Carrier GW Series Installation Instructions Manual
GW Series
Water--to--Water Geothermal Heat Pump
Sizes 024, 036, 048, 060, 072, 120
Installation Instructions
NOTE: Read the entire instruction manual before starting the
installation.
TABLE OF CONTENTS
PAGE N O.
SAFETY CONSIDERATIONS 1.....................
INSTALLATION RECOMMENDATIONS 2............
CHECK EQUIPMENT & JOBSITE 2.................
LOCATION / CLEARANCE 2.......................
APPLICATION CONSIDERATIONS 3................
Earth Coupled (Geothermal) Systems 3..............
Well Water Systems 4............................
INSTALLATION 6.................................
MINIMAL SYSTEM VOLUME 6.....................
PIPING 6.........................................
ELECTRICAL 7...................................
SAFETY DEVICES AND UPM CONTROLLER 7.......
SEQUENCE OF OPERATION 9......................
Cooling Mode 9.................................
Heating Mode 9.................................
HEAT RECOVERY PACKAGE 11.....................
INITIAL START--UP 12..............................
SYSTEM CHECKOUT 12............................
UNIT START--UP 12.................................
TROUBLESHOOTING 14............................
Information in these installation instructions pertains only to GW
series units.
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
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.
!
WARNING
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.
!
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.
INSTALLATION RECOMMENDATIONS
The GW Water--to--Water Heat Pump is Underwriters Laboratories
(UL) and (cUL) listed for safety. The water-- to-- water heat pumps
are designed to operate with entering fluid temperature between
25_Fto110_F.
Safety devices are built into each unit to provide the maximum
system protection possible when properly installed and maintained.
IMPORTANT:50_ Min. EWT (entering water temperature) for
well water applications with sufficient water flow to prevent
freezing. Antifreeze solution is required for all closed loop
applications. Earth Coupled (Geothermal) applications should have
sufficient antifreeze solution to protect against extreme conditions
and equipment failure. Frozen water coils are not covered under
warranty.
IMPORTANT: This product should not be used for temporarily
heating or cooling during construction. Doing so may effect the
unit’s warranty.
!
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
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. 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 space. 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
!
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.
2
CAUTION
APPLICATION CONSIDERATIONS
Typical Load Side Applications
There are many load side applications for which the
water--to--water heat pump/ liquid chiller is ideally suited.
Some typical uses are as follows:
Hydronic baseboard heating, hydronic in--slab floor heating, forced
air fan coil heating or cooling, ice and snow melting, heating
potable water, (when allowed by code) heating swimming pool and
spa*, process fluid heating or cooling.
When specifying load side fluid volume it is important to consider
the heat pump output capacities and flow rates. Insufficient load
side fluid volume may cause unstable heat pump operation (short
cycling). Pressure/temperature ports should be used to set flow
rates.
*A water--to-- water series Heat Pump/Liquid Chiller can be utilized
for direct pool/spa heating without a secondary heat exchanger. In
this application cupronickel heat exchangers must be used.
1. POLYETHELENE WITH
INSULATION
2. GROUND LOOP PUMPING PACKAGE (GLP)
3. GROUND LOOP CONNECTION KIT
4. P/T PLUGS
5. LOAD SIDE CONNECTIONS*
6. LOW VOLTAGE CONTROL CONNECTION*
7. VIBRATION PAD
8. LINE VOLTAGE DISCONNECT
Automatic chemical feeders must never be installed upstream of
the unit. An external bypass should be installed to avoid
over--flowing the heat exchanger to prevent coil erosion. The pool
pH levels and chemical balances must be maintained to avoid
possible heat exchanger damage.
Earth Coupled (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.
Anti-- freeze solutions are utilized when entering loop temperatures
drop below 50_F or where piping will be routed through areas
subject to freezing. A flow rate between 2.5 to 3.0 gpm per
nominal ton of cooling is recommended for this application. See
Flow Center Curve for sizing information. Refer to the Flow
Center installation manuals for more specific instructions.
* NOTE: Water and electrical connection locations vary depending
on model. Connect as required per unit labels.
A14173
Fig. 1 -- Earth Coupled Application
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.
Water quantity should be plentiful, between 1.5 and 3.0 gpm per
ton of cooling, and of good quality. To avoid the possibility of
freezing in the heating mode, the well water should be above 50_F.
Water pressure must always be maintained in the heat exchanger by
placing a water control valve on the outlet of the water--to--water
unit. A bladder type expansion tank may be used to maintain
pressure on the system. All solenoid valves should be slow closing
to avoid water hammer.
The discharge water from the water--to--water unit is not
contaminated in any manner and can be disposed of in various
ways depending on the local codes (i.e. discharge well, dry well,
storm sewer, drain field, stream, pond, etc.) Pilot operated or slow
closing valves are recommended to reduce water hammering.
!
CAUTION
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.
* NOTE: Water and electrical connection locations vary
depending on model. Connect as required per unit labels.
1. PRESSURE TANK
2. BALL VALVES
3. SOLENOID VALVE (SLOW CLOSING)
4. HOSE KIT
5. P/T KIT
6. LOAD SIDE CONNECTIONS*
7. LOW VOLTAGE CONTROL CONNECTION*
8. VIBRATION PAD
9. LINE VOLTAGE DISCONNECT
A14172
Fig. 2 -- Well Water Application
4
Table 1 – Water Quality Requirements for Open--Loop Geothermal Heat Pump System
Water Quality Parameter HX Material Closed Recirculating Open Loop and Recirculating Well
Scaling Potential - Primary Measurement
Above the given limits, scaling is likely to occur. Scaling indexes should be calculated using the limits below:
pH/Calcium Hardness
Method
Index Limits for Probable Scaling Situations - (Operation outside these limits is not recommended)
Scaling indexes should be calculated at 150°F for direct use and HWG applications, and at 90°F for indirect HX use.
A monitoring plan should be implemented.
Ryznar Stability Index All --
Langelier Saturation Index All --
Iron Fouling
Iron Fe² (Ferrous)
(Bacterial Iron Potential)
Iron Fouling All --
Corrosion Prevention
pH All
Hydrogen Sulfide (H2S) All --
Ammonia ion as hydroxide,
chloride, nitrate and sulfate
compounds
Maximum Chloride Levels
Erosion and Clogging
Particulate Size and
Erosion
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
All -- pH <7.5 and Ca Hardness <100ppm
6.0 - 7.5
If > 7.5 minimize steel pipe use
-0.5 to +0.5
If <-0.5 minimize steel pipe use.
Based upon 150°F HWG and Direct well,
84°F Indirect Well HX
<0.2 ppm (Ferrous)
All --
If Fe²* (ferrous) >0.2 ppm with pH 6-8, O2<5 ppm check
for iron bacteria
<0.5 ppm of Oxygen
Above this level deposition will occur
Monitor/treat as needed
6-8.5
Minimize steel pipe below 7 and no open tanks with pH <8
6-8.5
At H S>0.2 ppm, avoid use of copper and copper nickel
piping or HXs. Rotten egg smell appears at 0.5 ppm level.
Copper alloy (bronze or brass) cast components are OK
to <0.5 ppm
All -- <0.5 ppm
Maximum Allowable at Maximum Water Temperature
50°F 75°F 100°F
Copper -- <20 ppm NR NR
cupronickel -- <150 ppm NR NR
304 SS -- <400 ppm <250 ppm <150 ppm
316 SS -- <1000 ppm <550 ppm <375 ppm
Titanium -- >1000 ppm >550 ppm >375 ppm
All
<10 ppm of particles and a
maximum velocity of 1.8 m/s.
Filtered for maximum 841 micron [0.84 mm 20 mesh] size
<10 ppm (<1 ppm "sandfree" for re-injection) of particles
and a maximum velocity of 1.8 m/s. Filtered for maximum
841 micron [0.84 mm. 20 mesh] size. Any particulate that
is not removed can potentially clog components
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