Modine Manufacturing GEO16-501.4 Service Manual

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GEO16-501.4

5H0839240000

January, 2016

INSTALLATION AND SERVICE MANUAL

ground source heat pump split unit

model GS/ES

NOTE: Energy Star only applies to certain configurations.

NOTE: GS Split Units are Energy Star Rated only when matched with the appropriate Modine GA Air Handler or Modine A-Coil. Model ES Split Units are not Energy Star Rated.

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. GS/ES Split 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 use these units to heat or cool the building during construction. Mechanical components can quickly become clogged with debris. System damage may result.

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

ooding the compressor with liquid.

4. 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 22.1-24.1, 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

Unit Location........................................5

Installation ........................................ 5

SI (Metric) Conversion Factors........................5

Water Connections.................................6

Wiring ..........................................10

Electrical Specications ..............................13

Start-Up Procedure..................................14

Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Maintenance.......................................19

Replacement Parts................................20

Serial Plate – Example .............................20

Troubleshooting ....................................21

Start Up/Troubleshooting Form ........................25

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

GEO16-501.4

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) GS - Residential Split Unit ES - Commercial Split Unit

3 - Unit Configuration (UC) I - Indoor

4,5,6 - Nominal Cooling Capacity (MBH) 024 - 24,000 Btu/hr 036 - 36,000 Btu/hr 048 - 48,000 Btu/hr 060 - 60,000 Btu/hr 072 - 72,000 Btu/hr

7 - Development Sequence Designation (DS) D - Current

8 - Compressor Configuration (CC) 2 - Two Stage 4 - Two Stage w/Soft Start

9,10 - Supply Voltage (SV) 03 - 208-230/60/1

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

11 - Controls Type (CT) 4 - Modine Controls System

12 - Air Coil (AC) N - None

13 - Geo (Source) Coaxial Coil Material (GM) C - Copper N - Cupro-Nickel

14 - Hydronic (Load) Coaxial Coil Material (HM) X - None

15 - Hot Water Generator or Desuperheater (HWG) 0 - None 1 - Hot Water Generator - Factory Installed Pump

16 - Motor Type (MT) N - None

17 - Supply Air Configuration (SA) N - None

18 - Return Air Configuration (RA) N - None

YEAR OF MANUFACTURE

SPO NUMBER

Serial Number

SPO MODEL

STACKED UNIT

0 - Standard 1 - Stacked

S 0 40 20 1 2 11 14 1234 12345

SEQUENTIAL NUMBER

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

MOTOR SUPPLIER

40 - AO Smith 51 - Genteq 00 - None

COMPRESSOR

1 - Copeland

BLOWER SUPPLIER

20 - Morrison 00 - None

WEEK OF MANUFACTURE

GEO16-501.4

UNIT DIMENSIONS

Figure 4.1 - Unit Dimensions

Table 4.1 - Dimensions (inches)

Models 024 036 048 060

A 23.13 23.13 23.13 23.13 23.13

Overall

Cabinet

Electrical

Geo & DHW

Control M 11.57 11.57 11.57 11.57 11.57

Refrigerant

Liquid Line

Connection - Sweat

Suction Line

Connection - Sweat

Coil Connection

Size (Female Swivel)

Approx. Shipping

Weight (lbs.)

B 25.65 25.65 25.65 25.65 25.65

C 25.65 25.65 25.65 25.65 25.65

D 17.07 15.44 17.31 17.07 17.07

E 14.26 12.82 14.68 14.26 14.26

F 11.76 10.32 12.18 11.76 11.76

H 2.00 2.00 2.00 2.00 2.00

J 7.14 7.14 7.14 7.14 7.14

K 14.24 14.24 14.24 14.24 14.24

L 21.25 18.62 17.36 21.25 21.25

N 8.28 7.54 8.32 8.28 8.28

O 5.35 4.85 5.38 5.35 5.35

3/8 3/8 3/8 1/2 1/2

5/8 3/4 3/4 7/8 7/8

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

218 218 268 306 308

072

GEO16-501.4

UNIT LOCATION / INSTALLATION

Table 5.1 - 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 m3/min

(°F-32) x 0.555

°C

To Convert Multiply By To Obtain

CFH 1.699 m3/min Btu/ft3 0.0374 mJ/m pound 0.453 kg Btu/hr 0.000293 kW/hr gallons 3.785 liters 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.

Storage

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

CAUTION

Do store or install units in corrosive environments or in locations subject to temperature or humidity extremes (e.g., attics, garages, rooftops, etc.). 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.

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 in Figure 4.1.

INSTALLATION

IMPORTANT

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.

The unit must be located in a conditioned space that will remain above freezing and where humidity levels could cause cabinet condensation.

GEO16-501.4

INSTALLATION

Unit Installation

1. Units should be mounted on a vibration-absorbing pad slightly larger than the base of the unit. See Table 6.1 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 6.1 - Vibration Absorbing Pads - High Density Plastic

Pad Size Part Number Models

32" X 32" 5H0835220000 024-036

36" X 36" 5H0835230000 048-072

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.

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"

Figure 6.1 - Water Connection Breakdown

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. Refer to Figure 6.1. Install the brass spacer and rubber gasket in swivel connector prior to attempting any connection (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.

Installation with Existing Air Handler or Refrigerant Coil

Modine recommends installing Split units with a new matching Modine Air Handling or A-coil unit, but the Split unit may be matched with an existing air handler or coil if the following conditions are met:

1. Coil must be R-410A rated and use a heat pump thermal expansion valve with internal check valve.

2. The air coil and line set have been ushed with a compound

that vaporizes in accordance with the instructions provided

with the ushing agent.

Follow the air handler manufacturer’s installation instructions to

install the air handler. Note that such installations do not qualify for Energy Star.

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

GEO16-501.4

INSTALLATION

Dual Fuel Setup

A conventional fossil fuel forced air furnace may also be used for an air handler, as well as a supplemental heat source. The furnace must provide at least 400 CFM/Ton of nominal unit cooling capacity. Refer to the Cased / Uncased Coil I&S manual

for exact airow requirement for the rated matched systems.

The furnace should be disabled until auxiliary heating is called for, then the heat pump should be disabled when the furnace

takes over the heat load. Refer to the furnace manufacturer’s

installation instructions for directions on installation of the furnace, coil, and wiring. A Dual Fuel Thermostat is required to prevent damage to the split unit (see Figure 12.1).

Refrigerant Line Sets

Only ACR grade copper tubing should be used. Recommended line sets are shown in Table 9.2. Refer to the table for proper line sizing, as well as maximum allowable lengths of the line set. The table is based on equivalent line length. Equivalent Line Length is the combination of the actual lengths of all straight

runs and the equivalent length of all bends valves and ttings in

a particular line. Refer to the ASHRAE Fundamentals Handbook for determining the equivalent lengths of bends, valves and

ttings. If calculated equivalent line length is between two

lengths in Table 9.2, use the size for the next longer length. Line sets over 60 feet are not recommended and can lead to oil

return problems, which can dramatically reduce the life of the compressor, and excessive pressure drop, which can reduce

capacity and efciency of the system.

Vertical lines should be kept to a minimum. Large vertical lifts will increase pressure drop in the liquid line. Whenever possible, the air handler or cased / uncased A-coil should be installed above the unit to aid in oil return. Horizontal suction lines should be pitched slightly toward the unit to aid in oil return. Do not exceed the largest suction line size in the table for each given unit size. Bends and turns should be avoided if possible and all wall penetrations should be sealed. Line sets must be suspended properly and should not contact anything except the hangers and insulation. Ends of copper lines should be kept sealed until joints are brazed. All lines should be insulated

with 3/8" thick insulation at minimum. The lter drier should be

replaced whenever the lines are broken into for service.

All brazing should be done with nitrogen owing through the

inside of the tubing at 2-3 psi to prevent oxidation. A low silver phos-copper braze alloy is recommended. When brazing to the Split Unit service valves, wrap the valves in a wet rag to prevent damage to the valves. NOTE: The Split Unit is shipped with a factory refrigerant charge. The service valves should not be opened until the entire line set has been leak tested, purged and evacuated.

Existing Line Sets

New line sets are recommended, but required if the following conditions exist:

• A compressor burnout occurred in the previous system

• Oil traps were installed in the existing line sets

• The existing line set sizes are not equal the recommended line sets

• The existing line set shows signs of damage, corrosion, abrasion or fatigue

Thermal Expansion Valve

The Split Ground Source Unit is equipped with a thermal expansion valve (TXV) that is pre-set from the factory for performance. No adjustment is necessary unless service has been done on the TXV. Table 9.1 shows the Split Unit TXV initial factory settings. Note that the matched Split System has

two TXV’s, each with independent factory settings. One TXV is

included with the A-coil or Air Handler, and one is installed in the Split unit. Refer to the Cased / Uncased or Air Handler I&S manual for the initial factory TXV settings at the A-coil.

WARNING

R-22 RETROFITS

It is highly recommended that a new line set be installed for

any R-22 system retrot. If it is impossible to replace the line set, the line set must be ushed prior to the installation

of the R-410A split system. It is also critical that the installer clear traps of all residual mineral oils.

GEO16-501.4

INSTALLATION

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.

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

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.

Figure 8.1 - Typical DHW Piping Diagram

COLD

WATER

HOT

WATER

OUT

IMPORTANT

All piping and connections must be made in accordance with local plumbing codes. All components should be located in a conditioned space that is maintained above 50°F at all times.

Hot Water Generator (Desuperheater) Installation (If Equipped)

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. Control of the DHW pump is via electro-mechanical temperature switches. The pump is energized whenever the unit is running a conditioning cycle, the DWH supply temperature (water leaving the desuperheater coil) is < = 120°F and the compressor discharge temperature is > = 100°F.

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 feet.

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.

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 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.

Figure 8.2 - Typical DHW Piping Diagram with Two Tanks

Table 8.1 - DHW Pipe Sizes

GEO16-501.4

AIR VENT

DHW IN

DHW OUT

DRAIN CONNECTION

AIR VENT

DHW IN

DHW OUT

DRAIN CONNECTION

Maximum pipe length (one way) to achieve optimum flow

Models

024 0.8 50 -

036 1.2 50 -

048 1.6 45 50

060 2.0 25 50

072 2.4 10 50

DHW Flow

(gpm)

COLD

WATER

TANK 1 HEATING SOURCE

DISABLED

DRAIN VALVE

Copper

DRAIN VALVE

HOT

WATER

OUT

1/2"

COLD

WATER

3/4" Copper

HOT

WATER

OUT

INSTALLATION

Leak Testing and Evacuating the Refrigeration System

Pressurize the line set and air coil with 150 psi dry nitrogen and thoroughly check for leaks. Once a leak free system is

veried, purge the system and evacuate the line set and air

coil to at least 500 microns. Use both service ports to prevent false readings. A quality vacuum pump capable of accurately measuring vacuum depth is required to ensure system is ready for charging. System must hold vacuum for a minimum for 30 minutes.

Charging the System

Do not overcharge the system. Charge all systems by weight as determined from Table 9.2 and the supplied factory charge. Factory charge includes, split unit charge, A-coil charge and a 25' line set. If the line set varies from 25', then a charge adjustment must be calculated.

Table 9.1 - Initial Split Unit TXV Superheat Settings

Models

024 036 048 060 072

TXV Turns

Closed

Verify final settings after initial adjustments.

3-1/4 4-3/4 5-1/4 6-1/4 5-1/4

Table 9.2 - Line Sizing and Initial Refrigerant Charges

Equivalent Line Length

Air Handler

Size

024 024 024

036 036 036

048 048 048

060 060 060

072 N/A 072

 Initial system charge includes Split unit charge, 25' line charge, and Air Coil charge. Adjust charge via actual system subcooling and superheat measurements.

Additional charge for R-410A is 1.0 oz/ft for 1/2" line and 0.5 oz/ft for 3/8" line

A-Coil Size

Split Unit

Size

20 Feet 40 Feet 60 Feet

Suction Liquid Suction Liquid Suction Liquid

5/8" 3/8" 5/8" 3/8" 3/4" 3/8" 93 96

3/4" 3/8" 3/4" 3/8" 3/4" 1/2" 99 103

3/4" 3/8" 7/8" 3/8" 7/8" 1/2" 125 128

7/8" 1/2" 7/8" 1/2" 1-1/8" 1/2" 171 175

Split Unit

Factory

Charge (oz)

 - No HWG

Split Unit

Factory

Charge (oz)

 - w/HWG

GEO16-501.4

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 13.1 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 10.1).

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 10.1 - 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 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 and wiring diagram for instructions on enabling the pump.

Transformer Wiring

The system supplies the power to the controller via a 24V transformer. 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 11.1). Refer to the wiring diagram provided with the unit for for details.

GEO16-501.4

INSTALLATION

Figure 11.1 - 208-230V Transformer 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.

Thermostat Wiring

The thermostat wires are connected directly to the appropriate terminal blocks in the electrical box. Refer to the unit wiring diagram or control manual for details.

Thermostat Installation and Wiring

The thermostat should be located on an interior wall in a larger

room approximately 54" off the oor and away from supply

duct drafts. DO NOT locate the thermostat in areas subject to sunlight, drafts or on external walls.

GEO16-501.4

INSTALLATION

Dual Fuel Setup / Thermostat Wiring

When matched with an A-coil and a furnace for the air handler, a dual fuel thermostat is required to prevent furnace from engaging when heat pump is operating. The heat pump is the

rst and second stage of heating and the furnace is the auxiliary

heat.

Figure 12.1 - Field Wiring to Fossil Fuel Furnace

500

〈〈

Control Panel Terminals

〈〈

C 24VAC Common

R 24VAC Hot

G Fan

Y1 Compressor Stage 1

Y2 Compressor Stage 2

W1 Aux Ht Stg 1

W2 Aux Ht Stg 2

Condensate Overflow Alarm

Modine Air Handlers and Cased / Uncased A-coils are supplied

with a condensate pan overow switch which should be wired

back to the Split System with two wires. Terminals are provided

in control panel for eld wiring of condensate overow switch.

Remove the blue jumper wire and wire COS to terminals 533 &

534. Refer to wiring diagram and Figure 12.2.

If the Modine Split unit is matched with an existing air handler or air coil, it is highly recommended a normally closed, condensate

overow switch is installed in the air coil drain pan and wired to

the unit control board. When installed, the controller will shut down the unit in the event of a plugged condensate drain line. Failure to wire the switch to unit may result in damage to the furnace or property.

The condensate switch accessory assembly, 3H0387860001, is

available for eld installation. It is supplied with 75’ of lead wire.

The condensate alarm is a 24V, normally closed, dry contact. The installer may route the leads back to the unit or run two wires.

Figure 12.2 - Condensate Overflow Switch Wiring

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 valve manufacturer's instructions for proper wiring.

Furnace Terminals

GEO16-501.4

ELECTRICAL DATA

Table 13.1 - Electrical Data

Models

024 036 048 060

Supply Voltage 208-230/60/1

Min / Max

Voltage

FLA 15.7 19.7 28.1 34.7 37.6

MCA 18.5 23.5 33.5 41.8 45.4

MOP 30.0 40.0 50.0 70.0 70.0

197 / 253

072

GEO16-501.4

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 thermostat, control wiring and the freeze

protection setpoint completed.

• Transformer wiring is correct.

• Water supply to heat pump is completed.

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

• Air and debris are purged from the ground loop.

• Antifreeze added to ground loop, 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.

• Condensate line is open, condensate drain line is correctly

pitched.

• Blower rotates freely.

• Check air coil for cleanliness.

• Filter is clean and in position.

• Clean all debris from the ducting system.

• Service/access panels are in place.

• Entering air and water temperatures are within operating limits

in Table 16.2.

CAUTION

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.

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

GS/ES systems are pre-programed 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 14.1 - 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.

Unit Startup Procedure

The Startup/Troubleshooting form found on page 25 of this manual may be used to assist during unit startup.

1. Put thermostat in standby or off mode.

2. Turn on line power to heat pump.

3. Turn thermostat fan position to “ON” and verify blower operation.

4. Put thermostat in heating mode.

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

6. After a few minutes, check the supply air and verify warm air delivery.

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

coaxial coil to values in Table 15.1.

8. Monitor ground water supply (GWI) and return (GWO) temperatures. If temperature drop is within expected operating range as shown in Table 16.1, continue with testing.

Propylene

Glycol

GEO16-501.4

START-UP PROCEDURE

9. If temperature drop is outside of expected operating range, check refrigerant pressures and compare to those shown in Table 16.1.

10. Check air temperature rise across the coil. Air temperature

rise should be between 20°F and 30°F.

11. Check for vibration, noise and leaks.

12. Lower thermostat set point below room temperature and

verify that compressor and ow center deactivate.

13. Initiate a control signal to place the unit in the cooling mode.

Cooling set point must be set below room temperature.

14. Cooling will energize after a time delay.

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

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

temperatures. If temperature rise is within expected operating range as shown in Table 16.1, continue with testing.

17. If temperature drop is outside of expected operating range,

check refrigerant pressures and compare to those shown in Table 16.1.

18. Check for an air temperature drop of 15°F to 25°F across

the air coil.

19. Check for vibration, noise and leaks.

20. Adjust the cooling set point above the room temperature and

verify that the compressor and ow center deactivate.

21. 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.

22. 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

thermostat(s).

Blower: The blower will cycle with a call for cooling or heating.

Cool: Upon receiving a a G, Y1, and O signal from the

thermostat, the blower, compressor and reversing valve will be

energized. On two stage units with ECM, the rst stage of the

compressor will be energized and the blower will provide the

rst stage airow. The compressor will be limited by a timer

that will provide anti-cycle protection. When a subsequent Y2 signal is received, the second stage of the compressor will be

energized and the blower will provide second stage airow (two

stage units with ECM only). Heat: Upon receiving a G and Y1 and signal from the

thermostat, the blower and compressor will be energized. On

two stage units with ECM, the rst stage of the compressor will be energized and the blower will provide the rst stage airow.

The compressor will be limited by a timer that will provide anticycle protection. When a subsequent Y2 signal is received, the second stage of the compressor will be energized and the

blower will provide second stage airow (two stage units with

ECM only).

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

Supplemental Electric Heat (Field Installed Accessory): Upon receiving a W1 signal from the thermostat, heat is energized. Upon receiving a W2/E signal from the thermostat, electric heat is energized.

Table 15.1 - Water Pressure Drop, psi (Based on Entering Water Temperature)

Models GPM 30°F 40°F 60°F 90°F 110°F

4.0 0.8 0.8 0.7 0.6 0.6

024

036

048

060

072

5.0 1.1 1.1 0.9 0.8 0.8

6.0 1.4 1.4 1.2 1.1 1.0

7.0 1.8 1.8 1.5 1.4 1.3

8.0 2.2 2.1 1.9 1.7 1.6

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 0.6 0.6 0.5 0.5 0.4

8.0 0.9 0.9 0.8 0.7 0.7

10.0 1.3 1.3 1.1 1.0 1.0

12.0 1.7 1.7 1.5 1.4 1.3

14.0 2.2 2.2 2.0 1.8 1.7

9.0 1.1 1.2 1.0 0.9 1.0

12.0 1.8 1.9 1.7 1.5 1.6

15.0 2.7 2.7 2.5 2.2 2.3

18.0 3.8 3.7 3.4 3.1 3.0

21.0 5.0 4.9 4.5 4.1 3.9

24.0 6.3 6.2 5.8 5.3 4.9

Table 15.2 - Antifreeze Pressure Drop Corrections

Antifreeze Type

Ethylene Glycol

Propylene Glycol

Ethanol

Methanol

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

Correction Factor

Equation 15.1 - 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:

WPDA = WPDS x ACF

Where:

WPDA = Water Pressure Drop at Actual Conditions

WPDS = Water Pressure Drop at Standard Conditions

(water) from Table 18.1

ACF = Antifreeze Correction Factor from Table 18.2

GEO16-501.4

START-UP PROCEDURE

Table 16.1 - 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 15-21

3.0 72-80 290-315 8-12 3-9 3-5 17-23

1.5 100-110 315-345 9-13 5-11 7-9 22-28

3.0 104-114 320-350 9-13 5-11 5-7 24-30

1.5 134-144 355-395 10-14 6-12 9-11 30-36

3.0 138-148 360-390 10-14 6-12 7-9 32-38

Water Flow

(gpm/ton)

1.5 122-130 220-235 13-19 10-16 19-23 21-25

3.0 120-128 190-210 13-19 10-16 9-12 21-25

1.5 127-136 210-280 11-15 8-14 19-23 20-24

3.0 125-134 250-270 11-15 8-14 9-12 20-24

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

3.0 130-142 330-350 10-14 8-14 9-12 18-22

Table 16.2 - Operating Limits

Operating Limits Cooling, °F Heating, °F

Min. Ambient 45 45

Rated Ambient 80.6 68

Max Ambient 100 85

Min. Entering Air 50 40

Rated Entering Air, db/wb 80.6/66.2 68/59

Suction

Pressure

(psig)

Suction

Pressure

(psig)

Heating - No Desuperheater

Discharge

Pressure

(psig)

Superheat

(°F)

Cooling - No Desuperheater

Discharge

Pressure

(psig)

Superheat

(°F)

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 dependant upon three primary factors:

1) water temperature, 2) return air temperature, and 3) ambient temperature. 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.

Subcool

(°F)

Subcool

(°F)

Water

Temperature

Drop (°F)

Water

Temperature

Rise (°F)

Air

Temperature

Rise (°F)

Air

Temperature

Drop (°F)

Max. Entering Air, db/wb 110/83 80

Min. Entering Water 30 20

Normal Entering Water 50-90 30-60

Max. Entering Water 120 90

GEO16-501.4

START-UP PROCEDURE

Table 17.1 - Compressor Winding Resistance (Ohms)

Compressor C to S C to R S to R

ZPS20K5E-PFV 1.64 1.30 2.94

ZPS26K5E -PFV 1.91 1.02 2.93

ZPS30K5E -PFV 1.52 0.89 2.40

ZPS35K5E -PFV 1.55 0.62 2.17

ZPS40K5E-PFV 1.87 0.52 2.38

ZPS49K5E-PFV 1.67 0.42 2.09

ZPS51K5E-PFV 1.67 0.42 2.09

ZPS60K5E-PFV 1.91 0.36 2.27

Table 17.2 - 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 Air Flow / Load Water Flow - Heating High High High High Low High Low / Normal

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

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

High Air Flow / 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 Indoor Air / Load Water Temp - Heating Low Low Low Low / Normal High High Normal / High

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

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

High Indoor Air / 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) Normal Low Normal 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 drier to verify a restriction.

Head Press.

High Low Low / Normal High High Low Low

Suct.

Press.

Comp Amp

Draw

Superheat Subcool

Air Temp

Diff.

Water (Source)

Temp Diff

GEO16-501.4

TECHNICAL DATA

Table 18.1 - Technical Data

Model Size

024 036 048 060 072

Compressor Two Stage Copeland Ultratech

Coaxial Coil Internal Water Volume, gal. 1.1 1.8 2.1 2.5 2.5

Nominal Coaxial Water Flow Rate, GPM 6.0 9.0 12.0 15.0 18.0

Nominal Cooling Capacity, Tons ① 2.0 3.0 4.0 5.0 6.0

MATCHING GA/EA AIR HANDLER 024 036 048 060 072

MATCHING CASED / UNCASED COIL, 3H038824- 1024 / 0024 1036 / 0036 1048 / 0048 1060 / 0060 -

➀ Cooling capacity based on 350 CFM , 75/63°F Dry Bulb/Wet Bulb Return Air

GEO16-501.4

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 22.1 - 24.1, 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 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.

Coaxial Coil Maintenance – Ground Loop Applications

Generally water 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.

Air Filters

Filters must be clean to obtain maximum performance. They should be inspected monthly under normal operating conditions and be replaced when necessary. Units should never be

operated without a lter.

Condensate Drain

In areas where airborne bacteria produce slime in the drain pan, it may be necessary to treat chemically with an algaecide approximately every three months to minimize the problem. It may be necessary to clean the condensate pan periodically to insure indoor air quality. The condensate drain can pick up lint

and dirt, especially with dirty lters. Inspect twice a year to avoid the possibility of overow.

Compressor

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

Blower Motors

All units have lubricated fan motors. Do not lubricate unless obvious, dry operation is inspected. Periodic oiling is not required (may lead to excessive dirt buildup & motor failure). Check the operation amperage annually to ensure the amp draw is not greater than 10% of data indicated on the name plate. ECM fan motors need NO oiling.

GEO16-501.4

MAINTENANCE / REPLACEMENT PARTS

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 and air ow are correct.

REPLACEMENT PARTS

For ease of identication when ordering replacement parts

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

20.1). When a component part fails, a replacement part should be obtained by contacting the local distributor or Modine Sales Representative. The 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 20.1 - Serial Plate EXAMPLE

Table 20.1 - Common Replacement Parts

Models

Compressor Contactor

024 5H1038032021 5H083431001 5H1028300004 5H083423001

036 5H1038033021 5H083431001 5H1028300001 5H083423001

048 5H1038034021 5H083431001 5H1028300001 5H083423001

060 5H1038035121 5H083431001 5H1028300003 5H083423001

072 5H1038036021 5H083431001 5H1028300003 5H083423001

High Pressure

Switch

024 5H0835610000 5H0835620000 5H0834050001

036 5H0835610000 5H0835620000 5H0834050001

048 5H0835610000 5H0835620000 5H0834050002

060 5H0835610000 5H0835620000 5H0834050003

072 5H0835610000 5H0835620000 5H0834050003

Low Pressure

Reversing

Valve

Switch

Desuperheater

Pump

Filter - Drier

GEO16-501.4

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 and air side temperatures changes against Typical Operating Data. If the performance is within the ranges in the

table and the air and 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. Thermostat inputs – Thermostat inputs are 24VAC

signals and can be veried using a volt meter between C

and Y, G, O, W.

b. Outputs – Compressor and reversing valve output relays

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

GEO16-501.4

TROUBLESHOOTING

Table 22.1 - Troubleshooting

Fault

Mode

Htg Clg

X X

Possible Cause Verify Action

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

No power to unit

Compressor not operating

Blower does not run

X X

X X Defective thermostat Verify operation of thermostat. Replace if defective.

X X

Open disconnect switch

Blown fuse / circuit breaker tripped

Low supply voltage

Thermostat position Verify that thermostat is in heating or cooling position. Test operation of thermostat.

Defective thermostat Verify operation of thermostat; verify thermostat

Thermostat wiring Verify thermostat wiring at unit and signals at unit. Repair wiring, if needed.

Transformer Check primary and secondary transformer voltages. If no primary, verify wiring

Power wiring defect Check for loose or broken wires at compressor,

Locked out on safety controls

Defective compressor overload

Compressor motor burn out or open windings

Defective compressor contactor

Loss of compressor run signal

Defective run capacitor

Thermostat wiring Verify thermostat wiring at unit. Repair wiring, if needed.

Loss of power to motor (208/240V units)

Defective PSC motor Check line voltage at motor with G call. If power at motor, check capacitor. Replace motor or

Defective ECM motor

Unit is oversized Verify load calculations and unit selection.

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

Check fuses and circuit breaker. Reset circuit breaker or replace fuses with proper

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

signals at unit.

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

contactor and capacitor.

Check controller display for fault. Address lockout and reset controller.

Ensure that compressor is cool and overload has had sufficient time to reset. Ohmmeter shows a resistance across R & S terminals and OPEN or infinite 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 verified and contactor won’t pull in. No 24VAC on compressor contactor coil when 24VAC is present at controller and controller fuse is intact.

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

Verify voltage across 240VAC L1 IN & L2 IN. If no voltage, on L1 and L2, check wiring on board and

Verify line voltage at motor. If power at motor, verify control signals.

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

size and type. Verify total load on system and proper fuse / circuit breaker sizing.

Call power company.

Replace, if defective.

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.

Replace, if faulty.

top of contactor; repair wiring as needed.

capacitor, if defective.

GEO16-501.4

TROUBLESHOOTING

Table 23.1 - Troubleshooting

Fault

Unit “short cycles”

Low pressure cutout

High pressure cutout

Mode

Htg Clg

X X

X X Wiring and controls Examine all wiring points. Tighten all wiring points.

X X

Possible Cause Verify Action

Dirty Air Filter Check air filter Replace, if necessary.

Thermostat location Check to see if thermostat is installed near a supply

Defective compressor overloads

Reduced water flow Check flow center operation Troubleshoot flow center

Scaled or plugged coaxial coil

Water supply too cold

Entering air too cold Measure return air, should be above 60ºF. Bring return air temperature within design parameters.

Reduced air flow Verify blower operation. Troubleshoot blower operation.

Low refrigerant charge

Plugged bi-flow filter / drier

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

Defective low pressure switch

Reduced water flow

Water supply too

hot

Scaled or plugged

coaxial coil

Reduced or no air flow in heating

Air temperature out of range

Defective high pressure switch

Overcharged with refrigerant

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

Non-condensables in system

Loss of control

signal

air grill.

Ensure that compressor is cool and overload has had sufficient time to reset. Ohmmeter shows a resistance across R & S terminals and OPEN or infinite resistance between C & R or C & S terminals.

Manually open water valve and measure water flow. Adjust to proper flow rate.

Plugged water strainer or filter. Replace or clean, if dirty.

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

Verify GEO IN with temperature probe. Verify loop sizing; verify that all air has been purged

Check air filter. Replace or clean, if dirty.

Check for airflow restrictions in ducting system. Address any ductwork airflow restrictions.

Check external static. Check external static against blower table.

Check for refrigerant leaks. If leaks found, evacuate, repair and recharge to factory

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 flow center operation. Troubleshoot flow center.

Manually open water valve and measure water flow. Adjust to proper flow rate.

Plugged water strainer or filter. Replace or clean, if dirty.

Verify GEO IN with temperature probe. Verify loop sizing; bring water temperature within

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

Verify blower operation. Troubleshoot blower operation.

Check air filter. Replace or clean, if dirty.

Check for airflow restrictions in ducting system. Address any ductwork airflow restrictions.

Check external static. Check external static against blower table.

Measure return air, should be below 95ºF. Bring return air 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

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

Relocate, if necessary.

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

from ground heat exchanger; bring water temperature within design parameters.

recommended charge.

Replace filter, if necessary.

If defective, replace.

design parameters.

Replace, if defective.

charge.

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

GEO16-501.4

TROUBLESHOOTING

Table 24.1 - Troubleshooting

Fault

Unit will not operate in cooling mode

Insufficient cooling or heating

Condensate overflow

Auxiliary heater is always “ON”

Noisy unit

Mode

Htg Clg

X X

Possible Cause Verify Action

Defective reversing valve

Thermostat setup / wiring

Thermostat operation Verify proper thermostat signals to unit. Replace, if necessary.

No water flow, high pressure cutout

Dirty Air Filter Check air filter. Replace or clean, if dirty.

Unit undersized Verify load calculations and unit selection. If excessive, it may possible to rectify with shading and

Thermostat location Check to see if thermostat is installed near a supply air

Defective reversing valve

Reduced or no air flow in heating

Reduced air flow in cooling

Duct losses Check supply and return air temperatures at heat

Ambient losses Check for losses / gains due to ambient air infiltration

Low refrigerant charge

Scaled or plugged coaxial coil

Reduced water flow Check flow center operation. Troubleshoot flow center.

Water supply too hot Verify GEO IN with temperature probe.. Verify loop sizing; bring water temperature within design

Reduced water flow Check flow center operation. Troubleshoot flow center.

Water supply too cold

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

Compressor Troubleshoot compressor operation. If discharge pressure is too low and suction pressure

Non-condensables in system

Blocked drain Check for blockage and clean drain.

Improper trap Check trap dimensions and location.

Poor drainage Check piping slope, away from unit and toward outlet.

Defective auxiliary heater PCB

Compressor Make sure the compressor is not in direct contact with

Rattles and vibrates Check for loose screws, panels, or internal components.

Air flow is noisy Undersized duct work will cause high airflow velocities

Pump cavitation Purge air from closed loop system.

Verify operation of reversing valve and solenoid coil. If defective, replace. When it is necessary to replace the

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

Check flow with flow meter. Check pump operation.

grill.

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

Verify blower operation. Troubleshoot blower operation.

Check air filter. Replace or clean, if dirty.

Check for airflow restrictions in ducting system. Address any ductwork airflow restrictions.

Check external static. Check external static against blower table.

Verify blower operation. Troubleshoot blower operation.

Check air filter. Replace or clean, if dirty.

Check for airflow restrictions in ducting system. Address any ductwork airflow restrictions.

Check external static. Check external static against blower table.

pump and at furthest registers. If difference is significant, duct losses are occurring.

through doors and windows.

Check superheat and subcooling values. Check for refrigerant leaks.

Check temperature drop across coaxial coil. Replace or clean, if dirty.

Manually open water valve and measure water flow. Adjust to proper flow rate.

Plugged water strainer or filter. Clean or replace.

Manually open water valve and measure water flow. Adjust to proper flow rate.

Plugged water strainer or filter. Replace or clean, if dirty.

Verify GEO IN with temperature probe. Verify loop sizing; bring water temperature within design

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

Check venting.

Cycle power to system, using an amp meter verify amperage draw.

Check 24VAC voltage signals to the auxiliary heater printed circuit board.

the base or sides of the cabinet. Cold surroundings can cause liquid slugging, increase ambient temperature.

Remove compressor mounting bolts.

Tighten and secure. Piping could be hitting the metal surfaces. Add insulation between the contact.

and noisy operation.

reversing valve, wrap it with a wet cloth and direct the heat away. Excessive heat can damage the valve.

insulation.

Relocate, if necessary.

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.

Repair duct losses.

Address issue.

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

parameters.

too high, compressor is not pumping properly. Replace compressor.

Replace printed circuit board.

GEO16-501.4

SPLIT UNIT START UP / TROUBLESHOOTING FORM

Technician Notes

Customer Name ___________________________________________________ Date _________________________

Address _______________________________________________________________ Loop Type _________________

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. When

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

GEO16-501.4

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GEO16-501.4

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GEO16-501.4

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

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

“APPLICABLE WARRANTY PERIOD”

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 GEO16-501.4 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual