Carrier GC Series Installation Instructions Manual
GC Series
Geothermal Heat Pump
Sizes 024, 036, 048, 060, 072
Installation Instructions
NOTE: Read the entire instruction manual before starting the installation.
TABLE OF CONTENTS
PAGE N O .
SAFETY CONSIDERATIONS 2.....................
INTRODUCTION 2...............................
APPLICATION CONSIDERATIONS 3...............
Geothermal Systems 3...........................
Well Water Systems 4............................
INSTALLATION RECOMMENDATIONS 6...........
MOUNTING VERTICAL UNITS 6...................
MOUNTING HORIZONTAL UNITS 6................
CONDENSATE DRAIN 7...........................
DUCT SYSTEM 7.................................
Air Ducts 7....................................
PIPING 7........................................
PIPING & PLUMBING INSTALLATION 8............
Loop Pump Connections 8........................
Water Solenoid Valves 8.........................
Flow Regulator Valve 8..........................
Typical Open Loop Piping 9......................
Utility Curtailment 12...........................
Energy Tracking 12.............................
FACTORY INSTALLED OPTIONS 12................
Heat Recovery Package (HRP) 12..................
ELECTRICAL 14.................................
Electrical Connections 14.........................
Low--Voltage Circuit Fusing and Reference 14........
Ground Connections 14..........................
ELECTRONIC THERMOSTAT INSTALLATION 15...
Communicating 15.............................
Non--Communicating (Emergency Mode Only) 15.....
FIELD INSTALLED COMPONENTS 16..............
Electric Heaters 16..............................
Outdoor Air Temperature Sensor 16................
Outdoor Air Thermistor 17.......................
Electronic Air Cleaner Connections 17..............
Humidifier Connections 17.......................
System Shutdown Accessories 17..................
Generator 17..................................
Ventilation Accessory 17.........................
Compressor Start Accessories 17...................
TIMER SPEEDUP (TEST MODE) 18.................
PAGE N O .
PRE START--UP CHECKLIST 18...................
USER INTERFACE QUICK SET--UP 18..............
SYSTEM INITIAL POWER UP AND CHECKOUT 18..
SYSTEM VERIFICATION 19.......................
MAIN CONTROL BOARDS 19......................
UPM Board 19.................................
UPM Sequence of Operation 22....................
ECM Board 23.................................
ECM Sequence of Operation 23....................
OPERATING TEMP. AND PRESSURES TABLES 25...
AUXILIARY HEAT LOCKOUT 24..................
BLOWER AIRFLOW DELIVERY CHART 30.........
WATER SIDE PRESSURE DROP TABLE 30..........
BLOWER PERFORMANCE DATA TABLE 31........
INITIAL STAR--UP OF HRP SYSTEM 32.............
SYSTEM FUNCTION & SEQ. OF OPERATION 33.....
Communications and Status Function Lights 33.......
Time Delays 33................................
Compressor Operation 33........................
Troubleshooting units for proper switching between
low and high stages 33.........................
Unloader Test Procedure 33.....................
Two Stage Compressor 33......................
Compressor Internal Pressure Relief (IPR) 33........
Compressor Control Contactor 33.................
Troubleshoot Compressor 33....................
TROUBLESHOOTING 34..........................
UPM Fault Code Table 34........................
ECM BOARD TROUBLESHOOTING 36...........
LED Description & Fault Code Table 35...........
ECM Blower Start--up & Troubleshooting 36........
Emergency Heating & Cooling Modes 36...........
ECM Board Start--Up &
System Comm. Troubleshooting 36...............
ECM Board Status (Fault) Codes 36...............
ECM MOTOR TROUBLESHOOTING 36...........
SYSTEMS COMMUNICATION FAILURE 39.......
MODEL PLUG 39.............................
SERVICE TOOL 39............................
10K Temperature Sensor Resistance Table 40.........
CONFIGURATIONS 41............................
MAINTENANCE 45...............................
SAFETY CONSIDERATIONS
Improper installation, adjustment, alteration, service, maintenance,
or use can cause explosion, fire, electrical shock, or other
conditions which may cause death, personal injury, or property
damage. Consult a qualified installer, service agency, or your
distributor or branch for information or assistance. The qualified
installer or agency must use factory --authorized kits or accessories
when modifying this product. Refer to the individual instructions
packaged with the kits or accessories when installing.
Follow all safety codes. Wear safety glasses, protective clothing,
and work gloves. Use quenching cloth for brazing operations.
Have fire extinguisher available. Read these instructions
thoroughly and follow all warnings or cautions included in
literature and attached to the unit. Consult local building codes and
current editions of the National Electrical Code ( NEC ) NFPA 70.
In Canada, refer to current editions of the Canadian electrical code
CSA 22.1.
Recognize safety information. This is the safety--alert symbol
When you see this symbol on the unit and in instructions or
manuals, be alert to the potential for personal injury. Understand
these signal words; DANGER, WARNING, and CAUTION. These
words are used with the safety--alert symbol. DANGER identifies
the most serious hazards which will result in severe personal injury
or death. WARNING signifies hazards which could result in
personal injury or death. CAUTION is used to identify unsafe
practices which would result in minor personal injury or product
and property damage. NOTE is used to highlight suggestions
which will result in enhanced installation, reliability, or operation.
!
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Before installing, modifying, or servicing system, main
electrical disconnect switch must be in the OFF position.
There may be more than 1 disconnect switch. Lock out and
tag switch with a suitable warning label.
WARNING
!
WARNING
!
CAUTION
CUT HAZARD
Failure to follow this caution may result in personal injury.
Sheet metal parts may have sharp edges or burrs. Use care and
wear appropriate protective clothing and gloves when
handling parts.
!
UNIT DAMAGE AND/OR OPERATION HAZARD
Failure to follow this caution may result in equipment
damage and/or improper equipment operation.
It is extremely important to take the proper precautions to
insure that the heat pump unit is installed in the proper
!
!
location and that measures have been taken to prevent
rupturing the water coil due to freezing conditions.
Frozen water coils are not covered under the limited
product warranty.
CAUTION
INTRODUCTION
GC units are designed to be installed with a communicating User
Interface. The unit will provide airflow at a rate commanded by the
User Interface. The nominal airflow/ton rate is 350 CFM/ton. The
User Interface will modify the commanded airflow under certain
operating modes. Refer to the User Interface literature for further
system control details. This unit will not respond to commands
from a common thermostat except under certain emergency
situations explained in this document. The instructions contained
herein provide guidance to successfully install the blower.
These units are designed specifically for Puronr (R--410A)
refrigerant and must only be used with Puronr refrigerant.
These units are designed to meet low air leak requirements
currently in effect. Because of this, units need special attention in
the condensate pan and drain connection area and when brazing
tubing.
Factory--authorized, field--installed electric heater packages are
available in 5 through 20 kW. See Product Data for available
accessory kits.
UNIT OPERATION AND SAFETY HAZARD
Failure to follow this warning could result in personal injury
or equipment damage.
PuronR refrigerant systems operate at higher pressures than
standard R-- 22 systems. Do not use R -- 22 service equipment
or components on PuronR refrigerant equipment.
!
WARNING
EXPLOSION HAZARD
Failure to follow this warning could
result in death, serious personal injury,
and/or property damage.
Never use air or gases containing
oxygen for leak testing or operating
refrigerant compressors. Pressurized
mixtures of air or gases containing
oxygen can lead to an explosion.
1
2
3
A14032
Fig. 1 -- Standard Package
1. GC Series Water-- To Air Heat Pump
2. Installation and Owner’s Manual
3. Hanging Bracket Kit (HZ unit only)
2
APPLICATION CONSIDERATIONS
Geothermal Systems
Closed loop and pond applications require specialized design
knowledge. No attempt at these installations should be made unless
the dealer has received specialized training. It is recommend that
design and installation of the ground loop be per International
Ground Source Heat Pump Assoc. (IGSHPA) standards.
Anti-- freeze solutions are utilized when low evaporating conditions
are expected to occur. Refer to the Flow Center installation
manuals for more specific instructions.
(1) Line Voltage Disconnect (unit) (8) Ground Loop Connection Kit
(2) Flex Duct Connection (9) Ground Loop Pumping Package
(3) Low Voltage Control Connection (10) Polyethylene with Insulation
(4) Line Voltage Connection (11) Line Voltage Disconnect (electric heater)
(5) P/T Ports
(6) Vibration Pad
(7) Condensate Drain Connection
Fig. 2 -- Example Geothermal System Setup
Diagram shows typical
installation and is for
illustration purposes
only. Ensure access to
Heat Pump is not
restricted.
A14132
3
Well Water Systems
IMPORTANT: Table 1 must be consulted for water quality
requirements when using open loop systems. A water sample must
be obtained and tested, with the results compared to the table.
Scaling potential should be assessed using the pH/Calcium
hardness method. If the pH is <7.5 and the calcium hardness is
l<100 ppm, the potential for scaling is low. For numbers out of the
range listed, a monitoring plan must be implemented due to
probable scaling.
Other potential issues such as iron fouling, corrosion, erosion and
clogging must be considered. Careful attention to water conditions
must be exercised when considering a well water application.
Failure to perform water testing and/or applying a geothermal heat
pump to a water supply that does not fall within the accepted
quality parameters will be considered a mis--application of the unit
and resulting heat exchanger failures will not be covered under
warranty. Where a geothermal system will be used with adverse
water conditions, a suitable plate--frame heat exchanger MUST be
used to isolate the well water from the geothermal unit.
Proper testing is required to assure the well water quality is suitable
for use with water source equipment.
In conditions anticipating moderate scale formation or in brackish
water, a cupronickel heat exchanger is recommended. Copper is
adequate for ground water that is not high in mineral content.
In well water applications, water pressure must always be
maintained in the heat exchanger. This can be accomplished with a
control valve installed in the discharge line.
When using a single water well to supply both domestic water and
the heat pump, care must be taken to insure that the well can
provide sufficient flow for both.
In well water applications, a slow closing solenoid valve must be
used to prevent water hammer (hammering or stuttering sound in
the pipeline). Water Solenoid valves should be connected using kit
#4129. Water solenoid must be installed in the discharge/leaving
water line. Make sure that the VA draw of the valve does not
exceed the contact rating of the thermostat. A flow regulator valve
should be installed down stream from the water solenoid valve.
12
!
UNIT OPERATION HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
Discharge air configuration change is not possible on Heat
Pumps equipped with Electric Heat Option.
CAUTION
1
13
2
11
5
9
(1) Flex Duct Connection (8) Hose Kits (optional)
(2) Low Voltage Control Connection (9) Pressure Tank (optional)
(3) Vibration Pad (10) P/T Ports (optional)
(4) Ball Valves (11) Line Voltage Connection
(5) Solenoid Valve Slow Closing (12) Electric Heater Line Voltage Disconnect
(6) Condensate Drain Connection (13) Unit Line Voltage Disconnect
(7) Drain Valves (14) Flow Regulator
6
14
3
7
8
4
Fig. 3 -- Example Well Water System Setup
4
10
Typical Installation shown for
illustration purposes only.
A14130
Table 1 – Water Quality Requirements for Open--Loop Geothermal Heat Pump System
POTENTIAL PROBLEM WATER CHARACTERISTIC
COPPER CUPRO---NICKEL
pH (Acidity / Alkalinity) 7 --- 9 7 --- 9
SCALING
Hardness (CaCO3, MgCO3) < 350 ppm < 350 ppm
Ryznar Stability Index 6.0 --- 7.5 6.0 --- 7.5
Langelier Saturation Index --- 0 . 5 --- + 0 . 5 --- 0 . 5 --- + 0 . 5
CORROSION
Hydrogen Sulfide (H2S) < 0.5 ppm* 10---50 ppm
Sulfates < 125 ppm < 125 ppm
Chlorine < 0.5 ppm < 0.5 ppm
Chlorides < 20 ppm < 150 ppm
Carbon Dioxide < 50 ppm < 50 ppm
Ammonia < 2 ppm < 2 ppm
Ammonia Chloride < 0.5 ppm < 0.5 ppm
Ammonia Nitrate < 0.5 ppm < 0.5 ppm
Ammonia Hydroxide < 0.5 ppm < 0.5 ppm
Ammonia Sulfate < 0.5 ppm < 0.5 ppm
Dissolved Solids < 1,000 ppm < 1,500 ppm
IRON FOULING
Iron (Fe2+ Iron Bacteria Potential) < 0.2 ppm < 0.2 ppm
Iron Oxide < 1 ppm < 1 ppm
EROSION
Suspended Solids < 10 ppm, < 600 μmsize** < 10 ppm, < 600 μmsize**
Maximum Water Velocity 6ft./sec. 6ft./sec.
* No ”rotten egg” smell present at < 0.5 ppm H2S.
** Equivalent to 30 mesh strainer
NOTES:
S Closed recirculating system is identified by a closed pressurized piping system.
S Recirculating open wells should observe the open recirculating design considerations.
S NR - application not recommended
S "—" No design Maximum
S Following the above recommendation, along with adequate water flow rates, will greatly decrease the rate of fouling/scaling of the coaxial heat
exchanger.
ACCEPTABLE VALUE
5
INSTALLATION RECOMMENDATIONS
The Water--to-- Air Heat Pumps are designed to operate with
entering fluid temperature between 20_Fto90_F in the heating
mode and between 30_F to 120_F in the cooling mode.
NOTE:50_ minimum Entering Water Temperature (EWT) is
recommended for well water applications with sufficient water
flow to prevent freezing. Antifreeze solution is required for all
closed loop applications or EWT less than 45_. Cooling
Tower/Boiler and Geothermal applications should have sufficient
antifreeze solution to protect against extreme conditions and
equipment failure. Frozen water coils are not covered under
warranty. Other equivalent methods of temperature control are
acceptable.
Check Equipment and Job Site
Moving and Storage
If the equipment is not needed for immediate installation upon its
arrival at the job site, it should be left in its shipping carton and
stored in a clean, dry area. Units must only be stored or moved in
the normal upright position as indicated by the “UP” arrows on
each carton at all times.
!
CAUTION
EQUIPMENT DAMAGE HAZARD
Failure to follow this caution may result in equipment damage.
If unit stacking is required for storage, stack units as follows:
Do not stack units larger than 6 tons!
Vertical units: less than 6 tons, no more than two high.
Horizontals units: less than 6 tons, no more than three high.
Inspect Equipment
Be certain to inspect all cartons or crates on each unit as received at
the job site before signing the freight bill. Verify that all items have
been received and that there are no visible damages; note any
shortages or damages on all copies of the freight bill. In the event
of damage or shortage, remember that the purchaser is responsible
for filing the necessary claims with the carrier. Concealed damages
not discovered until after removing the units from the packaging
must be reported to the carrier within 24 hours of receipt.
Location / Clearance
Locate the unit in an indoor area that allows easy removal of the
filter and access panels, and has enough room for service personnel
to perform maintenance or repair. For maintenance and
serviceability, a clearance of 2ft (.61 m) minimum around the unit
is recommended.
Provide sufficient room to make fluid, electrical, and duct
connection(s). If the unit is located in a confined space such as a
closet, provisions must be made for return air to freely enter the
face of unit’s air coil. On horizontal units, allow adequate room
below the unit for a condensate drain trap and do not locate the unit
above supply piping.
!
UNIT OPERATION HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
These units are not approved for outdoor installation;
therefore, they must be installed inside the structure being
conditioned. Do not locate in areas that are subject to
freezing.
CAUTION
MOUNTING VERTICAL UNITS
Vertical units should be mounted level on a vibration absorbing
pad slightly larger than the base to minimize vibration transmission
to the building structure. It is not necessary to anchor the unit to the
floor. See Fig. 4.
NOTE: The condensate drain pan is internally sloped. There is no
internal P--trap. An external trap is required.
VIBRATION PAD
FULL SIZE
A14117
Fig. 4 -- Vibration Absorbing Pad
MOUNTING HORIZONTAL UNITS
While horizontal units may be installed on any level surface strong
enough to hold their weight, they are typically suspended above a
ceiling by threaded rods. The manufacturer recommends these be
attached to the unit corners by hanger bracket kits. The rods must
be securely anchored to the ceiling. Refer to the hanging bracket
assembly and installation instructions for details.
IMPORTANT: Horizontal units installed above the ceiling
must conform to all local codes. An auxiliary drain pan, if
required by code, should be at least four inches larger than the
bottom of the heat pump.
Plumbing connected to the heat pump must not come in direct
contact with joists, trusses, walls, etc. Some applications require an
attic floor installation of the horizontal unit. In this case, the unit
should be set in a full size secondary drain pan on top of a
vibration absorbing mesh.
The Secondary drain pan prevents possible condensate overflow or
water leakage damage to the ceiling.
The secondary drain pan is usually placed on a plywood base
isolated from the ceiling joists by additional layers of vibration
absorbing mesh.
In both cases, a 3/4”drain connected to this secondary pan should
be run to an eave at a location that will be noticeable. If the unit is
located in a crawl space, the bottom of the unit must be at least 4”
above grade to prevent flooding of the electrical parts due to heavy
rains.
NOTE: HZ unit condensate drain pan is NOT internally sloped.
IMPORTANT: Horizontal (HZ) units must be installed pitched
toward the Condensate Drain Connection 1/8” per foot.
6
CONDENSATE DRAIN
IMPORTANT: This connection must be in conformance with
local plumbing codes. A trap must be installed in the
condensate line to insure free condensate flow. Units are NOT
internally trapped or sloped for condensate drain.
IMPORTANT: Condensate piping must be pitched toward the
drain 1/8” per foot.
NOTE: The condensate drain outlet on the cabinet is on a low
point of the cabinet so additional height may need to be considered
on unit base pad to allow for proper drain trap and slope.
Fig. 5 -- Condensate Drain
A vertical air vent is sometimes required to avoid air pockets. The
length of the trap depends on the amount of positive or negative
pressure on the drain pan. A second trap must not be included.
Unit condensate drain connection may spin freely. Use backup
wrench to hold fitting in place while connecting external piping.
A14118
DUCT SYSTEM
A supply air outlet collar and return air duct flange are provided on
all units to facilitate duct connections.
NOTE: Supply air duct and return air duct flanges are shipped
unfolded with unit.
Fold the duct flange outwards along the perforated line. Refer to
unit Dimensional Drawings for physical dimensions of the collar
and flange.
A flexible connector is recommended for supply and return air duct
connections on metal duct systems. All metal ducting should be
insulated with a minimum of one inch duct insulation to avoid heat
loss or gain and prevent condensate from forming during the
cooling operation.
Application of the unit to uninsulated duct work is not
recommended as the unit’s performance will be adversely affected.
!
UNIT OPERATION HAZARD
Failure to follow this caution may result in improper
equipment operation.
Do not connect discharge ducts directly to the blower
outlet.
The factory provided air filter must be removed when using a filter
back return air grill. The factory filter should be left in place on a
free return or standard ducted system.
If the unit will be installed in a new installation which includes new
duct work, the installation should be designed using current Air
Conditioning Contractors of America (ACCA), North American
Technician Excellence (NATE), or other applicable standards for
duct sizing.
If the unit is to be connected to existing duct work, a check should
be made to assure that the duct system has the capacity to handle
the air required for the unit application.
CAUTION
If the duct system is too small, larger duct work should be installed.
Check for existing leaks and repair.
The duct system and all diffusers should be sized to handle the
designed air flow quietly. To maximize sound attenuation of the
unit blower, the supply and return air plenums should be insulated.
There should be no direct straight air path through the return air
grille into the heat pump. The return air inlet to the heat pump must
have at least one 90 degree turn away from the space return air
grille. If air noise or excessive air flow are a problem, the blower
speed can be changed to a lower speed to reduce air flow.
Air Ducts
Connect supply--air duct over outside of 3/4--in. flange provided
on supply--air opening. Secure duct to flange with proper fasteners
for type of duct used, and seal duct--to--unit joint.
Duct connection flanges are provided on unit air discharge
connection.
Use flexible connectors between ductwork and unit to prevent
transmission of vibration. When electric heater is installed, use heat
resistant material for flexible connector between ductwork and unit
at discharge connection. Ductwork passing through unconditioned
space must be insulated and covered with vapor barrier.
Ductwork Acoustical Tr eatment
Metal duct systems that do not have a 90_elbow and 10 ft. of main
duct to first branch takeoff may require internal acoustical
insulation lining. As an alternative, fibrous ductwork may be used
if constructed and installed in accordance with the latest edition of
SMACNA construction standard on fibrous glass ducts. Both
acoustical lining and fibrous ductwork shall comply with National
Fire Protection Association Standards 90A or B as tested by UL
Standard 181 for Class 1 air ducts.
PIPING
Supply and return piping must be as large as the unit connections
on the heat pump (larger on long runs).
!
UNIT OPERATION HAZARD
Failure to follow this caution may result in improper
equipment operation.
Never use flexible hoses of a smaller inside diameter than
that of the fluid connections on the unit.
GC units are supplied with either a copper or optional cupronickel
condenser.
NOTE: Proper testing is recommended to assure the well water
quality is suitable for use with water source equipment. When in
doubt, use cupronickel. See Application Considerations notes on
page 3.
In conditions anticipating moderate scale formation or in brackish
water, a cupronickel heat exchanger is recommended.
Both the supply and discharge water lines will sweat if subjected to
low water temperature. These lines should be insulated to prevent
damage from condensation. All manual flow valves used in the
system must be ball valves. Globe and gate valves must not be
used due to high pressure drop and poor throttling characteristics.
!
EQUIPMENT DAMAGE AND/OR UNIT
OPERATION HAZARD
Failure to follow this caution may result in equipment
damage and/or improper operation.
Never exceed the recommended water flow rates as serious
damage or erosion of the water--to--refrigerant heat
exchanger could occur.
CAUTION
CAUTION
7
Always check carefully for water leaks and repair appropriately.
Units are equipped with female pipe thread fittings. Consult Unit
Dimensional Drawings.
NOTE: Teflon tape sealer should be used when connecting water
piping connections to the units to ensure against leaks and possible
heat exchanger fouling.
NOTE: The unit is shipped with water connection O -- rings. A
10--pack of O --rings (part #4026) can be ordered through
Replacement Components (RC).
IMPORTANT: Do not over--tighten connections.
Flexible hoses should be used between the unit and the rigid
system to avoid possible vibration. Ball valves should be installed
in the supply and return lines for unit isolation. A flow regulator
should be used to set flow rate. Ball valves, flow regulator and
water solenoid valve for open loop / well water systems only.
Water Solenoid Valves
Open loop well water applications require a water solenoid valve.
The purpose of the valve is to allow water to flow through the
GHP only during operation.
For ground water/open loop installations, solenoid valves
MVBR3F and MVBR4F are recommended due to its fast
opening/slow closing timing feature (see Fig. 6). This valve will
open in approximately 5 seconds. Solenoid valves that are slow
opening are not recommended as water in the unit’s coax may
freeze during start--up of a heating call. A frozen coax is not
covered under warranty. MVBR3 and MVBR4F valves are also
slow closing to eliminate potential water hammer.
Information on the MVBR3F and MVBR4F valves is shown
below.
!
CAUTION
EQUIPMENT DAMAGE AND/OR UNIT
OPERATION HAZARD
Failure to follow this caution may result in equipment
damage and/or improper operation.
Do not apply additional controlled devices to the control
circuit power supply without consulting the factory.
Doing so may void equipment warranties.
PIPING AND PLUMBING INSTALLATION
Loop Pump Connections
Flow centers using variable speed loop pumps are recommended
with these units. Variable speed pumps are more efficient and
reduce operating costs, provide full advantages of water flow rate,
temperature and display HE/HR.
When using variable speed flow centers with GC units, a special
wiring kit (part number 4129) is required.
Refer to the Flow Center installation manual for piping and wiring
instructions.
For applications using 2 GHPs and 1 flow center, refer to Table 2.
Table 2 – Requirements for Two Units Sharing One
Flow Center
Ty p e
Single Speed
Flow Centers
Variable Speed
Flow Center
(flow and temperature version
required)
* 3977 wiring kit (1) is shipped with flow center (use for 1st unit). An
additional kit is needed for 2nd heat pump.
Flow Center
Pump Sharing
Relay
Required
ACPSRN (1*) 3977
2 Double Pole /
Double Throw
(DPDT) Relays
(field supplied)
Wiring Kit
Required
for GC
Unit
(2) 4129
Mode Operation
Activates pump
when either GHP
calls
If one unit calls,
the controller will
provide 1st stage
flow rate (set at
controller menu).
If both units call,
the controller will
provide 2nd
stage flow rate.
Fig. 6 -- Solenoid Valves
A150629
Table 3 – Motorized Solenoid Valves
Part Numb er Description
MVBR3F Valve, motorized solenoid, forged brass ¾“ FPT, 24V
MVBR3F Valve, motorized solenoid, forged brass 1” FPT, 24V
*Start up note – The first time the water solenoid valve is
operated, it may require 30 to 45 seconds to power open. This
time is to charge an internal capacitor. After the initial “power up”
the valve will open in 5 seconds. If the line voltage power has
been turned off for service of the unit, the system will go through
the same first time power up sequence.
NOTE: Refer to Fig. 10 -- 13 For solenoid valve wiring.
Flow Regulator Valve
A flow regulator valve should be used to set the flow rate through
the heat pump. The lowest entering fluid temperature (EWT)
expected should be used to determine the flow rate per ton. 1.5
GPM per ton is acceptable for 50_F(10_C) EWT or higher. 2
GPM per ton should be used if EWT is below 50_F(10_C). (See
Fig. 7 and Table 4)
A150630
Fig. 7 -- Flow Regulator
Table 4 – Flow Regulators
Part Numb er Flow Regulator Valves
FR2 Valve, flow regu lator, 3/4” FPT x 3/4” FPT, 2 GPM
FR3 Valve, flow regu lator, 3/4” FPT x 3/4” FPT, 3 GPM
FR4 Valve, flow regu lator, 3/4” FPT x 3/4” FPT, 4 GPM
FR5 Valve, flow regu lator, 3/4” FPT x 3/4” FPT, 5 GPM
FR6 Valve, flow regu lator, 3/4” FPT x 3/4” FPT, 6 GPM
FR7 Valve, flow regu lator, 3/4” FPT x 3/4” FPT, 7 GPM
8
Typical Open Loop Piping
Open loop systems require a water solenoid valve to turn on the
water when the heat pump compressor is energized, and to turn off
the water when the compressor is off.
A slow--closing motorized valve (MVBR3F or MVBR4F) is
recommended to help reduce water hammer. A flow regulator
limits water flow to avoid using more water than the heat pump
requires, which wastes water and increases pumping costs. A hose
kit provides vibration isolation, as well as convenient fittings to
install P/T (pressure/temperature) plugs for checking water
Heat Pump
MVBR4F solenoid valve
1” rubber hose*
P/T Plug*
Heat Pump
Elbow*
LW T
1” hose barb
x 1” MPT*
1” MPT x 3/4” MPT
temperature and pressure drop at start--up and during
troubleshooting.
Fig. 8 shows the typical piping arrangement for a single solenoid
valve. For single speed heat pumps and smaller two--stage heat
pumps (3 tons and smaller), one valve is typical. For larger
two--stage heat pumps, there is an opportunity to save a significant
amount of energy (and avoid wasting water) with the use of two
solenoid valves, one for first stage, and both for second stage (Fig.
9).
MVBR Solenoid Valve Flow Regulator
1” ball valve
Pressure Tank
Piping to discharge***
†
EWT
1” hose barb
x 1” MPT*
*
Part of HK4MM hose kit
**
***
Consult local regulations for discharge requirements
†
††
Consider variable speed pump in place of pressure tank and pressure switch
1” ball valve
(optional)
Fig. 8 -- Single Solenoid Valve
Solenoid Valve
Stage One
Flow Regulator
Stage One
Ball Valve
From Heat Pump
Flow Regulator
Stage Two
Solenoid Valve
Stage Two
NOTE: Wiring kit #4129 is recommended for easy 24 volt connection staging solenoids with compressor.
Fig. 9 -- Two Solenoid Valves
Submersible
††
Pump
9
Water Solenoid Valve Wiring Diagrams for Open Loop Systems
T
24 VAC Controls
THERMOSTAT HE AT P U M P
R
G
O
Y2
W
C
Y1
W/YC
Jumper
END
SWIT C H
R
G
O
Y2
W
C
Y1
MVBR3F or MVBR4F
Fig. 10 -- Single Solenoid Valve Wiring
A180273
HERMOSTAT H E AT P UMP
R
G
O
W
C
Y1
MVBR3F or MVBR4F
Y2
MVBR3F or MVBR4F
W/YC
W/YC
Jumper
END
SWIT C H
END
SWIT C H
Fig. 11 -- Two Solenoid Valve Wiring
R
G
O
W
C
Y1
Y2
A180274
Communicating Controls
NOTE: SeeFig13fortwovalvesystems.
UPM Circuit Board
W/YC
MVBR3F or MVBR4F
Fig. 12 -- Two Solenoid Valves
END
SWITCH
A180275
10
IMPORTANT:
Ensure that wire
colors match up
From PL5 ext. harnessFrom PL5 ext. harness
Yellow
Brown
Brown
Gray
harness (brown
to brown, blue
to blue, black to
black.
MVBR3F or MVBR4F
VALVE #1
END
W/YC
SWIT C H
W/YC
MVBR3F or MVBR4F
VALVE #2
Brown
C
at valve #1 & 2
Yellow
at valve #1
To CC and Y2S
Gray
Existing female plug
4129 Extension Harness
NOTE: Y2 (connector ST1) is used for a utility curtailment input,
and is not available for use as an output for the second valve.
However, the wiring harness extension (part # 4129) used for
variable speed flow centers (closed loop applications) provides a
second stage connection as shown above (gray/brown wires). The
wiring kit should be used for systems with two solenoid valves
(yellow wire for stage 1, gray wire for stage 2, brown wire for
commontobothvalves).
Fig. 13 -- Communicating Controls -- Two Solenoid Valve
END
SWIT C H
W/Y
W/Y
UPM Circuit Board
at valve #2
IMPORTANT
A180276
11
Utility Curtailment
Utility curtailment is a voluntary energy saving program offered
through utility companies in some locations. Utility company will
provide the equipment that allows them to cut back demand on
equipment during peak demand times. A qualified HVAC
technician should install the device to ensure system compatibility.
Refer to Fig. 14 for typical wiring to the UPM.
To set up curtailment with user interface, enter the service screens,
Setup, then select Utility Curtailment.
There will be 3 options to enable or disable the curtailment:
1. Disabled: the utility curtailment, if wired into the UPM, will
be ignored.
2. *Low Stage: when utility curtailment relay opens, the unit
will only operate at low--stage.
3. *Off: when utility curtailment relay opens, the unit will
shut down until the utility relay closes.
* There will be a brief delay to cause the unit to stage or shut
down (approximately 0.40 to 1.20 minutes can be expected).
FACTORY INSTALLED OPTIONS
A number of factory installed options are available on the GC
Series of Heat Pumps. The following details the purpose, function
and components of each option.
Heat Recovery Package (HRP)
(optional)
The heat recovery package is a factory installed option on GC
series heat pumps. The HRP can be used to heat potable water
during unit operation using waste heat from the compressor
discharge gas. In some cases the HRP can provide most or all of
the hot water requirements for a typical home.
The HRP consists of three major components:
1. Double wall, vented refrigerant to water heat exchanger
2. Circulating pump
3. Control circuit
The heat exchanger is rated for use with potable water and is
acceptable for use as a domestic water heating device in most
building codes.
The pump circulates water between the domestic hot water tank
and HRP heat exchanger in the Heat Pump. The control circuit
ensures that the HRP only operates when there is available heat
from the compressor and when the water is within a safe
temperature range of below 140_F. When the heat pump
compressor operates, the HRP will monitor the temperature of the
discharge gas from the compressor. Once discharge gas is hot
enough to provide useful heat to the domestic water tank, the
circulating pump will be enabled, drawing water from the tank,
through the HRP heat exchanger and then depositing the heated
water back into the tank.
If the water temperature reaches 140_F, the circulating pump is
disabled to prevent over heating of the domestic water. The HRP is
provided with an on/off switch in case the end user desires that the
HRP be inactivated (typically during the winter months when
space heating is most important).
UTILITY RELAY
UTILITY SIGNAL
OPEN RELAY
* SUPPLIED BY UTILITY PROVIDER
Fig. 14 -- Utility Curtailment
*
A150166
Energy Tracking
The Energy Tracking feature is available when unit is used with the
InfinityR Touch Control and EvolutionR Connext Control.
Energy Tracking has the ability to monitor and estimate the energy
consumption of the unit and displays the data on the wall control.
Software version 14.0 or later is required for energy tracking.
The Energy Tracking Kit (KHAGT0101KIT) includes a sensor and
wiring harness. The kit must be installed on the geothermal unit
for energy tracking functionality. See kit for installation
instructions.
NOTE: Version 14.0 or later software is required for energy
tracking.
!
UNIT DAMAGE AND/OR OPERATION HAZARD
Failure to follow this caution may result in unit damage
and/or improper equipment operation.
If heat recovery unit is installed in an area where freezing
may occur, the unit must be drained during winter months
to prevent heat exchanger damage. Heat exchanger
ruptures that occur due to freezing will void the heat
recovery package warranty along with the heat pump
warranty.
NOTE: If factory installed HRP is not utilized in the field, it is
recommended to disconnect the HRP switch.
CAUTION
12
Water Tank Preparation
1. Turn off electrical or fuel supply to the water heater.
2. Attach garden hose to water tank drain connection and run
other end of hose out doors or to an open drain.
3. Close cold water inlet valve to water heater tank.
4. Drain tank by opening drain valve on the bottom of the
tank, then open pressure relief valve or hot water faucet.
5. Once drained the tank should be flushed with cold water
until the water leaving the drain hose is clear and free of
sediment.
6. Close all valves and remove the drain hose.
7. Install HR water piping.
HRP Water Piping
All hot water piping MUST be a minimum of 5/8” O.D. copper
tube to a maximum distance of 15 feet. For distances beyond 15
feet, but not exceeding 60 feet, use 1/2” copper tube. Separately
insulate all exposed surface of both connecting water lines with
3/8” wall closed cell insulation. Install isolation valves on supply
and return to the heat recovery. (See Fig. 15)
Water Tank Refill
1. Open the cold water supply to the tank.
2. Open a hot water faucet to vent air from the system until
water flows from the faucet, then close.
3. Depress the hot water tank pressure relief valve handle to
ensure there is no air remaining in the tank.
4. Carefully inspect all plumbing for water leaks. Correct as
required.
5. Using the air bleed valve, purge all air from water piping,
allowing all air to bleed out until water appears at valve.
6. Before restoring the power or fuel supply to the water
heater, adjust the temperature setting on the tank thermostat(s) to ensure maximum utilization of heat available from
the refrigeration system and to conserve the most energy.
On tanks with thermostats on both upper and lower elements, the lower element should be turned down to 100_F,
while the upper element should be adjusted to 120_F.
Depending upon the specific needs of the customer, you
may need to adjust the upper element differently.
On tanks with a single thermostat, lower the thermostat setting to 120_F or the “LOW” position. After thermostat adjustments are completed, replace access cover and restore
electrical or fuel supply to water heater.
IMPORTANT: Copper should be used for piping from HRP to
domestic water tank(s). Use 5/8” (16mm) O.D. copper or
larger. Refer to local codes for hot water piping. Insulate the
water lines between the GHP and the water heater with a
minimum of 3/8” (10mm) closed cell insulation.
Hot Water Out
Domestic Hot Water Supply
Domestic Cold Water Supply
Water Heater
(w/active elements)
Two Tank System (preferred)
Domestic Cold Water Supply
Hot Water Out
Cold Water In
One Tank System
Air Bleed Valve
Shut-off Ball Valve
HP
Air Bleed Valve
Shut-off Ball Valve
Water Heater
(w/active elements)
Package unit shown. GC package unit arrangement similar wit h different water locations on unit.
Water Heater
(no active elements
pre-heat tank)
Fig. 15 -- HRP Water Piping
13
HP
A150174
ELECTRICAL
Electrical Connections
!
WARNING
ELECTRICAL OPERATION HAZARD
Failure to follow this warning could result in personal injury
or death.
Before installing or servicing unit, always turn off all power
to unit. There may be more than 1 disconnect switch. Turn
off accessory heater power if applicable.
!
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury
or death.
If a disconnect switch is to be mounted on the unit, select a
location where drill or fastener will not contact electrical or
refrigerant components.
!
WARNING
Low--Voltage Circuit Fusing and Reference
The low--voltage circuit is fused by a board--mounted 3--amp.
automotive fuse placed in series with transformer SEC1 and R
circuit. The C circuit of transformer circuit is referenced to chassis
ground through a printed circuit run at SEC2 and metal PC board
mounting eyelets. Check to be sure PC Board is mounted securely
using both factory installed screws.
NOTE: Mis--wiring or shorting any of the low voltage
connections may cause the low voltage fuse to open but will not
damage the User Interface or ECM board. Simply rewire and
replace fuse to correct fault.
Ground Connections
!
WARNING
ELECTRICAL OPERATION HAZARD
Failure to follow this warning could result in personal injury
or death.
The cabinet must have an uninterrupted or unbroken ground
according to NEC, ANSI/NFPA 70 and local codes to
minimize personal injury if an electrical fault should occur.
The ground may consist of electrical wire or metal conduit
when installed in accordance with existing electrical codes.
(See Ground/Conduit Note below.)
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury
or death.
Field wires on the line side of the disconnect remain live,
even when the pull--out is removed. Service and maintenance
to incoming wiring can not be performed until the main
disconnect switch (remote to the unit) is turned off.
NOTE: Before proceeding with electrical connections, make
certain that supply voltage, frequency, and phase are as specified
on unit rating plate. Be sure that electrical service provided by the
utility is sufficient to handle the additional load imposed by this
equipment. See unit wiring label for proper field high-- and low-voltage wiring. Make all electrical connections in accordance with
NEC and any local codes or ordinances that may apply. Use copper
wire only. The unit must have a separate branch electric circuit with
a field--supplied disconnect switch located within sight from and
readily accessible from the unit.
24--V Control System Connections to Bus Com Harness
Connection
Field
Use the field ABCD connector provided with the User Interface.
Connect this plug to the factory wired female ABCD connector on
the bus com harness (see Fig. 17). Use No. 18 AWG color--coded,
insulated (35_C minimum) wires to make low--voltage connections
between User Interface and unit. If User Interface is located more
than 100 ft. from unit (as measured along the low--voltage wires),
use No. 16 AWG color--coded, insulated (35_C minimum) wires or
in accordance with local codes.
Connect low--voltage leads to User Interface . (See Fig. 18.)
NOTE: Where local codes require User Interface wiring be routed
through conduit or raceways, splices can be made inside blower
unit. All wiring must be NEC Class l and must be separated from
incoming power leads.
NOTE: Use UL listed conduit and conduit connector to connect
supply wire(s) to unit and obtain proper grounding. If conduit
connection uses reducing washers, a separate ground wire must be
used. Grounding may also be accomplished by using grounding
lug provided in control box. Use of dual or multiple supply circuits
will require grounding of each circuit to ground lugs provided on
unit and heaters.
Refer to electrical component box layout. See Fig. 16.
!
UNIT OPERATION HAZARD
Failure to follow this caution may result in equipment
damage and/or improper operation.
SField wiring must comply with local and national electrical
codes.
SPower to the unit must be within the operating voltagerange
indicated on the unit nameplate or on the performance data
sheet.
SOperation of unit on improper line voltage or with excessive
phase imbalance will be hazardous to the unit, constitutes
abuse, and may void the warranty.
Properly sized fuses or HACR circuit breakers must be installed for
branch circuit protection. See unit nameplate for maximum fuse or
breaker size.
NOTE: Use copper wire only between disconnect switch and
unit.
The unit is provided with a concentric knock-- out for attaching
common trade sizes of conduit, route power supply wiring through
this opening.
Always connect the ground lead to the grounding lug provided in
the control box and power leads to the line side of compressor
contactor as indicated on the wiring diagrams.
CAUTION
14
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