Climate Master Flow Controller Installation Manual
C
LIMATE
M
ASTER
¤
Flow Controller
GEOTHERMAL PUMPING MODULE
INSTALLED BY:
Flow Controller
Installation, Operation, &
Maintenance Instructions
12/98
TABLE OF CONTENTS
Flow Controller Description 2
Flow Controller Mounting 2
Piping Installation 3
Electrical Wiring 4
Flushing the Earth Loop 5
Antifreeze Selection 6
Antifreeze Charging 7
Heat Pump Freezestat Setting 8
Pressure Drop Tables 9
Earth Loop Pressurization 9
Flow Controller Start-Up 10
Pump Cartridge Replacement 10
Closed Loop Design 11
Polyethylene Pressure Drop 14
Rubber Hose Pressure Drop 15
Closed Loop Installation 16
Building Entry 18
1
FLOW CONTROLLER DESCRIPTION
10.75"
Unit Side
13.75"
TTaacco
o
TTaacco
o
Loop Side
4.38"
8.75"
Figure 1 - Flow Controller Dimensions
The AFCS1A and 2A are insulated flow controllers
containing all flush, fill, and isolation connections for a
residential and light commercial geothermal closed loop
system that require a flow rate of no more than 20 gpm.
The AFCS1A and 2A are equipped with a large bore 1 1/
4" FPT swivel fittings for both earth loop and heat pump
unit connections. Either 1 (AFCS1A) or 2 (AFCS2A)
Taco 0013 chilled water rated cartridge type circulators
3.75"
15.00"
8.50"
are included with the flow controller. Included in this kit
are:
• 2 Lag bolts for mounting AFC onto stud walls
• 4 Self-drilling sheet metal screws for mounting AFC
onto heat pump
• 2 1" MPT PVC plug for sealing flush ports after
installation
FLOW CONTROLLER MOUNTING
General
The installation of the ClimateMaster Flow Controller
shall be made in accordance with all applicable codes.
Mounting the Flow Controller
The flow controller should be located as close to the unit
as possible to limit the length of the rubber hose kit and
thus its associated pressure drop. In general the flow
controller can be mounted in any orientation with the
exception of when the pump shafts are in a vertical
position as when it is laid flat on the floor or any similar
position. The controller is typically mounted in one of
three locations. Be certain there is adequate access to all
required flush ports and valves before mounting.
Stud Wall - Mounting on stud wall with or without
drywall can be accomplished by using the two supplied
lag bolts through the top and bottom center holes directly
into the studs as shown in Figure 2.
Self-drilling screws into sheet metal 4 places.
DO NOT PUNCTURE INTERNAL
COMPONENTS!
Unit Side
o
TTaacco
Loop Side
Heat Pump Cabinet
TTaacco
o
Figure 2 - Mounting Flow Controller on Stud Wall
2
Side of Unit - Mounting on the side of the unit can be
accomplished by using the four self-drilling screws
directly into the sheet metal access panels or cabinet as
shown in Figure 3. Be careful not to puncture any
internal piping or other components with the screws. It
should be remembered that heat pump access will be
limited in this mounting position.
Tubing Insulation
brought up to cover
complete connection
1-1/4”
MPT
Remove
Cover
TTaacco
Unit Side
o
Loop Side
Figure 4 - AFCS1 Piping Detail
Figure 3 - Mounting Flow Controller on Side of Unit
Concrete wall - Mounting onto a concrete wall can be
accomplished by using 4 1/4" ‘Tapcon’ screws (supplied
by others) directly into the concrete wall.
Piping Installation
The Flow controller features 1 1/4" FPT swivel fittings
for flexible and easy installation. Table 1 illustrates the
connection options available for the AFCS1A and 2A.
Avoid using 3/4" piping on flows greater than 6 gpm.
Pressure drop in piping systems should be calculated to
insure adequate flow through the unit. All piping should
be insulated with closed cell insulation of 1/2" wall
thickness. Table 2 shows the insulation requirements for
typical piping materials. Piping insulation should be
glued and sealed to prevent condensation using closed
cell insulation glue. The swivel connectors on the flow
controller are designed to be hand tightened only.
Table 2 - Typical Piping Insulation Materials
Piping Material Insul Description
1" Hose Kit 1-3/8" ID - 1/2" wall
1" IPS PE 1-1/4" ID - 1/2" wall
1-1/4" IPS PE 1-5/8" ID - 1/2" wall
2" IPS PE 2-3/8" ID - 1/2" wall
Loop side piping is typically polyethylene piping
directly into the flow controller. Connection to the flow
controller can be accomplished by a fusion-to-brass MPT
adapter (GFMA66). In multiple flow controller systems
such as multifamily housing, PVC can also be used on
the loop side, remembering however that the transition
from PVC to PE should be accomplished by a flange
connection and PVC is approved for use only as an
indoor piping material in earth loops.
Unit side piping is typically connected using the
ClimateMaster hose kit (AHK5E) which contains all
fittings necessary for connection between the flow
controller and the unit as shown in Figure 5. In the
AFCS1A remove cover and make connections as shown
in Figure 4, remembering all areas of the piping should
be insulated to prevent condensation.
In multiple unit systems, PVC adapters (1 1/4" MPT x
PVC socket) to the flow controller and standard PVC
piping materials can be used to ‘tee’ more than one unit
into the flow controller. It is recommended that a hose kit
still be used at the end of the PVC piping run to facilitate
ease of installation and service of the units as shown in
Figure 6. Insulate all exposed piping. Plastic-to-metal
threads should not be used due to their leakage potential.
To Heat Pump 1"
Swivel Fitting
P/T Port
Rubber Hose Max of
15" Each Side
To Flow Controller 1 1/4"
Swivel Fitting
All Stainless
Hose Clamp
Figure 5 - AHK5E Hose Kit Typical Detail
Table 1 - AFCS1A and 2A Connection Materials
To Fittings
PVC 1-1/4" MPT x 1" PVC Glue Socket
PE Fusion 1-1/4" MPT x 1-1/4" PE Fusion
PE Barb 1-1/4" MPT x 1-1/4" insert barb*
Copper Sweat 1-1/4" MPT x 1" sweat**
Copper Thread 1-1/4" MPT x 1" MPT Nipple
* Use double all-stainless hose clamps
** Sweat before connecting to flow controller
From Flow Controller
1 1/4" MPT x Glue Socket
15" each side
1 or 1 1/2"
SCH 40 PVC
Insert Barb x Glue Socket
Rubber Hose Max of
15" each side
To Heat Pump #1 To Heat Pump #2
Rubber Hose Max of
Figure 6 - Two Units Utilizing One Flow Controller
(one side shown)
3
FLOW CONTROLLER ELECTRICAL WIRING
Power wiring to the flow controller should conform to all
applicable codes. Figure 7 illustrates the wiring required
for the Classic and Figure 8a and 8b for Genesis. Note
the flow controller is available in only in 230V single
phase voltage. Pumps are fused through a pair of circuit
breakers in the unit control boxes. See electrical table for
flow controller characteristics.
External Loop Pump(s)
208/230 Volt-4 Amp Max.
Transformer
L2 L1
CRR
Unit Ground
Loop Pump
Term Blk
HWG Pump
Term Blk
PR
CCM PCB
T1
HPS
LPS
Y
X
Compressor
Contactor
Pump Ground
Min Sec.
T
C
Electrical Table
Model Volts Amps HP
AFCS1A 230 .88 1/8
AFCS2A 230 1.76 1/4
Circuit Breakers
Transformer
External Loop Pump(s)
208/230 Volt-4 Amp Max.
CRR
T1
Y
CCM PCB
HPS
LPS
X
PR
Min Sec.
T
C
Compressor
Contactor
L2 L1
Loop Pump
Term Blk
T1
HPS
LPS
Y
X
Ground
CCM PCB
Min Sec.
T
C
Thermostat
Connection
Compressor
Contactor
HWG Pump
Term Blk
ICM2 Controller
Figure 7 - Power Wiring to Classic Series
o
TTaacco
External Pump
Power Supply
See electrical table for
wire and breaker size
Figure 8B - Power Wiring to Genesis Series
Contactor -CC
Transformer
Figure 8A - Power Wiring to Ultra Classic Series
Capacitor
Circ Brkr
HWG PB2
Loop PB1
T2
Grnd
L1
L2
BR
CXM Control
CB
Low Voltage
Connector
T1
T1
T2
4
FLUSHING THE EARTH LOOP
Once piping is completed between the unit, flow controller, and the ground loop, final purging and charging of
the loop is needed.
A flush cart (at least a 1.5 hp pump) is needed to achieve
adequate flow velocity in the loop, to purge air and dirt
particles from the loop itself. Antifreeze solution is used
in most areas to prevent freezing. All air and debris must
be removed from the earth loop piping system before
operation. Flush the loop with a high volume of water at
a high velocity (2 fps in all piping) both directions, using
a filter in the loop return line of the flush cart to eliminate debris from the loop system. The steps below must
be followed for proper flushing.
Loop
Flush Cart
Flow
Controller
Valve
Positions
Garden Hose
Unit
Figure 9A - Valve Position A - Loop Fill
Fill loop with water from a garden hose through flush
cart before using flush cart pump to ensure an even fill
and increase flushing speed. When water consistently
returns back to the flush reservoir switch to valve
position B.
Flush Cart
Loop
Flow
Controller
Valve
Positions
This position should be switched while filling, to fill the
unit heat exchanger and hose kit. This should be maintained until water consistently is returned into the flush
reservoir.
Loop
Dead Head
Pump Test
for Air
Unit
Flush Cart
Flow
Controller
Valve
Positions
Figure 9C - Valve Position C- Loop Flush
Switch to valve position C. The supply water may be
shut off and the flush cart turned on to begin flushing.
Once the flush reservoir is full, do not allow the water
level in the flush cart tank to drop below the pump inlet
line or air can be pumped back out to the earth loop. Try
to maintain a fluid level in the tank above the return tee
so that air cannot be continuously mixed back into the
fluid. 50 psi surges can be used to help purge air pockets
by simply shutting off the return valve going into the
flush cart reservoir. This ‘dead heads’ the pump to 50 psi.
To dead head the pump until maximum pumping pressure is reached, open the valve back up and a pressure
surge will be sent through the loop to help purge air
pockets from the piping system. Notice the drop in fluid
level in the flush cart tank. If all air is purged from the
system, the level will drop only 1-2" in a 10" diameter
PVC flush tank (about a half gallon) since liquids are
incompressible. If the level drops more than this,
flushing should continue since air is still being compressed in the loop fluid. Do this a number of times.
When the fluid level is dropping less than 1-2" in a 10"
diameter tank the flow can be reversed.
Garden Hose
Unit
Figure 9B - Valve Position B - Unit Fill
5
Dead Head
Pump Test
for Air
Flush Cart
Add Antifreeze
Now if Needed
Loop
Flow
Controller
Valve
Positions
1
Dead Head
Pump to
Pressurize
to 50 PSI
Flush Cart
2
Close to Isolate
Flow Controller
Loop
3
Close Flow
Controller
Valves for
Operation
Mode
Valve
Positions
Unit
Figure 9D - Valve Position D - Full Flush
Now by switching both valves to this position water will
flow both through the loop and the unit heat exchanger.
Finally the "dead head" test should be checked again for
an indication of air in the loop. This fluid level drop is
your only indication of air in the loop. Antifreeze may
be added during this part of the flushing procedure
(see antifreeze section for details).
Close the flush cart return valve, and after pressurizing,
close the flush cart supply valve to pressurize the loop to
a static pressure of at least 50 psi. If water pressure is
ANTIFREEZE SELECTION
General
In areas where minimum entering loop temperatures drop
below 40°F or where piping will be routed through areas
subject to freezing, antifreeze is needed. Alcohols and
glycols are commonly used as antifreezes, however your
local representative should be consulted for the antifreeze
best suited to your area. Freeze protection should be
maintained to 15°F below the lowest expected entering
loop temperature. For example, if 30°F is the minimum
expected entering loop temperature, the leaving loop
temperature would be 25-22°F and freeze protection
should be at 15°F (30°F-15°F=15°F). All alcohols should
be premixed and pumped from a reservoir outside of the
building when possible or introduced under water level to
prevent fuming. Initially calculate the total volume of
fluid in the piping system using Table 3. Then use the
percentage by volume shown in Table 4 for the amount
of antifreeze. Antifreeze concentration should be checked
from a well mixed sample using a hydrometer to measure
specific gravity.
Unit
Figure 9E - Valve Position E - Pressurize and Operation
low, use an air compressor to bump the pressure up
through the P/T port. The loop may be isolated by
moving to valve position E keeping watch on the
pressure gauge of the flush cart for pressure greater than
50 psi. Loop static pressure will fluctuate with the
seasons and pressures will be higher in the winter months
than during the cooling season. This fluctuation is normal
and should be considered when charging the system
initially. Unhook flush cart from the flow controller.
Install counter sink plugs using sealant compatible with
PVC.
Antifreeze Characteristics
Selection of the antifreeze solution for ClimateMaster
closed loop earth coupled systems requires the consideration of many important factors which have long-term
implications on the performance and life of the equipment. Each area of concern leads to a different “best
choice” of antifreeze. The fact is that there is no “ideal”
antifreeze and any choice will require compromises in
one area or another. Some of the factors to consider are
safety, thermal performance, corrosiveness, local codes,
stability, convenience, and cost.
Methanol - Methanol or wood alcohol is considered
toxic in any form, good heat transfer, low to mid price,
flammable in concentrations greater than 25%, noncorrosive, and low viscosity. Methanol has delivered
outstanding performance in earth loops for over 10 years.
Its only drawbacks are toxicity and flammability.
Although methanol enjoys widespread consumer use as a
windshield washer fluid in even higher concentrations,
6
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