GROUND LOOP PUMPING PACKAGES

MODEL NOMENCLATURE

GROUND LOOPPUMP PACKAGE

VINTAGE

GL 001 - 1 XB A

QUANTITY OF PUMPS

208/230-1-60

THREE WAY VALVE

B - BRASSC - COMPOSITE

Table of Contents

Model Nomenclature....................................................................................................1

Inspection .........................................................................................................................2

Typical Application ........................................................................................................2

Mounting...........................................................................................................................2

Electrical.............................................................................................................................2

Earth Loop Flushing ......................................................................................................2

Antifreeze ..........................................................................................................................3

Fluid Volume ....................................................................................................................4

Anti-Freeze Requirements ..........................................................................................3

Pressure Drop Chart ......................................................................................................4

Trouble Shooting............................................................................................................4

FORWARDThe complete instruction manual should be read carefullybefore beginning installation. Follow the instructionsprecisely to insure proper operation of the system. Theinstructions are to be left with the homeowner for futurereference if needed. All local, state and national codessupercede these instructions and must be strictly adhered.

UNCRATING AND INSPECTIONCheck for shipping damage, both visible and concealed ifthere exists any indication of damage immediately file aclaim with the shipping company. You are the only one tofile a claim regardless of why the damage was incurred orby whom. Remove the access cover and check all of thecomponent parts to make sure they are properly securedbefore installing the unit. Parts broken loose from theirsecured position with resultant damage is considereddamage during shipment.

APPLICATIONThe Ground Loop package adequately supplies thepumping power to circulate fluid requirements for mostresidential and light commercial earth coupled ground loopsystems. See the enclosed table for pumping performance.

MOUNTING AND INSTALLATIONMounting of the Ground Loop package is accomplished bythe use of (6) six 1/4 inch bolts in the package base. Thepackage may be mounted on the unit opposite the returnair opening or on a nearby wall. When installing thepackage on a unit, be certain not to drill into anycomponents in the unit. When mounting the package on awall, it is recommended not to exceed (10) ten feet in lineardistance from the unit to the package. If more than (10) tenfeet exists, excessive pressure drop could occur causingreduced flow rates having an adverse effect on systemperformance. IMPORTANT-Package must be mounted withthe pump shaft PARALLEL to the horizon. Failure to do sowill cause premature failure of the thrust bearings.

GROUND LOOP PACKAGE PIPING CONNECTIONSConnections from and to the unit are accomplished byutilizing the Ground Loop Connection kit. PVC pipe is notrecommended for ground loop applications due to it’srigidity at low temperatures and it’s pliability at hightemperatures. Inside piping and connections must beinsulated to prevent condensation water to damage. It isrecommended to pressure check the system beforeproceeding with final insulation.

ELECTRICALElectrical connection is accomplished in the field. TheGround Loop package pump motors are connected to theload side of the compressor contactor terminals thusallowing the pumps to run on demand of the unit. It isimportant that the pumps be appropriately fused andgrounded. The N.E.C. prevails in wiring techniques. Pleasefollow the wiring diagram for proper connection. Alwayscheck the pump motor nameplate for the correct voltagebefore connecting and start-up.

EARTH LOOP FLUSHING AND FILLING:It is imperative that all air and foreign material are expelled

from the earth coupled piping system before operation.This is accomplished by flushing the loop in both directionswith a high volume of water at a high velocity at 2 ft/sec.Your distributor will have the required flush cart andassociated equipment required for this operation. Pleasefollow the steps outlined below for proper flushingprocedures:

1. Remove countersunk plugs (1) located in flush port (2)of three-way flow control valves. (3) Hook up flushports to flush cart, liquid must be present in supplylines at all times.

2. Position the flow control valves (3) so as to open theports to the loop (4) and close the ports to the unit. (5)*Arrows located on the control valves indicate flowdirections. When the center hub white line appearsadjacent to the arrows, the flow path is established.

3. Flush the loop in both direction to insure that all air andforeign matter is eliminated. Allowing the water level todrop below the pump inlet line on the flush cart willallow air back air back into the loop. When air bubblesare no longer present in the return line, flow should bereversed. This procedure should be repeated severaltimes until no air is present. If air is left in the loop, itwill have an immediate effect on the units coaxial heatexchanger causing corrosion and any other associatedferrous metal components. It is absolutely imperativethat the system is clean and completely free of air.

4. With the flush cart running, position the three-wayvalves so that the loop is now isolated. This will create apositive pressure on the loop and the flush cart maythen be shut off. It is important to close the valve onthe outlet side of the loop first to obtain this requiredpositive pressure.

FLUSHING THE PUMP UNIT1. With the three way valve now closed to the loop and

open to the unit, repeat steps (3) and (4) as outlinedabove.

GROUND LOOP PUMPING PACKAGES2

2. If the cart is not available due to the installation of theGround Loop and pumping package prior to the unitsarrival, antifreeze may be utilized for flushing the unit.As previously mentioned, it is imperative that all air andforeign matter are absent from the unit.

ANTI-FREEZEIn areas where loop temperatures drop below a fixedminimum temperature per given unit, anti-freeze mayberequired to prevent frost build-up and eventual freezing ofthe unit heat exchanger. It would be convenient to assign anarbitrary minimum allowable loop fluid temperature beforefrosting occurs, however; this is not the case. Freezeconditions are based on a number of variables such as fluidflow rates, fluid temperatures, equipment suctiontemperatures and corresponding saturated suctiontemperatures. These parameters vary with individualequipment design inherent with engineering design criteria.If unsure of actual operating conditions, to be safe, use anti-freeze if loop temperatures drop below 45 degrees F˚.

Some commonly used anti-freezes are the Methanol andGlycols. You should first check with local authorities and theE.P.A. to determine which substances are appropriate andallowable for use in your area. Your distributor can alsoassist you in your anti-freeze selection.

ANTI-FREEZE CHARGING1. The flush container should be filled with the proper

amount of anti-freeze, to adequately protect the unitsheat exchanger.

2. Run the discharge line to a drain.

3. With the flow valves closed to the unit and open fromthe inlet valve flush port to the Ground Loop, start theflush pump.

4. Open the flush gradually introducing the requiredamount of anti-freeze.

5. Shut down the flush pump and disconnect from thepumping package. Install the threaded flush port capsinto the flush ports using pliable pipe sealant. *Do notuse PVC cement.

6. Take extreme care in handling Methanol that can becombustible. forms of Glycol can be toxic if ingested.

* CAUTION: Equipment warranties may be void if damage iscaused by improper or negligent anti-freeze application.

PRESSURE - TEMPERATURE PLUGSP/T Plugs are provided with the ground loop connection kits asa means of measuring system fluid flow, pressure drop andtemperature. The fluid flow (GPM) through the unit can beverified by measuring the pressure drop across the unit heatexchanger or condenser. Once the pressure drop is determined,then refer to the unit specification data sheet section labeledcondenser water flow. This section provides flow rates withcorresponding pressure drops.

EARTH LOOP PRESSURE:A slightly positive system pressure 5 PSIG on suction of pump isrequired to operate the ground loop pumps. System pressureswill fluctuate as the earth loop relaxes and fluid temperatureschange. Typical Earth Loop pressures range from 5 to 40 PSIG.Some initial Ground Loop settling may occur on initial start up

which may cause fluctuating pressures briefly. Pressures shouldstabilize after some initial run-time.

START-UP OF FHP GROUND LOOP PUMPING PACKAGE1. Check electrical power supply for proper voltage.

2. Check valves to make sure they are properlypositioned. Ground loop and unit ports open, flushports fully closed and capped.

3. Check and record unit pressure drop, ground looppressure drop, and system flow rate.

4. Check and record heat pump performance utilizingengineering brochures and installation and start-upmanuals.

GL002

GROUND LOOP PUMPING PACKAGES

GL001

3

Rev. 2/05

TABLE 1 - Appropriate Fluid Volume per 100’ of Pipe

TABLE 2 - Anti-Freeze

PIPE SIZE VOLUME (Gal/100’Pipe)Copper 1” 4.1Copper 1.25” 6.4Copper 1.5” 9.2Polybutylene 1” - CTS SDR 13.5 3.7Polybutylene 1.25” - CTS SDR 13.5 5.6Polybutylene 1.5” CTS - SDR 13.5 7.8Polybutylene 2” - CTS SDR 13.5 13.4Polyethylene .75” - IPS SDR 11 2.8Polyethylene 1” - IPS SDR 11 4.5Polyethylene 1.25” - IPS SDR 11 7.8Polyethylene 1.50” - IPS SDR 11 11.5Polyethylene 2” - IPS SDR 11 18.0

Type Minimum Temperature for Freeze Protection10Fº 15Fº 20Fº 25Fº

Methanol 25% 21% 16% 10%Propylene Glycol 26% 23% 19% 9%Ethylene Glycol* 21% 18% 13% 8%Calcium Chloride 95%** 1.5# 1.2# 1.0# .6#Calcium Chloride 78%** 1.8# 1.5# 1.2# .7#GS4 35% 30% 21% 13%

* All percentages are by volume (gal/gal), not weight** All weights are pounds of Calcium Chloride required per gallon of water.

PROBLEM POSSIBLE CAUSE CHECKS AND CORRECTIONS

Unit trips out on lowpressure

Low Flow / No Flow

Low Flow / No Flow

Water drips out CondensateWater leak

No powerBlown fuseBroken or loose wiresPump shaft stuck

Air LockImproperly sized pumpDefective pumpNo positive Pressure

Viscous solutionLoop fluid freezing or frozen

Kink in loop piping

Insulate pipingTighten connections

See low flow / No flow

Check power supplyReplace fuse - check for causeReplace or tighten wiresRemove the indicator plug from the center of each circularpump and ensure that shaft is rotating.Flush the loop to eliminate airAdd pump capacityReplaceCheck for leaks; add fluid; flush loop in earth loop(need more than 2 psi)Change type of anti-freezeSwitch “T” Stat to air conditioning to see if flow improves atwarmer temperature; add anti-freezeand measure freeze protection

Straighten or replace

Defective pumpAir in loopVibration

ReplaceFlush loop againCheck mounting

Pressure Loss LeakTemperature changePipe expansion

RepairPressure should vary as temperature changes(10-30 psi)Plastic pipe relaxing

GROUND LOOP PUMPING PACKAGES

GRUNDFOS ® UP 26-116F Pump Curve

Noisy

4

TROUBLE SHOOTING