Spec. is_____________BTU’s

ALWAYS Turn Desuperheater (Hot Water Generator) off before

checking unit performance

PCA0404290126

HE/HR = dT X GPM X Fluid Factor

Suction

Compressor

Discharge

Air

Coil

HWG

RVExpansion


Dryer

FP2

Liquid

°F °F

40 PSI

SAT°F

°F °F

40°F 34°F

45.5 PSI

°F

PSI

12/22/05Rev3vcb

SC =

-

SH =

-


°F

SAT°FPSI

Saturated

Liquid Line

FP1

Sensor

Use Handout Worksheet

6

5.5

../../../../../go%20to%20%20geo.ppt#11. Slide 11


• HE = dT X GPM X Fluid Factor

• HE = 6 X 9 gpm X 485(antifreeze)

• HE = ___________BTU’s

• Specification is_____________BTU’s

ALWAYS Turn Desuperheater (Hot Water Generator) off before checking

equipment performance

PCA0404290126


Fluid Factors

Water is 500

Antifreeze is 485

HE/HR= Delta T x GPM x (500 or 485)

• HE = 6 X 9 gpm X 485

• HE = 26,190 BTU’s

• Specification is_______ BTU’s

ALWAYS Turn Desuperheater (Hot Water Generator) off

before checking equipment performance.

PCA0404290126



• HE = 6 X 9 gpm X 485

• HE = 26,190 BTU’s

• Specification is 26,800 BTU’s

ALWAYS Turn Desuperheater (Hot Water Generator) off

before checking equipment performance

PCA0404290126



Suction

Compressor

Discharge

Desuperheater

Condenses

Sub Cools

Air

Coil

Liquid

HWG

Saturated

Liquid

Pressure drop

Flash gas

Temperature drop

Evaporation

Super Heat

Increases Pressure

Increase Temperature

Super Heats

Vapor

RV

Vapor

To

DHW Tank

To Loop

Source

Expansion

Device

Heating Cycle

CoaxCoax

Vapor

2/14/06vcb

Tech 1 Page 6 Figure 2

Properties of refrigerant in

the Heating Cycle

Calibrating Service Gauges

(°F) (°F) (°F) (°F) (°F)

R410A R22 R410A R22 R410A R22 R410A R22 R410A R22

-40 11.6 0.5 0 48.7 23.9 40 118.0 68.5 80 235.3 143.6 120 417.7 259.8

-39 12.2 0.9 1 49.9 24.8 41 120.3 69.9 81 239.0 145.9 121 423.2 263.4

-38 12.9 1.3 2 51.2 25.6 42 122.6 71.4 82 242.7 148.3 122 428.8 266.9

-37 13.5 1.7 3 52.5 26.4 43 125.0 72.9 83 246.5 150.7 123 434.5 270.5

-36 14.2 2.2 4 53.8 27.3 44 127.3 74.5 84 250.3 153.2 124 440.2 274.2

-35 14.9 2.6 5 55.2 28.2 45 129.7 76.0 85 254.1 155.6 125 445.9 277.9

-34 15.6 3.0 6 56.6 29.1 46 132.3 77.6 86 258.0 158.1 126 451.8 281.6

-33 16.3 3.5 7 58.0 30.0 47 134.6 79.1 87 262.0 160.6 127 457.6 285.3

-32 17.0 3.9 8 59.4 30.9 48 137.1 80.7 88 266.0 163.2 128 463.5 289.1

-31 17.8 4.4 9 60.9 31.8 49 139.6 82.4 89 270.0 165.8 129 469.5 292.9

-30 18.5 4.9 10 62.3 32.8 50 142.2 84.0 90 274.1 168.4 130 475.6 296.7

-29 19.3 5.4 11 63.8 33.7 51 144.8 85.7 91 278.2 171.0 131 481.6 300.6

-28 20.1 5.8 12 65.4 34.7 52 147.4 87.3 92 282.3 173.6 132 487.8 304.5

-27 20.9 6.4 13 66.9 35.7 53 150.1 89.1 93 286.5 176.3 133 494.0 308.5

-26 21.7 6.9 14 68.6 36.7 54 152.8 90.8 94 290.8 179.0 134 500.2 312.0

-25 22.5 7.4 15 70.0 37.7 55 155.6 92.5 95 295.1 181.7 135 506.5 316.0

-24 23.4 7.9 16 71.7 38.7 56 158.2 94.3 96 299.4 184.5 136 512.9 320.0

-23 24.2 8.5 17 73.3 39.8 57 161.0 96.1 97 303.8 187.3 137 519.3 324.0

-22 25.1 9.0 18 75.0 40.8 58 163.9 97.9 98 308.2 190.1 138 525.8 328.0

-21 26.0 9.6 19 76.6 41.9 59 166.7 99.7 99 312.7 193.0 139 532.4 333.0

-20 26.9 10.1 20 78.3 43.0 60 169.6 101.6 100 317.2 195.9 140 539.0 337.0

-19 27.8 10.7 21 80.1 44.1 61 172.6 103.5 101 321.8 198.8 141 545.6 341.0

-18 28.7 11.3 22 81.8 45.3 62 175.5 105.4 102 326.4 201.7 142 552.3 345.0

-17 29.7 11.9 23 83.6 46.4 63 178.5 107.3 103 331.0 204.7 143 559.1 350.0

-16 30.7 12.5 24 85.4 47.6 64 181.6 109.2 104 335.7 207.7 144 565.9 354.0

-15 31.7 13.2 25 87.3 48.7 65 184.3 111.2 105 340.5 210.7 145 572.8 358.0

-14 32.7 13.8 26 89.1 49.9 66 187.7 113.2 106 345.3 213.8 146 579.8 363.0

-13 33.7 14.4 27 91.0 51.1 67 190.9 115.2 107 350.1 216.8 147 586.8 367.0

-12 34.7 15.1 28 92.9 52.4 68 194.1 117.2 108 355.0 222.0 148 593.8 372.0

-11 35.8 15.8 29 94.9 53.6 69 197.3 119.3 109 360.0 223.1 149 601.0 376.0

-10 36.8 16.5 30 96.8 54.9 70 200.6 121.4 110 365.0 226.3 150 608.1 381.0

-9 37.9 17.2 31 98.8 56.2 71 203.9 123.5 111 370.0 229.5 151 615.4 386.0

-8 39.0 17.9 32 100.8 57.5 72 207.2 125.6 112 375.1 232.7 152 622.7 390.0

-7 40.2 18.6 33 102.9 58.8 73 210.6 127.8 113 380.2 236.0 153 630.1 395.0

-6 41.3 19.3 34 105.0 60.1 74 214.0 130.0 114 385.4 239.3 154 637.5 400.0

-5 52.4 20.0 35 107.1 61.5 75 217.4 132.2 115 390.7 242.7 155 645.0 405.0

-4 43.7 20.8 36 109.2 62.8 76 220.9 134.4 116 396.0 246.0 156 652.5 409.0

-3 44.9 21.6 37 111.4 64.2 77 224.4 136.7 117 401.3 249.4 157 660.2 414.0

-2 46.1 22.4 38 113.6 65.6 78 228.0 138.9 118 406.7 252.9 158 667.3 419.0

-1 47.3 23.1 39 115.8 67.0 79 231.6 141.3 119 412.2 256.3 159 675.6 424.0

160 683.4 429.0

PSIGPSIG PSIG PSIG PSIG

11/16/05vcb

Temperature - Pressure ChartR410A - R22

Liquid Line - Filter Drier

On Every R410A Unit

The same desiccant (XH-11) MUST BE used as replacement

ANYTIME Refrigerant Circuit has been Opened.

Typical TXV Cutaway

10/29/05REV3vcb

Diaphragm

Valve Seat

Pushrods

Pin

Bulb Pressure

Opens Valve

Evaporator Pressure

Closes ValveSpring Pressure

Superheat

Su

ctio

n L

ine

Tech1 Figure 6 page 10

Closes Valve

TXV Pressure Force Balance

Force Description:

1. (opening force): Pressure

exerted on top of diaphragm

and created by the temperature

of the bulb and refrigerant in

the charge.

2. (closing force): Suction

pressure exerted under

diaphragm

3. (closing force): Factory preset

superheat spring

4. (opening force): Liquid

pressure acting on pin area.

This force is eliminated in the

balanced port construction.

1

2

3

4

Diaphragm

Rules of Movement

1 + 4 > 2 + 3 Valve will move open

1 + 4 < 2 + 3 Valve will move close

1 + 4 = 2 + 3 Valve will stay in position

Typical Operating Condition Chart

When checking need to know EWT

Measuring Superheat

Measuring Subcooling

Heating Cycle R410A / Properly Charged

Heating Cycle R410A / Over Charged

Heating Cycle R410A / Undercharged

Suction

Compressor

Discharge

Air

Coil

FP2

Liquid

HWG

Reversing

ValveExpansion


Dryer

92°F

PSI

SAT

70°F 90°F

30°F °F

PSI

160°F

290 PSI

TXV - Example Problem - 1

37°F

SAT°F74 PSI

12/22/05REV3vcb

SH =

-

SC =

-

TTV038 Heating

Saturated

Liquid Line

FP1

Sensor

°F


28

038 Heating

Suction

Compressor

Discharge

Air

Coil

FP2

Liquid

HWG

Reversing

ValveExpansion

Device CoaxCoax

12/22/05Rev5vcb

Filter

Dryer

92°F °F

PSI

94 SAT °F

70°F 90°F

30°F

PSI

160°F

290 PSI


37°F

17 SAT°F74 PSI

SH =

-

SC =

-

TTV038 Heating

28°F

Saturated

Liquid Line

FP1

Sensor


Need to know

EWT 30

Superheat

subcool

Get your saturation temps

Suction

Compressor

Discharge

Air

Coil

FP2

Liquid

HWG

Reversing

ValveExpansion

Device CoaxCoax

12/22/05Rev4vcb

Filter

Dryer

92°F

PSI

94 SAT °F

70°F 90°F

30°F 28°F

160°F

290 PSI


37°F

17 SAT°F74 PSI

TTV038 Heating

PSISH = 37

- 17

SC = 94

- 92

20 2

°F

Saturated

Liquid Line

FP1

Sensor


Need to know

EWT 30

Do your math

Typical Operating Condition Chart

When checking need to know EWT

Evacuation

• Deep Vacuum Method

– Preferred Method

– Pump must be capable of 500 micron vacuum

– Must use micron gauge

• Triple Evacuation

– Only if pump cannot attain 500 microns

– Not covered by warranty labor

PCM0404290064

Vacuum Down to 500 Microns

R-410A Review

• R-410A Refrigerant Operates at 50%-70% Higher Pressures than R-22

– Be Sure that Servicing Equipment and Replacement Components are Designed to Operate with R-410A.

• R-410A Systems Should be Charged with Liquid Refrigerant

– Use a Metering Device (Throttling Valve) in the Manifold Hose

PCM0404290070

R-410A Review

• POE Oils Absorb Moisture Rapidly

– Do not Expose Oil to Atmosphere

• Wrap All Filter Driers and Valves (TXV,

Reversing Valve) with Wet Cloth when

Brazing

• Do not Use any R-22 Replacement

Components Unless Approved for R-410A

PCM0404290072

R-410A Review

• Always Use Dry Nitrogen when Brazing

• Replace Filter Drier when System is Opened

• Do not Vent R-410A Into the Atmosphere

PCM0404290073

Liquid Line Drier

100% Molecular Sieve only*

- Must be XH-11 desiccant

- Only Way to Get Moisture to Acceptable

Level

ALWAYS Replace Filter Drier When

System is Opened

Suction Line Drier Should Be Used Only in

Burn-Out (for Short Time)*Activated alumina can remove the R32 molecule

PBR0404290041

POE Oil and Moisture

• Always Change Filter Drier When System is

Opened

• Use Pump to Transfer Oil (Don’t Pour Oil)

• Containers of POE Oil Should Not be Reused

if not Needed Immediately

• Immediately Seal All Components

• Pulling a Vacuum Does not Remove All

Water Trapped in the Oil

POE Oil and Moisture

• Filter Drier is the Only Way to Remove Moisture from the Oil

• Oil Smells Like Coconut Suntain Oil

• Avoid Exposure to Skin– Over-exposure Can Cause Skin Irritation and/or

Redness

– Use Vinyl or Nitrile Gloves (not Latex)

R-410A

Refrigerant Charging

• Field Charging

– Preferred Charging Method is to Charge Liquid Refrigerant Before Starting the Unit.

• Correct Amount of Refrigerant Should be Weighed in

• Liquid Charging is Faster

– Vapor Charging was Recommended in the Past for Small Systems

• Can be Appropriate for R-410A with Proper Tools (See Next Slide)

Liquid Charging

in Vapor Line

Throttling Valve Allows Liquid

Refrigerant to be Throttled (Added

as a Vapor) to the Low Side.

Duct Installation

• Size to handle airflow quietly-400 cfm/ton

• Flexible Duct Connectors recommended for

metal duct systems

• Use internal lining to minimize blower noise in

both supply and return plenums

• Inspect duct system for proper size, sealing, and

delivery of proper air distribution.

• Always inspect system.

• ACCA Manual D should apply to duct Design

Unit Installation

Vertical Unit Installation

Oversize supply plenums, use start collarsizes sent with unit. Use transitional takeoffs/good duct design for proper air flow

H/V Packaged IOM Page 19

DO NOT oversize supply plenums. Use"take off" collar included with unit. Usetransistional take-off's with good ductdesign for proper airflow.

Size S/A Plenum to MatchMain Trunk for ProperDuct Design and Good AirFlow.

Use Air Pad PNASP30 or polystyreneinsulation board forquietest operation.Bricks, blocks orvibration pads.

Internally insulate returntransistion duct to reducenoise

Rounded returntransistion

Use turning vanes insupply transistion

Internally insulate supplytrunk for first 4' each wayto reduce noise.

12/23/05vcb

Flexible canvas ductconnector to reducenoise and vibration

VERY IMPORTANT

ECM Blower Performance

Ground-Water Heat Pump Applications

Basic Design Rules:

Well Water Requirements

- EWT > 55 deg. F - 1.5 GPM/Ton

- EWT < 50 deg. F – 2.0 GPM/Ton

Example:

(EWT 50 deg. F 3 ton unit @ 2 GPM = 6 GPM

required)

- Water Well Capacity (max. GPM) should be

verified before application

- Water Quality should be verified before

application (compare results to Standards as

published in IOM)


Suggest these types of flow

devices on the LEAVING

water side.

Taco Water ValveWiring Diagram

R Water Source Unit

Low Voltage Terminal

Strip

C

Thermostat

Y

12

3

Y

AVM

Taco ValveHeater Switch

C

Ground Loop Heat Pump Applications

Ground Loop Heat Pump Applications

Always be on the alert for this, make sure you and your contractors

use new, clean containers. Check Product MSDS Sheets for details.

Design all Closed Loops Here

Frozen Koax

Ground-Loop Heat Pump Applications

Methanol Specific Gravity

Freeze Protection - Degrees °F

Methanol

Flow Controller 2 IOM Chart 1A Page 8

Loop Circuit Header Manifold

Reverse Return piping method

Flush Cart

Unit Installation

Hot Water Generator (HWG)

• Electric Domestic Water Tanks best. If using Gas

or Oil use “Pre-Heat” tank.

• Use 50 gallon (minimum) Electric Storage tank

• Maximum piping not to exceed 50 ft.

• Use 5/8 O.D. Copper Tubing or larger

• Insulate HWG piping with Closed Cell Insulation

(3/8 min.)

• HWG option is separate-factory installed (except

Outdoor unit) “Double Wall, Vented” Coaxial Heat

Exchanger suitable for Potable use.

1/19/06vcb

HWG Piping

1/19/06vcb

HWG Piping - Two Tank

Unit Installation

Hot Water Generator (HWG)

Initial Start Up & Check out

• Purge air from piping…open valves before energizing

HWG pump

• Confirm DHW Tank lower heating element thermostat is

set at 100 degree °F or lowest setting

• After unit has operated 10-15 minutes, connect 230V

HWG Pump wiring to unit HWG “PB1” terminals

• Adjust HWG piping valves until apx. 5-10 deg F rise

between HWG Water In/Water Out is achieved. (This will

yield approximately 0.4 gpm/ton flow rate)

Main Coax – No HWG optionCompressor chassis without HWG option

HWG Coax option installed with Main CoaxCompressor chassis with HWG option

HWG – Double Wall

“vented” Coax

Unit – Single Wall Coax

Refrigerant

“Atmospheric”

vent

Water

Double Wall Vented HWG

Coaxial Heat Exchanger

Use this text to

reference its safe for

direct use with Potable

water systems

Usually, it will satisfy

most inspectors

concerned with

possible cross

contamination or

liability issues

• Same “footprint” as single

speed compressor

• Thicker shell than R22

version

• Anti-rotation device to

insure quiet operation

• Solenoid closes gas bypass

ports and increases

capacity to 100% from 67%

• R-410A compressors have

lower failure rates than R22

Copeland UltraTech

Solenoid Valve

AC/DC

converter

“unloading”

control

Copeland UltraTech

Two-Stage Unloading Scroll

Gas By-pass - Ports Open Ports Closed

How to check the molded plug (two pin)

Voltage Check: Apply control voltage to the plug wires (18 to 28 VAC).

The measured dc voltage at the female connectors in the plug should be around 15 to 27 vdc.

Condensate Overflow Sensor

Electric Heat Staging JumpersMeasure 18/24 VDC at W1 & 24V on 1st Stage Aux

Measure 18/24 VDC at W2 & 24V on 2nd Stage Aux

DC

ECM2 Wiring

Interface Board with ECM Style Blower

ECM2 Fan Motor

Low Voltage Inputs

On Pins 1 to 16

ECM Info

ECM Info

P1 to P15 = 14.7 VAC

P1 to P6 w Y1 Call = 14.7 VAC

P1 to P14 w Y2 Call = 14.7 VAC

P1 to P2 w W Call = 14.7 VAC

P1 to P5 = 15.1 VAC

P1 to P4 Delay = 15.1 VAC

P1 to P7 in Normal Position = “O” VAC

P1 to P7 in Plus Position = 15.1 VAC

P1 to P7 in Minus Position = 15.1 VAC

P1 to P8 = “0” VAC

P1 to P9 w No Call from “O” = “0” VAC

P1 to P9 w Call from “O” = 14.6 VAC

P1 to P10 w Power to HP = 27.9 VAC

P1 to P11 w Power to HP = 15.4 VAC

P1 to P12 = 27.9 VAC

P1 to P13 = “0” to 3.9 VAC

P1 to P16 w “G” Call = 6.6 VAC

P1 to P16 No “G” Call = “0” VAC

ECM Info

Start Up / Check Out Form

Thank You!

Questions?

service & installation

Documents