Water to Water Geothermal Heat Pump

Transcription

1 Water to Water Geothermal Heat Pump Installation & Operating Instructions Model: THA/THT-*** Application Geo source closed loop or ground water Hydronic water heat/cool output Air handler, water coil, heat/cool, radiant floor heating Single stage (THA), and two stage (THT) units Tested to UL Standards 1995 and CSA Standards C Phase Models Also see and use GI102 Domestic Water Heater, Desuperheater Energy Star promotes the desuperheater and it is offered as an optional item for all TTHERM GEO heat pumps. Our exclusive GEO Logic control system optimizes the operation of a desuperheater, operating the system only when there is adequate energy available to provide heat to the domestic hot water. However, to maximize the time the desuperheater aides in providing domestic hot water, a hot water preheat tank is suggested. Note The GEO Logic control board has various required setup adjustments. See Field Setup section. TTHERM GEO heat pumps leave the factory setup to operate on an open loop. See Desuperheater section of this manual. DO NOT DESTROY THIS MANUAL. PLEASE READ CAREFULLY AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE BY A SERVICE TECHNICIAN. Important information Model Number: Serial Number: Installing Contractor: 12/03/2012 GI101

2 Table of Contents Introduction 1 Product Configurator (GC002) 3 Mechanical Specifications 4 Electrical Data 6 Product Dimensions 7 Installation Requirements 10 Mechanical Installation Overview 11 Mechanical Installation Source Water 11 Antifreeze 15 Open Loop Solenoid 16 Desuperheater, Domestic Hot Water 18 Hydronic Installation Concerns 20 Hydronic Plumbing 23 Electrical Installation 26 Hydronic Control Wiring 27 GEO Logic Controller 29 Accessories/Options 30 Field Setup Overview 32 Master Thermostat to Hydronic Control Module Connections 32 Heat Pump to Hydronic Control Module Connections 32 Mounting external flow switches THA 060/072 & THT units 33 Open & Closed Loop Jumper (J11) 34 Duel Fuel/Utility Control 35 Operation Indicators 36 Power On Startup 40 Operational Tips 42 Preventative Maintenance 43 Troubleshooting GEO Logic Control 44 THA & THT Operating Conditions Tables 47 Drawing GR101 THA 3 & 4-Ton Refrigerant Circuit 49 Drawing GR102 THA 5 & 6-Ton Refrigerant Circuit 51 Drawing GR103 THT Refrigerant Circuit 53 Drawing UAW556 THA Electrical Diagram 55 Drawing UAW558 THT Electrical Diagram 56 Drawing UAW559 THT 3-Phase Electrical Diagram 57 Warranty Information GX /03/2012 GI101

3 Introduction Geothermal heat pumps are able to heat and cool spaces with efficiencies exceeding 350% by taking advantage of solar heat stored in the earth s crust and the earth s relatively stable temperatures. In the winter time, heat is moved from the earth into the home and concentrated using a refrigeration system. Since the heat already exists in the soil, the cost of operation of the geothermal heat pump is, in effect transportation cost for the free heat. In the summer, heat is removed from the home by reversing the refrigeration process and sending heat back out into the earth. A geothermal system consists of an earth source (either open loop or earth loop heat exchanger), a geothermal heat pump containing the refrigeration system and a system for delivering the energy to the conditioned space. To learn more about geothermal heating, please visit our web site at This is a prewired package Hydronic Geothermal Heat Pump system with the necessary controls for various hydronic applications. There are various temperature sensors, pressure sensors, water flow switch, etc. which continuously monitor the heat pump system. The interaction of these sensing components, room thermostat requests, and the various heat pump refrigeration components are all controlled by an integrated microprocessor system (GEO Logic). The various setup conditions for this microprocessor based controller determine the application and geo product series. These setups are initially programmed by the factory, but special PC software and cable are available for reprogramming as required for controller replacement and/or other options which may apply to the specific installation. See Additional Equipment Concerns, Field Setup or Programming, Operation Indicators, User Instructions, Control Sequence, and Troubleshooting sections within this manual for further details on the GEO Logic control. The THA units are single compressor units, while the THT units have two compressors with separate refrigeration circuits, a common source water circuit and a common load water circuit. The optional TTHERM GEO Hydronic Control Module (M2-0152) will monitor the buffer tank and control up to two separate single stage hydronic heat pumps or a single two stage hydronic heat pump. Utility control, electric backup heat, backup furnace, backup boiler, and dual fuel applications are easily accommodated. Contact information: Office Hours: 8 AM - 5 PM, Central Time Zone Phone: Fax: sales@tthermgeo.com Moving and Storage Units should be stored in original packaging in a clean dry area. Store and move units in normal upright position. Do not stack units. Transport in vertical position only. Initial Inspection Be certain to inspect all cartons and crates as units are received before signing the freight bill. Verify that all items received have no physical damage. Report any damages or shortages on the freight bill. The purchaser is responsible for filing the necessary claims with the carrier. Concealed or hidden damages not discovered until removing packaging must be reported to the carrier within 15 days of receipt. Unit Location and Mounting Locate the unit in an indoor area where the ambient temperature will remain above 45 F [8 C]. TTHERM GEO provides 4 removable panels (all 4 sides) for servicing ease (3 sides THT 098, 120, 144). This unit is zero clearance rated; however, allow enough room to remove panels for service and maintenance. We suggest setting unit on a sound vibration pad, (see accessories price sheet E2-0122) and use a rubber hose kit to minimize the transfer of any vibration to the living space. Please read and understand conditions associated with proper installation, unauthorized changes, and POWER ON procedures. Warranty Statement See the last page of this manual for detailed limited warranty coverage explanation. 12/03/ GI101

4 Safety Considerations WARNING BEFORE PERFORMING SERVICE OR MAINTENANCE OPERATIONS ON A SYSTEM, TURN OFF MAIN POWER SWITCHES TO THE INDOOR UNIT. IF APPLICABLE, TURN OFF THE ACCESSORY HEATER POWER SWITCH. ELECTRICAL SHOCK COULD CAUSE PERSONAL INJURY. Installing and servicing heating and air conditioning equipment can be hazardous due to system pressure and electrical components. Only trained and qualified service personnel should install, repair or service heating and air conditioning equipment. Minimally trained personnel can perform the basic maintenance functions of cleaning coils and cleaning and replacing filters. All other operations should be performed by trained service personnel. When working on heating and air conditioning equipment, observe precautions in the literature, tags and labels attached to the unit and other safety precautions that may apply, such as the following safety measures: Follow all safety codes. Wear safety glasses and work gloves. Use a quenching cloth for brazing operations. Have a fire extinguisher available for all brazing operations. Warnings, Cautions, and Notes Throughout this manual there are warnings, cautions, and notes containing various levels of important information. Read all of these items carefully before performing any installation, servicing or troubleshooting. Warnings are for any item which MUST be followed and failure to do so could result in serious injury or even death and/or serious damage to the equipment Cautions relate to potentially hazardous or important practices which if ignored could cause minor to moderate injury or cause equipment damage or performance problems. Notes are used to indicate items of high importance but are not related to a hazardous situation. 12/03/ GI101

5 TTHERM GEO Heat Pump Configurator T V T C L D X 1 - X X Model Number Digits TVT-048-1CLDX1-XX TTHERM GEO (1) Unit Style (2) C = Combo H = Hydronic S = Split V = Vertical Unit Type (3) A = Single Stage T = Two Stage Nominal Tonnage (4, 5, 6) 024 = 2-ton 036 = 3-ton 042 = 3.5-ton 048 = 4-ton 060 = 5-ton 072 = 6-ton 096 = 8-ton 120 = 10-ton 144 = 12-ton Voltage Option (7) 1 = 208/230V, 1 Ph 2 = 208/230V, 3 Ph 3 = 460/480V, 3 Ph Auxiliary kw Option* (13, 14) 05 = 4.8 kw 10 = 9.6 kw 15 = 14.4 kw 20 = 19.2 kw XX = None *Can be factory or field installed Vintage (12) 1 Miscellaneous Kits (11) A = Soft Start Kit (Installed) X = None Desuperheater Option (10) D = Desuperheater w/factory Installed Pump X = None Configuration Option (9) L = Left Return (Standard)* R = Right Return C = Split Air Coil X = N/A or No Split Air Coil *Left return can be field converted to right return Heat Exchanger Option (8) C = Copper N = Cupronickel M = Copper (Load) & Cupronickel (Source) S = Stainless (THT only) 10/12/2012 GC002

6 THA-*** Mechanical Specifications R410A Single Stage Compressor MODEL THA-036 (3 ton) THA-048 (4 ton) THA-060 (5 ton) THA-072 (6 ton) Source & Load GPM Heating Source & Load GPM Cooling Factory Charge R410A 3 lbs. 14 oz. 5 lbs. 4 oz. 6 lbs. 6 oz. 7 lbs. 8 oz. Source Temperature F (min/max) 20 / / / /120 Water Connection (NPT female) ¼ 1-¼ Loop Coil & Piping Water Volume (gal) Load Coil Water Volume (gal) Desuperheater Connection (NPT female) ½ ½ ½ ½ Weight Packaged (lbs) Width of Cabinet (inches) Height (Inches) Depth (Inches) HEAT EXCHANGER PRESSURE DROP TABLE Water-to-Water (Source Side and Load Side, Pure 68 F Model GPM PSID Model GPM PSID Model GPM PSID Model GPM PSID ton ton ton ton PRESSURE DROP MULTIPLIERS Freeze Point ( F) 20 F 25 F 30 F 35 F 40 F Pure Water Multiplier Methanol 12.5%* Multiplier Propylene Glycol 20%* Multiplier Ethanol 20%* Multiplier *By volume Feet of Head = PSI x 2.31 ISO Performance Energy Star Ground Water Heat Pump Ground Loop Heat Pump Cooling Heating Cooling 59 F Heating 50 F Model Full Load 77 F Full Load 32 F Capacity EER Capacity Capacity EER Capacity COP COP Btu/h Btu/h/W Btu/h Btu/h Btu/h/W Btu/h THA THA THA THA Heating capacities based upon 104 F hydronic return water. Cooling capacities based upon 53 F hydronic return water. Ground Loop Heat Pump ratings based on 15% antifreeze solution. All ratings based upon operation at lower voltage of dual voltage rated models. 12/03/ GI101

7 THT-*** Mechanical Specifications R410A Dual Compressor MODEL THT-096 (8 ton) THT-120 (10 ton) THT-144 (12 ton) Source & Load GPM Heating Source & Load GPM Cooling Factory Charge R410A* 2 x 4 lbs. 2 oz. 2 x 4 lbs. 2 oz. 2 x 4 lbs. 2 oz. Source Temperature F (min/max) 20 / / /120 Water Connection (NPT male) 1-½ 1-½ 1-½ Loop Coil & Piping Water Volume (gal) Load Coil Water Volume (gal) Weight Packaged (lbs) *Dual compressor models contain dual refrigeration circuits, amount shown is for each circuit. HEAT EXCHANGER PRESSURE DROP TABLE Water-to-Water (Source Side and Load Side, Pure 68 F Model GPM PSID Model GPM PSID Model GPM PSID THT THT-120 THT PRESSURE DROP MULTIPLIERS Freeze Point ( F) 20 F 25 F 30 F 35 F 40 F Pure Water Multiplier Methanol 12.5%* Multiplier Propylene Glycol 20%* Multiplier Ethanol 20%* Multiplier *By volume Feet of Head = PSI x 2.31 Model THT-096 THT-120 THT-144 Capacity Modulation ISO Performance Energy Star Ground Water Heat Pump Cooling 59 F Heating 50 F Ground Loop Heat Pump Cooling Heating 77 F/68 F 32 F/41 F Capacity EER Capacity Capacity EER Capacity COP COP Btu/h Btu/h/W Btu/h Btu/h Btu/h/W Btu/h FL PL FL PL FL PL Heating capacities based upon 104 F hydronic return water. Cooling capacities based upon 53 F hydronic return water. Ground Loop Heat Pump ratings based on 15% antifreeze solution. All ratings based upon operation at lower voltage of dual voltage rated models. 12/03/ GI101

8 Model THA-*** Electrical Data Single Phase Load Desup. Source Voltage Compressor Total Min. Pump Pump Pump (60 Hz) RLA LRA FLA FLA FLA FLA Ampac. THA / THA / THA / THA / Model THT-*** Electrical Data Single Phase Load Desup. Source Voltage Compressor Total Min. Pump Pump Pump (60 Hz) RLA LRA FLA FLA FLA FLA Ampac. Max. Fuse/ HACR Max. Fuse/ HACR THT / x x x x 2 60 x 2 THT / x x x x 2 60 x 2 THT / x x x x 2 80 x 2 Note: Dual compressor models contain dual power circuits for the compressors, amperages shown are for each circuit. For 3-phase models please refer to GI /03/ GI101

9 Product Dimensions THA-036 & THA /03/ GI101

10 Product Dimensions THA-060 & THA /03/ GI101

11 Product Dimensions THT-096, THT-120 & THT /03/ GI101

12 Installation Requirements 1. All installation work must be performed by trained, qualified contractors or technicians. TTHERM GEO sponsors installation and service schools to assist the installer. Contact TTHERM GEO at for upcoming dealer training events. WARNING ALL ELECTRICAL WIRING MUST BE IN ACCORDANCE WITH NATIONAL ELECTRIC CODE AND LOCAL ELECTRIC CODES, ORDINANCES, AND REGULATIONS. WARNING OBSERVE ELECTRIC POLARITY AND WIRING COLORS. FAILURE TO OBSERVE COULD CAUSE ELECTRIC SHOCK AND/OR DAMAGE TO THE EQUIPMENT. CAUTION This unit can only be used for its intended design as described in this manual. Any internal wiring changes, modifications to the circuit board, modifications or bypass of any controls, or installation practices not according to the details of this manual will void the product warranty, the safety certification label, and manufacturer product liability. TTHERM GEO cannot be held responsible for field modifications, incorrect installations, and conditions which may bypass or compromise the built-in safety features and controls. 2. If this is a Dual Heat system, this product relates only to the addition to the furnace ducting system external to the gas or oil force air furnace. The owner/installer assumes all responsibility and/or liability associated with any needed installation of the gas/oil furnace, fuel system, flue, chimney, etc. Any instructions or comments made within this manual (or factory phone assistance) relating to the gas/oil furnace are provided as comments of assistance and helps only. CAUTION This unit shall not be operated in either heating or cooling until all fluids and flow rates have been checked. Closed loop and hydronic systems must have antifreeze protected to 18 degrees. Manufacturer s warranty is void if this unit fails because of a freeze ruptured heat exchanger. CAUTION Hazards or unsafe practices could result in property damage, product damage, severe personal injury and/or death. 3. All removed or discharged refrigerant must be recovered. Local and federal statutes are to be observed. Should a compressor need replacing, the compressor oil is to remain with the compressor. Refrigerant lines on the compressor must be sealed. 4. Remember, safety is the installer s responsibility and the installer must know this product well enough to instruct the end user on its safe use. 5. At TTHERM GEO, the safety of the installer and the end user is of highest priority. Remember, safety is the installer s responsibility and the installer must know this product well enough to instruct the end user on its safe use. Professional installers should be trained and experienced in the areas of handling electrical components, sheet metal products, and material handling processes. 12/03/ GI101

13 Mechanical Installation Overview Heat pumps use the fluid in the source loop as the energy source and the fluid on the load side for energy delivery. Thus the design and installation of the source and load fluid system may be the most important part of this heat pump system. The following items should be carefully considered and properly followed for all installations: Heating capacity Size the geothermal heat pump according to the normal heating requirements as the building exists today. Do not necessarily match to the existing furnace nameplate because it may be oversized. The geothermal heat pump should be properly sized for the heat loss of the house. Heat loss and heat gain audits should be done to determine proper equipment sizing. The hydronic distribution system must be designed to deliver the forced air and low mass radiant floor BTU s with 110 water temp, and high mass radiant floor with 100 water temp. The cooler the delivery temperature in heating mode, the higher the system efficiency. Closed Loop Applications Closed loop system re-circulates the same water/antifreeze solution through a closed system of underground high-density polyethylene pipe. As the solution passes Horizontal Closed Loop through the pipe it collects heat (in the heating mode) that is being transferred from the relatively warm surrounding soil through the pipe and into the relatively cold solution. The solution is circulated back to the heat pump that extracts its heat and then returns to the ground to absorb more heat from the earth. Earth loops must be sized properly for each particular geographic area and individual capacity requirements. The TTHERM GEO heat pumps are designed to operate on either vertical or horizontal closed loop applications. (Figures 1 & 2) Vertical loops are installed with a well drilling rig up to 200 feet (61 meters) deep or more. Horizontal systems are installed with excavating or trenching equipment approximately six to eight feet ( meters) deep, depending on geographic location and length of pipe used. Horizontal bored loops are installed 15 feet deep. Figure 1 Vertical Closed Loop Lake or Pond Loops Closed loop systems may also be used in lakes or rivers to supply a heat source to the heat pump. Typically a loop consisting of geothermal Figure 2 pipe can be designed and placed in an area at least 12ft (3.7 meters) deep with some water currents present. In any lake, pond or river, municipal and local codes must be observed in regards to a lake or pond loop. The use of an environmentally friendly loop fluid like Propylene Glycol should be considered in the event damage should ever occur to the loop. Consult sales at TTHERM GEO or a trained loop installer for proper loop design and installation. State and local codes apply. Mechanical Installation Source Water WARNING LOOP DESIGN IS EXTREMELY IMPORTANT FOR PROPER HEAT PUMP OPERATION. INCORRECT LOOP DESIGN WILL REDUCE HEAT PUMP EFFICIENCY, CAUSE POOR PERFORMANCE OR MAY RENDER THE SYSTEM UNUSABLE. CONTACT AN IGSHPA OR CGC CERTIFIED GEOTHERMAL LOOP CONTRACTOR FOR PROPER INSTALLATIONS. 12/03/ GI101

14 Water Connections General The following pages outline typical piping arrangements for the most common source water connection options, as well as flushing and filling procedures and antifreeze requirements for closed loop systems. TTHERM GEO recommends hose kits for the source water connection points at the heat pump. Hose kits provide a flexible connection to reduce and isolate vibrations transmitted from the compressor into other parts of the system. Hose kits also provide P/T ports for monitoring pressure and temperature (see below). Note TTHERM GEO heat pumps are factory set for open loop. J11 must be removed for proper operation on an antifreeze protected closed loop. See figure on page 31 for the location of J11. Once closed loops are completed, they must be pressure tested to at least 60 PSI to ensure integrity. Once pressure is tested, loop must be purged of all foreign debris and filled with fluid. All air must be removed at this time by flushing the system. (Page 15, Table 2) shows approximate fluid volumes. P/T Adapter Pressure/Temperature (P/T) ports Should be installed in the adaptor elbow on the entering and leaving water line of the heat pump on a closed system. (Figure 3) A thermometer can be inserted into the P/T ports to check entering and leaving water temperatures. A pressure gauge can also be inserted into these P/T ports to determine the pressure differential between the entering and leaving water. This pressure differential can then be compared to the engineering specifications data to determine the flow rate of the system. Figure 3 A Flow Meter is an important part of the system. It provides a visual indicator of loop flow in GPM. A flow meter can be installed on either side of the pump pack, but must be installed per manufacturer recommendations so it reads accurately. Non Pressurized Loops require an air separator/stand pipe to eliminate air and to hold enough fluid to compensate for the expansion and contraction of the loop pipe and fluid. Purge and fill valves should be placed between the loop manifold valves and the insulated pump pack. See figure 4. Pressurized Loops do not require an air separator. They require purge and fill ports between the loop manifold valves and the insulated pump pack. See figure 5. After purging a pressurized loop, it should maintain 45 to 60 psi static pressure. The geothermal loop pipe stretches under pressure so may need to be pressurized above the desired pressure several times to achieve the recommended static pressure. Pressurized loops must maintain enough static pressure to compensate for the expansion and contraction of the loop pipe and fluid. Loop Pump Selection Select a loop circulation pump based upon the GPM required and total system pressure drop. See specification, page 4. Geothermal heat pump Btu/h capacity and efficiency are directly related to the GPM flow through the unit as well as the velocity through the loop pipe. Vibration pad We recommend setting the unit on a sound vibration pad, available from most distributors or see accessories/options table E Water quality for models with standard copper heat exchanger coils require the installer to evaluate water quality and meet minimum water properties. ph < 7.5 Calcium harness < 100 PPM Iron fouling < 0.2 PPM (Ferrous) < 0.5 PPM of oxygen Hydrogen sulfide (H 2 S) < 0.5 PPM Chloride levels < 20 PPM Erosion/clogging < 10 PPM, particles Filter, if required < 800 micron size Softened water is recommended along with 2 oz of common house chlorine bleach for every 10 gallons of water. 12/03/ GI101

15 Figure 4 Non-Pressurized Closed Loop with Flow Center Typical piping arrangement. 12/03/ GI101

16 Figure 5 Pressurized Closed Loop with Flow Center Typical piping diagram. 12/03/ GI101

17 Antifreeze When considering the earth loop solution, water quality is very important. TTHERM GEO recommends a minimum of soft water (not well water) treated with 2 oz. of household chlorine bleach for each 10 gallons of total volume. TTHERM GEO recommends Rhomar Enviro-Guard HD propylene glycol antifreeze at a concentration of 23% which will yield a freeze protection of 18 F. Rhomar s Enviro-Guard HD propylene glycol has the appropriate additives to protect the system at this concentration. Over antifreeze protecting a loop field decreases pumping capacity when the loop gets cold and reduces thermal transfer. Under protecting a loop field will cause the THERM GEO heat pump to take action to protect itself from damage. This action will result in a loss of geothermal capacity, and AUX heat may be required to maintain the temperature in the home. Table 2 Approximate Fluid Volume (gal) per 100ft Pipe Size Volume Pipe Size Volume ¾ IPS SDR Rubber Hose 1 IPS SDR Polyethylene 1-1/4 IPS SDR Copper 1-1/2 IPS SDR Type M 2 IPS SDR WARNING PREVENTING FREEZE-UP IS INSTALLER/USER RESPONSIBILITY. DAMAGE CAUSED BY FREEZE-UP IS NOT COVERED BY WARRANTY. CAUTION Softened water is recommended along with 2 oz. of common household chlorine bleach for every 10 gallons of water. WARNING NOT ALL GLYCOLS PROVIDE THE SAME LEVEL OF CONCENTRATION. MOST GLYCOLS DO NOT CONTAIN ENOUGH INHIBITORS FOR THE RECOMMENDED CONCENTRATION LEVELS.FOR GEOTHERMAL SYSTEMS. Open Loop An open system gets its name from the open discharge of water after it has been used by the heat pump. A well pump and well must be available that can supply all of the water requirements of the heat pump along with any other water requirements drawing off that same well. The well must be capable of supplying the heat pumps required flow rated for up to 24 hours per day for the coldest winter day. Figure 6 shows the necessary components for water piping of an open system. First a bladder type pressure tank with a draw down of at least 1-1/2 to 2 times the well pump capacity must be installed on the supply side of the heat pump to prevent short cycling the well pump. Constant pressure well pumps need to deliver the GPM flow rate of the TTHERM GEO heat pump and other possible consecutive demands. Shut off valves and boiler drains on the entering and leaving water lines are necessary for future maintenance. A screen strainer is placed on the supply line with a mesh size of 40 to 60 and enough surface area to allow for particle buildup between cleanings. Hose kits are installed between the heat pump and ridged plumbing to reduce vibration transfer. Hose kits have pressure temperature (P/T) ports placed in the supply and discharge hydrant elbows so that thermometers or pressure gauges can be inserted into the water stream. On the well water discharge side of the heat pump a flow meter is installed to provide a visual indicator of open loop flow in GPM. The water solenoid valve must be installed to control water flow through the unit. After the water solenoid a flow control valve is installed to limit maximum flow through the heat pump. The ball valve installed in the leaving water line can be used to create a small amount of back pressure to quiet the flow control valve if needed. Discharge water 12/03/ GI101

18 temperature should not drop below 39 at any time during the unit s operation. Remove handle on the entering and leaving water ball valves to prevent accidental change of flow. The solenoid valve is then wired to two leads (brown/yellow and gray) provided. This valve will open when the unit is running and close when the unit stops. The visual flow meter will allow visual inspection of the flow requirements, and can be useful in determining when maintenance is required. Schedule 40 PVC piping, copper tubing, polyethylene or rubber hose can be used for supply and discharge water lines. Make sure line sizes are large enough to supply the required flow with a reasonable pressure drop (generally 1.00 diameter). Water discharge is generally made to a drain field, stream, pond, tile line, or storm sewer in accordance with local codes. Solenoid Valve Wiring (for Open Loop Systems) Inside the cabinet, tie-wrapped to the OUT water pipe, are two leads (brn/yel and gray) for direct connection to a 24VAC solenoid. CAUTION Using a drain field requires soil conditions and adequate sizing to assure rapid percolation or the required flow rates will not be achieved. Consult local codes and ordinances to assure compliance. Do not discharge water to a septic system. The heat pump should never be operated with flow rates (GPM) less than specified. Discharge water should never be lower than 39 F. Operation of the unit with less than required flow rate or no flow may result in freezing water in the water to refrigerant heat exchanger. This will cause the unit to shut down on lowpressure lockout. If the unit locks out Low pressure, verify that the unit has the required flow and reset the unit by shutting off power to the unit for one minute. Do not continually reset the unit; if the unit locks out more than once call your service professional. Continued reset of the unit can freeze water inside the water coil to the point of rupturing the water coil (no warranty for freeze ruptured coils). 12/03/ GI101

19 Figure 6: Open Loop Typical piping diagram. Note TTHERM GEO heat pumps are factory set for open loop operation. Open Loop Operation TTHERM GEO heat pumps are factory set for open loop operation. Open or Closed loop operation is set with jumper J11 on the left side of the GEO Logic controller. The jumper must be in place on J11 if the unit is operated on an open loop. The GEO Logic controller protects the heat exchanger from freezing by causing the compressor to shut down when the leaving water temperature reaches 39 F. The compressor will remain off for 2 Anti-Cycle-Delay s, and the EARTH LOOP FLOW/ SOURCE WATER LIMIT & HP STAGE 1 LED s will pulse, while the water runs and warms up. The compressor will then restart again providing heat until the LWT again reaches 39 F. If this routine continues the heat pump may not be able to maintain the temperature in the house and the backup heat will come on. Possible causes of low discharge temperature on a open loop: 1. Supply water filter that needs cleaning 2. Inadequate water supply 3. Water discharge line that is plugging up 4. Entering water temperature less than 50 degrees Water Coil Maintenance Water quality is a major concern for open systems. Problems can occur from scaling, particle buildup, suspended solids, corrosion, ph levels outside the 7-9 ranges, or biological growth. A cupronickel heat exchanger is recommended for open loop applications. If poor water quality is known to exist in your area a closed loop system may be the best alternative. Water coil cleaning on an open loop system may be necessary on a regular basis. 12/03/ GI101

20 Optional Desuperheater, Domestic Hot Water General TTHERM GEO series units may be equipped with a double wall desuperheater and an integrated circulating pump that can provide Supplemental Domestic hot Water (SDW). This is done by stripping heat from the superheated gas leaving the compressor. Fuses the desuperheater pump is fed from the circuit board s 10-amp fuses. The fuses are located on the pump relay board in the line voltage control box. Note, the desuperheater pump is disabled from the factory. At the pump relay board top, moving the black/red wire from the P tab to the SWH tab enables the desuperheater. General Plumbing and Installation Suggestions 1. Insulated ½ copper piping should be used from the hot water tank to the desuperheater connections on the left side of the unit. The copper tubing should be straight to maintain good water velocity and prevent air pockets from forming at the pump inlet. CAUTION Never use pex tubing when connecting a desuperheater to the domestic water system. Normal cycling of the desuperheater pump can cause the discharge water temperature to exceed the rated temperature of the pex causing the pex to fail. This has caused flooding in basements. Desuperheater must be plumbed in copper. 2. Shut off valves should also be used to service the desuperheater pump without draining the entire hot water tank. Note: Always be sure these valves are open when pump is running. 3. Pump problems develop by running the pump dry or with air in the system. All air must be purged from the desuperheater plumbing before the pump is engaged. 4. To purge the air from the desuperheater lines close the ball valve between the desuperheater return, boiler drain, and the bottom port of the water heater. Open the boiler drain allowing water to flow through the complete desuperheater circuit purging out the air. When all the air is purged, close the boiler drain and open the ball valve to the bottom of the water heater. 5. Never operate the system without the high temperature switch (normally factory installed) as tank temperatures could become dangerously high. 6. Poor water quality may reduce the effectiveness of the desuperheater pump or not allow the pump to circulate. 7. Desuperheater maintenance includes periodically opening the drain on the hot water tank to remove any deposits. Hard water may cause scale buildup in the desuperheater coil reducing its effectiveness. 8. The temperature difference between the water entering and leaving the desuperheater will depend on the desuperheater entering water temperature. The desuperheater will make less hot water in cooling mode. 9. For the maximum efficiency from the provided desuperheater module, TTHERM GEO suggests a water heater preheat tank as shown in Figure 7. The Figure 7A single tank plumbing and application is shown for information only. There are a number of ways the desuperheater/pump can be plumbed into the building/household water heater tank. However, many common methods used are not very effective because they simply circulate already heated water from the water heater tank through the desuperheater. The heat pump desuperheater cannot effectively produce hot water energy if the temperature of the water entering the desuperheater is close to or beyond the compressor gas capability to transfer energy into this circulated water typically 110 F to 130 F. In TTHERM GEO hydronic heat pumps the desuperheater is automatically disabled when it is unable to add additional hot water energy to the water heater or preheat tank on THA units. THT units will have the option of the desuperheater operating whenever a compressor runs or can be disabled in cooling only by removing jumper J 14 on the GEO Logic controller bd.. 12/03/ GI101

21 Figure 7 Desuperheater Piping, Preheat Tank This is the most effective and efficient arrangement for high hot water needs. This is also the recommended method when using a gas water heater with a desuperheater. The preheat tank need not be as big as the standard water heater; 40- gallon size can be very effective. With this two tank system the desuperheater will always act as a water pre-heater and the standard water heater (electric elements or gas) only requires tempering energy which is a very small percentage of domestic water heater energy required. Figure 7A Desuperheater, Single Tank Concept The water flow is from the top tee, through the desuperheater, pushing the heated water into the water heater bottom. The ball valve at the water heater bottom (between drain valve and tank) allows shut-off and an easy method of purging the desuperheater piping with water forcing through the system and out the hose bib drain. Note: Both ball valves must be open whenever the desuperheater pump is energized. Figure 7 Note: Inspect the dip tube in the water heater cold inlet for a check valve. If a check valve is present it must be removed or damage to the desuperheater circulator will occur. Before restoring electrical supply to the water heater, adjust the temperature setting on the tank. On tanks with both upper and lower elements, the lower element should be turned down to the lowest setting, approximately 100 F. The upper element should be adjusted to 120 F to 130 F. Depending upon the specific needs of the customer, you may want to adjust the upper element differently. On tanks with a single element, lower the thermostat setting to 120 F. Figure 7A CAUTION Do not run desuperheater pump without supply from water heater. This will damage the pump. 12/03/ GI101

22 HYDRONIC INSTALLATION CONCERNS Many issues need to be considered when installing a geothermal hydronic system if it is to function reliably and efficiently. This review addresses several common issues that can hopefully help avoid installation and operating difficulties. As you encounter new issues please let us know so we may add them to future white papers. Plumbing Be sure that check valves are properly located and positioned. Check valves should be used when two or more flow paths have the same source and return ports. Make sure that pumps, air eliminators, expansion tanks and fittings are installed properly. You should add them to isolate each component that may require future service. Be aware of the potential for certain areas to thermo-siphon. All lines that will be carrying cold hydronic water or cold loop water should be insulated to avoid condensation during hot humid weather. All hydronic lines should be copper or oxygen barrier Pex tubing. Be certain to size piping and pumps according to the expected flow and pressure drop. Limit the number of fittings used as they add to the pressure drop of the system. We recommend 1 hydronic piping on the THA- 036, 048 and 1¼ on the THA-060, 072 and the THT-096, 120, 144 units. If the total hydronic pipe length to and from the buffer tank is more than 40 feet, or if there is an exceptional amount of resistance in the circuit due to the number of fittings or valves, use the next larger size pipe. If plumbing with Pex, tubing sizes should be one size larger than equivalent copper. TTHERM GEO recommends a hose kit with P/T ports for the heat pump plumbing that goes from the heat pump to the hydronic pump. 1 high pressure hose is used for THA , and 1¼ on the THA-060, 072 and the THT-096, 120, 144 units. This helps isolate the heat pump, reduces plumbing resistance and includes P/T ports for measuring the temperature, and pressure differential for checking water flow and performance. Pump Selection The Grundfos UP26-99F pump is recommended for the hydronic circuit all on units utilizing a buffer tank. This pump is sized to pump from the buffer tank to the heat pump only. Foam insulated pump packs are recommended on the hydronic side, for units that are to be operated in cooling mode. This will minimize sweating in cooling mode. Do not install pumps with the shaft in the vertical position, as they do not tolerate end thrust well. The pumps should never be mounted with the electrical down. Fan Coils Fan coils are used to provide forced air cooling and/or forced air heating. It is important the coil be designed for cooling applications to get proper dehumidification. The fan coil should get the hottest water available in heating mode and the coldest water available in cooling mode. Therefore, the fan coil is always plumbed to the heat pump output line either directly or off a tee when a buffer tank is used. Be sure to observe the correct direction of water flow through the fan coil for the best heating and cooling capacity, and for maximum dehumidification in the cooling mode. The water and air should enter the water coil in opposite directions to achieve the rated capacity of the water coil. Be sure to observe the CWS (cold water supply) & CWR (cold water return) pipe labels on ALL fan coils and uncased A coils. The fan coil thermostat controls the operation of the circulating pump relay, fan relay and second stage heat relay (if equipped) as well as the system mode. Verify that the fan coil thermostat is properly programmed so that the fan operates in first stage heat and that the thermostat set-up is correct. Radiant Floor Systems A separate thermostat usually operates the radiant floor system. The thermostat activates a relay to control a circulating pump which pumps water though the manifold and the floor loop system. If there is more than one zone on a manifold, each zone will have a separate thermostat, which provides input to a zone control or to separate zone pumps. The zone control opens the manifold zone valve(s) for its zone and/or turns on the pump. When using separate zone pumps, each zone must include a check valve to prevent back flow. Since high mass floor heat systems do not require water as hot as the fan coil, the circulating pumps usually draw the water from the buffer tank, which is a mix of heat pump output and returning water. It is very important that the radiant floor system is disabled in the cooling mode so that the floors do not condense. 12/03/ GI101

23 Buffer Tank It is critical that the heat pump is sized to the ability of the delivery system (radiant floor or fan coil) to dissipate the full output of the heat pump in either the heating or air conditioning mode. If there is any doubt that the smallest zone cannot deliver the full output of the heat pump, use a buffer tank. Please consult with your sales representative for proper tank sizing. When a buffer tank is used, the heat pump output and input must be connected directly to the buffer tank to prevent a parallel flow circuit from bypassing the tank. If a single zone is calling, it will pump out of the buffer tank until the zone thermostat is satisfied. Set point controls are used to sense tank temperature and operate the heat pump. When only a small zone is calling, the capacity of the tank may be sufficient to satisfy the zone call. In such a case the heat pump may not be required to run. As the temperature of the buffer tank drops below the control s set point (in heat mode) the set point control s internal relay closes and turns on the heat pump until the tank achieves the correct temperature. NOTE, the buffer tank should be fully insulated, including the bottom to avoid condensation problems. Water Quality It is very important to fill the hydronic system with good quality water to prevent bacteria or algae growth in the antifreeze solution. This growth can cause a buildup on the heat exchanger surfaces, reducing efficiency, capacity and cause lockouts. The water used to fill the system should have 100-PPM grains hardness or less. There are different qualities of water, which are acceptable for use in these systems. Starting with the lowest to the highest, softened water, bottled water, reverse osmosis (RO) water, and distilled water. NOTE: When using reverse osmosis (RO) or distilled water you MUST use a glycol such as EnviroGard Ultra HD that contains additional inhibitors for glycol concentrations below 35%. Using good quality water and adding 2 ounces of household chlorine bleach for each 10 gallons of fluid, or boiler system conditioner can reduce the possibility of a problem. Antifreeze Protection Antifreeze protection is required on the hydronic side of a water-to-water heat pump to protect the heat pump in the air conditioning mode. It should be diluted with 77% softened water to a 23% concentration of antifreeze. This provides adequate freeze protection. When calculating the amount of glycol required, be sure to include the volume of fluid in the buffer tank. Additionally, include two gallons of fluid for each fan coil, and two gallons for each hydronic heat pump. With excessive piping length or oversized piping, its extra volume needs to be considered, as well. The propylene glycol should be 23% of total fluid volume, yielding freeze protection of 18F. IT IS IMPORTANT TO VERIFY THAT THE FREEZE PROTECTION IS CORRECT. Rhomar s Enviro-Guard HD propylene glycol has the appropriate additives to protect the system at this concentration. WARNING PREVENTING FREEZE-UP IS INSTALLER/USER RESPONSIBILITY. DAMAGE CAUSED BY FREEZE-UP IS NOT COVERED BY WARRANTY. CAUTION Softened water is recommended along with 2 oz. of common household chlorine bleach for every 10 gallons of water. WARNING NOT ALL GLYCOLS PROVIDE THE SAME LEVEL OF CONCENTRATION. MOST GLYCOLS DO NOT CONTAIN ENOUGH INHIBITORS FOR THE RECOMMENDED CONCENTRATION LEVELS.FOR GEOTHERMAL SYSTEMS. 12/03/ GI101

24 Optional TTHERM GEO Hydronic Control Module The Hydronic Control Module has two stages for heating and two stages for cooling. This module can be used with one or two heat pumps or one heat pump with a gas or electric boiler and control up to three zones. These zones can be three fan coils or combinations of fan coils and radiant heat zones. The Hydronic Control Module has one set point control for the heating mode and another for the cooling mode. When the fan coil thermostat is set in the heating mode, the B terminal from the stat closes the heating relay and powers the heating set point control. With the fan coil stat set in the cooling mode, the O terminal closes the cooling relay and powers the cooling set point control as well as the O terminal in the heat pump, energizing the heat pump reversing valve. Additionally, the radiant floor lock-out relay is opened, preventing the radiant floor system pumps from operating in the cooling mode. The Hydronic Control Module has two TTI-152 two stage set point controllers, one for heat and one for cool. Best Installation Practices We highly recommend the following practices be followed when installing a geothermal heat pump system. Install components that have been proven to work together successfully. Insulate ALL cold water hydronic plumbing. TAG system with antifreeze type, protection level and installation date. A loop field layout diagram should be created and left with the heat pump for future reference. Complete the Heat Pump Operational Statistics start-up sheet attached to this manual on each installation. 12/03/ GI101

25 HYDRONIC PLUMBING In geothermal hydronic plumbing we are primarily concerned with supply water temperature. Fan coils need the hottest water in heating and the coolest water in cooling to maximize their performance. Geothermal hydronic systems maximize efficiencies by not producing water higher than 115 F in heating. As a result the Btu s must be delivered by increasing flow and keeping the temperature differential across the load small. To accomplish this, flow (GPM) is critical. During installation the placement of components like tees and elbows, pipe sizing, and circulator sizing must be carefully determined for the system to operate at maximum efficiency. If oxygen barrier pex is used as distribution lines, always use one size larger than the size copper that would have been used. When in doubt always choose the next larger size pipe. When the plumbing has been completed the system will need to be filled with thermal transfer fluid. TTHERM GEO recommends a mixture of 23% propylene glycol and 77% softened water in both the closed source loop and the hydronic system. Two ounces of household chlorine bleach should be added to both systems for each 10 gallons of transfer fluid. The following conceptual plumbing diagrams provide an example of well-designed hydronic distribution systems. Hydronic Plumbing Dia. #1 illustrates a typical family residence where a single fan coil, basement radiant floor, and garage radiant floor will meet the heating and cooling needs. A 52 gallon storage tank ports will only support GPM flow rates for this configuration, therefore the THA-060 would be the largest heat pump that could be used. All piping dimensions assume copper pipe is used. Hydronic Plumbing Diagram #1 12/03/ GI101

26 Hydronic Plumbing Diagram #2 illustrates a larger family residence with more zones. Each zone requires enough water flow to make it perform at peak efficiency. The buffer tank with 2 ports is able to handle the increased flow from more zones and larger heat pumps. A 50 gallon tank with 2 ports can accommodate single heat pumps up the THT-144. This single heat pump diagram can be configured to many different applications. All piping dimensions assume copper pipe is used. Hydronic Plumbing Diagram #2 12/03/ GI101

27 Hydronic Plumbing Diagram #3 illustrates a multiple heat pump application that can be scaled from a very large private residence to commercial applications. The number of zones and heat pumps are only limited by the size of the tank and the flow limitations of the piping and the ports in the tank. All piping dimensions assume copper pipe is used. Hydronic Plumbing Diagram #3 12/03/ GI101

28 Electrical Installation 3-phase models (both 208 and 480) also see and use GI102. WARNING DISCONNECT ALL ELECTRICAL POWER BEFORE ELECTRICALLY CONNECTING OR SERVICING THE UNIT. FAILURE TO DISCONNECT THE ELECTRICAL POWER BEFORE WORKING ON THIS PRODUCT CAN CREATE A HAZARD LEADING TO PERSONAL INJURY OR DEATH. Line Voltage The nameplate and/or Installation and Operating Manual specification page provides RLA, LRA, and total amps requirement. Select the proper wire size to comply with your type of wire routing and NEC field wiring requirements. The field power supply connection is at the compressor contactor, at the end of the line voltage control box. Disconnect field provided external safety disconnect is required, see nameplate max amps. Loop pumps control box, upper right, is the pump relay board with field terminal block connection for the source loop pump station and where applicable the 2 nd loop pump. These outputs are controlled by GEO Logic, but protected with 10-amp fusing. Load pump terminals are located between the source pump and 2 nd source pump terminals. The load pump is used to circulate the hydronic fluid through the hydronic heat exchanger. This output is controlled by GEO Logic, but protected with 10-amp fusing. Flow Switch see installation instruction packaged with the flow switches located in the bottom of the cabinet. Grounding route and install the proper size ground conductor between the ground lug above the compressor contactor and the building service entrance panel ground bus. This must be a conductor wire size according to NEC code for the total amp rating of the installed model. The conduit is not sufficient ground conductor. WARNING USE ONLY COPPER WIRE FOR CONNECTION TO THE CIRCUIT BREAKER TERMINALS AND INSIDE THIS PRODUCT S CABINET. WARNING TO AVOID THE RISK OF ELECTRIC SHOCK OR DEATH, WIRING TO THE UNIT MUST BE PROPERLY GROUNDED. FAILURE TO PROPERLY GROUND THE UNIT CAN RESULT IN A HAZARD LEADING TO PERSONAL INJURY OR DEATH. 12/03/ GI101

29 Below is a diagram of the TTHERM GEO Hydronic Control Module M illustrating low voltage connections. This module provides isolated termination for all the low voltage controlled components necessary to complete a hydronic heating and cooling system. The module also controls the temperature in the buffer tank during heat and cool modes of operation. Hydronic Control Module Wiring 12/03/ GI101

30 THT 2 Stage wiring using the (M2-0152) Hydronic Control Module The Control Module is set up to control two single stage THA units. When a THT 2 stage unit is used 24 volts from the Heat Pump #1 terminal needs to be jumpered to Heat Pump #2 terminal. The THT Y2 terminal is then connected the Y terminal of the Heat Pump #2 terminal block. See illustration to the right. Below is a picture of the control module showing the circuit board, the two TTI 152 aqua stats, and the high voltage terminals. The high voltage terminals provide power to the control module itself, and the three zone pumps used to circulate water to the zones controlled by thermostats one, two, and three. Forced Air Handler/Water Coil If the Hydronic Control Module (M2-0152) is not used, a room thermostat for the forced air coil and its appropriate control mechanism must operate the air handler and the pump for the water coil. Also, if it is to be used for cooling, the thermostat must provide the O terminal reversing valve signal to the TTHERM GEO unit to switch it into cool mode. This will require an isolation relay. NOTE Once the master thermostat is set for COOL it must remain in COOL for the summer season. If it is turned off or switched back and forth, the buffer tank could actually heat up in summer 12/03/ GI101

31 GEO Logic Controller GEO Logic Features The GEO Logic controller has a control strategy that will provide multi level operational safeguards that will maximize the capabilities and efficiencies of the heat pump. The LED information lights on the front communicate the THERM GEO s current stage and mode of operation. GEO Logic also has the capability to communicate diagnostic information so it can be kept running at maximum efficiency. Application The GEO Logic controller is standard on all TTHERM GEO Heat Pump models. The GEO Logic controller is designed to run under different operating modes. Basic water to air packaged unit Basic water to air packaged unit with Electro Industries strip heat Basic water to air packaged unit with added gas furnace using the T2-TT-INT-1 option Basic water to air split unit, using the T2-TT-INT-1 option Basic water to water packaged unit Abbreviations used in the section: ACD anti-cycle delay timer (factory 3minutes) AUX strip heat module, an option installed within the TTHERM GEO cabinet CC compressor contactor CDT compressor refrigerant discharge temperature CFM cubic feet per minute airflow COMP compressor CSL compressor safety logic subset, separate processor and power supply which monitors and controls the major compressor protection sensors DDT desuperheater refrigerant discharge temperature ECM - electronically commutated blower motor Hard Lockout the CSL has completed a sequence and shut down the compressor. The GEO Logic processes this status, forwards this status to various connections/indicators lights, and provides AUX backup heat from stat-y. This operating state is only cleared by a power reset. LED light emitting diode. LWT source leaving water temperature RPM revolutions per minute SB standby furnace or equivalent heating unit or mode Soft Lockout reference CSL limit conditions, there is a set number of retries once lockout has been declared. When the system is operating in this retry range, for communication purposes this is considered soft lockout. ST- supply temperature (output air or water) sensor STG stage 1, 2 or 3 of electric heat CAUTION - Type of Thermostat Thermostats required for multiple zones The Hydronic Control Module (M2-0152) requires a thermostat capable of running in conventional mode, providing a B signal in heat mode and an O signal in cooling. This thermostat with O and B signals is only required on the master thermostat terminal. Zones 2 &3 can use any conventional thermostat with up to 2 stages of heat and 1 stage of cool. Thermostat Required for a single zone Use a heat pump thermostat with an O signal for cooling, and a compressor signal Y for heat/cool. The thermostat will also need to supply a W2 signal for Aux heat which may be electric or gas. 12/03/ GI101

32 NOTE If a programmable Thermostat is used, it is recommended that the program be set to disable. In programmable mode, the heating system must be oversized in order to recover from the setback. Since heat pumps are not typically oversized, they require a longer time to recover from the setback period. During this recovery period the system will likely call for electric heat to decrease the recovery time, resulting in lower efficiency. A closed loop performs best when the connected heat pump is allowed to cycle on and off. This cycling allows the closed loop to absorb more heat from the earth and move it into the home. The installer must be familiar with the manufacturer s low voltage wiring terminology, screw terminal terminology/colors, etc. This manufacturer s terminology must be related to TTHERM GEO heat pump s screw terminal identification within this controller. The intent of this instruction manual is not to train each installer on the terminology related to the specific product (thermostat) you are installing. ADDITIONAL OPTIONS: TTHERM GEO Alarm (Optional) When the TTHERM GEO heat pump declares a lockout, this device will sound an audible alarm, and turn on the red LED light. The alarm has a 3-wire cable that connects to the (Alarm, V+, C) tabs on the bottom of the GEO Logic board. The 3-wire hookup can be extended as much as 100 feet (30 meters), use 18 or 20 gauge wire. The audible alarm can be turned off with the pushbutton on the front of the enclosure. But if the system is not repaired within 4 hours the audible alarm will again sound. The LED light will continue until the system is repaired and power off reset. The system may recover on its own, but the LED will continue indicating there was a fault situation. This LED is only turned off by a power off reset at the disconnect. If the alarm option is installed with a wire to the air coil drip pan, this option also includes a condensate overflow alarm. The same audible alarm and LED apply, except the LED is pulsing for drain overflow. Fuse source loop pump, 10A PC Software and Cable ( Windows 95-7) Accessories/Options Part Number T9-UFUSE6670 T2-ET-SOFT-GL1 Thermostat Simulator w/acd over-ride T2-TT-CS-1 Hand Held GEO Logic scan tool T2-30 x 38 Air Pad E Hydronic Control Module M Load Flow Switch THA T2-FS Load Flow Switch THA & THT T2-FS /03/ GI101

33 Figure 8 GEO Logic Board Assignment WARNING ANY CHANGES MADE TO SWITCH SETTIINGS, JUMPERS, OR ACCESSORIES CONNECTED TO THE GEO LOGIC CONTROLLER WILL REQUIRE THE GEO LOGIC CONTROLLER TO BE POWER CYCLED FOR THE CHANGES TO TAKE EFFECT. 12/03/ GI101

34 Field Setup Overview When installing TTHERM GEO THA or THT hydronic heat pumps a control strategy must be considered. Whenever the heat pump is started the source and load sides of the heat pump must support the unit s BTU capacity. If Y is energized the heat pump will make hot water. If Y & O are energized at the same time the heat pump will make chilled water. The THT units require Y2 to be energized to start the second compressor. If Y2 is jumpered to Y1 both compressors will start, the second compressor starting a few seconds after the first. If Y2 is connected to a second stage controller, it will control when the second compressor runs. TTHERM GEO THA and THT hydronic heat pumps are factory (GEO Logic) configured for antifreeze protected hydronic fluid. This hydronic fluid should be 77% softened water and 23% concentration of propylene glycol, which will yield a freeze protection of 18 F. WARNING PREVENTING FREEZE-UP IS INSTALLER/USER RESPONSIBILITY. DAMAGE CAUSED BY FREEZE-UP IS NOT COVERED BY WARRANTY. Thermostat In hydronic systems, thermostats control the energy distribution system. In the case of the Hydronic Control Module (M2-0152) the thermostats will be connected to the module s thermostat terminals. The master thermostat requires 8 wires, fan coil thermostats 2 & 3 only need 6 wires. Connect all the standard heat pump connections to the Hydronic Control Module. This will require 8 conductor thermostat wire. This thermostat wire should be routed through the knockout in the upper left side of the cabinet, adjacent to GEO Logic controller using the proper strain relief. Master Thermostat to the Hydronic Control Module connections: R 24 volt ac power from fan coil #1 via the control module G constant fan O sets up the hydronic control module for cooling, and the heat pump for cooling mode B - sets up the hydronic control module for heating, and the heat pump for cooling mode Y hydronic cooling call W hydronic heating call W2 - starts the auxiliary heat sequence of operation C 24 volt ac common from fan coil #1 via the control module Heat pump to Hydronic Control Module connections: R 24 volt ac power from TTHERM GEO heat pump G no current function O activates the reversing valve for cooling mode Y 1 st stage compressor C/X - 24 volt ac common from TTHERM GEO heat pump L TTHERM GEO heat pump lockout protection circuit indicator Y2 the Y2 terminal on THT units will be wired to Heat Pump #2 terminal block as shown in Dia. #3 in the hydronic control module s manual. SWAP Board: The THT units have a SWAP board installed which will alternate which compressor starts first. When the yellow LED on the swap bd. is ON, the rear compressor started lead or will start lead on the next call. This feature will balance the run time between the two compressors. If the option to run only 1 st stage in cooling is set with the Hand Held Analyzer or the Computer Software, the compressors will still swap, only running one compressor at a time. WARNING SOURCE (EARTH LOOP) ENTERING WATER FLOW SWITCH MUST BE INSTALLED ON ALL UNITS EXCEPT THE 3 & 4 TON. 12/03/ GI101

35 Mounting the external flow switches on THA 060/072 & THT 096/120/144 units: Flow Switches and associated plumbing parts will be installed in the Source IN & Load IN ports TTHERM GEO has 1 ¼ hose kits to simplify the source and load connections. Installation Instructions: 1. On THA 060/072 units the flow switch Tee is installed directly into the Source IN and Load IN ports. a. Be sure the longer end of the manufactured flow switch Tee is inserted into the Source IN and Load IN ports. b. Using pipe dope tighten the flow switch Tee into the IN port tight enough to seal while positioning the flow switch in a vertical orientation. While tightening the flow switch Tee be careful not to damage the threads or flow switch sealing surface. c. Install the Flow Switch to the flow switch Tee being sure the O-ring is positioned properly and the arrow on top of the flow switch is pointing towards the heat pump. d. Connect the flow switch/switches to the appropriate brown wires marked source flow switch and the black/yellow and gray wires marked load flow switch. (Load Flow Switch optional) 2. THT 096/120/144 units a contractor provided 1 ½ to 1 ¼ reducer coupling will need to be installed on the Source IN and the Load IN ports before installing the flow switches. (1 ½ to 1 ¼ reducer coupling is included in Hose Kit L3-004-TTG) (Load Flow Switch optional) a. After the reducer couplings are installed, the installation process is the same as the THA 060/072. See the instructions above a. d. 12/03/ GI101

36 NOTE Temperature Sensors Temperature sensors installed in TTHERM GEO heat pumps are NOT thermisters. They are digital devices calibrated at the manufacturer. They are polarity sensitive. Be sure to connect the red and white wires in their correct shared terminals. The black wire is the data stream wire and will have its own screw terminal. Sensor Related Comments If additional cable length is required, you must use the following rules for extending the cable. Use unshielded (low capacitance, preferred twisted) 3 or 4-wire low voltage cable. Do not, under any circumstances, use leftover wires within the normal thermostat cable. Route the sensor cable making sure you do not crimp, cut, staple, or damage the cable in any way. Keep sensor cables at least 12 (30.5cm) away from any line voltage wiring, romex, etc. If you must cross line voltage, the lines must cross at a 90 angle. Tip when working with the plug-in sensor terminal block and a cable (example, ST), start with black wire. This can help hold the cable when working with the double white and red s. The sensor has polarity, is sensitive to incorrect voltage, and must be protected from static voltage. Do not cross connect or inadvertently short out sensor wires with power on. Permanent sensor damage may result. Open or Closed Loop Jumper NOTE Open or Closed Loop Jumper J11 This jumper comes from the factory shorting the pins and is configured for open loop. For closed loop operation jumper J11 must be disabled/open. Open Loop Water Solenoid Connections The optional water solenoid 24 volt connections are located inside the cabinet near the source water out connection. The cabinet has a knock out provided for these wires. Desuperheater Pump Activation Observe the pump relay board, high voltage compartment upper right corner, there is tagged black/red wire connected to a parking tab just above the row of small relays. In this position the desuperheater pump is not active and this position acts as a manually operated switch for the desuperheater pump. After installation is complete with proper water circulation from the water heater, this tagged wire can be moved from its P tab to the SWH tab (should be open from the factory) outlined by a rectangular box. Anytime in the future there is a need to deactivate the desuperheater pump, again pull off this tagged wire and move it to the P tab (directly above the row of small relays). The desuperheater will operate under GEO Logic control in both heat and cool modes with jumper J14 on. If jumper J14 is removed the desuperheater will only operate in heat mode. When plumbing the desuperheater, refer to the diagrams in the desuperheater section of the manual. WARNING NEVER USE PEX TUBING WHEN CONNECTING A DESUPERHEATER TO THE DOMESTIC WATER SYSTEM. NORMAL CYCLING OF THE DESUPERHEATER PUMP CAN CAUSE THE DISCHARGE WATER TEMPERATURE TO EXCEED THE RATED TEMPERATURE OF THE PEX CAUSING THE PEX TO FAIL. THIS HAS CAUSED FLOODING IN BASEMENTS. DESUPERHEATER MUST BE PLUMBED IN COPPER. WARNING THE DESUPERHEATER MOTOR SHALL NEVER BE ACTIVATED OR RUN UNTIL THERE IS PROPER CONNECTION TO THE WATER HEATER AND THE AIR HAS BEEN PURGED OUT OF THIS WATER CONNECTION. DAMAGE WILL RESULT TO THE DESUPERHEATER PUMP IF IT IS RAN DRY. 12/03/ GI101

37 Grounding The 24 volt transformer and GEO Logic board common are connected to the equipment ground terminal. The high voltage source ground (green) must be connected to the equipment ground terminal. High Voltage Wiring The TTHERM GEO heat pumps will require at least one high voltage circuit. The Electrical Data tables on page 6 will provide the information necessary to determine the correct size circuit. The high voltage wires should be routed through the knockout(s) on the right side of the cabinet adjacent to the high voltage compartment. WARNING HIGH VOLTAGE WIRES SHALL NEVER BE ROUTED THROUGH THE LOW VOLTAGE COMPARTMENT. Dual Fuel/Utility Control Utility Control Utility control is accomplished by controlling the Y signal between the Hydronic Control Module and the TTHERM GEO heat pump. Dual Fuel In a single compressor hydronic system the supplemental fossil fuel heat source is controlled as follows: 1. Furnace -Water coil above a furnace. The second stage of the thermostat will activate the furnace. 2. Boiler Boiler supplementing heat to buffer tank. The second stage of the HEAT TTI 152 aqua stat monitoring the buffer tank temperature will activate the boiler. In a multiple compressor hydronic system the fossil fuel heat source is controlled as follows: 1. Furnace - Water coil above a furnace. The second stage of the thermostat will activate the furnace. 2. Boiler Boiler supplementing heat to buffer tank. An auxiliary HEAT TTI 152 aqua stat monitoring the buffer tank temperature will activate the boiler. 12/03/ GI101

38 Operational Indicators Front Panel LED s: POWER ON (Green LED) ON Solid Normal Pulsing Bad sensor 1 blink every 2 seconds - Bad ST sensor (Hydronic Leaving Water sensor) 2 blinks every 2 seconds - Bad DDT sensor (Dual Compressor units Bad CDT sensor Rear Compressor) 3 blinks every 2 seconds - Bad LWT sensor (Source Leaving Water sensor) 4 blinks every 2 seconds - Bad CDT sensor (Dual Compressor units Bad CDT front Compressor) HP STAGE 1 (Bicolor LED) RED - Heating Mode: ON Solid - Stat Y input is active. Pulsing - ACD is timing. (anti-cycle delay timer) Normal compressor delay at start up or a delay to allow refrigerant pressures or temperature sensors to reach a normal starting pressure or operating temperature range. GREEN - Cooling Mode: ON Solid - Stat Y input is active. Pulsing - ACD is timing. (anti-cycle delay timer) Normal compressor delay at start up or a delay to allow refrigerant pressures or temperature sensors to reach a normal starting pressure or operating temperature range. 12/03/ GI101

39 HP STAGE 2 (Yellow LED) - (Dual Compressor units only) ON Solid - HP-Y2 is running. AUX HEAT (Yellow LED) - (Not functional on Hydronic Systems) ON Solid - AUX is ON. Comment three AUX LED s on the inside of the board indicate how many stages of electric heat have been activated. Pulsing - Open safety limit. The primary high temp limit has opened in the electric heat module. EARTH LOOP FLOW/SOURCE WATER LIMIT (Red LED) ON Solid Source Flow Lockout = No source flow Pulsing: Open Loop - LWT < 'Open Loop, Source LWT Warning (Heat)' Closed Loop - LWT < 'Closed Loop, Source LWT Warning (Heat)'. If LWT is less than this value a shutdown with 2 x ACD s (6 min) is performed This will NOT cause a hard lockout; it is simply a warning and a pause in the system for possible system correction or notification for further service action. Blip Load Flow Lockout = No Hydronic flow (Load Flow Switch optional) LO PRESSURE/LOW TEMP LIMIT (Red LED) ON Solid - Low pressure lockout Pulsing Load side discharge temperature too cold. Load Water - ST < 'Lo Press. Load Leaving Water Temperature ST Warning (Cool)' If ST is less than this value a shutdown with 2 x ACD s (6 min) is performed. This will NOT cause a hard lockout; it is simply a warning and a pause in the system for possible system correction or notification for further service action. HI PRESSURE/HIGH TEMP LIMIT (Red LED) ON Solid - High pressure lockout Pulsing Load side discharge temperature too hot. Load Water - ST > 'Hi Press. Load Leaving Water Temperature ST Warning (Heat)' If ST is greater than this value a shutdown with 2 x ACD s (6 min) is performed. This will NOT cause a hard lockout; it is simply a warning and a pause in the system for possible system correction or notification for further service action. Refrigerant High Temp Lockout (Red LED) ON Solid - CDT - Single or Front Compressor Discharge Temperature Lockout Pulsing CDT Rear Compressor Discharge Temperature Lockout (THT units only) Blip CDT Both Compressors Discharge Temperature Lockout (THT units only) If CDT is greater than this value a soft lockout with 2 x ACD s (6 min) is performed. The 4th time this happens in the same heating or cooling cycle the unit will go into a hard lockout. 12/03/ GI101

40 Back of Circuit Board LED s STG 1-3 (Red LED s) Not used on hydronic units CC (Green LED) ON when the compressor contactor (CC) is ON. ECM STATUS (Green LED) Not used on Hydronic Units ECM RPM (Yellow LED) Not used on Hydronic Units FAULT COUNT (Red LED, left side next to model size dial switch) Normally OFF Counts out a code for the current fault (see Fault Codes) PROGRAM FAULT CODES (FAULT COUNT LED): 1 Pulse = Lost Source Flow 2 Pulses = Refrigerant High Pressure Limit (550 psi) 3 Pulses = Refrigerant Low Pressure Limit (40 psi) 4 Pulses = Loss of refrigerant charge 5 Pulses = Under Voltage detect (source voltage less than 195 volts) 6 Pulses = CDT Safety Limit (230 degrees) 7 Pulses = See ECM Motor Fault section (TVA & TVT units only) 8 Pulses = Lost load water flow (THA & THT units only) 9 Pulses = Leaving source water or load freeze limit 12/03/ GI101

41 High and Low Pressure Switches The heat pump is equipped with both high and low pressure switches that shut the unit off if the refrigerant pressure exceeds 550 PSI or goes below 40 PSI. Do not reset a system in the heating mode without first verifying water flow. WARNING DO NOT RESET THE SYSTEM MORE THAN ONCE REPEATED RESETTING OF THE LOCKOUT CAN CAUSE SERIOUS DAMAGE. IF A REPEAT LOCKOUT OCCURS, CONTACT YOUR SERVICE DEALER IMMEDIATELY. User Visual Warnings Various front panel LED s have pulsing indication when certain key temperature parameters reach a point where system corrective action is advised. GEO Logic has default points where the manufacturer feels notification should be made. When any one of these temperature points is reached the compressor is shut down for 2 x ACD s (6 min.). At the end of this shutdown delay the compressor will again be activated as an automatic reset type function. This does not lead to a lockout, it is simply a warning and a pause in the system for possible system correction or notification for further service action. These LED s will be pulsing during the 2 x ACD (6 min.) shutdown/auto reset cycle. Default Values Trip Point Function Sensor Differential Water to Water Increase Decrease Lo pressure ST 35 3 Hi pressure ST Loop temp. LWT 39 open, 20 closed - 12/03/ GI101

42 Power On Startup Before applying power to the heat pump, check the following items: 1. All plumbing to the heat pump, tank, fan coil/s and radiant floor zones is complete and operational. a. Verify closed loop transfer fluid antifreeze protected to +18 degrees. b. Verify hydronic transfer fluid antifreeze protected to +18 degrees WARNING FREEZE RUPTURE IS NOT COVERED UNDER WARRANTY. 2. Verify low voltage wiring of the thermostats, control module, heat pump, fan coil, and radiant floor zones are complete. 3. Set thermostat to the OFF position. 4. Verify all high voltage wiring is correct including disconnect and wire sizes. 5. If the heat pump is located in a warm area above 45 F [8 C], starting the system with low ambient temperature conditions is more difficult. 6. You may now apply power to the unit. A 3 minute delay on power up is programmed into the GEO Logic board before the compressor will operate. This delay prevents short cycling of the unit. Note there may be additional time delays caused by the thermostat. 7. Verify source water flow see specification page. Open loop systems - manually open water solenoid valve on well system to check flow. Closed loop systems operate earth loop pumps to verify flow of antifreeze protected loop fluid. Antifreeze should be circulated for several hours if not premixed at install. MAKE SURE THE J11 JUMPER IS REMOVED FOR CLOSED LOOP OPERATION. The following steps will assure that your system is heating and cooling properly. After the initial time delay is completed the heat pump is now ready for operation. It is during these steps the information is collected to complete the Hydronic Heat Pump Operational Statistics sheet. This sheet is attached to this manual. It should be removed, filled out and kept with the manual for future reference. 1. Do not connect refrigerant gauges to this unit unless the data collected indicates there is a problem. NOTE The master thermostat controlled fan coil must be powered for the system to operate. Temporary radiant floor only wiring is shown in Diagram 5 in the hydronic control module manual 2. Place the master thermostat to the HEAT position. The HEAT TTI 152 aqua stat will turn on in the Hydronic Control Module. The heat pump will start in heat mode and run to satisfy the buffer tank. Pumps have an initial purge cycle, then compressor will start. A dual compressor unit will start both stages on a tank colder than 2 nd stage setpoint + the differential. The control module will shut the #2 compressor off before the tank satisfies. Check and record source water flow rate in GPM, see specification chart at the beginning of this manual for minimum water flow requirement. Check and record antifreeze protection level. 12/03/ GI101

43 3. After the unit has run for about 3 minutes. (If dual compressor, recheck below after #2 compressor is off.) Check and record the source supply and return water temperatures. Check and record the source supply and return water pressures in PSI. Check and record the hydronic supply and return water temperatures. Check and record the hydronic supply and return water pressures is PSI. Check and record the running voltage. Check and record the total amp draw. Check and record the compressor amp draw. 4. Raise the thermostat only enough to call 1 st stage. Again wait 3 minutes. Check and record the fan coil supply and return water temperatures. Check and record the fan coil supply and return water pressures in PSI. Check and record the fan coil supply and return air temperatures. Check and record the running voltage. Check and record the total amp draw. 5. Raise the thermostat to call for AUX electric heat. Wait 3 minutes. Check and record the fan coil supply and return air temperatures Check and record the fan coil amp draw. This may require checking 2 circuits. If the fan coil is a furnace the AUX call will start the gas furnace. The compressor will shut down when the buffer tank reaches the heat setpoint plus the differential. 6. Turn the thermostat to the off position. If the compressor is running it will shut down in a few seconds. The fan coil blower will stop unless set for constant fan. The HEAT TTI 152 aqua stats will turn off. 7. Place the thermostat in the COOL position. The COOL TTI 152 aqua stat will turn on in the Hydronic Control Module. The heat pump will start in cool mode and run to satisfy the buffer tank. Pumps have an initial purge cycle, then compressor will start. A dual compressor unit will start both stages on a tank warmer than 2 nd stage setpoint + the differential. The control module will shut down the #2 compressor off before the tank satisfies. Check and record source water flow rate in GPM, see specification chart at the beginning of this manual for minimum water flow requirement. 8. After the unit has run about 3 minutes. (If dual compressor, recheck below after #2 compressor is off.) Check and record the source supply and return water temperatures. Check and record the hydronic supply and return water temperatures. Check and record the running voltage. Check and record the total amp draw. Check and record the compressor amp draw. 9. Lower the thermostat only enough to call 1 st stage. Again wait 3 minutes. Check and record the fan coil supply and return water temperatures. Check and record the fan coil supply and return air temperatures. Check and record the running voltage. Check and record the total amp draw. 10. Check to be sure all radiant floor zones are off or not functional. 11. Be sure all operational data has been collected and recorded on the Water to Water Heat Pump Operational Statistics sheet. Record the data in the manual as well as on the back of the warranty card. 12. Reset the thermostat to normal mode and temperature settings for the season. 13. Instruct the owner on correct operation of the thermostat and heat pump system. 12/03/ GI101

44 Operational Tips GEO Logic - The GEO Logic board performs the functions controlling the compressor operation, system lockout, compressor anti-short cycle, and a three minute delay after power is applied. Review Operational Indicator section on page 35 of this manual before proceeding. Pump Purge a stat Y call starts the, loop source pump, Hydronic pump, open loop solenoid, and desuperheater pump. The stat-y call to CSL is delayed by 5 seconds. These four items allow for circulation before the compressor is turned on. After the time delay expires, the compressor contactor will be energized as long as the high and low pressure switches are closed. If either switch is open after the delay expires, the compressor will not energize. If either switch opens while the compressor is energized, it will de-energize immediately and begin the anti- cycle delay timer. The compressor will not be allowed to turn on again until the 2 X ACD (6 minutes) expires and both pressure switches are closed. If the GEO Logic controller experiences three high pressure, low pressure soft lockouts in a single thermostat call period, it will hard lock out the compressor. During both hard and soft lockouts the fault codes are displayed. The flow switch has a bypass timer in which the GEO Logic board will ignore an open flow switch for the first 15 seconds. If the flow switch opens the GEO Logic controller will de-energize the compressor and initiate a single soft lockout. If the GEO Logic controller experiences a second flow switch fault during a single thermostat call period, it will hard lock out the compressor. NOTE This is a fluid flow limit switch; it is not a GPM sensor for determining adequate flow. It is only a flow indicator, and cannot be used to determine minimum required flow. A manual reset of power will be required to reset any hard lockout condition. At stat-y call end, loop source pump, desuperheater pump, hydronic pump, and solenoid turn off immediately. Problems that could cause a lockout situation include: 1. Source water flow problems 2. Hydronic water flow problems 3. Internal heat pump operation problems 4. Excessive cold water temperature conditions, source and load 5. Excessive hot water temperature conditions, source and load 6. Under Voltage (source voltage less than 195 volts) The GEO Logic control has a CSL Fault Count LED to indicate which type of fault or lockout has occurred. The ACD function puts a time-out period of 3 minutes on the compressor before re-starting on a normal cycle.. This function protects the compressor from repeated on/off operation in the event of a loose wire or faulty thermostat. 12/03/ GI101

45 Preventive Maintenance Fan Coil Air Filter Maintenance A dirty fan coil air filter will result in lower efficiency and performance. Under normal operating conditions, a monthly cleaning or replacement should be satisfactory. Heat Pump Water Coil Maintenance (source or hydronic) In closed loop systems, water coil maintenance is generally not needed. However, if a dirty installation or deterioration of the piping has caused debris to accumulate in the system, the water coil should be cleaned using standard cleaning procedures. For open loop systems installed in areas with a high mineral content, it is best to schedule regular periodic maintenance to inspect and clean the coil if necessary. A dirty or fouled heat exchanger can cause the units to trip either low or high pressure. Should cleaning become necessary, do so using the following standard cleaning procedure: see water coil preventive maintenance on page 20. Fan Coil Condensate Drip Pan and Drain Inspection and cleaning of the condensate drain system during the cooling season will help prevent the system from plugging up, potentially causing water damage to your structure and floor coverings. Inspect the condensate drain line to make certain it remains clear of obstructions. In some areas, airborne bacteria can cause algae to grow in the drip pan. In these areas, it may be necessary to treat the drain pan with an algae inhibiting chemical, as this algae together with lint and dust could plug the drain piping. Fan coils with the water coil in a negative pressure chamber will need a trap that is vented after the trap for the condensate to drain properly. Water Coil In order to keep your fan coil operation at peak efficiency, the water coil should be inspected and cleaned when necessary. If the coil is excessively dirty, the coil can be cleaned with a household vacuum cleaner and a soft brush. The aluminum fins are fragile and bend easily, so take great care not to damage the fins, and remember these fins are sharp, so take the needed safety precautions. Water Coil Preventive Maintenance Water Coil Maintenance In closed loop systems, water coil maintenance is generally not needed. However, if a dirty installation or deterioration of the piping has caused debris to accumulate in the system, the water coil should be cleaned using standard cleaning procedures. For open loop systems installed in areas with a high mineral content, it is best to schedule regular periodic maintenance to inspect and clean the coils if necessary. Should cleaning become necessary, do so using the following standard cleaning procedure: Chlorine Cleaning (Bacterial Growth) 1. Turn off the main breaker to the heat pump. 2. Connect a circulating pump to hose bibs on entering water and leaving waterside of heat exchanger. 3. Suggested mixture is 1 part chlorine bleach to 4 parts water. The chlorine should be strong enough to kill the bacteria. 4. Close shut off valves upstream and downstream of heat exchanger. 5. Open hose bibs to allow circulation of bleach solution. 6. Start pump and circulate solution through heat exchanger for 15 minutes to one hour. Solution should change color to indicate the chlorine is killing the bacteria and removing it from the heat exchanger. 7. Flush used solution down the drain by adding fresh water supply. Flush until leaving water is clear. Dispose of the chlorine solution properly. 8. Repeat procedure until solution runs clear through the chlorine circulation process. 9. Flush entire heat pump system with water. This procedure can be repeated annually, semiannually, or as often as it takes to keep bacteria out of the heat exchanger, or when bacteria appears in a visual flow meter to the point the flow cannot be read. Muriatic Acid Cleaning (Difficult Scaling and Particle Buildup Problems) Consult installer due to dangerous nature of acids. Iron out solutions and de-scaling products are also useful 12/03/ GI101

46 Troubleshooting GEO Logic Control Sensor Temperature Calibration all four remote sensors are digital electronic and factory calibrated. Normally these do not require field calibration or verification. However, if sensor temperature error is determined, use the special PC software and PC USB port cable to set the appropriate offset.. The PC screen has direct readout of the four monitored temperatures, it allows a visual determination of temperature settings, and can be used to offset the temperature sensors for troubleshooting and demonstration purposes. NOTE Temperature Sensors Temperature sensors installed in TTHERM GEO heat pumps are NOT thermisters. They are digital devices calibrated at the manufacturer. They are polarity sensitive. Be sure to connect the red and white wires in their correct shared terminals. The black wire is the data stream wire and will have its own screw terminal. Bad sensor, safety if the internal logic detects open sensor wire, a shorted sensor wires, or a incorrectly wired sensor; the green POWER LED reverts to a pulsing mode. See Operational Indicators. Bad sensor, operating default condition the detection of bad sensor forces the controller to a fixed stage operation. Software declared bad sensor default ST = 70 F LWT (heating) = 32 F LWT (cooling) = 77 F CDT = 200 F (DDT = 190 F (CDT on dual compressor models = 200 F)). Check the GEO Logic Controller, Operational Indicators, section of this manual for in depth description of the diagnostic information available by observing the LED s. Internal fuses the source loop, hydronic loop pumps, and desuperheater pump are fused on the high voltage pump relay board. The pump hookup decal provides the fuse size and details. The GEO Logic controller is protected by the circuit breaker on the low voltage transformer. Troubleshooting/Repair Helps 1. This GEO Logic controller contains several interference suppression components, but as an electronic logic product, unpredictable and unusual transients or interferences may sometimes cause strange results. If the GEO Logic controller is acting strange, one immediate step would be a power down reset. Simply turn off the 240 volt source power. When the green POWER LED goes out, count to 10, and re-energize power supply. 2. The terminal blocks for control wire hook-up are designed for a wire insertion and screw clamp down. If there is no wire connected and the screw is loose, the screw may not necessarily make a good electrical contact to the inside components. Example if you jumper the thermostat terminals without thermostat wire connection or if you are attempting to measure voltage on the screw head, you may get erroneous or unpredictable results if the screw is not tightened down. 3. The THT, dual compressor units, have two separate refrigerant circuits. Each compressor has its own refrigerant circuit. The high pressure switches and low pressure switches in both circuits are wired in series. If the heat pump locks out low pressure or high pressure, each of the refrigerant circuits will need the pressures monitored to determine which circuit caused the lockout. 4. Use general heating/heat pump system logic information and basic understanding of the terminal block wiring functions when measuring voltage to determine proper operation. Open Loop Operation TTHERM GEO heat pumps are factory set for open loop operation. Open/Closed loop operation is set with Jumper J 11 on the left side of the GEO Logic controller. The jumper must be in place on J11 if the unit is operated on an open loop. The GEO Logic controller protects the heat exchanger from freezing by causing the compressor to shut down when the leaving water temperature reaches 39 F open loop and 20 F closed loop. The compressor will remain off for 2 ACD s, and the EARTH LOOP FLOW/ SOURCE WATER LIMIT & HP STAGE 1 LED s will pulse, while the water runs and warms up. The compressor will then restart again providing heat until the LWT again reaches 39 F open loop and 20 F closed loop. If this routine continues the heat pump will not be able to maintain the temperature in the house and the backup heat will come on. Possible causes would include: Open Loop Closed Loop 12/03/ GI101

47 1. Supply water filter that needs cleaning 1. Inadequate source water flow 2. Inadequate source water flow 2. Antifreeze protection inadequate 3. Water discharge line that is plugging up 3. Heat exchanger needs to be cleaned 4. Entering water temperature less than 50 degrees 5. Heat exchanger needs to be cleaned WARNING IF THE TTHERM GEO HEAT PUMP IS IN A HARG LOCKOUT WITH THE EARTH LOOP FLOW/ SOURCE WATER LED ON SOLID, DO NOT RESET THE POWER TO THIS HEAT PUMP UNTIL EARTH LOOP FLOW HAS BEEN ESTABLISHED. IF THE COMPRESSOR IS OPERATED IN HEATING MODE WITHOUT WATER FLOW, THE EARTH LOOP HEAT EXCHANGER COULD FREEZE RUPTURE. FREEZE REPTURE IS NOT COVERED UNDER WARRANTY. Troubleshooting the pump relay board The pump relay board has 4 LED s which display which relay is closed. Yellow is on when open loop water solenoid is energized. Green is on when the source and load pumps are energized. Red is on when the desuperheater pump relay has SWH terminal energized.. Blue is on when the 2 nd source loop pump is energized. The relay board has 2 10 amp fuses providing power for source loop, hydronic, and the desuperheater pumps. These fuses are 10 Amp type GSF. Checking the high voltage input terminals The high voltage enters the pump relay board on the upper left side, terminals W1 & W2. This high voltage comes from the source side of the contactor L1 is connected to W1 and L2 is connected to W2. WARNING DISCONNECT ALL ELECTRICAL POWER BEFORE ELECTRICALLY CONNECTING OR SERVICING THE UNIT. FAILURE TO DISCONNECT THE ELECTRICAL POWER BEFORE WORKING ON THIS PRODUCT CAN CREATE A HAZARD LEADING TO PERSONAL INJURY OR DEATH. Checking the high voltage output terminals The high voltage leaves the pump relay board in 2 locations. 1. Terminal Block (TB1) is located in the upper right side of the pump relay board. See the decal located to the right of the TB1 to determine wiring. High voltage should be present at the respective terminals when the corresponding LED is on Load pump terminals will be hot at the same time as source pump terminals. Tip if source voltage is present on the board, one of the LEDs is on, and high voltage is not present at the corresponding terminals, the switching relay is bad and the board will need to be replaced. 2. One of the desuperheater terminals (SWH) is located between the fuses and the other SHW terminal is below the fuses. These terminals carry High Voltage. To determine if the desuperheater pump has power measure across these two terminals. If a desuperheater pump needs to be disabled be sure the high voltage to the TTHERM GEO heat pump is disabled. Remove the SHW wire from between the fuses and place it on the parking tab (P) above the relays. The pump relay board has one low voltage output for the 24 volt AC water solenoid. The 24VAC common wire is gray and is connected to terminal T7 on the right side of the pump relay board. The 24VAC hot wire is brown/yellow and is connected to terminal T4. Tip if the yellow LED #4 is on and the low voltage is not present at the water solenoid terminals, the switching relay is bad and the board will need to be replaced. 12/03/ GI101

48 Troubleshooting General WARNING Refrigerant Evacuation WHEN REFRIGERANT IS EVACUATED FROM A UNIT WITHOUT ANTIFREEZE IN THE WATER TO REFRIGERANT HEAT EXCHANGERS, WATER IN THE UNPROTECTED HEAT EXCHANGER MUST BE REMOVED OR CONTINUOUSLY FLOWING TO AVOID A POTENTIAL HEAT EXCHANGER FAILURE CAUSED BY FREEZE RUPTURE. FLOWING WATER THROUGH THE HEAT EXCHANGERS EVEN IF ANTIFREEZE PROTECTED WILL SPEED THE EVACUATION PROCESS. Troubleshooting Guide for Water-to-Water Geothermal Heating Head pressure Subcool Suction pressure Superheat Compressor Amp draw Load temp differential Source temp differential Undercharged system Low Low Low High Low Low Low Overcharged system High High High Low High High High Low load flow High Low High High High High Low High load flow Low Low High High High Low High Low source flow Low High Low Low Low Low High High source flow High Low High High High High Low Low return load temperature High return load temperature Low High Low Low Low High High High Low High High High Low Low Scaled source coil Low High Low Low Low Low Low Restricted filter/drier Low High Low High Low Low Low Bad TXV / No Bulb charge Low High Low High Low Low Low Troubleshooting Guide for Water-to-Water Geothermal cooling Head pressure Subcool Suction pressure Superheat Compressor Amp draw Load temp differential Source temp differential Undercharged system Low Low Low High Low Low Low Overcharged system High High High Low High Low Low Low load flow Low High Low Low Low High Low High load flow Low Low High High High Low High Low source flow High Low High High High Low High High source flow Low High Low Low Low High Low Low return load temperature High return load temperature Low High Low Low Low Low Low High Low High High High Low High Scaled source coil High Low High High High Low Low Restricted filter/drier Low High Low High Low Low Low Bad TXV / No Bulb charge Low High Low High Low Low Low 12/03/ GI101

49 Unit Operating Conditions Heat Model THA-036 Stage Source Temp Source temp Δ Source GPM Load Temp Δ Load GPM Total Amps 240 Discharge Pressure Discharge temp Sub cool at TXV Suction pressure at bulb Suction temp at bulb Superheat at bulb N/A N/A N/A THA-048 N/A N/A N/A THA-060 N/A N/A THA-072 N/A N/A THT THT THT /03/ GI101

50 Unit Operating Conditions Cool Model THA-036 THA-048 THA-060 THA-072 THT-096 THT-120 THT-144 Stage Source Temp Source temp Δ Source GPM Load Temp Δ Load GPM Total Amps (240) Discharge Pressure Discharge temp Sub cool at TXV Suction pressure at bulb Suction temp at bulb Superheat at bulb N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A /03/ GI101

51 WATER TO WATER, 3 TO 4-TON - HEATING MODE 1/2-C T-3 T-2A LOAD COIL COND W-RT W-ST P WATER LOAD SWH-RT P SWH COIL SWH-ST 140 LIMIT COMP HL LL PT SWH COIL SWH-ST SWH-RT RV TXV T F/D LOOP COIL FL EWT LWT LOAD COIL P W-ST W-RT Name Compressor Pressure high limit Pressure low limit Pressure test port Supplementary heat exchanger Ref: WH supply Ref: WH return Reversing valve Expansion valve Temperature sensor Filter/dryer Source heat exchanger Flow switch Loop entering Loop leaving Water heat exchanger Ref: Loop pump Ref: Load supply Ref: Load return T-3A TXV RV 7/8-B 1/2-A2 1/2-A1 LOOP COIL EVAP T-4 F/D 1/2-D 1/4-G BULB 7/8-F LL PT-1 HL PT-2 COMP POWER SOURCE (AMPS) LWT FL EWT 7/8-E P P GEO LOOP FIELD TM GR101 P.1 Rev

52 WATER TO WATER, 3 TO 4-TON - COOLING MODE 1/2-C T-3 T-2A LOAD COIL EVAP W-RT W-ST P WATER LOAD SWH-RT P SWH COIL SWH-ST 140 LIMIT COMP HL LL PT SWH COIL SWH-ST SWH-RT RV TXV T F/D LOOP COIL FL EWT LWT LOAD COIL P W-ST W-RT Name Compressor Pressure high limit Pressure low limit Pressure test port Supplementary heat exchanger Ref: WH supply Ref: WH return Reversing valve Expansion valve Temperature sensor Filter/dryer Source heat exchanger Flow switch Loop entering Loop leaving Water heat exchanger Ref: Loop pump Ref: Load supply Ref: Load return T-3A 7/8-B TXV RV 1/2-A2 1/2-A1 LOOP COIL T-4 COND F/D 1/2-D 1/4-G BULB 7/8-F LL PT-1 HL PT-2 COMP POWER SOURCE (AMPS) LWT P FL EWT P GEO LOOP FIELD 7/8-E TM GR101 P.2 Rev

53 WATER TO WATER - 5 & 6-TON - HEATING MODE T-3 1/2-C COND LOAD COIL T-2A W-RT COND P W-ST WATER LOAD SWH-RT P SWH COIL SWH-ST 140 LIMIT COMP HL LL PT SWH COIL SWH-ST SWH-RT RV TXV T F/D LOOP COIL FL EWT LWT LOAD COIL P W-ST W-RT Name Compressor Pressure high limit Pressure low limit Pressure test port Supplementary heat exchanger Ref: WH supply Ref: WH return Reversing valve Expansion valve Temperature sensor Filter/dryer Source heat exchanger Flow switch Loop entering Loop leaving Water heat exchanger Ref: Loop pump Ref: Load supply Ref: Load return T-3A TXV RV 7/8-B 1/2-A2 1/2-A1 EVAP LOOP COIL T-4 EVAP F/D 1/2-D 1/4-G 7/8-E BULB 7/8-F LL PT-1 HL PT-2 COMP POWER SOURCE (AMPS) FL 1 LWT EWT P P GEO LOOP FIELD TM NOTES: 1 FIELD INSTALLED, REQUIRED. GR102 P.1 Rev

54 WATER TO WATER - 5 & 6-TON - COOLING MODE 1/2-C T-3 EVAP T-2A LOAD COIL EVAP W-RT P W-ST WATER LOAD SWH-RT P SWH COIL SWH-ST 140 LIMIT COMP HL LL PT SWH COIL SWH-ST SWH-RT RV TXV T F/D LOOP COIL FL EWT LWT LOAD COIL P W-ST W-RT Name Compressor Pressure high limit Pressure low limit Pressure test port Supplementary heat exchanger Ref: WH supply Ref: WH return Reversing valve Expansion valve Temperature sensor Filter/dryer Source heat exchanger Flow switch Loop entering Loop leaving Water heat exchanger Ref: Loop pump Ref: Load supply Ref: Load return T-3A 7/8-B TXV RV 1/2-A2 1/2-A1 COND LOOP COIL T-4 COND F/D 1/2-D 7/8-E 1/4-G BULB 7/8-F LL PT-1 HL PT-2 COMP POWER SOURCE (AMPS) FL 1 LWT EWT P P GEO LOOP FIELD NOTES: TM 1 FIELD INSTALLED, REQUIRED. GR102 P.2 Rev

55 Name WATER TO WATER - 8 TO 12-TON - HEATING MODE LOAD P TXV W-RT COND W-ST RV 7/8-B BULB 1/2-A2 LL SWH-ST SWH COIL 1/2-A1 HL P TANK SWH-RT PT-2 COMP HL LL PT SWH COIL SWH-ST SWH-RT RV TXV T F/D LOOP COIL FL EWT LWT LOAD COIL P W-ST W-RT Compressor Pressure high limit Pressure low limit Pressure test port Desuperheater heat exchanger Ref: WH supply Ref: WH return Reversing valve Expansion valve Temperature sensor Filter/dryer Source heat exchanger Flow switch Loop entering Loop leaving Water heat exchanger Ref: Loop pump Ref: Load supply Ref: Load return 1/4-G 7/8-F POWER SOURCE (AMPS) PT-1 COMP FRONT 7/8-E 140 LIMIT TANK F/D SWH COIL 7/8-B GEO LOOP P EVAP 7/8 RV BULB 1/2-A2 LL 1/2-A1 HL PT-2 P F/D TXV 1/4-G 7/8-F POWER SOURCE (AMPS) TM PT-1 COMP REAR GR103 P.1 Rev

56 Name WATER TO WATER - 8 TO 12-TON - COOLING MODE LOAD P TXV W-RT EVAP W-ST RV 7/8-B BULB 1/2-A2 LL SWH-ST SWH COIL 1/2-A1 HL P TANK SWH-RT PT-2 COMP HL LL PT SWH COIL SWH-ST SWH-RT RV TXV T F/D LOOP COIL FL EWT LWT LOAD COIL P W-ST W-RT Compressor Pressure high limit Pressure low limit Pressure test port Desuperheater heat exchanger Ref: WH supply Ref: WH return Reversing valve Expansion valve Temperature sensor Filter/dryer Source heat exchanger Flow switch Loop entering Loop leaving Water heat exchanger Ref: Loop pump Ref: Load supply Ref: Load return 1/4-G 7/8-F POWER SOURCE (AMPS) PT-1 COMP FRONT 7/8-E 140 LIMIT TANK F/D SWH COIL 7/8-B GEO LOOP P COND 7/8 RV BULB 1/2-A2 LL 1/2-A1 HL PT-2 P F/D TXV 1/4-G 7/8-F POWER SOURCE (AMPS) TM PT-1 COMP REAR GR103 P.2 Rev

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60 TTHERM GEO Residential Limited Product Warranty Effective February 1, 2012 TTHERM GEO warrants to the owner, at the original installation site, for a period of three (3) years from date of original purchase, that the product and product parts manufactured by TTHERM GEO are free from manufacturing defects in materials and workmanship, when used under normal conditions and when such product has not been modified or changed in any manner after leaving the manufacturing plant. If any product or product parts manufactured by TTHERM GEO are found to have manufacturing defects in materials or workmanship, such will be repaired or replaced by TTHERM GEO. TTHERM GEO shall have the opportunity to directly, or through its authorized representative, examine and inspect the alleged defective product or product parts. TTHERM GEO may request that the materials be returned to TTHERM GEO at owner s expense for factory inspection. The determination as to whether product or product parts shall be repaired, or in the alternative, replaced, shall be made by TTHERM GEO or its authorized representative. TEN YEAR (10) LIMITED WARRANTY ON REFRIGERATION COMPONENTS TTHERM GEO warrants that the compressor, reversing valve, expansion valve and heat exchanger(s) of its products are free from defects in materials and workmanship through the tenth year following date of original purchase. If any compressor, reversing valve, expansion valve or heat exchanger(s) are found to have a manufacturing defect in materials or workmanship, TTHERM GEO will repair or replace them at their discretion. LIFETIME LIMITED WARRANTY ON UNIT CABINET TTHERM GEO warrants that the cabinet to be free from defects in materials and workmanship for the life of the unit. If any panel fails TTHERM GEO will repair or replace them at their discretion. TTHERM GEO shall cover labor costs according to the Repair / Replacement Labor Allowance Schedule for a period of three (3) years from the date of original purchase, at the original installation site on all parts excluding the compressor, reversing valve, expansion valve, and heat exchanger(s). TTHERM GEO shall cover labor costs according to the Repair / Replacement Labor Allowance Schedule for a period of ten (10) years from the date of original purchase, at the original installation site, on parts including the compressor, reversing valve, expansion valve, and heat exchanger(s). The Repair / Replacement Labor Allowance is designed to reduce the cost of repairs. This Repair / Replacement Labor Allowance may not cover the entire labor fee charged by your dealer / contractor. TTHERM GEO TTHERMGEO.COM sales@tthermgeo.com P: F: Page 1 of 2 GX002