Modine Manufacturing 036, 048, 066, 060, 096 Service Manual

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GEO16-504.2

5H0835730000

August, 2015

INSTALLATION AND SERVICE MANUAL

hydronic ground source heat pumps

models GH and EH

NOTE: Energy Star only applies to certain configurations.

WArNING

This unit contains R-410A high pressure refrigerant. Hazards exist that could result in personal injury or death. Installation, maintenance, and service must only be performed by an HVAC technician

quali ed in R-410A refrigerant and using proper

tools and equipment. Due to much higher pressure of R-410A refrigerant, DO NOT USE service equipment or tools designed for refrigerants other than R-410A.

WArNING

Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury or death, and could cause exposure to substances which have been determined by various state agencies to cause cancer, birth defects or other reproductive harm. Read the installation, operating and maintenance instructions thoroughly before installing or servicing this equipment.

PLEASE BE SURE TO LEAVE IT WITH THE OWNER WHEN YOU LEAVE THE JOB.

ImpOrTANT

1. The use of this manual is speci cally intended for a quali ed installation and service agency. A quali ed installation and service agency must

perform all installation and service of these appliances.

2. GH/EH units contain the refrigerant R-410A. Review the R-410A Material Safety Data Sheet

(MSDS) for hazards and  rst aid measures.

3. Refrigerant charging should only be carried out

by an EPA-certi ed air conditioning contractor.

Inspection On Arrival

1. Inspect unit upon arrival. In case of damage, report it immediately to transportation company and your local factory sales representative.

2. Check rating plate on unit to verify that power supply meets available electric power at point of installation.

3. Inspect unit received for conformance with description of

product ordered (including speci cations where applicable).

THIS MANUAL IS THE PROPERTY OF THE OWNER.

SPECIAL PRECAUTIONS

THE INSTALLATION AND MAINTENANCE INSTRUCTIONS IN THIS MANUAL MUST BE FOLLOWED TO PROVIDE SAFE, EFFICIENT, AND TROUBLE-FREE OPERATION. IN ADDITION, PARTICULAR CARE MUST BE EXERCISED REGARDING THE SPECIAL PRECAUTIONS LISTED BELOW. FAILURE TO PROPERLY ADDRESS THESE CRITICAL AREAS COULD RESULT IN PROPERTY DAMAGE OR LOSS, PERSONAL INJURY, OR DEATH. THESE INSTRUCTIONS ARE SUBJECT TO ANY MORE RESTRICTIVE LOCAL OR NATIONAL CODES.

HAZARD INTENSITY LEVELS

1. DANGER: Indicates an imminently hazardous situation

which, if not avoided, WILL result in death or serious injury.

2. WARNING: Indicates a potentially hazardous situation which,

if not avoided, COULD result in death or serious injury.

3. CAUTION: Indicates a potentially hazardous situation which,

if not avoided, MAY result in minor or moderate injury.

4. IMPORTANT: Indicates a situation which, if not avoided, MAY

result in a potential safety concern.

DANGEr

1. Appliances must not be installed where they may be exposed

to potentially explosive or ammable atmosphere.

2. Water temperatures over 125°F can cause severe burns instantly resulting in severe injury or death. Feel water before showering or bathing. Ensure that the primary water heating source setpoints are higher than the heat pump water discharge temperature of 120°F.

WArNING

1. Disconnect power supply before making wiring

connections to prevent electrical shock and equipment damage.

2. All appliances must be wired strictly in accordance with

the wiring diagram furnished with the appliance. Any wiring different from the wiring diagram could result in a hazard to persons and property.

3. Any original factory wiring that requires replacement must

be replaced with wiring material having a temperature rating of at least 105°C.

4. Ensure that the supply voltage to the appliance, as

indicated on the serial plate, is not 5% greater than rated voltage.

5. This unit contains R-410A high pressure refrigerant.

Hazards exist that could result in personal injury or death. Installation, maintenance, and service must only

be performed by an HVAC technician qualied in R-410A

refrigerant and using proper tools and equipment. Due to much higher pressure of R-410A refrigerant, DO NOT USE service equipment or tools designed for refrigerants other than R-410A.

6. When servicing or repairing this equipment, use only

factory-approved service replacement parts. A complete replacement parts list may be obtained by contacting Modine Manufacturing Company. Refer to the rating plate on the appliance for complete appliance model number, serial number, and company address. Any substitution of parts or controls not approved by the factory will be at the

owner’s risk.

CAUTION

1. Ensure that the supply voltage to the appliance, as indicated on the serial plate, is not 5% less than the rated voltage.

2. Do not overcharge the refrigeration system. This can lead to elevated compressor discharge pressure and possibly

ooding the compressor with liquid.

3. Do not attempt to reuse any mechanical or electrical component which has been wet. Such component must be replaced.

ImpOrTANT

1. Start-up and adjustment procedures must be performed

by a qualied service agency.

2. All refrigeration checks must be made by a qualied

R-410A refrigeration technician.

3. Do not release refrigerant to the atmosphere. When adding or removing refrigerant, all national, state/province, and local laws must be followed.

4. The ground heat exchanger (open or closed loop or water source to be connected to the unit must be designed, constructed, and prepared in accordance with industry guidelines (IGSHPA, ASHRAE, NGWA, etc.) and best practices, and any more restrictive local codes and

regulations by a qualied service agency. Failure to

properly, size, install, or prepare the source could result in reduced performance, a reduction in the normal life of the units, and a hazard to persons and property.

5. Units selected for open loop ground source applications should have a cupronickel source coaxial heat exchanger to reduce mineral buildup and scaling. Open loop systems

should have the source coaxial coil ushed periodically to

maintain peak performance.

6. All piping and connections must be made in accordance with local plumbing codes.

7. To check most of the Possible Remedies in the troubleshooting guide listed in Tables 20.1-22.1, refer to the applicable sections of the manual.

Table of Contents

General Information ..................................1

Inspection on Arrival ..................................1

Special Precautions ..................................2

Model/Serial Number Designations ......................3

Unit Dimensions .....................................4

SI (Metric) Conversion Factors..........................6

Unit Location........................................6

Installation ........................................ 6

Water Connections .................................7

Hot Water Generator ...............................8

Wiring ...........................................9

Electrical Specications ..............................11

Start-Up Procedure..................................12

Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Maintenance.......................................16

Replacement Parts................................17

Serial Plate – Example .............................17

Troubleshooting ....................................19

Start Up/Troubleshooting Form ........................23

Warranty...................................Back Page

GEO16-504.2

MODEL NOMENCLATURE

Figure 3.1 - Model Number Designations

1,2 3 4,5,6 7 8 9,10 11 12 13 14 15 16 17 18

MT UC MBH DS CC SV CT AC GM HM HWG MT SA RA

1,2 - Model Type (MT)

GH - Residential Hydronic (Water to Water) EH - Commercial Hydronic (Water to Water)

3 - Unit Conguration (UC)

R - Reversible W - Non-Reversible

4,5,6 - Nominal Cooling Capacity (MBH)

036 - 36,000 Btu/hr 048 - 48,000 Btu/hr 060 - 60,000 Btu/hr 066 - 66,000 Btu/hr 096 - 96,000 Btuh/hr 120 - 120,000 Btuh/hr 132 - 132,000 Btuh/hr

7 - Development Sequence Designation (DS)

C - Current

8 - Compressor Conguration (CC)

1 - Single Stage 3 - Single Stage with Soft Start

9,10 - Supply Voltage (SV)

02 - 208/60/1 03 - 208-230/60/1 04 - 208/60/3 05 - 208-230/60/3

11 - Controls Type (CT)

4 - Modine Controls System

12 - Air Coil (AC)

N - None

13 - Geo (Source) Coaxial Coil Material (GM)

C - Copper N - Cupronickel

14 - Hydronic (Load) Coaxial Coil Material (HM)

C - Copper N - Cupronickel

15 - Hot Water Generator or Desuperheater (HWG)

0 - None 1 - HWG with Factory Installed Pump

16 - Motor Type (MT)

N - None

17 - Supply Air Conguration (SA)

N - None

18 - Return Air Conguration (RA)

N - None

Figure 3.2 - Serial Number Designations

WARRANTY TERM

1 - 1 Years Parts Commercial 2 - 10 Years Parts / 5 Years Labor Residential 3 - 10 Years Parts / 10 Years Labor Extended Residential

Serial Number

SPO MODEL

S 0 40 20 1 2 11 14 1234 12345

STACKED UNIT

0 - Standard 1 - Stacked

MOTOR SUPPLIER

40 - AO Smith 51 - Genteq 00 - None

BLOWER SUPPLIER

20 - Morrison 00 - None

COMPRESSOR

1 - Copeland

YEAR OF MANUFACTURE

WEEK OF MANUFACTURE

SPO NUMBER

SEQUENTIAL NUMBER

Number varies from 0000 to 9999. Each unit within the same week of manufacture is to have unique number

GEO16-504.2

UNIT DIMENSIONS

Figure 4.1 - Dimensional Drawings - Models 036-066

Table 4.1 - Dimensions (inches) - Models 036-066

Models 036 048 060 066

A 23.13 23.13 23.13 23.13

Overall Cabinet

Electrical

Geo, Hyd, & DHW

Control M 11.57 11.57 11.57 11.57

Approx. Shipping

Weight (lbs.)

Coil Connection Size

(Female Swivel)

B 25.65 25.65 25.65 25.65

C 32.63 32.63 32.63 32.63

E 15.44 17.07 15.44 15.44

F 12.82 14.26 12.82 12.82

G 10.32 11.76 10.32 10.32

H 2.00 2.00 2.00 2.00

J 7.14 7.14 7.14 7.14

K 14.24 14.24 14.24 14.24

L 18.62 20.32 18.62 18.62

240 327 442 443

1" NPT 1" NPT 1" NPT 1" NPT

GEO16-504.2

UNIT DIMENSIONS

Figure 5.1 - Dimensional Drawings - Models 096-132

Table 5.1 - Dimensions (inches) - Models 096-132

Models

A 46.26 46.26 46.26

Overall Cabinet

Electrical

Bottom Unit

Geo, Hyd, &

DHW

Control M 11.57 11.57 11.57

Electrical

Top Unit

Geo, Hyd, &

DHW

Control U 34.70 34.70 34.70

Approx. Shipping Weight (lbs.) 655 884 885

Coil Connection Size (Female Swivel) 1" NPT 1" NPT 1" NPT

B 25.65 25.65 25.65

C 32.63 32.63 32.63

E 17.07 15.44 15.44

F 14.26 12.82 12.82

G 11.76 10.32 10.32

H 2.00 2.00 2.00

J 7.14 7.14 7.14

K 14.24 14.24 14.24

L 20.32 18.62 18.62

O 40.20 38.57 38.57

P 37.39 35.95 35.95

Q 34.89 33.45 33.45

N 43.42 41.72 41.72

R 25.10 25.10 25.10

S 30.28 30.28 30.28

T 37.37 37.37 37.37

096 120 132

GEO16-504.2

UNIT LOCATION / INSTALLATION

Table 6.1 - SI (Metric) Conversion Factors

To Convert Multiply By To Obtain

"W.C. 0.24 kPa psig 6.893 kPa °F inches 25.4 mm feet 0.305 meters CFM 0.028 m

(°F-32) x 0.555

°C

To Convert Multiply By To Obtain

CFH 1.699 m3/min

0.0374 mJ/m

Btu/ft pound 0.453 kg Btu/hr 0.000293 kW/hr gallons 3.785 liters

/min

psig 27.7 "W.C.

UNIT LOCATION

DANGEr

Appliances must not be installed where they may be exposed to

potentially explosive or ammable atmosphere.

Handling

Each unit will be shipped to the site on a wood skid. Whenever possible, all lifting and handling of the unit should be done with the packing and skid in position.

When slinging or using a forklift to lift the unit, the support points

should be sufciently apart to give stability when lifting. Unless

otherwise noted, the lifting points should be equidistant from the centerline. Extreme care should be taken not to drop the unit.

Considerable damage can occur to the unit during positioning, in particular, to the paneling and exterior paint. Use an adequate number of personnel and the correct tools when moving the unit. The unit is designed to remain upright so care should be taken when lifting the unit up steps.

The use of torque screwdrivers on panel, cover or component mounting screws is not recommended. Hand-start all screws. If electric drills are used – set at the lowest possible torque.

Preparation

1. Before installation, ensure that the correct electrical power supplies are available for the unit.

2. Each unit requires an independently fused and isolated power supply.

3. Check to make sure that the units will have adequate installation clearance for easy access to remove all panels and access all internal components. Provide ample area to access external components in and around the unit and

system including water valves, ttings, and all electrical

connections.

4. Remove any accessory kits and shipping support material from the mechanical compartment.

5. Check refrigerant piping for dents or kinks.

6. Inspect all electrical connections. Connections must be clean and tight at the terminal.

Electrical

Electrical wiring should be done in accordance with all applicable national and local codes. It is the responsibility of the electrical contractor to adhere to such codes. The warranty will

be voided if wiring is not in accordance with the specications of

the unit. Modine recommends using copper conductors only.

All power supply wiring must be capable of carrying the maximum current load under no fault conditions at the stipulated voltages. Care should be taken to avoid signicant voltage drops.

A knockout for power connection is provided on the access side of the unit. See unit dimensions.

INSTALLATION

ImpOrTANT

Storage

Equipment should be stored in clean, dry area and in its original packaging.

Do not store or install units in corrosive environments or in locations subject to temperature or humidity extremes.

Performance, reliability, and service life can be signicantly

reduced. Transport and store units in an upright position. Tilting units greater than 60° beyond horizontal may result in damage to the compressor. If the unit is tilted past 60°, do not energize the compressor until the unit has been upright for a minimum of 6 hours to prevent compressor damage.

Unit Protection

To prevent damage, keep the unit in its original packaging or cover with an equivalent protective covering while on the job site. Cover open water connections to prevent debris from entering the system. Take extra precautions to protect the unit from damage or contamination when in an area where spraying, plastering and / or painting has not been completed. Physical damage or contamination from foreign debris may prevent proper start-up and costly equipment clean-up. Examine all

ttings, valves, or pipes and remove all dirt or debris before

installing unit.

1. The ground heat exchanger (open or closed loop) or water source to be connected to the unit must be designed, constructed, and prepared in accordance with industry guidelines (IGSHPA, ASHRAE, NGWA, etc.) and best practices, and any more restrictive local codes

and regulations by a qualied service agency. Failure to

properly, size, install, or prepare the source could result in reduced performance, a reduction in the normal life of the units, and a hazard to persons and property.

2. Units selected for open loop ground source applications should have a cupronickel source coaxial heat exchanger to reduce mineral buildup and scaling. Open loop systems

should have the source coaxial coil ushed periodically to

maintain peak performance.

Installation of these units is to be INDOORS only. The instructions detailed below are for the Installation of a “Standard” unit. Accommodations and adjustments will be required for the usage of additional unit accessories. Should assistance be required for the installation of these additional items, consult Modine at the phone number listed on the back cover of this manual.

GEO16-504.2

INSTALLATION

Unit Installation

1. Units should be mounted on a vibration-absorbing pad slightly larger than the base of the unit. See Table 7.1 below for

Modine vibration pad part numbers. If the unit isn’t mounted on a vibration-absorbing pad, it must be raised off the oor to prevent damage due to accidental ooding. It is not necessary to anchor the unit to the oor.

Table 7.1 - Vibration Absorbing Pads - High Density Plastic

Pad Size Part Number Models

32" X 32" 5H0835220000 036

36" X 36" 5H0835230000 048-132

2. Check to ensure that the unit is level in both directions and also plumb. If adjustment is necessary, Modine recommends the placement of metal shims in the outermost corners of the base.

3. Provide adequate clearance for all access panels.

4. Provide easy access for servicing water valves, ttings and

compressor.

5. Provide access to the controller and all electrical connections.

6. Provide a clear physical path to the unit. Adequate space should be provided to allow removal of the unit, if necessary.

Figure 7.1 - Water Connection Breakdown

Water Connections

1. All units utilize swivel pipe ttings for water connections that

are rated for 150 psi.

2. The connections have a rubber gasket seal similar to a garden

hose gasket, which, when mated to the ush end of most 1" threaded male pipe ttings (MPT), provides a leak-free seal

without the need for thread sealing tape or joint compound.

3. The water piping system should include pressure/temperature taps for serviceability.

4. Install the brass spacer and rubber gasket in swivel connector prior to attempting any connection, as shown in Figure 7.1 (rubber gasket and brass spacer kits are shipped with unit). To

make the connection, mate the eld supplied male pipe thread tting against the rubber gasket in the swivel connector and

thread the female locking ring onto the pipe threads, while maintaining the brass elbow in the desired direction. Tighten

the connectors by hand, and then gently snug the tting with

pliers to provide a leak-proof joint.

5. DO NOT OVERTIGHTEN, as leaks may occur.

6. NOTE: Never use exible hose smaller than 1" inside diameter on the unit. Limit the length to 10' per connection in one direction. Check carefully for leaks.

Factory installed

Snap ring in this groove

Swivel adaptor hand tighten

Brass snap ring Brass spacer Rubber gasket

Swivel adaptor

hand tighten

P/T Port - access

for temperature

and pressure

GEO16-504.2

INSTALLATION

Hot Water Generator (Desuperheater) Installation (If Equipped)

DANGEr

Water temperatures over 125°F can cause severe burns instantly resulting in severe injury or death. Feel water before showering or bathing. Ensure that the primary water heating source setpoints are higher than the heat pump water discharge temperature of 120°F.

ImpOrTANT

All piping and connections must be made in accordance with local plumbing codes.

A minimum 50 gallon water heater is recommended with the Desuperheater (DHW) option. Higher demand applications may use either one 80 gallon water heater or two 50 gallon water heaters piped in series. The hot water tank should be allowed to stratify by lowering the bottom element setpoint to 100°F and setting the top element setpoint to 125°F. Operation of the DHW is controlled by a sensor located on the domestic water in line, which must not be removed. Hot water will only be produced when the unit is running a conditioning cycle.

The desuperheater pump is disabled on delivery from the factory. It must be enabled by wiring the pump in the unit control panel after the DHW piping has been completed and purged. This is to prevent the domestic hot water pump from running before the DHW tank is piped to the heat pump. DHW option must not be enabled until all piping is complete and the DHW loop has been purged and bled or damage can occur.

Poor domestic water quality may result in debris buildup in the system. A water softener is recommended with hard water (greater than 10 grains or 170 total hardness). Extreme hard water will require additional maintenance and should be considered with the DHW option, as maintenance costs may outweigh potential savings.

Make sure all local electrical and plumbing codes are met for installing a hot water generator. The installing contractor is responsible for performing the installation accordingly.

Water piping lengths must be kept at a minimum. DO NOT use a one way length greater than 50'.

Coaxial drain tees that provide an inlet and outlet to the heat pump from the drain connection are not recommended. The decreased diameter of the inlet and outlet pipes to the heat pump make it possible for debris build up and completely stop

the ow of water to and from the desuperheater.

All components should be located in a conditioned space that is maintained above 50°F at all times.

1. Turn off power or fuel supply to the water heater.

2. Close cold water supply valve to heater.

3. Drain and ush the tank, then remove the drain valve.

4. Inspect the water heater cold water inlet pipe for a check valve and remove if present. Failure to do so will result in damage to the unit.

5. Use a tee to connect the cold water supply pipe to the DHW in connection on the unit. Be sure to install a check valve rated for at least 1/2" PSI and a shutoff valve on the cold water inlet pipe. Also install a shutoff valve on the supply line to the unit, as well as an air vent at the highest point of the system.

6. Run DHW piping using a minimum of 1/2" OD copper tubing. See Table 8.1 for recommended line sizes.

7. Use a tee to connect the unit DHW out connection to the water heater drain connection. Be sure to install a shutoff valve on the pipe as near to the water heater as possible.

8. Reinstall the drain valve on one side of the tee.

Figure 8.1 - Typical DHW Piping Diagram

COLD

HOT

WATER

OUT

AIR VENT

DHW IN

DHW OUT

DRAIN CONNECTION

WATER

DRAIN VALVE

Figure 8.2 - Typical DHW Piping Diagram with Two Tanks

AIR VENT

DHW IN

DHW OUT

DRAIN CONNECTION

COLD

WATER

TANK 1 HEATING SOURCE

DISABLED

DRAIN VALVE

HOT

WATER

OUT

COLD

WATER

HOT

WATER

OUT

Table 8.1 - DHW Pipe Sizes ➀

Maximum pipe length (one way) to achieve optimum ow

Models DHW Flow (gpm) 1/2" Copper 3/4" Copper

036 1.2 50 -

048 & 096 

060 & 120 

066 & 132 

 096, 120, and 132 are stacked units, data is for individual unit.

9. Open all valves, except the system drain valve, and ll the

system with water. Bleed all air and check for leaks.

10. Insulate all piping with 3/8" closed cell insulation.

11. Refer to “Start Up Procedure” for DHW setup and start up.

1.6 45 50

2.0 25 50

2.4 10 50

GEO16-504.2

INSTALLATION

Wiring

WArNING

1. Disconnect power supply before making wiring connections to prevent electrical shock and equipment damage.

2. All appliances must be wired strictly in accordance with the wiring diagram furnished with the appliance. Any wiring different from the wiring diagram could result in a hazard to persons and property.

3. Any original factory wiring that requires replacement must be replaced with wiring material having a temperature rating of at least 105°C.

4. Ensure that the supply voltage to the appliance, as indicated on the serial plate, is not 5% greater than rated voltage.

CAUTION

Ensure that the supply voltage to the appliance, as indicated on the serial plate, is not 5% less than the rated voltage.

Installation of wiring must conform with local building codes, or in the absence of local codes, with the National Electric Code ANSI/NFPA 70 - Latest Edition. Unit must be electrically grounded in conformance to this code. In Canada, wiring must comply with CSA C22.1, Part 1, Electrical Code.

Electric wiring must be sized to carry the full load amp draw of the motor, starter and any controls that are used with the unit. See Table 11.1 for electrical data.

Any damage to or failure of units caused by incorrect wiring of the units is not covered by warranty.

Terminal Strip Connections

The terminal strip connections are designed to clamp down on the wires. To properly connect the wires to the terminal strip:

1. Push a small at-head screwdriver into the square hole on the terminal. Press rmly until the screwdriver hits the back stop

and opens the terminal (see Figure 9.1).

2. Remove approximately 3/8" of insulation from the end of the wire and push the stripped wire into the oval hole in the terminal.

3. Remove the screwdriver. Pull on the wire to make sure that it is securely clamped in the terminal.

4. Make sure that the terminal clamp is in contact with bare wire (insulation removed).

Figure 9.1 - Terminal Strip

Unit Power Connection

Refer to the unit serial plate for unit voltage and phase. Available power must be the same as indicated on serial plate.

Remove access panel and electrical box cover. Using unit power knockout, route power lines through unit and into main electrical panel. Connect line voltage wires to the L1 and L2 (& L3, if three phase voltage) lugs of the contactor. Consult the unit electrical data on the serial plate for correct overcurrent protection sizing. Connect ground wire to ground lug in electrical panel. Replace electrical box cover and access panel prior to unit startup.

Hot Water Generator Pump Wiring

The domestic hot water pump is not wired in the factory to prevent pump burnout in case the unit is powered before the domestic hot water tank is plumbed or full of water. Refer to the control manual for instructions on enabling the pump.

Transformer Wiring

The system supplies the power to the controller via a 24V transformer. On 208V systems, the transformer is factory wired and is ready for operation. On 208-230V systems, the transformer comes factory wired for 230V operation. If the unit is to be powered with 208V, the transformer must be wired for

208V. A terminal strip with a jumper is provided for easy eld conguration (see Figure 10.1). Refer to the wiring diagram

provided with the unit for details.

GEO16-504.2

INSTALLATION

Figure 10.1 - 208-230V Transformer Wiring

Hydronic Pump Wiring

The hydronic pump must be connected to the terminal blocks in the electrical box. The pumps will automatically be cycled as required by the unit. Be sure to wire the pump prior to turning the system on.

Aquastat Wiring

The aquastat wires are connected directly to the terminal blocks in the electrical box.

Open Loop Control Valve Wiring

Always maintain water pressure in the heat exchanger by placing water control valves at the outlet of the unit to prevent mineral precipitation during the off cycle. Pilot operated slow closing valves are recommended to reduce water hammer. If water hammer persists, an expansion tank can be mounted on the piping to help absorb the excess hammer shock. Slow closing valve must have an end switch that enables/disables the compressor. See Figure 10.2 for proper wiring.

Figure 10.2 - Optional Open Loop Valve Wiring

Flow Center Wiring

The ow center must be connected to the terminal blocks in

the electrical box. The pumps will automatically be cycled as

required by the unit. Be sure to wire the ow center prior to

turning the system on.

Sensor Wiring

All sensors are factory wired and installed.

GEO16-504.2

ELECTRICAL SPECIFICATIONS

Table 11.1 - Electrical Ratings

Models

036

048

060

066

096 

120 

132 

 Stacked unit, electrical data is for individual unit.

Digits

9 & 10

Power Code

02,03 208-230/1/60 197 / 253 20.0 112.0 1.8 1.8 0.4 0.5 24.5 29.5 30.0

04,05 208-230/3/60 197 / 253 14.3 95.0 1.8 1.8 0.4 0.5 18.8 22.4 30.0

02,03 208-230/1/60 197 / 253 29.4 134.0 1.8 3.6 0.4 0.5 35.7 43.1 50.0

04,05 208-230/3/60 197 / 253 17.1 110.0 1.8 3.6 0.4 0.5 23.4 27.7 30.0

02,03 208-230/1/60 197 / 253 31.6 178.0 1.8 3.6 0.4 0.5 37.9 45.8 50.0

04,05 208-230/3/60 197 / 253 21.0 146.0 1.8 3.6 0.4 0.5 27.3 32.6 40.0

02,03 208-230/1/60 197 / 253 41.1 185.0 1.8 3.6 0.4 0.5 47.4 57.7 60.0

04,05 208-230/3/60 197 / 253 24.2 179.0 1.8 3.6 0.4 0.5 30.5 36.6 40.0

02,03 208-230/1/60 197 / 253 29.4 134.0 1.8 3.6 0.4 0.5 35.7 43.1 50.0

04,05 208-230/3/60 197 / 253 17.1 110.0 1.8 3.6 0.4 0.5 23.4 27.7 30.0

02,03 208-230/1/60 197 / 253 31.6 178.0 1.8 3.6 0.4 0.5 37.9 45.8 50.0

04,05 208-230/3/60 197 / 253 21.0 146.0 1.8 3.6 0.4 0.5 27.3 32.6 40.0

02,03 208-230/1/60 197 / 253 41.1 185.0 1.8 3.6 0.4 0.5 47.4 57.7 60.0

04,05 208-230/3/60 197 / 253 24.2 179.0 1.8 3.6 0.4 0.5 30.5 36.6 40.0

Rated Voltage

Voltage

(min/max)

Compressor Pumps

RLA LRA Load FLC DHW

Control

Total

Unit FLA

MCA

MAX

FUSE

GEO16-504.2

START-UP PROCEDURE

CAUTION

ImpOrTANT

Start-up and adjustment procedures must be performed by a

qualied service agency.

The unit has been factory tested and set for proper operation, but a full unit start-up is recommended.

NOTE: If any abnormal operation occurs during the startup procedure, refer to the troubleshooting section.

NOTE: Always start the system in heating mode.

Pre-Start Checks

Before applying power to heat pump, use the following checklist to ensure a complete and proper installation.

• Check that the supply voltage matches the unit supply voltage

listed on the unit serial plate.

• Verify that all wiring is secure and properly protected.

• All high voltage wiring is correct including, fuses, breakers and

wire sizes.

• Trace circuits to insure that the unit has been wired according

to the wiring diagram.

• Check that the unit has no visible damage and that all the

components are secure.

• Check that all eld electrical and mechanical work has been

performed according to all applicable Federal, State, and Local codes.

• Check the supply voltage to the unit is within +/- 5% of the

voltage on the unit serial plate.

• Low voltage wiring for aquastat, control wiring and the freeze

protection setpoint completed.

• Transformer wiring is correct.

• Water supply to and load piping from heat pump is completed.

• Piping completed, water system cleaned and ushed of debris.

• Air and debris are purged from ground and load loops.

• Antifreeze added to ground and load loops, as required.

• Isolation valves are open, water control valves or loop pumps

wired.

• DHW piping is complete, all air purged from system and

charged with water.

• IMPORTANT: Ensure all valves in the DHW circuit are fully

open and pump is wired correctly.

• Service/access panels are in place.

• Entering water temperatures are within operating limits in

Table 14.1.

Verify that ALL water control valves are open and allow

water ow prior to engaging the compressor. Freezing of the

coax or water lines can permanently damage the heat pump.

CAUTION

To avoid equipment damage, DO NOT leave system lled in

a building without heat during the winter unless antifreeze is added to the water loop. Heat exchangers never fully drain by themselves and will freeze unless winterized with antifreeze.

Controller Setup

GH/EH systems are pre-programmed from the factory for easy installation, no installer setup is required for the unit to function.

The DHW pump is not wired from the factory on all units. This is done to protect the pump during installation and startup. If a DHW pump is in the system, it must be wired.

ImpOrTANT

Ensure that the freeze protection setpoint is properly set

(approximately 10°F above the uid freeze point) for the type and percentage of uid used in the ground loop.

Table 12.1 - Freeze Point of Pure Antifreeze Solutions, °F ➀

% Vol. Methanol Ethanol

5.0 26.2 29.5 29.3

7.5 23.0 28.1 27.7

10.0 19.7 26.4 26.1

12.5 16.2 24.6 24.4

15.0 12.6 22.6 22.5

17.5 8.8 20.4 20.5

20.0 4.9 18.1 18.4

22.5 — 15.6 16.1

25.0 — 12.9 13.8

27.5 — 10.0 11.3

30.0 — 7.0 8.8

➀

All values are typical, refer to antifreeze manufacturer data sheets for actual values.

Propylene

Glycol

GEO16-504.2

START-UP PROCEDURE

Unit Startup Procedure

The Startup / Troubleshooting form found on page 23 of this manual may be used to assist during unit startup.

1. Put aquastat in standby or off mode.

2. Turn on line power to heat pump.

3. Slowly raise the aquastat set-point until a heating call is generated and the compressor energizes.

4. After a few minutes, check the load out temperature and verify warm water delivery.

5. Verify water ow by comparing pressure drop across the

coaxial coil to values in Table 13.1.

6. Monitor ground water supply (GWI) and return (GWO) temperatures. If temperature drop is within expected operating range as shown in Table 14.1, continue with testing.

7. If temperature drop is outside of expected operating range, check refrigerant pressures and compare to values in Table 14.1.

8. Check for vibration, noise and leaks.

9. Lower aquastat set point below tank temperature and verify

that compressor and ow center deactivate.

10. Initiate a control signal to place the unit in the cooling mode. Cooling set point must be set below room temperature.

11. Cooling will energize after a time delay.

12. Be sure that the compressor and ow center are activated.

13. Monitor ground water supply (GWI) and return (GWO)

temperatures. If temperature rise is within expected operating range in Table 14.1, continue with testing.

14. If temperature drop is outside of expected operating range, check refrigerant pressures and compare to Table 14.1.

15. Check for vibration, noise and leaks.

16. Adjust the cooling set point above the tank temperature and

verify that the compressor and ow center deactivate.

17. If unit fails to operate as described, see troubleshooting section. If the unit still does not operate properly, contact Modine at the number listed on the back of this manual.

18. When testing is complete, set system to normal operating

mode.

DHW Startup Procedure

1. If the DHW was wired, the DHW pump will run whenever the heat pump is running and the DHW Supply temperature is below 120°F and the discharge temperature is above 100°F.

2. To verify operation of the DHW pump, ensure that the heat pump is running and the DHW temperature is below 120°F and the discharge temperature is above 100°F.

3. The temperature rise across the desuperheater should be 5-10°F.

Sequence of Operation

The unit’s controller will monitor calls for heat or cooling by

aquastat. Cool: When the temperature increases above the cooling

aquastat's set point and the dead band, the compressor and reversing valve will be energized. The compressor will be limited by a timer that will provide anti-cycle protection.

Heat: When the temperature falls below the heating aquastat's set point and the dead band, the compressor will be energized and the reversing valve de-energized. The compressor will be limited by a timer that will provide short-cycle protection.

Open Loop Systems: An optional valve can be tted to stop water ow when the compressor is not energized. This allows the variable pumping system to work more efciently.

Table 13.1 - Water Pressure Drop, psi (Based on Entering Water Temperature)

Models GPM 30°F 40°F 60°F 90°F 110°F

036

048

060

066

096 

120 

132 

 Pressure drop is for individual unit.

Table 13.2 - Antifreeze Pressure Drop Corrections

Antifreeze Type

Ethylene Glycol

Propylene Glycol

Equation 13.1 - Coaxial Coil Pressure Drop Antifreeze Correction

To nd actual pressure drop through either coaxial coil when the unit is operated with an antifreeze solution, rather than water:

Where:

WPD

ACF = Antifreeze Correction Factor from Table 18.2

GEO16-504.2

6.0 1.9 1.8 1.6 1.4 1.3

8.0 2.9 2.8 2.5 2.1 2.0

9.0 3.5 3.4 3.0 2.6 2.4

10.0 4.1 4.0 3.5 3.0 2.8

12.0 5.5 5.4 4.7 4.1 3.7

6.0 1.4 1.4 1.2 1.1 1.0

8.0 2.2 2.1 1.9 1.7 1.6

10.0 3.0 3.0 2.6 2.4 2.2

12.0 4.0 4.0 3.5 3.2 3.0

14.0 5.1 5.1 4.5 4.1 3.9

9.0 1.5 1.5 1.4 1.3 1.2

12.0 2.4 2.3 2.2 2.0 1.9

15.0 3.5 3.4 3.2 2.9 2.7

18.0 4.7 4.6 4.3 3.9 3.7

21.0 6.2 6.1 5.6 5.1 4.8

24.0 7.9 7.7 7.1 6.4 6.0

6.0 1.4 1.4 1.2 1.1 1.0

8.0 2.2 2.1 1.9 1.7 1.6

10.0 3.0 3.0 2.6 2.4 2.2

12.0 4.0 4.0 3.5 3.2 3.0

14.0 5.1 5.1 4.5 4.1 3.9

9.0 1.5 1.5 1.4 1.3 1.2

12.0 2.4 2.3 2.2 2.0 1.9

15.0 3.5 3.4 3.2 2.9 2.7

18.0 4.7 4.6 4.3 3.9 3.7

21.0 6.2 6.1 5.6 5.1 4.8

24.0 7.9 7.7 7.1 6.4 6.0

Antifreeze Solution

Percent by Weight

15% 1.12 20% 1.16 30% 1.22 15% 1.20 20% 1.27 30% 1.43 38% 1.55 14% 1.29

Ethanol

Methanol

20% 1.34 29% 1.43 10% 1.12 15% 1.16 20% 1.19 25% 1.21

WPDA = WPDS x ACF

= Water Pressure Drop at Actual Conditions

= Water Pressure Drop at Standard Conditions

(water) from Table 18.1

Correction Factor

START-UP PROCEDURE

Table 14.1 - Typical Operating Conditions

Entering Water

Temperature

(°F)

Entering Water

Temperature

(°F)

Water Flow

(gpm/ton)

1.5 68-76 285-310 8-12 3-9 5-7

3 72-80 290-315 8-12 3-9 3-5

1.5 100-110 315-345 9-13 5-11 7-9

3 104-114 320-350 9-13 5-11 5-7

1.5 134-144 355-395 10-14 6-12 9-11

3 138-148 360-390 10-14 6-12 7-9

Water Flow

(gpm/ton)

1.5 122-130 220-235 13-19 10-16 19-23

3 120-128 190-210 13-19 10-16 7-12

1.5 127-136 280-210 11-15 8-14 19-23

3 125-134 250-270 11-15 8-14 7-12

1.5 132-144 360-380 10-14 8-14 18-22

3 130-142 330-350 10-14 8-14 7-12

Suction

Pressure

(psig)

Suction

Pressure

(psig)

Heating - No Desuperheater

Discharge

Pressure

(psig)

Superheat

Cooling - No Desuperheater

Discharge

Pressure

(psig)

Superheat

(°F)

Subcool

(°F)

Subcool

(°F)

Source Water

Temperature Drop

(°F)

Source Water

Temperature Rise

(°F)

Table 14.2 - Operating Limits

Operating Limits Cooling (°F) Heating (°F)

Min. Entering Water 30 20

Normal Entering Water 85 60

SOURCE

Max. Entering Water 110 90

Min. Entering Water 50 60

Normal Entering Water 60 100

LOAD

Max. Entering Water 90 120

Table 14.3 - Compressor Winding Resistance

Compressor C to S C to R S to R

ZP16K5E-PFV 2.30 1.53 3.83

ZP21K5E-PFV 1.64 1.30 2.94

ZP25K5E-PFV 1.91 1.02 2.93

ZP29K5E-PFV 1.44 0.90 2.34

ZP34K5E-PFV 1.25 0.56 1.81

ZP36K5E-PFV 1.25 0.56 1.81

ZP39K5E-PFV 1.22 0.55 1.77

ZP51K5E-PFV 0.79 0.45 1.25

ZP57K5E-PFV 0.97 0.37 1.34

ZP72KCE-PFV 0.85 0.32 1.17

NOTE: Limits are acceptable for start-up conditions only.

Min / max limits are intended for bringing the space up / down to normal temperatures. Units are not designed to operate at the min / max conditions on a continual or regular basis. The operating limits are dependent upon three primary factors:

1) entering source temperature, 2) entering load temperature,

and 3) ow rate (gpm). When any of the factors are at the

minimum or maximum levels, the other two factors must be at the normal level for proper and reliable unit operation.

GEO16-504.2

START-UP PROCEDURE / PHYSICAL DATA

Table 15.1 - Refrigerant Circuit Malfunctions and Probable Causes ➀

The following chart will assist in troubleshooting and diagnosing causes of a problematic unit. The chart provides general guidance for system measurements relative to typical operating conditions.

Symptom

Cause

Undercharged System Low Low Low High Low Low Low

Overcharged System High High High Normal High Normal Normal

Low Load Water Flow - Heating High High High High Low High Low

Low Load Water Flow - Cooling Low Low Low Low / Normal High High Low

Low Source Water Flow - Heating Low Low Low Low High Low High

Low Source Water Flow - Cooling High High High High Low Low High

High Load Water Flow - Heating Low Low Low Low High Low Normal / High

High Load Water Flow - Cooling Normal / High High Normal / High High Low Low Normal / High

High Source Water Flow - Heating Normal / High High Normal / High High Low / Normal High Low

High Source Water Flow - Cooling Low Low Low Low High High Low

Low Load Water Temp - Heating Low Low Low Low / Normal High High Normal / High

Low Load Water Temp - Cooling Low Low Low Low / Normal High Low Low

High Load Water Temp - Heating High High High Normal / High Low / Normal Low Low

High Load Water Temp - Cooling High High High High Low Low High

Restricted TXV High Low Low / Normal High High Low Low

TXV Bulb Failure (Loss of Charge) High Low Low High High Low Low

Restricted Filter/Drier

Inefcient Compressor Low High Low High High Low Low

Scaled / Fouled Load Heat Exchanger - Heating High High High High Low Low Low

Scaled / Fouled Load Heat Exchanger - Cooling Low Low Low Low / Normal High Low Low

Scaled / Fouled Source Heat Exchanger - Heating Low Low Low Low / Normal High Low Low

Scaled / Fouled Source Heat Exchanger - Cooling High High High High Low Low Low

➀ Restricted filter / drier will have symptoms similar to restricted TXV. Check temperature drop across filter driver to verify a restriction.

➀

Head Press.

High Low Low / Normal High High Low Low

Suct.

Press.

Comp Amp

Draw

Superheat Subcool

Load

Temp Diff.

Water (Source)

Temp Diff

PHYSICAL DATA

Table 15.2 - Physical Data

Models 036 048 060 066 096 120 132

Reversible (H),

Non-Reversible (W)

Factory Charge, R-410A,

oz (per Unit)

Factory Charge, R-410A,

oz (per Unit) - w/HWG

Unit Style Single Unit Stacked Unit

Compressor Copeland Scroll

H W H W H W H W H W H W H W

53 51 70 67 101 100 112 112 70 67 101 100 112 11 2

56 55 74 71 104 104 115 11 5 74 71 104 104 11 5 11 5

GEO16-504.2

MAINTENANCE

WArNING

When servicing or repairing this equipment, use only factoryapproved service replacement parts. A complete replacement parts list may be obtained by contacting Modine Manufacturing Company. Refer to the rating plate on the appliance for complete appliance model number, serial number, and company address. Any substitution of parts or controls not

approved by the factory will be at the owner’s risk.

CAUTION

Do not attempt to reuse any mechanical or electrical component which has been wet. Such component must be replaced.

ImpOrTANT

To check most of the possible remedies in the troubleshooting guide listed in Tables 20.1-22.1, refer to the applicable sections of the manual.

The routine care and maintenance of this unit will increase longevity, provide for the proper operational performance, and reduce the probability of failure.

Once the unit is operational, it will be necessary to perform certain routine maintenance/service checks. Following is a maintenance schedule with the recommended checks. If your unit is equipped with special features, there may be additional checks that are required. Consult Modine for assistance.

The use of torque screwdrivers on panel, cover or component mounting screws is not recommended. Hand-start all screws. If electric drills are used – set at the lowest possible torque.

Coaxial Coil Maintenance - Ground Loop Applications

Generally coaxial coil maintenance is not needed for closed loop systems. However, if the piping is known to have high dirt or debris content, best practice is to establish a periodic maintenance schedule with the owner so the coil can be checked on a regular basis. Dirty installations are typically the result of deterioration of iron or galvanized piping or components in the system.

Open cooling towers requiring heavy chemical treatment and mineral buildup through water use can also contribute to higher maintenance. Should periodic coil cleaning be necessary, use standard coil cleaning procedures that are compatible with the heat exchanger material and copper water lines.

Generally, with greater water ow rates, the likelihood of scaling reduces. However, ow rates over 3 gpm per ton can produce

water (or debris) velocities that can erode the heat exchanger wall and ultimately produce leaks.

Desuperheater Coils

If potable water is hard or not chemically softened, the high temperature of the desuperheater can lead to scaling. This results in more scheduled maintenance. A buffer tank may be installed to help prevent scaling. Extreme hard water conditions should not use the desuperheater option. Should periodic coil cleaning be necessary, use coil cleaning procedures that are compatible with the heat exchanger material and copper water lines.

Compressor

Conduct annual amperage checks to insure that amp draw is no more than 10% greater than indicated on the operating data.

Coaxial Coil Maintenance - Ground Water Applications

If the system is installed in an area with a known high mineral content (125 P.P.M. or greater), best practice is to establish a periodic maintenance schedule with the owner so the coil can be checked on a regular basis. Should periodic coil cleaning be necessary, use coil cleaning procedures that are compatible with the heat exchanger material and copper water lines.

Generally, with greater water ow rates, the likelihood of scaling reduces. Therefore, the recommended minimum water ow is

1.5 gpm per ton. Recommended minimum ow rate for entering

water temperatures below 50°F is 2.0 gpm per ton.

Keep all air out of the water. An open loop system should be checked to ensure that the well head is not allowing air to

inltrate the water line. Lines should always be airtight. Keep

the system under pressure at all times. It is recommended in open loop systems that the water control valve be placed in the discharge line to prevent loss of pressure during off cycles. Closed loop systems must have positive static pressure.

GEO16-504.2

MAINTENANCE

Cabinet

If a ood occurs, try to expel water as soon as possible. Water

contact for any duration will cause corrosion on the cabinet

nish. All units mounted on the ground should be installed on

an absorption pad. This also helps prevent water from entering the cabinet. If the cabinet is dirty, do not spray with water, use a damp rag with mild detergent, and wipe the system clean.

Refrigerant System

The refrigerant circuit is sealed; service gauges should not be used unless the system is not operating correctly.

The operational charts show correct pressures, ow and

temperature. Before servicing the refrigerant circuit, ensure that

the water ows are correct.

Replacement Parts

For ease of identication when ordering replacement parts

or contacting the factory about your unit, please provide the complete model number and unit serial number. This information can be found on the serial plate attached to your unit (see Figure 17.1).

When a component part fails, a replacement part should be obtained by contacting your local distributor or Modine Sales Representative. Your sales representative can assist with Return Material Authorizations (RMAs) and potential warranty claims. The following details are required to process parts orders and warranty claims:

1. Full description of part required, including unit’s model

number.

2. The complete unit’s serial number.

3. Completed Return Material Authorization (RMA)

4. An appropriate purchase order number.

For further information email modinegeothermal@

ccsportal.com or call 1-877-679-4436 (4GEO).

Figure 17.1 - Serial Plate EXAMPLE

GEO16-504.2

REPLACEMENT PARTS

Table 18.1 - Common Replacement Parts

Part Description

Compressor

Hot Water Generator

02,03

Power Code

Compressor

04,05

All Models

036 048 060 066 098 120 132

Code

01,03

3 Soft Start 5H0834140002

All Control Transformer 5H0749490001

All Contactor 5H0834310001

Code

01,03 Compressor 5H1028043612 5H1028045112 5H1028045712 5H1028047212 5H1028045112 5H1028045712 5H1028047212

All Control Transformer 5H0749490001

All Contactor 5H0834310003

Compressor 5H1028043611 5H1028045111 5H1028045711 5H1028047211 5H1028045111 5H1028045711 5H1028047211

Compressor Run

Capacitor

Desuperheater (DHW)

Pump

Expansion Valve 5H0834040004 5H0834040005 5H0834040006 5H0834040006 5H0834040005 5H0834040006 5H0834040006

Filter / Drier 5H0834050002 5H0834050002 5H0834050003 5H0834050003 5H0834050002 5H0834050003 5H0834050003

Reversing Valve 5H1028300001 5H1028300001 5H1028300005 5H1028300005 5H1028300001 5H1028300005 5H1028300005

Water Line Fitting

Gasket / Spacer Set

High Pressure Switch 5H0834070001

Low Pressure Switch 5H0834070002

5H1036890003 5H1036890007 5H1036890008 5H1036890010 5H1036890007 5H1036890008 5H1036890010

5H0834230001

3H0387930000

GEO16-504.2

TROUBLESHOOTING

General

When encountering a unit with operational faults, complete these preliminary system checks before utilizing the troubleshooting charts.

In order to maintain system integrity, performance and

efciency, do not install service gauges unless unit operation

appears abnormal and all other diagnostic checks are normal. Verify water source and load side temperatures changes against typical operating data. If the performance is within the ranges in

the table and the water ows have been veried, then gauges

may be installed in order to check subcooling and superheat.

1. Verify that the unit and ow center power supplies are on.

2. Verify that all fuses or disconnects switches are intact.

3. Inspect unit for obvious defects (e.g., leaking connections,

loose or damaged wiring, etc.).

4. Verify eld inputs and outputs (refer to wiring diagram).

a. Aquastat inputs – Aquastat inputs are 24VAC signals and

can be veried using a volt meter.

b. Outputs – Compressor and reversing valve output relays

are 24VAC and can be veried using a voltmeter. The ow

center and DHW pump are powered through 240V relays.

Operation can be veried using a voltmeter or clamp-on

ammeter.

5. After completing these checks, refer to the troubleshooting

tables on the next pages.

GEO16-504.2

TROUBLESHOOTING

Mode

Cause

Htg

Clg

Locked out on safety controls

Table 20.1 - Troubleshooting

Fault

No power

to unit

X X Power Failure No voltage at line side of compressor contactor. Check disconnect switch and power distribution panel.

X X

Possible

Open disconnect

switch

Blown fuse /

circuit breaker

tripped

Verify Action

At heat pump disconnect, voltmeter shows voltage on the line side but not on the load side.

Check fuses and circuit breaker.

Determine why the disconnect switch was opened. Close disconnect if safe to do so.

Reset circuit breaker or replace fuses with proper size and type. Verify total load on system and proper fuse / circuit breaker sizing.

Compressor

not

operating

X X

X X Aquastat wiring Verify wiring at unit and signals at unit. Repair wiring, if needed.

X X Transformer

X X

Low supply

voltage

Power wiring

defect

Defective

compressor

overload

Compressor

motor burn out

or open windings

Defective

compressor

contactor

Loss of

compressor run

signal

Voltmeter shows abnormally low voltage at heat pump disconnect switch (below 95% of serial plate voltage).

Check primary and secondary transformer voltages.

Check transformer secondary voltage circuit breaker. Reset breaker if tripped.

Check for loose or broken wires at compressor, contactor and capacitor.

Check for fault. Address lockout and cycle power to unit to reset controller.

Ensure that compressor is cool and overload has had

sufcient time to reset. Ohmmeter shows a resistance across R & S terminals and OPEN or innite resistance

between C & R or C & S terminals.

Ohmmeter shows no resistance or OPEN between common and run terminals.

*NOTE: Make sure the compressor is rested.

Voltage on line side and contactor pulled in, but no voltage on one or both terminals on the load side.

Voltage on line side, 24VAC across contactor coil and no voltage on load side.

Voltage on line side of contactor veried and contactor won’t pull in. No 24VAC on compressor contactor coil when

24VAC is present at controller and controller fuse is intact.

Call power company.

If no primary, verify wiring. If no, or low secondary, check transformer wiring. If wiring ok, replace transformer.

Repair wiring, if needed.

If windings are open or overload is faulty, replace compressor.

Troubleshoot cause and replace motor.

Points damaged. Replace contactor.

Bad coil, replace contactor.

Replace controller.

Unit

“short cycles”

X X

X X Unit is oversized Verify load calculations and unit selection.

X X

Defective run

capacitor

Defective

compressor

overloads

Wiring and

controls

Measure resistance across capacitor terminals. If shorts exist, capacitor is defective.

Ensure that compressor is cool and overload has had

sufcient time to reset. Ohmmeter shows a resistance across R & S terminals and OPEN or innite resistance

between C & R or C & S terminals.

Examine all wiring points. Tighten all wiring points.

Replace, if faulty.

If windings are open or overload is faulty, replace compressor.

GEO16-504.2

TROUBLESHOOTING

Table 21.1 - Troubleshooting

Fault

Low

pressure

cutout

Mode

Htg Clg

Possible

Cause

Reduced water

Scaled or plugged

coaxial coil

Water supply

too cold

Entering water

too cold

Reduced water

ow

Verify Action

Check ow center operation. Troubleshoot ow center.

Manually open water valve and measure water ow. Adjust to proper ow rate.

Plugged water strainer or lter. Replace or clean, if dirty.

Check temperature drop across coaxial coil. Clean, if necessary.

Verify GEO IN with temperature probe.

Measure return water temperature, should be above 50ºF. Bring return water temperature within design parameters.

Verify hydronic pump operation. Troubleshoot pump.

Manually open water valve and measure water ow. Adjust to proper ow rate.

Plugged water strainer or lter. Replace or clean, if dirty.

Verify loop sizing; verify that all air has been purged from ground heat exchanger; bring water temperature within design parameters.

High

pressure

cutout

X X

X X Restricted TXV Verify superheat and subcooling values. Replace, if necessary.

X X

X X Restricted TXV Verify superheat and subcooling values. Replace, if necessary.

X X

Low refrigerant

charge

Plugged bi-ow

lter / drier

Defective low

pressure switch

Reduced water

ow

Water supply

too hot

Scaled or plugged

coaxial coil

Reduced water

Water

temperature out

of range

Defective high

pressure switch

Overcharged with

refrigerant

Non-condensables

in system

low

Check for refrigerant leaks.

Verify that low pressure cut-out occurs in heating mode and not in cooling mode.

Monitor suction pressure while operating, verify low

pressure cut-out pressure (25 +/- 5 psig).

Check ow center operation. Troubleshoot ow center.

Manually open water valve and measure water ow. Adjust to proper ow rate.

Plugged water strainer or lter. Clean or replace.

Verify GEO IN with temperature probe.

Check temperature drop across coaxial coil. Clean, if necessary.

Verify hydronic pump operation. Troubleshoot pump operation.

Manually open water valve and measure water ow. Adjust to proper ow rate.

Plugged water strainer or lter. Replace or clean, if dirty.

Measure return water temperature, should be below 90ºF. Bring return water temperature within design parameters.

Monitor discharge pressure while operating, verify high

pressure cut-out pressure (600 +/- 25 psig).

Verify superheat and subcooling values. Evacuate and recharge to factory recommended charge.

If leaks found, evacuate, repair and recharge to factory recommended charge.

Replace lter if necessary.

Replace, if defective.

Verify loop sizing; bring water temperature within design parameters.

Replace, if defective.

GEO16-504.2

TROUBLESHOOTING

Table 22.1 - Troubleshooting

Fault

Mode

Htg Clg

Loss of control

Possible

Cause

signal

Verify Action

In cooling mode, verify 24VAC at RV coil and at REV terminals.

If 24VAC exists, troubleshoot RV and coil. If no control signal, troubleshoot aquastat signals.

Unit

will not

operate

in cooling

mode

Insufcient

cooling or

heating

Noisy unit

Defective

reversing valve

Aquastat

setup / wiring

Aquastat

operation

No water ow,

high pressure

cutout

X X Unit undersized Verify load calculations and unit selection.

Defective

reversing valve

X X

X X Ambient losses

X X

X X Restricted TXV Verify superheat and subcooling values. Replace, if necessary.

X X Compressor Troubleshoot compressor operation.

X X

X X Remove compressor mounting bolts.

X X

Reduced water

ow

Low refrigerant

charge

Scaled or plugged

coaxial coil

Reduced water

ow

Water supply

too hot

Water supply

too cold

Non-

condensables

in system

Compressor

Rattles and

vibrates

Verify operation of reversing valve and solenoid coil.

Verify aquastat setup and wiring. Repair wiring, if needed.

Verify proper aquastat signals to unit. Replace, if necessary.

Check ow with ow meter. Check pump operation.

Verify operation of reversing valve and solenoid coil. Defective reversing valve creating bypass of refrigerant from discharge to suction side of compressor.

Verify hydronic pump operation. Troubleshoot pump operation.

Manually open water valve and measure water ow. Replace or clean if dirty.

Plugged water strainer or lter. Replace or clean, if dirty.

Check for losses / gains due to ambient air inltration

through doors and windows.

Check superheat and subcooling values. Check for refrigerant leaks.

Check temperature drop across coaxial coil. Clean, if necessary.

Check ow center operation. Troubleshoot ow center.

Manually open water valve and measure water ow. Adjust to proper ow rate.

Plugged water strainer or lter. Replace or clean, if dirty.

Verify GEO IN with temperature probe.

Verify superheat and subcooling values.

Make sure the compressor is not in direct contact with the base or sides of the cabinet. Cold surroundings can cause liquid slugging, increase ambient temperature.

Check for loose screws, panels, or internal components. Tighten and secure. Piping could be hitting the metal surfaces. Add insulation between the contact.

Replace, if defective. When it is necessary to replace the reversing valve, wrap it with a wet cloth and direct the heat away. Excessive heat can damage the valve.

If excessive, it may possible to rectify with shading and insulation.

Replace, if defective. When it is necessary to replace the reversing valve, wrap it with a wet cloth and direct the heat away. Excessive heat can damage the valve.

Address issue.

If leaks found, evacuate, repair and recharge to factory recommended charge.

Verify loop sizing; bring water temperature within design parameters.

If discharge pressure is too low and suction pressure too high, compressor is not pumping properly. Replace compressor.

Evacuate and recharge to factory recommended charge.

X X Pump cavitation Purge air from closed loop system.

GEO16-504.2

START UP / TROUBLESHOOTING FORM

Loop Type _________________

_______________

_______

When

Technician Notes

Customer Name ______________________________________ Date ________________

Address ______________________________________________________________

Model # ____________________________ Serial # ______________________________ Antifreeze

__ Startup __Troubleshooting, Complaint _____________________________________________________

COOLING CYCLE ANALYSIS

HEATING CYCLE ANALYSIS

Note: In order to maintain optimal performance, DO NOT hook up pressure gauges during start up procedures.

troubleshooting, conduct water side analysis first. If water-side performance is poor, use of pressure gauge and

When troubleshooting, conduct water side analysis  rst. If water side performance is poor, use of pressure gauge

refrigerant side analysis may be required.

and refrigerant side analysis may be required.

Technician Notes

GEO16-504.2

COMMERCIAL WARRANTY (For Residential Warranty, see GEO16-510)

Seller warrants its products to be free from defects in material and workmanship, EXCLUSIVE, HOWEVER, of failures attributable to the use of materials substituted under emergency conditions for materials normally employed. This warranty covers replacement of any parts furnished from the factory of Seller, but does not cover labor of any kind and materials not furnished by Seller, or any charges for any such labor or materials, whether such labor, materials or charges thereon are due to replacement of parts, adjustments, repairs, or any other work done. This warranty does not apply to any equipment which shall have been repaired or altered outside the factory of Seller in any way so as, in the judgment of Seller, to affect its stability, nor which has been subjected to misuse, negligence, or operating conditions in excess of those for which such equipment was designed. This warranty does not cover the effects of physical or chemical properties of water or steam or other liquids or gases used in the equipment.

BUYER AGREES THAT SELLER’S WARRANTY OF ITS PRODUCTS TO BE

FREE FROM DEFECT IN MATERIAL AND WORKMANSHIP, AS LIMITED HEREIN, SHALL BE IN LIEU OF AND EXCLUSIVE OF ALL OTHER WARRANTIES, EITHER EXPRESS OR IMPLIED, WHETHER ARISING FROM LAW, COURSE OF DEALING, USAGE OF TRADE, OR OTHERWISE,

THERE ARE NO OTHER WARRANTIES, INCLUDING WARRANTY OF MERCHANTABILITY OR FITNESS FOR PURPOSE, WHICH EXTEND BEYOND THE PRODUCT DESCRIPTION CONFIRMED BY BUYER AND SELLER AS OF THE DATE OF FINAL AGREEMENT.

This warranty is void if the input to the product exceeds the rated input as indicated on the product serial plate by more than 5% on gas-fired and oil-fired units, or if the product in the judgment of SELLER has been installed in a corrosive atmosphere, or subjected to corrosive fluids or gases, been subjected to misuse, negligence, accident, excessive thermal shock, excessive humidity, physical damage, impact, abrasion, unauthorized alterations, or operation

contrary to SELLER’S printed instructions, or if the serial number has been

altered, defaced or removed.

BUYER AGREES THAT IN NO EVENT WILL SELLER BE LIABLE FOR COSTS OF PROCESSING, LOST PROFITS, INJURY TO GOODWILL, OR ANY OTHER CONSEQUENTIAL OR INCIDENTAL DAMAGES OF ANY KIND RESULTING FROM THE ORDER OR USE OF ITS PRODUCT, WHETHER ARISING FROM BREACH OF WARRANTY, NONCONFORMITY TO ORDERED SPECIFICATIONS, DELAY IN DELIVERY, OR ANY LOSS SUSTAINED BY THE BUYER.

BUYER’S REMEDY FOR BREACH OF WARRANTY, EXCLUSIVE OF ALL

OTHER REMEDIES PROVIDED BY LAW, IS LIMITED TO REPAIR OR REPLACEMENT AT THE FACTORY OF SELLER, ANY COMPONENT WHICH SHALL, WITHIN THE APPLICABLE WARRANTY PERIOD DEFINED HEREIN AND UPON PRIOR WRITTEN APPROVAL, BE RETURNED TO SELLER WITH TRANSPORTATION CHARGES PREPAID AND WHICH THE EXAMINATION OF SELLER SHALL DISCLOSE TO HAVE BEEN DEFECTIVE; EXCEPT THAT WHEN THE PRODUCT IS TO BE USED BY BUYER AS A COMPONENT PART OF EQUIPMENT MANUFACTURED BY BUYER,

BUYER’S REMEDY FOR BREACH, AS LIMITED HEREIN, SHALL BE

LIMITED TO ONE YEAR FROM DATE OF SHIPMENT FROM SELLER. FOR GAS-FIRED PRODUCTS INSTALLED IN HIGH HUMIDITY APPLICATIONS

AND UTILIZING STAINLESS STEEL HEAT EXCHANGERS, BUYER’S

REMEDY FOR BREACH, AS LIMITED HEREIN, SHALL BE LIMITED TO TEN YEARS FROM DATE OF SHIPMENT FROM SELLER.

These warranties are issued only to the original owner-user and cannot be transferred or assigned. No provision is made in these warranties for any labor allowance or field labor participation. Seller will not honor any expenses

incurred in its behalf with regard to repairs to any of Seller’s products. No

credit shall be issued for any defective part returned without proper written authorization (including, but not limited to, model number, serial number, date of failure, etc.) and freight prepaid.

OPTIONAL SUPPLEMENTAL WARRANTY Provided a supplemental warranty has been purchased, Seller extends the

warranty herein for an additional four (4) years on certain compressors. Provided a supplemental warranty has been purchased, Seller extends the warranty herein for an additional four (4) years or nine (9) years on certain heat exchangers.

EXCLUSION OF CONSUMABLES & CONDITIONS BEYOND SELLER’S

CONTROL This warranty shall not be applicable to any of the following items: refrigerant

gas, belts, filters, fuses and other items consumed or worn out by normal wear and tear or conditions beyond Seller’s control, including (without limitation as to generality) polluted or contaminated or foreign matter contained in the air or water utilized for heat exchanger (condenser) cooling or if the failure of the part is caused by improper air or water supply, or improper or incorrect sizing of power supply.

Component

Applicable Models

Heat Exchangers

Gas-Fired Units

Heat Exchangers

Low Intensity Infrared Units

Compressors

Condensing Units for Cassettes

Burners

Low Intensity Infrared Units

Other

Components excluding Heat Exchangers, Coils, Condensers, Burners, Sheet Metal

Heat Exchangers/Coils

Indoor and Outdoor Duct Furnaces and System Units, Steam/Hot Water Units, Oil-Fired Units, Electric Units, Cassettes, Vertical Unit Ventilators, Geothermal Units

Compressors

Vertical Unit Ventilators, Geothermal Units

Burners

High Intensity Infrared Units

Sheet Metal Parts

All Products

“APPLICABLE WARRANTY PERIOD”

TEN YEARS FROM DATE OF FIRST BENEFICIAL USE BY BUYER OR ANY OTHER USER, WITHIN TEN YEARS FROM DATE OF RESALE BY BUYER OR ANY OTHER USER, WITHIN TEN YEARS FROM DATE OF RESALE BY BUYER IN ANY UNCHANGED CONDITION, OR WITHIN ONE HUNDRED TWENTY-SIX MONTHS FROM DATE OF SHIPMENT FROM SELLER, WHICHEVER OCCURS FIRST

FIVE YEARS FROM DATE OF FIRST BENEFICIAL USE BY BUYER OR ANY OTHER USER, WITHIN FIVE YEARS FROM DATE OF RESALE BY BUYER OR ANY OTHER USER, WITHIN FIVE YEARS FROM DATE OF RESALE BY BUYER IN ANY UNCHANGED CONDITION, OR WITHIN SIXTY-SIX MONTHS FROM DATE OF SHIPMENT FROM SELLER, WHICHEVER OCCURS FIRST

TWO YEARS FROM DATE OF FIRST BENEFICIAL USE BY BUYER OR ANY OTHER USER, WITHIN TWO YEARS FROM DATE OF RESALE BY BUYER IN ANY UNCHANGED CONDITION, OR WITHIN THIRTY MONTHS FROM DATE OF SHIPMENT FROM SELLER, WHICHEVER OCCURS FIRST

ONE YEAR FROM DATE OF FIRST BENEFICIAL USE BY BUYER OR ANY OTHER USER, WITHIN ONE YEAR FROM DATE OF RESALE BY BUYER IN ANY UNCHANGED CONDITION, OR WITHIN EIGHTEEN MONTHS FROM DATE OF SHIPMENT FROM SELLER, WHICHEVER OCCURS FIRST

As Modine Manufacturing Company has a continuous product improvement program, it reserves the right to change design and specifications without notice.

Modine Manufacturing Company

1500 DeKoven Avenue Racine, WI 53403 Phone: 1.877.679.4436 (4GEO)

www.modinehvac.com

Modine Manufacturing 036, 048, 066, 060, 096 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual