BMC GTC60S2-ADNX, GTC60S2-ADCX, GTC36S2-ADNX, GTADP-3642-B, GTADP-3642-C User Manual

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MIS-2830

WATER SOURCE HEAT PUMP

MODELS:

INSTALLATION INSTRUCTIONS

GTB1-A Blower Section

GTA3600UD1AA Coil Section GTA4860UD1AA Coil Section GTADP-3642-B Coil Section GTADP-3642-C Coil Section GTADP-4860-C Coil Section GTC36S2-ADCX Compressor Section GTC48S2-ADCX Compressor Section GTC60S2-ADCX Compressor Section GTC36S2-ADNX Compressor Section GTC48S2-ADNX Compressor Section GTC60S2-ADNX Compressor Section

BMC, Inc. Bryan, Ohio 43506

Earth Loop Fluid

Temperatures 25° - 110°

Ground Water Temperatures 45° - 75°

Manufactured under the following

U.S. patent number:

8,127,566

Manual: 2100-537I Supersedes: 2100-537H File: Volume I, Tab 8 Date: 10-11-12

Manual 2100-537 Page 1 of 54

CONTENTS

Getting Other Informations and Publications ..............3

General Information Geo-Trio (GT Series)

Water Source Nomenclature .................................................... 4

Blower Conversion & Line Power Connect ............................ 15

Application and Location

General ............................................................................ 18

Shipping Damage ................................................................... 18

Application ............................................................................ 18

Dual Fuel Heating / Cooling

Location ............................................................................ 18

Ductwork ............................................................................ 18

Filters ............................................................................ 19

Condensate Drain .................................................................. 19

Piping Access to Unit ..............................................................19

................................................... 18

Wiring Instructions

General ............................................................................ 22

Control Circuit Wiring.............................................................. 22

Wall Thermostats & Low Voltage Connections

....................... 22

Ground Loop (Earth Coupled Water Loop Applications)

Note ............................................................................ 24

Circulation System Design ..................................................... 24

Start Up Procedure for Ground Loop System ........................ 25

Ground Water (Well System Applications)

Note ............................................................................ 27

Water Connections .................................................................27

Well Pump Sizing ...........................................................27 & 28

Start Up Procedure for Ground Water System ....................... 29

Water Corrosion .............................................................29 & 30

Remedies of Water Problems ................................................. 30

Lake and/or Pond Installations .......................................30 & 31

Desuperheater

Description ............................................................................ 32

Location ............................................................................ 32

Electrical Connection .............................................................. 32

Installation Procedure - General ............................................. 32

Oper. of Heat Recovery Unit ..................................................33

Start Up & Checkout ............................................................... 33

Maintenance & Control Board Seq. of Operation ...........33 & 37

Sequence of Operation

Blower ............................................................................ 38

Part / Full Load Cooling

Part / Full Load Heating .......................................................... 38

Supplementary Electric Heat .................................................. 38

Geothermal Logic Controls ..................................................... 38

High / Low Pressure Switch

Freeze Stat ............................................................................ 39

Condensate Overow ............................................................ 39

Under/Over Voltage Protection ...............................................39

Intelligent Reset ...................................................................... 39

Alarm Output Pressure Service Ports

System Start Up ..................................................................... 39

.......................................................................... 39

.......................................................... 38

................................................... 39

........................................................... 39

Refrigerant Charge

Line Set Installation (GTA Coil Sections) ................................ 42

Charge Adjustment ..............................................................42

Refrigerant Fitting Attachment Checking Charge Quantity

General / GTADP Coi Sections .............................................. 43

Line Set Installation (GTADP Coil Sections) ........................... 43

General / Topping Off System / Safety Practices ................... 44

............................................ 42

..................................................... 42

Service

Service Hints .......................................................................... 47

Unbrazing System Components ............................................. 47

Compressor Solenoid ............................................................. 47

Troubleshooting GE ECM 2.3 Motors .............................48 & 49

Troubleshooting Table ............................................................ 50

Power Connector T able ..........................................................50

Ground Source Heat Pump

Performance Report ................................................51-52

Wiring Diagrams

......................................................53-54

Figures

Fig u r e 1 A GTA****UD1AA Dimensions ................................. 7

Figure 1B GTADP Fossil Fuel ADP Coil Dimensions ............ 8

Figure 1C GTB1-A Dimensions ............................................. 9

Figure 1D GTC**S2-D Dimensions .....................................10

Figure 1E Assembled Upow/Counterow App. .................11

Figure 1F Horizontal App. Dimensions ............................... 12

Figure 2A Upow & Counterow Ducting Cong. ................. 13

Figure 2B Horiz. & Counterow Ducting Cong. .................. 14

Figure 3 Blower Conguration ..........................................16

Figure 4 Blower Power Connections ................................17

Figure 5A Upow Air Filter Applications .............................. 21

Figure 5B Counterow Air Filter Applications ...................... 21

Figure 5C Horiz. Left Discharge Air Filter App. .................... 21

Figure 5D Horiz. Front Discharge App. ............................... 21

Figure 6 Thermostat Wiring ..............................................23

Figure 7 Circulation System Design .................................24

Figure 8 Temperature & Pressure Measurement .............. 26

Figure 9 Perf. Model DORFC-1 Flow Ctr. ......................... 26

Figure 10 Perf. Model DORFC-2 Flow Ctr. ......................... 26

Figure 11 Water Connection Components.......................... 28

Figure 12 Cleaning Water Coil ............................................ 30

Figure 13 Lake or Pond Installation ....................................31

Figure 14 Wiring Diagram ...................................................34

Manual 2100-537I Page 2 of 54

Figure 15A Desuperheater Single Tank System ...................... 35

Figure 15B Desuperheater Dual Tank System ....................... 36

Figure 16 Thermistor ..........................................................37

Figure 17 Component Location ..........................................40

Figure 18 Control Panel ......................................................40

Figure 19 Refrigerant Flow Diagrams .................................41

Figure 20 Coil Spacer .........................................................43

Figure 21 Pressure Tables .................................................. 45

Figure 22 Control Disassembly ........................................... 49

Figure 23 Winding Test ....................................................... 49

Figure 24 Drip Loop ............................................................49

Figure 25 Control Connector Motor Half .............................50

Tables

Table 1 Indoor Blower Performance .................................. 5

Table 2 Flow Rates for Various Fluids ...............................5

Table 3 Specications ....................................................... 5

Table 4 Water Coil Pressure Drop ..................................... 6

Table 5 Electrical Heat Specications ............................. 19

Table 6 Filter Sizing Chart ............................................... 20

Table 7 Control Circuit Wiring .......................................... 22

Table 8 Constant Flow Valves .........................................27

Table 9 Pre-Charged Line Set Qty .................................. 42

Quick Reference Troubleshooting Chart ................................46

GETTING OTHER INFORMATION AND PUBLICATIONS

These publications can help you install the air

conditioner or heat pump. You can usually nd these

at your local library or purchase them directly from the publisher. Be sure to consult current edition of each standard.

National Electrical Code .......................ANSI/NFPA 70

Standard for the Installation ...............ANSI/NFPA 90A

of Air Conditioning and Ventilating Systems

Standard for W arm 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 Classication for ......................IGSHPA

the Design of Ground-Coupled Heat Pump Systems

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

Ground Source Installation Standards .............IGSHPA

Closed-Loop Geothermal Systems ..................IGSHPA

– Slinky Installation Guide

IGSHPA International Ground Source Heat Pump Association 490 Cordell South

Stillwater, OK 74078-8018

Manual 2100-537I Page 3 of 54

Geo-Trio™ GT Series Geothermal / Water Source Heat Pump Nomenclature

“A” Coil Section

GT A 3600 UD 1 A A

Geo-Trio

“A” = Coil Section

3600 (3 Ton) 4860 (4 & 5 Ton)

Series

Revision Level

A = E Coated Coils

Fossil Fuel “A” Coil Section

GT ADP – 3642 – B

Geo-Trio

ADP = Advanced Distributor Products

3642 (3 Ton) 4860 (4 & 5 Ton)

B = 17.50" Wide Furnace C = 21.00" Wide Furnace

Blower Section

GT B 1 – A

Option

Geo-Trio

B = Blower Section

Revision Level

Option

A = 230 Volt 1-Phase

Compressor Section

GT C 36 S 2 – A D C X

Geo-Trio

C = Compressor Section

Manual 2100-537I Page 4 of 54

Nominal Capacity

S = Step Capacity

36 = 36K 48 = 48K 60 = 60K

Revision Level

Option

A = 230 Volt 1-Phase

D = Desuperheater

C = Copper Coil N = Cupronickel Coil

X = Future Use

TABLE 1 — INDOOR BLOWER PERFORMANCE (RATED CFM)



MODEL

GTC36S2 0.15 0.60 600 700 850 1200 1300 2.6 GTC48S2 0.20 0.60 750 875 1075 1500 1600 3.2 GTC60S2 0.20 0.60 900 1050 1300 1800 1800 3.6



Rated

ESP



MAX

ESP



Continuous

Airow



Mild Climate

Operation

in Part Load

Cooling



Part Load

Airow

Full Load

Airow



Electric Heat

Airow



Minimum Air

Filter Face

Area Ft.2

 Motorwillautomaticallystepthroughthevariousairowswiththermostaticcontrol  ESP = External Static Pressure (inches of water)  Maximum allowable duct static  ContinuousairowistheCFMbeingcirculatedwithmanualfanoperationwithoutanyadditionalfunctionoccurring.  Willoccurautomaticallyforrst5minutesofPartLoadCoolingOperation.  WilloccurautomaticallyafterveminutesofPartLoadCoolingOperation.  Will occur automatically with control signal input.  As per ASHRAE Guidelines of 500 FPM Velocities.

NOTE: All values can be changed + 10% via the + adjustment dip switches on the tap select control inclusive in the GTB1-A Blower Section (see instructions later in this manual, or on wiring diagram in blower section).

TABLE 2 — FLOW RATES FOR VARIOUS FLUIDS

APPLICATION

Ground Loop (15% Methanol, Propylene Glycol, etc.) 8 12 15 Ground Water 6 7 9 Water Loop (Cooling Tower) 9.2 12.1 14.3

GTC36S2 GTC48S2 GTC60S2

MODELS

TABLE 3 — SPECIFICATIONS

MODEL GTC36S2 GTC48S2 GTC60S2

Electrical Rating (60HZ/1PH) 230/208-60-1 Operating Voltage Range 253-197 VAC Minimum Circuit Ampacity 24.5 33.1 39.7 +Field Wire Size #10 #6 #4 Ground Wire Size #10 #10 #10 ++Delay Fuse or Circuit Breaker Max. 35 50 60

COMPRESSOR

Volts 230/208-60-1 Rated Load Amps (230/208) 10.6 / 11.9 15.3 / 17.0 20.2 / 22.7 Branch Circuit Selection Current 15.3 21.2 25.6 Locked Rotor Amps (230/208) 82 / 82 104 / 104 153 / 153

BLOWER MOTOR

Horsepower (ECM Motor) 3/4 Variable Speed Volts 230/208-60-1 Motor Amps (Stage #2 @ Rated CFM) 3.4 4.3 4.4

FLOW CENTER (Based on DORFC-2)

Volts 230/208-60-1 Amps 2.14 2.14 2.14

DESUPERHEATER PUMP MOTOR

Volts 230/208-60-1 Amps 0.15 0.15 0.15

+75°C copper wire ++ HACR type circuit breaker

Manual 2100-537I Page 5 of 54

TABLE 4

WATER COIL PRESSURE DROP

Model GTC36S2 GTC48S2 GTC60S2

GPM PSID Ft. Hd. PSID Ft. Hd. PSID Ft. Hd.

3 0.1 0.23 4 0.5 1.15 0.9 2.08 5 1.2 2.77 1.4 3.23 6 1.7 3.92 2.3 5.31 7 2.3 5.31 3.2 7.38 2 4.61 8 3.1 7.15 4.1 9.46 2.5 5.77

9 4.1 9.46 5.1 11.77 3.2 7.38 10 6.1 14.07 3.9 9.00 11 7.1 16.38 4.7 10.84 12 8.2 18.92 5.5 12.69 13 9.4 21.69 6.4 14.76 14 10.6 24.45 7.3 16.84 15 8.1 18.69 16 9 20.76 17 9.9 22.84 18

Manual 2100-537I Page 6 of 54

2 3/16"

3 5/16"

5 1/8"

15 11/16"

17 5/8"

1 1/2"

10 15/16"

7 1/4"

2 3/4"

MIS-2818

HORIZ. MAIN DRAIN K.O.

HORIZ. OVERFLOW K.O.

SUCTION CONNECTION

LIQUID CONNECTION

OVERFLOW

MAIN DRAIN

19 15/16"

3 1/2"

21 5/8"

2 3/16"

CONDENSATE

OVERFLOW WIRES

27 15/16"

13 5/8"

1 13/16"

22"

30"

20.50

-.000

+.125

WIDTH

16.13

-.000

+.125

HEIGHT

DRAIN PAN

GTA Coil Dimensions If Used Without Cabinet

PRIMARY DRAIN HOLE

SECONDARYDRAIN HOLE

MIS-2876 A

COATED

COIL

.125

2.25

-.000

28.25

-.000

+.125

DEPTH

FIGURE 1A – GTA****UD1AA

A-COIL SECTION DIMENSIONS

Manual 2100-537I Page 7 of 54

FIGURE 1B – GTADP****-*

FOSSIL FUEL ADP COIL SECTION DIMENSIONS

FIGURE 1B - GTADP****-*

FOSSIL FUEL ADP COIL SECTION DIMENSIONS

SUCTION CONNECTION

OVERFLOW

MAIN DRAIN

3/4" TYP

1 5/8"

5 1/4" "E"

"D"

"A"

"F"

"C"

6 1/16"

"G"

LIQUID CONNECTION

OVERFLOW

MAIN DRAIN

3/4" TYP

DIMENSION GTADP-3642-B

"A" 17 5/8" 21 1/8" "B" 25 1/2" 27 1/2" "C" 7 1/4" 6 3/4" "D" 2 1/8" 2 1/2" "E" 3 7/8" 4 1/4" "F" 13 7/8" 16 7/8" "G" 15 5/8" 18 5/8"

3/4"

TYP

"B"

21 1/4"

GTADP-3642-C GTADP-4860-C

MIS-3119

Manual 2100-537I Page 8 of 54

15 5/8"

24 9/16"

MIS-2819

30"

13 1/4"

16 3/8"

LOW VOLTAGE ENTRANCE

OPENING ON BOTH SIDES

OPTIONAL SIDE RETURN

HIGH VOLTAGE K.O. FOR REMOTE APPLICATIONS ONLY

3 5/8"

18 13/16"

1 1/4"

24"

15"

3 5/16"

1 1/2"

2 7/8"

21"

22"

FIGURE 1C – GTB1-A

BLOWER SECTION DIMENSIONS

Manual 2100-537I Page 9 of 54

MODEL DIM. A DIM. B

GTC36S2 21" 4 1/8"

GTC48S2 20" 3 7/8"

GTC60S2 18 1/2" 3 3/4"

DESUPERHEATER

WATER OUT

LIQUID LINE

SUCTION LINE

WATER IN

WATER OUT

DESUPERHEATER

WATER IN

12 1/4"

9 5/8"

2 1/2"

23 1/16"

1 7/8"

16 1/16"

6 15/16"

1 3/4"

22 1/16"

30"

HIGH VOLTAGE UNIT

LOW VOLTAGE WIRE ENTRANCE

POWER ENTRANCE

HIGH VOLTAGE OPTIONAL

FLOW CENTER WI RE ENTRANCE

MIS-2820 A

4 13/16"

16 15/16"

1 15/16"

FIGURE 1D – GTC**S2-D

COMPRESSOR SECTION DIMENSIONS

Manual 2100-537I Page 10 of 54

15 5/8"

24 9/16"

27 7/8"

37 1/16"

51 1/4"

55"

24 9/16"

15 5/8"

VOLTAGE

LOW

VOLTAGE

LOW VOLTAGE

HIGH

LOW VOLTAGE

18 13/16"

57 7/8"

25 3/4"

28 15/16"

37 7/8"

30"

REFRIGERANT

CONNECTIONS

65 5/8"

30"

21"

23"

21 5/8"

3/4"

31 1/4"

TOP DUCT OUTLET FLANGE

27 15/16"

19 13/16"

SECURE SECTIONS TOGETHER

USING BOLT PART #1012-015

AND WASHER PART #1012-109

MAIN DRAI N OUTLET

INLET

OVERFLOW DRAIN OU TLET

WATER OUT

OUTLET

DESUPERHEATER

WATER IN

61 5/8"

59 11/16"

33 1/4"

22"

23 7/16"

30 9/16"

"A"

MODEL DIM. A

GTC36S2 39 7/16"

GTC48S2 40 15/16"

GTC60S2 41 15/16"

RIGHT SIDEFRONT

LEFT SIDE

(UPFLOW ONLY)

ENTRANCE

TOP

AIR

(UPFLOW ONLY)

AIR

ENTRANCE

MIS-2821 B

FIGURE 1E – ASSEMBLED UPFLOW / COUNTERFLOW APPLICATION DIMENSIONS

Manual 2100-537I Page 11 of 54

Section

Blower

Section

Evaporator

GTHZ1

Horizontal

Drain Pan

(Req'd)

Horiz. Support Bracket

Low Voltage

Entrance

High Voltage

Entrance

Low Voltage

Entrance

Top View

30"

4311

4183

211

Front View

"27

Opening

Evaporator Opening Blower

Right Side View

24"

15"

Overflow Drain

Outlet

Main Drain

Refrigerant

Connections

"31

21"

8221

4433

8281

MIS-2824

Left Side View

Evaporator and Blower in Horizontal Position

(Remote Compressor Section)

NOTE:

Requires

horizontal

drain pan kit

Model GTHZ-1

FIGURE 1F – HORIZONTAL APPLICATION DIMENSIONS

Manual 2100-537I Page 12 of 54

Blower Air

Evap. Coil

Counterflow

Position

Cond. Coil

Water Out

Cond. Coil

Desuper.

Water In

Desuper.

Water Out

Supply

Return

Main Drain

Blower in

Alternate Position

7/8" Line Set

3/8" Line Set

Blower Air

Evap. Coil

Upflow

Cond. Coil

Position

Cond. Coil

Water Out

Desuper.

Water In

Desuper.

Water In

Water Out

Supply

Return

Secondary

Return

Drain

Main Drain

Blower in

Shipped Position

7/8" Line Set

Control Panel

MIS-2828

Control Panel

3/8" Line Set

Drain

Secondary

Air Filter Required

One FR23 (16 x 25 x 1) or

field supplied equivalent

required for upflow side

return installation

Bottom return upflow and

top return counterflow filter

provision must be field

supplied

NOTE:

Requires Switch #4 on Tap Select

Control to be Turned On.

FIGURE 2A – UPFLOW & COUNTERFLOW DUCTING CONFIGURATIONS

Manual 2100-537I Page 13 of 54

Blower Air

Return

Remote Condenser Section

Supply

Return

Counterflow

Return

Main Drain

Horizontal, Left Discharge

Return

MIS-2826

Evap. Coil

Position

Optional Top

Horizontal, Right Discharge

Drain

Desuper.

Secondary Drain

Position

Upflow

Drain

Main Drain

Secondary Drain

Secondary

Main Drain

Blower in

Shipped Position

Blower in

Shipped Position

Blower in

Alternate Position

Blower in

Supply

Cond. Coil

Water Out

Cond. Coil

Water In

Desuper.

Water In

Water Out

Secondary

Main Drain

Refrigerant

Return

Refrigerant

Connections

Refrigerant

Connections

Refrigerant

Connections

Model GTLID

NOTE:

Requires Switch #4

on Tap Select Control

to be Turned On.

FIGURE 2B – HORIZONTAL & COUNTERFLOW DUCTING CONFIGURATIONS

Manual 2100-537I Page 14 of 54

NOTE: Requires horizontal

drain pan kit Model GTHZ-1

< >

Air Filter Required on Return Air Side for All Installations

Upowinstallationscanuse(1)FR23(16x25x1)oreldsuppliedequivalentoneithersideofthe

blower section. Use of (2) on both sides is optional.

Bottomreturnforupowandtopreturnfordownowmustbeeldsupplied.

Forhorizontalatticorcrawlspaceinstallationslterarrangementmustbeeldsupplied&should

be located in readily accessible location for the user.

See additional information on Pages 19 & 20.

BLOWER CONVERSION FROM UPFLOW TO COUNTERFLOW OR HORIZONTAL RIGHT DISCHARGE

Following the directions on Figure 3 for counterow and

horizontal right discharge, the indoor blower must be

removed and turned over in its mounting conguration.

• Step 1 Remove both front service panels from the

GTB1-A.

• Step 2 Remove two screws securing blower at top of GTB1-A (See Figure 3), and slide the blower forward and out of the chassis.

• Step 3 Remove two screws from front ll plate on

bottom of GTB1-A, and slide both pieces of metal forward and out of chassis.

• Step 4 Dip switch #4 on blower tap select control must be turned “on”. (Refer to Wiring Diagram 4117-100.)

• Step 5 While turning on tap #4 above, adjust the other taps accordingly for the tonnage of unit being applied. (Refer to Wiring Diagram 4117-100.)

• Step 6 Turn blower over and slide into rails of

bottom rear of the GTB1-A front ll plate

that was removed in Step 3 above.

• Step 7 Remove bottom rear ll plate from bottom

front ll plate (discard rear), and resecure front ll plate into unit base and front of

blower.

• Step 8 Replace GTB1-A front service doors after making line and control voltage wiring connections.

BLOWER LINE POWER CONNECTION

Power connections for the GTB1-A can be made two different ways.

The rst is in “stacked” congurations, the blower can

be plugged into an electrical connection from the bottom of the compressor (GTC**S2 Model Unit). This will

work for either upow or counterow applications. All

electrical sizing has been sized to accommodate this. The second is with “remote” blower (meaning separate

from the compressor section). Supplied in the GTB1-A is an adaptor wire harness. On the right-hand side of the GTB1-A chassis is a ½" electrical knockout. This harness can be installed through this knockout with the supplied

strain relief into a standard electrical junction box (eld

supplied). Electrical load sizing is included on the serial plate of the GTB1-A for the required separate branch circuit (See Figure 4).

Manual 2100-537I Page 15 of 54

FRONT PANELS

REMOVE BOTH

REMOVE (2) SCREWS

SECURING BLOWER

AND SLIDE BLOWER

OUT OF CABINET

SECURING BLOWER TO

FRONT FILL PLATE

REINSTALL (2) S CREWS

REINSTALL BOTH

FRONT PANELS

REMOVE (2) SCREWS FROM

FRONT FILL PLATE AND SLIDE

BACK FILL PLATE OUT OF CABINET

DISCARD BACK

FILL PLATE

ROTATE BLOWER AND SLIDE

INTO BOTTOM OFFSETS

REINSTALL

FRONT FILL PLATE

MIS-2842 A

FIGURE 3 – BLOWER CONFIGURATIONS

Manual 2100-537I Page 16 of 54

STACKED CONFIGURATIONS

UPFLOW AND COUNTERFLOW

CONDENSER BASE FOR BOTH

PLUG BLOWER POWER

CONNECTOR INTO POWER

PLUG PROTRUDING THROUGH

MOUNT FIELD

SUPPLIED SINGLE

GANG ELECTRICAL

BOX ALIGNED OVER

HIGH VOLTAGE K.O.

MIS-2843

REMOVE SUPPLIED

WIRE HARNESS AND

STRAIN RELIEF BUSHING

FROM BLOWER POWER PLUG.

ROUTE WIRE HARNESS

THROUGH STRAIN RELIEF

AND INTO ELECTRICAL BOX

TO MAKE FIELD POWER

CONNECTION

FIGURE 4 – BLOWER POWER CONNECTIONS

Manual 2100-537I Page 17 of 54

APPLICA TION AND LOCA TION

GENERAL

The GT Series Geothermal Heat Pumps feature three sections (GTA - Air Coil Section, GTB - Blower Section and GTC -

Compressor Section) which cover upow (bottom, right/leftside return), counterow and horizontal (left and right-hand

discharge) applications. The individual sections are shipped internally wired, requiring

duct connections, thermostat wiring, 230/208 volt AC power wiring, refrigerant line connections and water piping. The equipment covered in this manual is to be installed by trained, experienced service and installation technicians.

For installations requiring the continued use of an

existing gas or oil red furnace, add-on cased “A” coils are available. Two 3-ton coils designed to t standard

“B” and “C” width furnaces and one 4/5 ton coil designed for a “C” cabinet are available. Refer to Page 4 of this manual for the model nomenclature and the

specication sheet for performance data.

For top discharge oil furnaces, the coil drain pan MUST be located a minimum of 6 inches above the top of the furnace cabinet. Two coil spacer accessories are

available to t Bard oil furnaces:

CSADP2220 22" x 20" x 6" All models except 140,000 Btu Low-Boy

CASDP2520 25" x 20" x 6" 140,000 Btu Low-Boy only

For all other brands, a coil support system must be eld

fabricated to maintain the 6" spacing.

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.

DUAL FUEL HEATING / COOLING

Dual fuel is the combination of a fossil fuel furnace, normally gas or oil, with a heat pump. In milder weather the heat pump uses the available outdoor warmth and will transport that heat into your house cheaper than burning gas or oil. When it gets very cold, around 35 degrees F., the heat pump automatically shuts down and the furnace heats the home. This combination gives you the maximum savings on both heating and cooling while providing you with ideal indoor comfort.

Dual fuel systems are becoming increasingly popular in lieu

of conventional high efciency furnaces with air conditioning

due to the energy savings and ease of installation. Today’s new hi-tech thermostats eliminate the need for complicated wiring and duel fuel control boards. Bard recommends using the Honeywell THX9321R5030 Prestige® Thermostat (Does not include outdoor sensor). Honeywell also offers the Prestige® Kit 2.0 which includes the THX9321R5030 Prestige® Thermostat, REM5000R1001 Portable Comfort Control and C7089R1013 Wireless Outdoor Sensor.

LOCATION

The unit may be installed in a basement, closet, or utility room provided adequate service access is ensured.

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 desuperheater 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 oor 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 exible connections be

used to connect the ductwork to the unit in order to keep the noise transmission to a minimum.

WARNING

In applying a duct heater, refer to duct heater installation instructions for minimum clearance to combustible materials, maximum allowed inlet air temperatures, and minimum air

volumerequirementsforKWusage.

Manual 2100-537I Page 18 of 54

CAUTION

NEVER OPERATE MORE THAN 10KW STRIP HEAT WITH GEOTHERMAL HEAT PUMP OPERATIONAL. USE ADDITIONAL KW STRIP HEAT BEYOND 10KW ONLY IN EMERGENCY HEAT MODE.

TABLE 5

ELECTRICAL HEAT SPECIFICATIONS

For Use

With

All

GTC*S2

Models

+ Based upon 75°C copper wire. All wiring must conform to National Electric Code (Latest Edition) and all local codes.

Heater

Package

8604-080 240/208-60-1 5.0 20.8 17,065 3.75 18.0 12,799 26.0 30 #10 8604-081 240/208-60-1 9.8 40.8 33,447 7.35 35.3 25,086 52.0 60 #6 8604-082 240/208-60-1 14.7 61.2 50,171 11.0 52.9 37,543 76.6 80 #4 8604-083 240/208-60-1 19.2 81.7 65,530 14.4 69.2 49,147 102.0 125 #1

Heater

Package

FILTER

This unit must NOT be operated without a lter installed on return air side of the system. Insufcient airow due to undersized duct systems, inadequate lter size, or dirty lters can result in nuisance tripping of the high or low pressure controls. The ductwork and lter sizing must be

designed per ASHRAE/ACCA Guidelines.

Step #1 Refer to Table 1 (Page 4) for specic unit airow

and static application information.

240 Volts 208 Volts

KW Amps BTUH KW Amps BTUH

PIPING ACCESS TO UNIT

Water piping to and from the unit enters the unit cabinet on the left side of the unit. The connection directly at the unit

is a special double o-ring tting with a retainer nut that secures it in place. (It is the same style tting used for the ow center connection on ground loop applications.)

NOTE: All double o-ring ttings require “hand tightening

only”. Do not use wrench or pliers as retainer nut can be damaged with excessive force.

Minimum

Circuit

Ampacity

Maximum

HACR

Circuit

Breaker

Field

Wire

Size

Step #2 Refer to Figures 5A, 5B, 5C and 5D (Page 20) for

typical installation lter congurations for your specic application.

Step #3 Refer to Table 6 Filter Sizing Chart (Page 19)

matching your airow and lter conguration to determine proper lter sizing.

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.

NOTE: This drain line will contain cold water and must be insulated to avoid droplets of water from compressor

on the pipe and dripping on nished oors or the ceiling

below the unit.

NOTE: Apply petroleum jelly to o-rings to prevent damage and to aid in insertion.

Various ttings are available so you may then connect

to the unit with various materials and methods. These

methods include 1" barbed ttings (straight and 90°), 1" MPT (straight and 90°), and 1-1/4" hot fusion tting

(straight only) (see Figure 7).

Manual 2100-537I Page 19 of 54

TABLE 6

FILTER SIZING CHART

Filter Nominal Size Surface Area FT2 Filter Type

Capability @ 300

FPM Velocity

Airow CFM

10" X 20" X 1" 1.39 12" X 20" X 1" 1.67 500 14" X 20" X 1" 1.94 580 14" X 25" X 1" 2.43 730 16" X 20" X 1" 2.22 670 16" X 25" X 1" 2.78 840 20" X 20" X 1" 2.78 840 20" X 25" X 1" 3.47 1050 24" X 24" X 1" 4.00 1200 10" X 20" X 2" 1.39 12" X 24" X 2" 2.00 600 1000 14" X 20" X 2" 1.94 580 975 14" X 25" X 2" 2.43 730 1215 16" X 20" X 2" 2.22 670 1120 16" X 25" X 2" 2.78 840 1400 20" X 20" X 2" 2.78 840 1400 20" X 25" X 2" 3.47 1050 1750 24" X 24" X 2" 4.0 1200 2000 10" X 20" X 1" 1.39 12" X 24" X 1" 2.00 600 1000 14" X 20" X 1" 1.94 590 980 14" X 25" X 1" 2.43 730 1215 16" X 20" X 1" 2.22 670 1115 16" X 25" X 1" 2.78 840 1400 20" X 20" X 1" 2.78 840 1400 20" X 25" X 1" 3.47 1050 1740 24" X 24" X 1" 4.00 1200 2000 10" X 20" X 2" 1.39 12" X 24" X 2" 2.00 600 1000 1250 14" X 20" X 2" 1.94 590 14" X 25" X 2" 2.43 730 1215 1520 16" X 20" X 2" 2.22 670 1115 1400 16" X 25" X 2" 2.78 840 1400 1740 20" X 20" X 2" 2.78 840 1400 1740 20" X 25" X 2" 3.47 1050 1740 2170 24" X 24" X 2" 4.00 1200 2000 2500 12" X 24" X 4" 2 16" X 20" X 4" 2.22 670 1115 1400 20" X 20" X 4" 2.78 840 1400 1740 20" X 25" X 4" 3.47 1050 1740 2170 24" X 24" X 4" 4 1200 2000 2500

1" Fiberglass

Disposable

2" Std. Fiberglass

Disposable

1" Pleated Filter

2" Pleated Filter

4" Pleated Filter

415

415 700

425 700

425 700 870

600 1000 1250

Airow CFM

Capability @ 500

Capability @ 625

FPM Velocity

Not Recommended Not Recommended

Not Recommended

980 1215

Toself-calcuateforadditionalltersizes:

Airow/NominalFilterSize(FT

) = Velocity

1600CFM/3.47(20"x25"lter)=461FPM(feetperminutevelocity)

Airow CFM

FPM Velocity

Manual 2100-537I Page 20 of 54

FIGURE 5A

MIS-2881

AIR FILTER

AIRFLOW

AIR FILTER

INFORMATION.

AIR FILTER

*NOTE: SINGLE FILTER MAY REQUIRE A TRANSITION FOR ADEQUATE FILTER SIZING. SEE FILTER APPLICATION

AIRFLOW

AIR FILTER

(ONE OR MULTIPLE)

CENTRAL RETURN GRILLE(S)

SIDE INLET(S); ONE OR BOTH SIDES OR IN COMBINATION WITH BOTTOM INLET

AIR FILTER

AIRFLOW

*NOTE: SINGLE FILTER MAY REQUIRE

A TRANSITION FOR ADEQUATE FILTER SIZING. SEE FILTER APPLICATION INFORMATION.

AIRFLOW

CONFIGURATION

"V" FILTER CONFIGURATION

AIRFLOW

"A" FILTER

CONFIGURATION

AIRFLOW AIRFLOW

SINGLE FILTER

MIS-2882

AIR FILTER

CENTRAL RETURN GRILLE(S) (ONE OR MULTIPLE)

MIS-2883

(ONE OR MULTIPLE)

CENTRAL RETURN GRILLE(S)

AIR FILTER

SIDE INLET(S); ONE OR BOTH SIDES OR IN COMBINATION WITH BOTTOM INLET

AIR FILTER

AIRFLOW

AIR FILTER

AIRFLOW

*NOTE: SINGLE FILTER MAY REQUIRE A TRANSITION FOR ADEQUATE FILTER SIZING. SEE FILTER APPLICATION INFORMATION.

AIR FILTER

AIRFLOW

MIS-2884

AIRFLOW

CONFIGURATION

SINGLE FILTER

"A"/"V" FILTER

CONFIGURATION

CENTRAL RETURN

(ONE OR MULTIPLE)

INFORMATION.

*NOTE: SINGLE FILTER MAY REQUIRE A TRANSITION FOR ADEQUATE FILTER SIZING. SEE FILTER APPLICATION

AIRFLOW

AIR FILTER APPLICATIONS

FIGURE 5B

UPFLOW

COUNTERFLOW

FIGURE 5C FIGURE 5D

HORIZONTAL LEFT DISCHARGE

FILTERS SHOULD ALWAYS BE APPLIED IN A MANNER THAT MAKES THEM EASY TO ACCESS & CHANGE.

HORIZONTAL FRONT DISCHARGE

Manual 2100-537I Page 21 of 54

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 specications supplied. A ground lug is

supplied in the control compartment for equipment ground. The unit rating plate lists a “Maximum Time Delay Fuse”

or “HACR” type circuit breaker 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 insure 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 7

CONTROL CIRCUIT WIRING

Rated VA of

Control Circuit

Transformer

50 2.1

Transformer

Secondary

FLA @ 24V

Maximum Total

Distance of Control

Circuit Wiring in Feet

20 gauge - 45

18 gauge - 60 16 gauge - 100 14 gauge - 160

12 gauge - 250

WALL THERMOSTAT SELECTION

The wall thermostat selection is important in that it needs to be minimally 2-stage heat and 2-stage cool for applications without electric heat.

For applications with electric heat, the thermostat will need to minimally be 3-stage heat and 2-stage cool. The second bank of electric heat (when equipped) should be wired through a secondary relay for operation only in Emergency Heat Mode, at which point compressor operation should be disabled.

Refer to Figure 6 on the following page for typcial thermostat connections.

Table 6 should be used to determine proper gauge of control circuit wiring required.

For low voltage connections, see Figure #6. There are multiple options based upon the type of installation in regards to low voltage electrical connections and what options are selected. These options include a motorized valve or motorized valve with end switch for ground water applications, and optional electric duct heater connections.

NOTE: Review the “lettered triangles” and the corresponding notes on the lower right-hand corner of Figure #6. When options are not used, the wires will need attached to the reference points accordingly.

Example: 1. Control Circuit transformer rated at 50 VA

2. Maximum total distance of control circuit wiring 85 feet.

From Table 7 minimum of 16 gauge wire should be used in the control circuit wiring.

Low Voltage Connection

These units use a grounded 24-volt AC low voltage circuit and require at least a 2-stage heating and a 2-stage cooling thermostat.

“R” terminal is 24 VAC hot. “C” terminal is 24 VAC grounded. “G” terminal is the fan input. “Y1” terminal is the compressor part load input. “Y2” terminal is the compressor full load input. “O” terminal is the reversing valve input. The reversing

valve must be energized for cooling mode. “L” terminal is the check light output/compressor lockout.

This terminal is activated on high pressure switch, low

pressure switch, condensate overow, or freeze stat trip.

This is a 24 VAC output. “W1” terminal is rst stage electric heat input. (If

equipped.) “E” terminal is the emergency heat input. This energizes

the emergency heat relay, and should be utilized to limit the amount of electric heat with the geothermal heat pump operational to limit outlet air temperature.

“W2” terminal is the second stage electric heat input. (If equipped.)

Manual 2100-537I Page 22 of 54

Notes:

NOTE: W1=FIRST STAGE AUX. HEAT

Heat Pump

in GTB1-A

COOCO

Optional Wiring

Thermostat

Tap Select Control

Optional

Sensor

Duct Heater

8403-060

3.) Motorized valv e with or without end

Water Loop)

3 Stage Heat,

2 Stage Cool

A Coil Overflow

Optional

Water Loop)

White/Black

White

Green

(Use With Water/

Green/Red

Motorized Valve

Without End Switch

Motorized Valve

With End Switc h

(Use with Water/

Black

Thermostat

Low Voltage Connection Diagram

O/B

ground water/water loop.

Field Installed Wiring

switch should be used when i nstalling a

W2=SECOND STAGE AUX./EMERGENCY HEAT

O/B

Optional

W1/E

1.) points connect when duct heater

not used.

2.) wire not used when motorized

valve with end switch is present.

NOTE: "O/B" TERMINAL

MUST BE PROGRAMMED

TO ENERGIZE IN COOLING

4117-102 C

Terminal Strip

in GTC*S2-D

FIGURE 6

THERMOSTAT WIRING

Manual 2100-537I Page 23 of 54

NOTE: APPLY PETROLEUM JELLY TO O-RINGS TO PREVENT DAMAGE AND AID IN INSERTION

WATER IN

WATER OUT

GOUND LOOP

PIPE FROM

GROUND LOOP

PIPE TO

BRASS ADAPTERS

NOTE: IF USED SUPPORT WALL BRACKET

WITH A FIELD FABRICATED

1" FLEXIBLE HOSE

HOSE CLAMPS

FLOW METER

OPTIONAL VISUAL

STRAIGHT BARBED

PUMP MODULE

MIS-2827 A

GROUND LOOP (EARTH COUPLED WATER LOOP APPLICATIONS)

NOTE:

Unit shipped from factory with 75 PSIG low pressure switch wired into control circuit and must be rewired to 55 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.

THE 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.

FIGURE 7

CIRCULATION SYSTEM DESIGN

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 inch or 3/4 inch 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 ow through the heat pump. Insufcient ow 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.

Manual 2100-537I Page 24 of 54

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, 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 airow 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. Blowing

should stop.

5. Flush, ll and pressurize the closed loop system per

IGSHPA guidelines.

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 uid ow using a direct reading ow meter or a

single water pressure gauge, measure the pressure drop at the pressure/temperature plugs across the water coil.

Compare the measurement with ow versus pressure drop table to determine the actual ow rate. If the ow

rate is too low, recheck the selection of the loop pump

module model for sufcient 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 ow and entering water

temperatures. If the refrigerant pressures do not match,

check for airow 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 airow

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 inches of vacuum. D. Recharge the unit with refrigerant by weight.

This is the only way to insure a proper charge.

Manual 2100-537I Page 25 of 54

120

110

100

Retaining cap, hand tighten only

Pete's test plug

Test plug cap

Barbed 90° adapter

MIS-2622 A

NOTE: Slide retaining cap back to expose double o-rings. Apply petroleum jelly to o-rings to prevent damage and aid in insertion

with guage adaptor

Dial face pressure guage

Thermometer

FIGURE 8

120

110

100

706050

Retaining cap, hand tighten only

Pete's test plug

Test plug cap

Barbed 90° adapter

MIS-2622 A

NOTE: Slide retaining cap back to expose double o-rings. Apply petroleum jelly to o-rings to prevent damage and aid in insertion

Thermometer

FIGURE 8

FIGURE 9

PERFORMANCE MODEL DORFC-1 FLOW CENTER

Head (Feet)

0 5 10 15 20 25 30 35

Flow (GPM)

Manual 2100-537I Page 26 of 54

FIGURE 10

PERFORMANCE MODEL DORFC-2 FLOW CENTER

Head (Feet)

0 5 10 15 20 25 30 35

Flow (GPM)

GROUND WATER

(WELL SYSTEM APPLICA TIONS)

NOTE:

Unit shipped from factory with 60 PSIG low pressure switch wired into control circuit for ground water applications.

WATER CONNECTIONS

It is very important that an adequate supply of clean, noncorrosive water at the proper pressure be provided before

the installation is made. Insufcient 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 xtures 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, Figure 11. Slow open/close with End

Switch (2), 24V, provides on/off control of the water ow to

the unit. Refer to the wiring diagram for correct hookup of the valve solenoid coil.

Constant Flow Valve (3) provides correct ow of water to

the unit regardless of variations in water pressure. Observe

the water ow direction indicated by the arrow on the side

of the valve body. Following is a table showing which valve is to be installed with which heat pump.

TABLE 8

CONSTANT FLOW VALVES

Part No.

CFV-5 15 (1) 5

Min. Available

Pressure PSIG

Flow Rate

GPM

Strainer (8) installed upstream of water coil inlet to collect

foreign material which would clog the ow valve orice.

The gure 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, so as to minimize pressure drop.

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.

Hose bib (1) provides access to the system to check water

ow through the constant ow valve to insure adequate water ow through the unit. A water meter is used to check the water ow 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 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 xtures. The well pump must be sized in such a way

that three requirements are met:

1. Adequate ow rate in GPM.

2. Adequate pressure at the xture.

3. Able to meet the above from the depth of the well-feet of lift.

CFV-6 15 (1) 6 CFV-7 15 (1) 7 CFV-9 15 (1) 9

CFV-10 15 (1) 10

(1)

Thepressuredropthroughtheconstantow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ow.

Manual 2100-537I Page 27 of 54

MIS-2825

The pressure requirements put on the pump are directly affected by the diameter of pipe being used, as well as,

by the water ow rate through the pipe. The worksheet

included in Manual 2100-078 should guarantee that the well pump has enough capacity. It should also ensure that

WATER CONNECTION COMPONENTS

NOTE:

Shown with Optional Top Kit for Remote Condenser Applications

the piping is not undersized, which would create too much pressure due to friction loss. High pressure losses due to

undersized pipe will reduce efciency and require larger

pumps and could also create water noise problems.

FIGURE 11

See descriptions for these reference numbers on Page 27.

Manual 2100-537I Page 28 of 54

SYSTEM START UP PROCEDURE FOR GROUND WA TER APPLICATIONS

1. Be sure main power to the unit is OFF at disconnect.

2. Set thermostat system switch to OFF, 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 airow 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 ow.

A. Connect a water ow meter to the drain cock

between the constant ow valve and the solenoid valve. Run a hose from the ow meter

to a drain or sink. Open the drain cock.

B. Check the water ow rate through constant

ow valve to be sure it is the same as the unit

is rated for. (Example: 6 GPM for a GTC36S2.)

C. When water ow is okay, close drain cock and

remove the water ow meter. The unit is now

ready to start.

7. Start the unit in cooling mode by moving the thermostat switch to cool. Fan should be set for AUTO.

A. 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 ow and entering water temperatures. If the refrigerant pressures do not match, check for airow

problem and then refrigeration system problem.

9. Switch the unit to the heat mode by moving the thermostat switch to heat. Fan should be set for AUTO.

A. 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 airow 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 inches of vacuum. D. Recharge the unit with refrigerant by weight.

This is the only way to insure 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 ow 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 ow 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. These are:

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 ushing the system

until all growth is removed.

2. Suspended Particles in the Water. Filtering will

usually remove most suspended particles (ne 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 lter is cleaned and periodically maintained,

suspended particles should pose no serious problem. Consult with your 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) or 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 signicantly.

Manual 2100-537I Page 29 of 54

MIS-2836

PUMP

HOSE BIB (A)

HOSE BIB (B)

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 inuence 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 justied 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. Refer to the “Cleaning Water Coil”, Figure

12. The acid solution can be introduced into the heat pump coil through the hose bib A. 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 ltration 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 foot 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 backll placed around the casing. The gravel bed should provide adequate ltration 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 2 times the cubic feet size of the dwelling that you are trying to heat (includes basement if heated).

B. The average water depth should be at least 4 feet and

there should be an area where the water depth is at least 12 to 15 feet deep.

FIGURE 12

CLEANING WATER COIL

Manual 2100-537I Page 30 of 54

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 ow rate

is required on all models when used on this type system.

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 feet 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-inch eld tile (rigid plastic or

corrugated) for water return to the lake or pond.

I. The drain line discharge should be located at least 100

feet from the dry well location.

J. The drain line should be installed with a slope of 2

inches per 10 feet 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, you can instead 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 2100-078 available from your distributor.

12’ to 15’

LAKE or POND

FIGURE 13

LAKE OR POND INSTALLATION

GRAVEL FILL

WATER LEVEL

WELL CAP

ELECTRICAL LINE

PITLESS ADAPTER

TO PRESSURE TANK

WATER

SUPPLY LINE

DROP

PIPE

PERFORATED PLASTIC CASING

SUBMERSIBLE

PUMP

15’ to 20’ DEEP

Manual 2100-537I Page 31 of 54

DESUPERHEATER

DESCRIPTION

The system is designed to heat domestic water using heat recovered from a water source unit’s hot discharge gas.

LOCATION

Because of potential damage from freezing or condensation, the unit must be located in a conditioned space, therefore the unit must be installed indoors.

Locate the storage tank as close to the geothermal heat pump and pump module as the installation permits. Keep in mind that water lines should be a maximum of 25 feet long measured one way. Also, the vertical lift should not exceed 20 feet. This is to keep pressure and heat losses to a minimum.

ELECTRICAL CONNECTION

The Desuperheater: The desuperheater logic control with the remote thermal

sensors are built already hard-wired into the unit control panel. 208/230-60-1 power for the desuperheater pump is supplied with the same power as the compressor. The 24 volt signals needed are also tied in with the compressor call signals.

WARNING

Never alter or plug factory installed pressure relief valve on water heater or auxiliary tank.

INSTALLATION PROCEDURE – GENERAL

Before beginning the installation, turn off all power supplies to the water heater and unit, and shut off the main water supply line.

TWO T ANK – In order to realize the maximum energy savings from the heat recovery system, it is recommended that a second water storage tank be installed in addition to

the main hot water heater. Fossil fuel red water heaters

must be a two-tank installation.

Tanks specically intended for hot water storage are

available from water heater manufacturers (solar hot water storage tanks). A well insulated electric water heater without the electric heating elements will also make a suitable storage tank.

The size of storage tank should be as large as space and economy permit but in no event should it be less than onehalf of the daily water requirements for the occupants. As a guide in estimating the daily family water requirements, The

Department of Energy recommends a gure of 16.07 gallons

of hot water per day per individual. For example, a family of four would require 64.3 gallons per day (4 x 16.07).

ONE T ANK – The single hot water tank may be a new hot water heater (sized to 100% of daily water requirements) or

the existing water heater in the case of a retrot installation. The existing water heater should be drained and ushed to

remove all loose sediment. This sediment could damage the circulating pump. The bottom heating element should be disconnected.

NOTE: Make sure water heater thermostats are set below 125° on One Tank Unit.

WATER PIPING – All water piping must adhere to all state and local codes. Refer to piping diagrams for recommended one and two tank installations. Piping connections are 1/2 inch nominal copper plumbing.

A cleanable “Y” type strainer should also be included to collect any sediment.

Manual 2100-537I Page 32 of 54

DESUPERHEATER

OPERATION OF THE HEAT RECOVERY UNIT

The pump module is a very simple device containing basic controls and a circulating pump. Heat is transferred from the hot refrigerant (discharge gas) to the cool water.

The operation of the Desuperheater Pump Module is

controlled rst by the operation of the Geothermal Heat

Pump and secondly by internal controls within the Pump Module. A low voltage signal from Thermostat “Y” is connected to the desuperheater control board and acts as the primary on/off switch for the circulating pump.

Also connected to this board is a temperature overlimit device which shuts down the desuperheater once inlet

water has exceeded 125° so the water cannot create a scald

condition. There are also two (2) thermistor sensors connected to

the control board. These thermistors are measuring and controlling to ensure there is a positive heat differential across the water being circulated. When operating in Part Load Condition, there are certain conditions (Ground Loop Temperatures versus Hot Water Temperatures) that potential exists where heat could transfer from the hot water into the refrigeration system instead of the refrigeration system into the hot water. Through the control board logic, these

thermistors ensure there is at least 2° positive differential

between entering/leaving water temperatures and will shut down the pump accordingly.

START UP AND CHECK OUT

Be sure all shut off valves are open and all power supplies are on. Open a hot water faucet to permit any air to bleed from the plumbing.

NOTE: The inherent design of this pump for maximum

efciency means this pump is not self-priming. It is imperative to check that the air has been adequately bled

from the system. There is a bleed-port built into the pump module that can be utilized after the system water has been fully restored. The bleed port is located directly above the pump in the GTC compressor unit.

Turn ON the air conditioning system and verify the circulating pump will operate. Feel the “Water to Unit” and “Water from Water Heater” tubes for noticeable difference in temperature. Turn OFF the system and verify that the circulating pump stops.

NOTE: When checking the refrigerant operating pressures of the ground source heat pump. The desuperheater must be turned off. With the desuperheater operating a wide variance in pressures can result, giving the service technician the indication there is a charge problem when the unit is operating correctly.

MAINTENANCE

CLEANING THE HEAT EXCHANGER – If scaling of the coil is strongly suspected, the coil can be cleaned with a solution of phosphoric acid (food grade acid). Follow the manufacturer’s directions for the proper mixing and use of cleaning agent.

Manual 2100-537I Page 33 of 54

FIGURE 14

LINEVOLTAGE

WATER SENSORS

TSTAT

3AMP

FUSE

POWER

PUMPOUTLET

N L

OVERTEMP. LIMIT

OUTLET INLET

R C

24VAC

L N

CONTROL

LOGIC

21 3

MIS-2844

PUMP CONTROL

BLACK

FROM GEOTHERMAL LOGIC CONTROL

RED

BLACK

RED

DESUPERHEATER

COMPRESSOR CONTACTOR SIGNAL

LIMIT

TEMPERATURE

MOTOR

RED

BLACK

THERMISTOR

BLACK

208/230-60-1 LINE POWER

PUMP

BLACK

BI-METAL

DESUPERHEATER

PUMP PLUG

GTC LOW VOLTAGE

TERMINAL STRIP

WIRING DIAGRAM

Manual 2100-537I Page 34 of 54

DESUPERHEATER PUMP

SHIPPED DISCONNECTED

FROM FACTORY, CONNECT

3 PIN POWER PLUG TO

CONTROL PANEL

EXISTING WATER HEATER

L.P., GAS, OIL, ELECTRIC

WATER HEATER FACTORY

INSTALLED HIGH PRESSURE

RELIEF VALVE

HIGH PRESSURE

RELIEF VALVE

HOT WATER

TO HOUSE

COLD WATER IN

STRAINER

DRAIN

SHUTOFF

VALVES

OUT

WATER SOURCE UNIT

NOTES: DO NOT OPERATE PUMP WITHOUT WATER LINES

CONNECTED AND WATER IN SYSTEM WITH SHUT OFF

VALVES OPEN.

ALL PLUMBING MUST CONFORM TO LOCAL CODES

WHEN WATER STORAGE IS INSTALLED IN VERTICAL

POSITION, PIPING TO "IN" SIDE OF PUMP MUST BE

INSTALLED AT BOTTOM AS SHOWN.

OPTIONAL

CHECK VALVE

(PER CODES)

MIS-2831

FIGURE 15A – DESUPERHEATER SINGLE TANK SYSTEM

Manual 2100-537I Page 35 of 54

SHUTOFF VALVES

DRAIN

L.P., GAS, OIL, ELECTRIC

EXISTING WATER HEATER

RELIEF VALVE

HIGH PRESSURE

TO HOUSE

COLD WATER IN

STRAINER

RELIEF VALVES

HIGH PRESSURE

DRAIN

HOT WATER

OUT

WATER SOURCE UNIT

VALVES

SHUTOFF

FACTORY INSTALLED

WATER HEATER

WHEN WATER STORAGE IS INSTALLED IN VERTICAL

ALL PLUMBING MUST CONFORM TO LOCAL CODES

INSTALLED AT BOTTOM AS SHOWN.

POSITION, PIPING TO "IN" SIDE OF PUMP MUST BE

MIS-2832

OUT

(PER CODES)

CHECK VALVE

OPTIONAL

BYPASS LOOP

OPTIONAL

NOTES: DO NOT OPERATE PUMP WITHOUT WATER LINES

CONNECTED AND WATER IN SYSTEM WITH SHUT OFF

VALVES OPEN.

ADDITIONAL HOT WATER

STORAGE TANK. NOT

ELECTRICALLY CONNECTED

DESUPERHEATER PUMP

SHIPPED DISCONNECTED

FROM FACTORY, CONNECT

3 PIN POWER PLUG TO

CONTROL PANEL

FIGURE 15B – DESUPERHEATER DUAL TANK SYSTEM

Manual 2100-537I Page 36 of 54

DESUPERHEATER CONTROL BOARD SEQUENCE OF OPERATION

The desuperheating control board will make a determination whether or not to energize the pump relay inclusive on the control board.

A. It will constantly monitor inputs from two

temperature sensors, Inlet & Outlet water sensors. B. It will constantly monitor the Y signal. C. Upon acknowledgment of Y signal, and following

two minutes, the control board will energize the

pump relay. D. After 1½ minutes, based on temperature difference

between Outlet & Inlet sensors, and the presence of

Y signal, the following will take place:

Figure 16 — THERMISTOR

TEMPERATURE F VS RESISTANCE R OF TEMPERATURE SENSOR

F R F R

53.0

52.0

53.0

54.0

55.0

56.0

57.0

58.0

59.0

60.0

61.0

62.0

63.0

64.0

65.0

66.0

67.0

68.0

69.0

70.0

71.0

72.0

73.0

74.0

75.0

76.0

77.0

78.0

79.0

80.0

81.0

82.0

83.0

84.0

85.0

86.0

87.0

88.0

19374 18867 18375 17989 17434 16984 16547 16122 15710 15310 14921 14544 14177 13820 13474 13137 12810 12492 12183

11883 11591 11307

11031 10762 10501 10247 10000

9760 9526 9299 9077 8862 8653 8449 8250 8057 7869 7686

1.) If temperature difference is greater than 3°F,

then the control will continue to energize pump relay.

2.) If temperature difference is less than 3°F, then

the control will de-energize the pump relay.

3.) The control will next wait for 10 minutes before repeating Step #1 (above).

E. The Over Temperature Limit Switch is placed in

series with the line voltage. Therefore, continuity between L of line voltage and L of pump output is forced broken when the Over Temperature Limit Switch opens (see Wiring Diagram).

F. The 3-amp fuse is put in series with the R

connection to the board. Whenever the fuse is blown, the control will lose power and consequently, the relay will disengage.

89.0

90.0

91.0

92.0

93.0

94.0

95.0

96.0

97.0

98.0

99.0

100.0

101.0

102.0

103.0

104.0

105.0

106.0

107.0

108.0

109.0

110.0

111.0

112.0

113.0

114.0

115.0

116.0

117.0

118.0

119.0

120.0

121.0

122.0

123.0

124.0

7507 7334 7165 7000 6840 6683 6531 6383 6239 6098 5961 5827 5697 5570 5446 5326 5208 5094 4982 4873 4767 4663 4562 4464 4367 4274 4182 4093 4006 3921 3838 3757 3678 3601 3526 3452

Manual 2100-537I Page 37 of 54

SEQUENCE OF OPERATION

BLOWER

Blower functions are all controlled through 24 VAC input signals from the control thermostat and 208/230 VAC being supplied to the motor continuously.

The installer must be sure to congure the tap select control

board (located in blower compartment) based upon the

specic model application. By default, the tap select control

(located in the blower compartment), is shipped from the

factory to operate at the airow ranges for the GTC60S2

model. Please see Wiring Diagram (Page 53) which details the required dip switch changes required between models.

NOTE 1: On a call from only “G” from the thermostat (call

for manual fan), the blower will operate at a signicantly reduced airow rate to allow for air circulation and ltration, but at reduced power consumption and sound

levels. NOTE 2: There are ±10% adjustments that are enabled

on the tap select control that will allow you to increase or decrease the air volume plus or minus 10%. Increasing the air volume may help with some slightly increased capacity and increased duct velocity if there is an air distribution issue. Decreasing the air volume with help improve latent capacity in a humid application, and will help to lower air distribution sound levels. Please see Wiring Diagram (Page

53) which details the required dip switch changes for this adjustment.

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” sending the signal to both the Tap Select Control located in the blower section and to the Geothermal Logic Control located in the compressor section. The tap select control uses the input signal versus the motor program, and the dip switch settings to determine the proper air volume rate to operate. The

Geothermal Logic Control veries that the High Pressure

Switch, the Low Pressure Switch, and the Freeze Stat controls are all in the “closed” position. It then energizes

the “A” terminal ouput to start the ow center (Ground

Loop Applications) or energizes the water solenoid (Ground Water/Water Loop Applications). Following 10 seconds of the “A” terminal energization, the compressor contactor is energized.

FULL LOAD COOLING

The system should already be in Part Load Cooling operation prior to Full Load Cooling being energized. Additionally what happens, 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 sends a signal to the Blower Tap Select Control in the blower compartment to drive the blower to the proper CFM.

PART LOAD HEATING (No Electric Heat)

When thermostat system is placed in HEAT, the reversing valve solenoid is no longer energized. On a call for part load heating, the thermostat completes a call from “R” to “Y1” sending the signal to both the Tap Select Control located in the blower compartment, and to the Geothermal Logic Control located in the compressor section. The tap select control uses the input signal versus the motor program, and the dip switch settings to determine the proper air volume rate to operate. The Geothermal Logic Control

veries that the High Pressure Switch, the Low Pressure

Switch, and the Freeze Stat controls are all in the “closed” position. It then energizes the “A” terminal output to start

the ow center (Ground Loop Applications) or energizes the

water solenoid (Ground Water/Water Loop Applications.) Following 10 seconds of the “A” terminal energization, the compressor contactor is energized.

FULL LOAD HEATING

The system should already be in Part Load Heating operation prior to Full Load Heating being energized. Additionally what happens, 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 sends a signal to the Blower Tap Select Control in the blower compartment to drive the blower to the proper CFM.

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 the rst bank of electric heat.

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 & CCG). When the “Y” input opens the compressor de-energizes.

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.

Anti-Short Cycle Timer – After compressor shutdown, or power disruption, a 5-minute timer is applied and prevents the compressor from operating.

Manual 2100-537I Page 38 of 54

SEQUENCE OF OPERATION

HIGH PRESSURE SWITCH

(TERMINALS HP1 & 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 & 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

rst 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.

FREEZE STAT (Optional Field Add-On Option)

(TERMINALS FS & FS2) Circuit will be proved as “closed” prior to energizing “A” or “CC” terminals. If freezestat 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.

UNDER & 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 & 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 ash

when an under or over voltage condition occurs. The over voltage protection can be disabled by removing the O/V jumper.

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.

NOTE: Jumper wire is factory installed.

CONDENSATE OVERFLOW

(Terminals CO & CO2) This input operates when the water level in the condensation 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 rst time

after 30 seconds, the control will go into hard lockout, and will energize the “L” output signal.

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 airow 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.

Manual 2100-537I Page 39 of 54

FIGURE 17 — COMPONENT LOCATION

LOW VOLTAGE

REVERSING VALVE

FILTER/DRIER

PUMP

COMPRESSOR

DESUPERHEATER COIL

EXPANSION VALVE

LOW PRESSURE SWITCHES

WATER COIL

HIGH PRESSURE SWITCH

PUMP MODULE HIGH VOLTAGE

UNIT HIGH VOLTAGE

MIS-2838

GEOTHERMAL LOGIC CONTROL

CAPACITOR

COMPRESSOR

DESUPERHEATER CONTROL BOARD

CIRCUIT BREAKERS

RELAY

PLUG

TERMINAL STRIP

CONTACTOR

COMPRESSOR

GROUND TERMINALS

PUMP MODULE POWER CONNECTION

MIS-2837

FIGURE 18 — CONTROL PANEL

Manual 2100-537I Page 40 of 54

FIGURE 19

Manual 2100-537I Page 41 of 54

REFRIGERANT CHARGE

LINE SET INSTALLATION – GTA COIL SECTIONS

CHARGE ADJUSTMENT

All supplied line sets with threaded refrigerant connections are factory evacuated and charged with R-410A refrigerant at the quantity required to optimize system performance. Refer to Table 9 to see this charge quantity if you need to reprocess the charge due to repairing damage or replacement of a defective component.

For those using Stub Kits GTLS-SK2-1 or GTLS-SK4-1,

you will rst need to braze up both ends of your line set

(to the point that it is sealed). Ports are provided on the GTLS-SK*-1 kits so that you can pull a vacuum on the line set and pre-charge with refrigerant before screwing on

the refrigerant ttings onto the pre-charged condenser and

evaporator (if using one with threaded connectors). For charge quantity, use Table 9 as a good general reference

to the required R-410A refrigerant required based upon your

line set length. Or, you can specically measure your line

set length, and add 1.4 ounces of R-410A refrigerant per 1' of line set length.

REFRIGERANT FITTING ATT ACHMENT

1. Coat all mating surface, including o-rings, with R-410A refrigerant oil (Polyol Ester).

2. Attach female ttings to coil/condensing unit portion

by hand-threading initially. Be careful not to cross thread assembly. For the pre-manufactured 3' line

set used with a vertical (stacked) conguration, the

ttings should be threaded simultaneously. Again, be

careful not to cross-thread either assembly.

3. Final torque should be achieved. Use the appropriate size wrench in conjunction with a second (backing)

wrench to ensure that ttings do not spin or twist on

the copper refrigerant lines. Use the following torque rates:

3/8" Lineset – 22-25 ft. lbs. (30-35 Nm) 7/8" Lineset – 44-47 ft. lbs. (60-65 Nm)

CHECKING REFRIGERANT CHARGE QUANTITY – GTA COIL SECTIONS

The correct R-410A charge is shown on the unit rating plate (including adders for the various line set lengths). Reference Figure 21 to validate proper system operation. However, it is recommended that if incorrect charge is suspected, the system refrigerant be reclaimed, evacuated, and charged to nameplate charge quantity and type (including necessary charge adjustment for the installed line set length).

The nameplate charge quantity is optimized for thermal

performance and efciency throughout all modes of

operation.

MODEL DESCRIPTION

GTLS-03-1 3' Line Set 1.2 3 4.2 GTLS-15-1 15' Line Set 6 15 21 GTLS-25-1 25' Line Set 10 25 35 GTLS-35-1 35' Line Set 14 35 49 GTLS-50-1 50' Line Set 20 50 70

Manual 2100-537I Page 42 of 54

TABLE 9

PRE-CHARGED LINE SET REFRIGERANT QUANTITY

R-410A CHARGE QUANTITY

(Ounces)

3/8" Line 7/8" Line Total

REFRIGERANT CHARGE

GENERAL – GTADP COIL SECTIONS

GENERAL (GTADP Add-On Coils)

These instructions are intended as a general guide and do not supersede the coil manufacturer’s installation instructions or local codes in any way. Read the manufacturer’s

installation manual and all “WARNING” statements prior to installing the evaporator coil.

The following is needed, in addition to the evaporator coil.

1. Line Set Stub Kit with Single Pair Ends – Bard Part No. GTLS-SK2-1

2. Line Set consisting of 7/8" and 3/8" soft rolled copper with insulation.

3. Coil Spacer (Oil Furnaces Only)

Coils are shipped with a 10 PSIG dry air holding charge. Puncture rubber plug on suction line to release charge before removing plugs. The absence of pressure does not

verify a leak. Check the coil for leaks prior to installing if a leak is suspected.

Position the coil/box directly on top of a gas furnace and secure using sheet metal screws. The drain pans are made

of a polymer that can withstand temperatures up to 450˚F.

If installed on an oil or drum type heat exchanger (a coil spacer is recommended to) maintain a 6 inch clearance

to protect the pan and to provide optimum air ow over

the coil. Coil should be level, or pitched slightly toward the drain connections. See Figure 20.

DO NOT CONNECT THE LINE SET TO THE CONDENSER SECTION

Pre-charge the line set and evaporator coil with the amount of R-410A calculated earlier.

REFRIGERANT FITTING ATT ACHMENT (After pre-charging line set & coil) (GTADP Add-On Coils)

1. Coat all mating surfaces, including o-rings, with R-410A refrigerant oil (Polyol Ester).

2. Attach female ttings to condensing unit portion by hand-threading initially. Be careful not to cross-

thread assembly.

3. Final torque should be achieved. Use the appropriate size wrench in conjunction with a second (backing)

wrench to ensure that the ttings do not spin or twist

on the copper refrigerant lines. Use the following torque rates:

3/8" Line Set: 22-25 ft. lbs. (30-35 Nm) 7/8" Line Set: 44-47 ft. lbs. (60-65 Nm)

FIGURE 20

COIL SPACER

LINE SET INSTALLATION (GTADP Add-On Coils)

Braze up one end of the line set to the GTLS-SK2-1 stub kit and the other end to the evaporator coil. Ports are provided in the GTLS-SK2-1 kit. Pull a vacuum (100 microns) on the line set and coil. Pre-charge the line set and coil with

refrigerant before screwing the refrigerant ttings onto the

pre-charged condenser section.

REFRIGERANT CHARGE QUANTITY – Line Set and Evaporator Coil (GTADP Add-On Coils)

The refrigerant charge shown on the GTC condenser section is based on being matched with a GTA coil section and not the ADP “A” coil. Charge adjustments are required for proper system operation when using an ADP coil. Use the following formulas to determine the amount of charge required.

• GTC36 Line Set Charge = Line Set Length (FT) X 1.4 oz. R-410A/FT – 3.0 oz.

• GTC48 Line Set Charge = Line Set Length (FT) X 1.4 oz. R-410A/FT – 9.0 oz.

• GTC60 Line Set Charge = Line Set Length (FT) X 1.4 oz. R-410A/FT + 20.0 oz.

Example:

A GTC48 condenser section is being installed with a GTADP-4860-C evaporator coil and a 25 foot line set.

GTC48 Line Set Charge = Line Set Length 25 (FT) X

1.4 oz. R-410A/FT – 9.0 oz. GTC48 Line Set Charge = 26.0 oz.

ATTACH WITH

SCREWS TO

FLANGE

COIL SPACER (IF REQUIRED)

MIS-3127

Manual 2100-537I Page 43 of 54

REFRIGERANT CHARGE

These units require R-410A refrigerant and Polyol Ester.

GENERAL:

1. Use separate service equipment to avoid cross contamination of oil and refrigerants.

2. Use recovery equipment rated for R-410A refrigerant.

3. Use manifold gauges rated for R-410A (800 psi/250 psi low).

4. R-410A is a binary blend of HFC-32 and HFC-125.

5. R-410A is nearly azeotropic - similar to R-22 and R-12. Although nearly azeotropic, charge with liquid refrigerant.

6. R-410A operates at 40-70% higher pressure than R-22, and systems designed for R-22 cannot withstand this higher pressure.

7. R-410A has an ozone depletion potential of zero, but must be reclaimed due to its global warming potential.

8. R-410A compressors use Polyol Ester.

9. Polyol Ester oil is hygroscopic; it will rapidly absorb moisture and strongly hold this moisture in the oil.

10. A liquid line dryer must be used - even a deep vacuum will not separate moisture from the oil.

11. Limit atmospheric exposure to 15 minutes.

12. If compressor removal is necessary, always plug compressor immediately after removal. Purge with small amount of nitrogen when inserting plugs.

SAFETY PRACTICES:

1. Never mix R-410A with other refrigerants.

2. Use gloves and safety glasses, Polyol Ester oils can be irritating to the skin, and liquid refrigerant will freeze the skin.

3. Never use air and R-410A to leak check; the

mixture may become ammable.

4. Do not inhale R-410A – the vapor attacks the nervous system, creating dizziness, loss of coordination and slurred speech. Cardiac irregularities, unconsciousness and ultimate death can result from breathing this concentration.

5. Do not burn R-410A. This decomposition produces hazardous vapors. Evacuate the area if exposed.

6. Use only cylinders rated DOT4BA/4BW 400.

7. Never ll cylinders over 80% of total capacity.

8. Store cylinders in a cool area, out of direct sunlight.

9. Never heat cylinders above 125°F.

10. Never trap liquid R-410A in manifold sets, gauge

lines or cylinders. R-410A expands signicantly

at warmer temperatures. Once a cylinder or line is full of liquid, any further rise in temperature will cause it to burst.

TOPPING OFF SYSTEM CHARGE

If a leak has occurred in the system, reclaiming, evacuating (see criteria above), and charging to the nameplate charge is recommended.

Topping off the system charge can be done without

problems. With R-410A, there are no signicant

changes in the refrigerant composition during multiple leaks and recharges. R-410A refrigerant is close to being an azeotropic blend (it behaves like a pure compound or single component refrigerant). The remaining refrigerant charge, in the system, may be used after leaks have occurred and then “top-off” the charge by utilizing the charging charts on the inner control panel cover as a guideline.

REMEMBER: When adding R-410A refrigerant, it must come out of the charging cylinder/tank as a liquid to avoid any fractionation, and to insure optimal system performance. Refer to instructions for the cylinder that is being utilized for proper method of liquid extraction.

Manual 2100-537I Page 44 of 54

FIGURE 21

PRESSURE TABLES

Model

GTC36S2

GTC48S2

GTC60S2

Model

GTC36S2 70° DB

GTC48S2 70° DB

GTC60S2 70° DB

Model

GTC36S2

GTC48S2

GTC60S2

Model

GTC36S2 70° DB

GTC48S2 70° DB

GTC60S2 70° DB

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

75° DB

62° WB

80° DB

67° WB

85° DB

72° WB

Return Air

Temperature

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

75° DB

62° WB

80° DB

67° WB

85° DB

72° WB

Return Air

Temperature

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

Low Side

High Side

Low Side

High Side

Low Side

High Side

Pressure

Low Side

High Side45242522525926266272

Low Side

High Side3624744258522706028168293763048431692327

Low Side

High Side3826446273542826229270301783108631994329

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

Low Side

High Side

Low Side

High Side

Low Side

High Side

Pressure

Low Side

High Side23238352474625657264682738028891296

Low Side

High Side2022831238

Low Side

High Side2723638247482575826868278792948930599315

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

108

111

148 116

152 124

157 109

148

117

151 126

157 116

139 124

143 134

148

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

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

116 130

124 133

134 138

119 131

128 135

137 139

127 122

135 125

145 130

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

113

163

177

118

121

167

182

127

130

173

188

111

113

162

176

119

121

166

181

128

130

172

187

117

154

169

125

158

173

134

163

179

119

121

144

159

127

129

148

163

136

139

153

168

121

123

146

160

130

132

149

164

140

142

155

170

127

137

152

136

141

156

146

161

24754257662667728189291

FULL LOAD COOLING — Fluid Temperature Entering Water Coil °F

116

118

121

123

126

128

129

192

206

221

235

250

264

286

124

126

129

132

134

137

196

211

226

241

256

133

136

139

142

203

219

234

115

117

191 123

196 132

203 117

183 125

188 135

195

123 173

132 177

142 184

125 174

134 179

144 185

127 167

136 171

147 177

119

205

220

125

127

211

226

134

137

218

233

117

118 213

198 126

126

203

219

135

210

226

FULL LOAD HEATING — Fluid Temperature Entering Water Coil °F

28279292863029331299322

PART LOAD COOLING — Fluid Temperature Entering Water Coil °F

126

128

188

202

134

137

192

207

144

147

199

214

127

129

189

203

136

139

193

208

147

149

200

215

128

182

197

137

187

202

147

193

209

PART LOAD HEATING — Fluid Temperature Entering Water Coil °F

250 121

234 129

240 139

249 118

228 126

234 135

242

130 216

139 222

150 230

132 217

141 223

151 230

128 212

137 217

148 225

144 265

122 249

131 255

141 264

118 243

127 249

136 258

133 231

142 237

153 245

134 231

143 237

154 246

129 227

138 233

148 241

102 305

100 300

271 147

280 124

263 133

270 143

279

119

257 127

264 137

273

100 339

102 338

135 245

144 252

155 261

136 246

145 252

156 261

129 242

138 248

148 257

111

317 109

311

109 326

138 294

148 304

125 285

134 292

144 302

120 278

129 285

138 295

106 332

108 350

110

347

135 265

144 271

155 281

137 266

146 273

157 283

130 262

139 269

149 278

120 328

117

322

119

336

309 138

317 149

328 127

306 135

314 145

325 122

298 130

305 140

316

117 342

119 361

118 357

135 284

145 291

155 301

137 287

147 294

158 305

131 282

140 289

150 299

131 337

129 332

129 347

130 331

139 340

149 351

128 328

137 336

147 348

123 318

132 326

142 337

129 353

129 372

126 366

135 303

145 310

156 321

138 308

148 316

159 327

131 302

141 310

151 320

143 346

140 341

140 357

131 353

140 362

150 375

129 349

138 358

148 371

125 338

134 347

144 359

140 363

140 383

134 376

135 322

145 330

156 341

139 328

149 337

160 348

132 322

141 330

152 342

154 354

152 351

150 368

131 376

140 385

151 399

130 371

139 380

149 393

127 358

135 367

145 380

151 373

150 394

142 385

135 341

145 349

156 362

140 349

150 358

161 370

133 342

142 351

153 363

165 363

163 360

160 378

132 398

141 408

152 422

131 392

140 402

151 416

128 378

137 388

147 402

162 383

161 405

150 395

136 360

145 369

156 382

141 370

151 379

162 392

134 362

143 371

154 384

176 372

175 370

170 389

132 420

142 431

152 446

132 413

141 424

152 439

130 398

139 409

149 423

174 394

171 416

158 404

136 379

145 389

156 402

142 390

152 400

163 414

134 382

144 392

155 405

188 381

186 379

181 399

133 442

142 454

153 470

133 435

142 446

153 462

131 419

140 429

151 444

185 404

182 427

166 414

136 398

145 408

156 422

143 411

153 421

164 436

135 402

145 412

156 426

199 389

198 389

191 410

LOW SIDE PRESSURE +/- 2 PSIG HIGH SIDE PRESSURE +/- 5 PSIG

TablesbaseduponratedCFM(airow)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 2100-537I Page 45 of 54

AUX.

INDOOR SECTIONPOWER SUPPLY

WATER COIL SECTION

ndoor Blower Motor

ev.

ater

Heat Gen.

and Coil

Valve Water Coil

Solenoid

Line Voltage Control Circuit Compressor Refrigerant System

Auxillary Heat Upstream of Coil

Undersized or Restricted Ductwork

Air Filters Dirty

Air Volume Low

Motor Winding Defective

Fins Dirty or Plugged

Plugged or Restricted Metering Device (Clg)

Low Water Temperature (Htg)

Water Volume Low (Clg)

Water Volume Low (Htg)

Scaled or Plugged Coil (CLg)

Scaled or Plugged Coil (Htg)

Plugged or Restricted Metering Device (Htg)

Defective Valve or Coil

Leaking

Solenoid Valve Stuck Open (Htg or Clg)

Solenoid Valve Stuck Closed (Clg)

Solenoid Valve Stuck Closed (Htg)

Unequalized Pressures

Non-Condensables

Low Suction Pressure

High Suction Pressure

Low Head Pressure

High Head Pressure

Refrigerant Overcharge

Refrigerant Charge Low

Motor Wingings Defective

Valve Defective

Seized

Bearings Defective

Discharge Line Hitting Inside of Shell

Indoor Blower Relay

Pressure Controls (High or Low)

Contactor Coil



Thermostat

Low Voltage



Control Transformer

Loose Terminals

Faulty Wiring



Start Capacitor

Run Capacitor

Potential Relay

Compressor Overload

Defective Contacts in Contactor



Low Voltage

Loose Terminals

Faulty Wiring

Blown Fuse or Tripped Breaker

Power Failure



 



 



  





 

   



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 

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





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

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

 



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

  

 

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

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

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  

 

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  

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 



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 

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 

 



QUICK REFERENCE TROUBLESHOOTING CHART FOR WATER TO AIR HEAT PUMP

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

Cycle

Heating or Cooling Cycles

Cooling

Denotes occasional cause

 Denotes common cause



Manual 2100-537I Page 46 of 54

Ice in Water Coil

Heating Cycle

SERVICE

SERVICE HINTS

1. Caution owner to maintain clean air lters at all times.

Also, not to needlessly close off supply and return air

registers. This reduces airow 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 ame. To prevent this occurrence, it is important

to check both the high and low side with manifold gauges before unbrazing.

ECM MOTOR

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.

COMPRESSOR SOLENOID

(See Sequence of Operation on Pages 37 & 38 for function.)

A nominal 24-volt direct current coil activates the internal compressor solenoid. The input control circuit voltage must be 18 to 28 volts 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 rectier 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 percent.

2. If step one does not give the expected results, shut unit off. Apply 18 to 28 volts 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 and remove the control circuit molded plug from the compressor and measure the solenoid coil resistance. The resistance should be 32 to 60 ohms depending on compressor temperature.

4. Next, check the molded plug.

Voltage check: Apply control voltage to the plug wires (18 to 28 volts ac). The measured dc voltage at the female connectors in the plug should be around 15 to 27 vdc.

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ame

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.

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 zero

ohms, while the other should read innity. Repeat with

other wire. The same female connector as before should

read zero, while the other connector again reads innity.

Reverse polarity on the ohmmeter leads and repeat. The

female connector that read innity previously should now

read close to zero ohms. Replace plug if either of these test methods does not show

the desired results.

Manual 2100-537I Page 47 of 54

TROUBLESHOOTING GE ECM 2.3

™

MOTORS

CAUTION:

Disconnect power from unit before removing or replacing connectors, or servicing motor. To avoid electric shock from the motor’s capacitors, disconnect power and wait at least 5 minutes before opening motor.

Symptom Cause/Procedure

Motor rocks slightly • This is normal start-up for ECM

when starting

Motor won’t start • Check blower turns by hand

• No movement

• Check low voltage (24 Vac R to C) at motor

• Check low voltage connections

(G, Y, W, R, C) at motor

• Check for unseated pins in connectors on

motor harness

• Test with a temporary jumper between R - G

• Check motor for tight shaft

• Perform motor/control replacement check

• Perform Moisture Check

• Motor rocks, • Check for loose or compliant motor mount

but won’t start

• Perform motor/control replacement check

Motor oscillates up • It is normal for motor to oscillate with no

load & down while being on shaft tested off of blower

Motor starts, but runs erratically

• Varies up and down • Check line voltage for variation or “sag” or intermittent • Check low voltage connections

(G, Y, W, R, C) at motor, unseated pins in motor harness connectors

• Check “Bk” for erratic CFM command (in

variable-speed applications)

• Check out system controls, Thermostat

• Perform Moisture Check

• “Hunts” or “puffs” at • Does removing panel or lter reduce high CFM (speed) “pufng”?

- Reduce restriction

- Reduce max airow

• Stays at low CFM • Check low voltage (Thermostat) wires and

despite system call connections

for cool or heat CFM • Verify fan is not in delay mode; wait until

delay complete

• “R” missing/not connected at motor

• Perform motor/control replacement check

• Stays at high CFM • “R” missing/not connected at motor

• Is fan in delay mode? - wait until delay time

complete

• Perform motor/control replacement check

• Blower won’t shut off •

Check for Triac switched thermostat or solid state relay

Excessive noise • Determine if it’s air noise, cabinet, duct or

motor noise; interview customer, if necessary

• Air noise • High static creating high blower speed?

- Is airow set properly?

- Does removing lter cause blower to slow down? Check lter

- Use low-pressure drop lter

- Check/correct duct restrictions

• Check power at motor

• Make sure blower wheel is tight on shaft

Current leakage from controls into G, Y or W?

Symptom Cause/Procedure

• Noisy blower or cabinet • Check for loose blower housing, panels, etc.

• High static creating high blower speed?

- Check for air whistling through seams in ducts, cabinets or panels

- Check for cabinet/duct deformation

• “Hunts” or “puffs” at • Does removing panel or lter reduce

high CFM (speed)

- Reduce restriction

- Reduce max. airow

Evidence of Moisture

• Motor failure or • Replace motor and

malfunction has occurred and moisture is present

• Evidence of moisture

present inside air mover

“pufng”?

• Perform Moisture Check

Perform Moisture Check

Do Don’t

• Check out motor, controls, • Automatically assume the motor is bad. wiring and connections thoroughly before replacing motor

• Orient connectors down so • Locate connectors above 7 and 4 o’clock

water can’t get in positions

- Install “drip loops”

• Use authorized motor and • Replace one motor or control model # with

model #’s for replacement another (unless an authorized replacement)

• Keep static pressure to a • Use high pressure drop lters some have

minimum: H20 drop!

- Recommend high • Use restricted returns efciency, low static lters

- Recommend keeping lters

clean.

- Design ductwork for min. static, max. comfort

- Look for and recommend ductwork improvement, where necessary

• Size the equipment wisely • Oversize system, then compensate with low airow

• Check orientation before • Plug in power connector backwards inserting motor connectors • Force plugs

½”

Moisture Check

• Connectors are oriented “down” (or as recommended by equipment

manufacturer)

• Arrange harness with “drip loop” under motor

• Is condensate drain plugged?

• Check for low airow (too much latent capacity)

• Check for undercharged condition

• Check and plug leaks in return ducts, cabinet

Comfort Check

• Check proper airow settings

• Low static pressure for lowest noise

• Set low continuous-fan CFM

• Use humidistat and 2-speed cooling units

• Use zoning controls designed for ECM that regulate CFM

• Thermostat in bad location?

Manual 2100-537I Page 48 of 54

Motor

Motor OK when R > 100k ohm

ECM 2.0

Only remove Hex Head Bolts

Connector Orientation

Between 4 and 8 o'clock

Drip Loop

Back of Control

Figure 5

Winding Test

Figure 4

Note: Use the shorter bolts and alignment pin supplied when replacing an ECM 2.0 control.

Figure 3

ECM

2.3/2.5 Power Connector

(5-pin)

Control Connector (16-pin)

Hex-head Screws

Motor Connector (3-pin)

Motor Connector

(3-pin)

Control Disassembly

Drip Loop

Push until Latch Seats Over Ramp

From Motor

Circuit

Board

TROUBLESHOOTING GE ECM

™

MOTORS CONT’D.

Replacing ECM Control Module

To replace the control module for the GE variable-speed indoor blower motor you need to take the following steps:

1. You MUST have the correct replacement module. The controls are

factory programmed for specic operating modes. Even though they look

alike, different modules may have completely different functionality.

USING THE WRONG CONTROL MODULE VOIDS ALL PRODUCT WARRANTIES AND MAY PRODUCE UNEXPECTED RESULTS.

2. Begin by removing AC power from the unit being serviced. DO NOT WORK ON THE MOTOR WITH AC POWER APPLIED. To avoid

electric shock from the motor’s capacitors, disconnect power and wait at least 5 minutes before opening motor.

3. It is not necessary to remove the motor from the blower assembly, nor the blower assembly from the unit. Unplug the two cable connectors to the motor control assembly. There are latches on each connector. DO NOT PULL ON THE WIRES. The plugs remove easily when properly released.

4. Locate the screws that retain to t metal of the unit and remove them. Remove two (2) nuts that retain the control to the bracket and then remove two (2) nuts that retain sheet metal motor control end plate. Refer to Figure 22.

5. Disconnect the three (3) wires interior of the motor control by using

your thumb and forenger squeezing the latch tab and the opposite side

of the connector plug, gently pulling the connector. DO NOT PULL ON THE WIRES, GRIP THE PLUG ONLY. Refer to Figure 22.

6. The control module is now completely detached from the motor. Verify with a standard ohmmeter that the resistance from each motor lead (in the motor plug just removed) to the motor shell is >100K ohms. Refer to Figure 23. (Measure to unpainted motor end plate.) If any motor lead fails this test, do not proceed to install the control module. THE MOTOR IS DEFECTIVE AND MUST BE REPLACED. Installing the new control module will cause it to fail also.

he motor control bracket to the sheet

7. Verify that the replacement control is correct for your application. Refer to the manufacturer’s authorized replacement list. USING THE

WRONG CONTROL WILL RESULT IN IMPROPER OR NO BLOWER OPERATION. Orient the control module so that the 3-wire

motor plug can be inserted into the socket in the control. Carefully insert the plug and press it into the socket until it latches. A SLIGHT CLICK

WILL BE HEARD WHEN PROPERLY INSERTED.

8. Reverse the steps #5, 4, 3 to reconnect the motor control to the motor wires, securing the motor control cover plate, mounting the control to the bracket, and mounting the motor control bracket back into the unit. MAKE SURE THE ORIENTATION YOU SELECT

FOR REPLACING THE CONTROL ASSURES THE CONTROL’S CABLE CONNECTORS WILL BE LOCATED DOWNWARD IN THE APPLICATION SO THAT WATER CANNOT RUN DOWN THE CABLES AND INTO THE CONTROL. DO NOT

OVERTIGHTEN THE BOLTS.

9. Plug the 16-pin control plug into the motor. The plug is keyed. Make sure the connector is properly seated and latched.

10. Plug the 5-pin power connector into the motor. Even though the plug is keyed, OBSERVE THE PROPER ORIENTATION. DO NOT FORCE THE CONNECTOR. It plugs in very easily when properly oriented. REVERSING THIS PLUG WILL CAUSE IMMEDIATE

FAILURE OF THE CONTROL MODULE.

11.

Final installation check. Make sure the motor is installed as follows: a. Motor connectors should be oriented between the 4 o’clock and 8 o’clock positions when the control is positioned in its

nal location and orientation.

b. Add a drip loop to the cables so that water cannot enter the motor by draining down the cables. Refer to Figure 24.

The installation is now complete. Reapply the AC power to the HVAC equipment and verify that the new motor control module is working properly. Follow the manufacturer’s procedures for disposition of the old control module.

Figure 22

Figure 23

Figure 24

Manual 2100-537I Page 49 of 54

TROUBLESHOOTING GE ECM

1 2 3 4 5 6 7 8

1615141312119

3 51 2 4

MIS-2839

™

MOTORS CONT’D.

MODE of

OPERATION

Thermostat

24 VAC Inuput

Signals

Pin #1 24 VAC "C" (Common) Signal, Always Energized Pin #2 X X Pin #3 24 VAC "C" (Common) Signal, Always Energized Pin #4 Pin #5 Cool Tap Select Tables, Varied Half-Wave Signals Based Upon Settings (Tonnage) Pin #6 X X X X X Pin #7 Pin #8 DC Volts "-" Output in Direct Correlation to CFM

Pin #9 X X Pin #10 Future Use; Not Currently Programmed for Function Pin #11 Heat Tap Select Tables, Varied Half-Wave Signals Based Upon Tonnage Pin #12 24 VAC Hot "R" Signal, Always Energized Pin #13 X Pin #14 X X Pin #15 X X X X X X X Pin #16 DC Volts "+" Output in Direct Correlation to CFM

Continuous

OFF

DelayTapProles,VariedHalf-WaveSignalsBasedUponSettings

AdjustmentTapProles,VariedHalf-WaveSignalsBasedUponSettings

Blower

— "G" "G", "Y1", "O" "G", "Y1", "Y2", "O" "G", "Y1" "G", "Y1", "Y2" "G", "Y1", "Y2", "W1" "G", "E", "W1", "W2"

Part Load

Cooling

Full Load Cooling

Part

Load

Heating

Full Load

Heating

Full Load Heating +

Electric Heat

Stage #1

Emergency Heat

Mode

FIGURE 25

CONTROL CONNECTOR MOTOR HALF

POWER CONNECTOR

MOTOR HALF

POWER CONNECTOR *

PWB HEADER AMP 1-350945-0

PIN Description

1 2

Jumper Pin 1 to Pin 2 for 120VAC Line Input Only **

3 Chassis Ground 4 AC Line 5 AC Line

Suggested mating connector Housing — AMP 350809-1 Contact — AMP 350537-1

** WARNING — Applying 240VAC line input with PIN 1 to PIN 2 jumper in place will permanently damage unit!

Manual 2100-537I Page 50 of 54

GROUND SOURCE HEAT PUMP

PERFORMANCE REPORT

This performance check report should be filled out by installer and retained with unit.

GROUND SOURCE HEAT PUMP

PERFORMANCE REPORT

Thisperformancecheckreportshouldbelledoutbyinstallerandretainedwithunit.

DATE

TAKEN BY:

1. UNIT: Mfgr Model No. S/N

2. Person Reporting

3. Company Reporting

4. Installed By Date Installed

5. User’s (Owner’s) Name

6. Unit Location

WATER SYSTEM INFORMATION

THERMOSTAT: Mfgr Model No. P/N

Address

7. Open Loop System (Water Well) Closed Loop System

A. If Open Loop where is water discharged?

8. The following questions are for

A. Closed loop system designed by

B. Type of antifreeze used % Solution

C. System type: Series Parallel

D. Pipe material Nominal Size

E. Pipe Installed:

1. Horizontal Total length of pipe ft

No. pipes in trench Depth bottom pipe ft

2. Vertical Total length of bore hole ft

Closed Loop systems only

Manual 2100-537I Page 51 of 54

THE FOLLOWING INFORMATION IS NEEDED

TO CHECK PERFORMANCE OF UNIT.

THE FOLLOWING INFORMATION IS NEEDED

TO CHECK PERFORMANCE OF UNIT.

FLUID SIDE DATA Cooling ** Heating

9. Entering fluid temperature F

10. Leaving fluid temperature F

11. Entering fluid pressure PSIG

12. Leaving fluid pressure PSIG

13. Pressure drop through coil PSIG

14. Gallons per minute through the water coil GPM

15. Liquid or discharge line pressure PSIG

16. Suction line pressure PSIG

17. Voltage at compressor (unit running) V

18. Amperage draw at line side of contactor A

19. Amperage at compressor common terminal A

20. * Suction line temperature 6” from compressor F

21. * Superheat at compressor F

22. * Liquid line temperature at metering device F

23. * Coil subcooling F

INDOOR SIDE DATA Cooling ** Heating

24. Dry bulb temperature at air entering indoor coil F

25. Wet bulb temperature of air entering indoor coil F

26. Dry bulb temperature of air leaving indoor coil F

27. Wet bulb temperature of air leaving indoor coil F

28. * Supply air static pressure (packaged unit) WC

29. * Return air static pressure (packaged unit) WC

30. Other information about installation

** When performing a heating test insure that 2nd stage heat is not activated * Items that are optional

Manual 2100-537I Page 52 of 54

TO 208V TRANSFORMER

FOR 208V OPERATION, MOVE THIS RED WIRE

TAP

Blower

Indoor

Motor

GREEN

OFF

POWER PLUG

RED

431 2

1 2

RED/WHITE

16-PIN BLOWER

POWER PLUG

240V

OFF

4-PIN UNIT

CONTROL PLUG

5-PIN MOTOR

BREAKER

RED/WHITE

YELLOW/RED

ORANGE

PURPLE

RED/YELLOW

RED/WHITE

RED

PURPLE/WHITE

BLUE

16 15 1314 12 1011 9

28 37

208/230-60-1

456

YELLOW/BLACK

BLACK/WHITE

BROWN

BLACK/WHITE

GRAY

BLUE/BLACK

YELLOW

OFF

CIRCUIT

CONTROL PLUG

FIELD CONNECTIONS TO THERMOSTAT

SWITCH #

BLACK

COM

OFF

TRANSFORMER

16-PIN BLOWER

AND CONDENSING SECTION

DIP

208V

MODEL

GTC36S1GTC48S1GTC60S1

ECM

CONTROL

OFF

OFFON

ADJUSTMENT TAPS

NONE "+10%" "-10%" NONE

OFF ON OFF ON OFF OFF ON ON

BLACK

BLACK/WHITE

4117-100 B

NOTE: SWITCH #4 MUST BE TURNED ON WHEN BLOWER IS CONVERTED TO COUNTERFLOW OR HORIZONTAL RIGHT DISCHARGE

Manual 2100-537I Page 53 of 54

USE COPPER CONDUCTORS

ONLY SUITABLE FOR AT LEAST

75° C.

WARNING

*DISCONNECT POWER BEFORE

DANGER

*ELECTRICAL SHOCK HAZARD

SERVICING.

Wire Identification numbers

for Bard use only.

L.P.S = Orange fault light illuminated when fault indicated.

H.P.S = Green fault light illuminated when fault indicated.

F.S. = Red fault light illumninated when fault indicated.

1 3

4 6

7 9

A B

21 3

PUSH

High Speed

Compressor

Solenoid

THERMISTOR

OUT

POWER

PUMP OUTPUT

LINE VOLTAGE

OVERTEMP

LIMIT

WATER SENSORS

T ' STAT

PUSH

T1L2T2

34 2 1

FOR ANTIFREEZE LOOP APPLICATIONS, CHANGE

LOW PRESSURE SWITCH TO YELLOW LEADS

ON LPC TERMINALS OF GEOTHERMAL LOGIC

CONTROL BOARD

HP1

C2R1R2

HP2

LP1

LP2OFS2

CO2

CCG

STATUS

O/V

TEST

WSD

GEOTHERMAL

LOGIC CONTROL

41 2 3

L I

PUMP

LINE

VOLTAGE

OUTPUT

PUMP

OUTPUT

LINE

VOLTAGE

T1L1

Compressor

L2T2

Compressor

Contactor

Compressor

Contactor

Capacitor

9 6 4 7

1 32

LP1

LP2

FS2

CCG

COG

GEOTHERMAL

LOGIC

CONTROL

HP1

HP2

COG

DESUPERHEATER

LOGIC

CONTROL

OVER-TEMP

OUT

LIMIT

Factory Optional

Low Voltage

High Voltage

Field

4117-101 C

PINK

BLUE/WHITE

BLUE

BLUE/WHITE

GRAY

GREEN

YELLOW

YELLOW/RED

YELLOW

YELLOW/RED

GREEN

BROWN/WHITE

COMPRESSOR

STAGING SOLENOID

REVERSING VALVE SOLENOID

24 VAC FROM AIR HANDLING UNIT

COND. = Yellow fault light illuminated when fault indicated.

RED/WHITE

RED

RED/WHITE

RED

SWITCH

LOW

SWITCH

CONTACTOR

RED

PRESSURE

RED

HIGH

COMPRESSOR

RED

PUMP MOTOR

WATER

CONNECTED

FIELD

VALVE

REVERSING

DESUPERHEATER

LIMIT

LUG

GROUND

BLACK

208/230-60-1

TEMPERATURE

TERMINAL STRIP

LOW VOLTAGE

LINE POWER

LABEL

CONTROL

DESUPERHEATER

CAPACITOR

SCREW TO TAB

FLOW CENTER

BREAKER

BLACK/WHITE

BLACK

SWITCH (WATER)

LOW PRESSURE

SWITCH (ANTI-FREEZE)

LOW PRESSURE

SWITCH

HIGH PRESSURE

RELAY

WHITE

BLACK

CIRCUIT

CONTACTOR

COMPRESSOR

THRU GEOTHERMAL LOGIC CONTROL

BLACK/WHITE

BLACK/

BLACK

TEMP. SENSORS

DESUPERHEATER

WHITE

CONNECTED FOR DIRECT CONTROL

WHITE

BLACK

BLACK/

POWER PLUG

4-PIN BLOWER

230V WATER CIRCULATING PUMP(S)

OPTIONAL

BLACK

BLACK/WHITE

BLACK

RED35RED35BLACK38BLACK

BLACK/WHITE

3-PIN PLUG

Status = Green Status LED will blink in normal operation.

LOGIC CONTROL

3-AMP

DESUPERHEATER

LOGIC CONTROL

DESUPERHEATER

CIRCUIT BREAKER

TERMINAL BLOCK

THERMISTOR

FLOW CENTER RELAY

POWER PLUG

LIMIT

208/230-60-1 POWER SOURCE

3-AMP

PUMP MOTOR

4-PIN BLOWER

CIRCUIT BREAKER

DESUPERHEATER

3-PIN PLUG

FLOW CENTER RELAY

FLOW CENTER

THERMISTOR

Manual 2100-537I Page 54 of 54

BMC GTC60S2-ADNX, GTC60S2-ADCX, GTC36S2-ADNX, GTADP-3642-B, GTADP-3642-C User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual