BMC GW024 Page 46 Installation Instructions Manual Download

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Manual 2100-583G

Page

46 of 48

BOTH HIGH & LOW SIDE OF HIGH AND LOW SIDE OF

THE SCROLL COMPRESSOR MUST BE CHECKED WITH

MANIFOLD GAUGES BEFORE UNBRAZING SYSTEM

COMPONENTS. FAILURE TO DO SO COULD CAUSE

PRESSURIZED REFRIGERANT AND OIL MIXTURE TO IGNITE

IF IT ESCAPES AND CONTACTS THE BRAZING FLAME

CAUSING PROPERTY DAMAGE, BODILY HARM, OR DEATH.

SERVICE HINTS

Check all power fuses or circuit breakers to ensure that

they are all the correct rating.

UNBRAZING SYSTEM COMPONENTS

If the refrigerant charge is removed from a scroll equipped

unit by bleeding the high side only, it is sometimes

possible for the scrolls to seal, preventing pressure

equalization through the compressor. This may leave

low side shell and suction line tubing pressurized. If the

brazing torch is then applied to the low side while the low

side shell and suction line contain pressure, the pressurized

refrigerant and oil mixture could ignite when it escapes

and contacts the brazing flame. To prevent this occurence,

it is important to check both the high and low side

system pressures with manifold gauges before unbrazing.

Removal of service port cores is highly recommended

as secondary insurance that all system pressure has been

relieved.

SERVICE

COMPRESSOR SOLENOID

See Sequence of Operation on Pages 28 & 29 for function.
A nominal 24-volt direct current coil activates the internal

compressor solenoid. The input control circuit voltage

must be 18 to 28 volts ac. The coil power requirements

is 5 VA. The external electrical connection is made with

a molded plug assembly. This plug contains a full wave

rectifier to supply direct current (dc volts) to the unloader

coil.

COMPRESSOR SOLENOID TEST PROCEDURE

– If it is suspected that the unloader is not working, the

following methods may be used to verify operation.

1. Operate the system and measure compressor

amperage. Cycle the compressor solenoid on

and off at 10-second intervals. The compressor

amperage should go up or down at least 25 percent.

2. If Step #1 does not give the expected results, shut

unit off. Apply 18 to 28 volts ac to the solenoid

molded plug leads and listen for a click as the

solenoid pulls in. Remove power and listen for

another click as the solenoid returns to its original

position.

3. If “clicks” cannot be heard, shut off power and

remove the control circuit molded plug from

the compressor and measure the solenoid coil

resistance. The resistance should be 32 to 60 ohms

depending on compressor temperature.

4. Next, check the molded plug:

Voltage Check:

Apply control voltage to the

plug wires (18 to 28 volts ac). The measured

dc voltage at the female connectors in the plug

should be around 15 to 27 volt dc.

Resistance Check:

Measure the resistance from

the end of the one molded plug lead to either of

the two female connectors in the plug. One of the

connectors should read close to zero ohms, while

the other should read infinity. Repeat with other

wire. The same female connector as before should

read zero, while the other connector again reads

infinity. Reverse polarity on the ohmmeter leads

and repeat. The female connector that read infinity

previously should now read close to zero ohms.

Replace plug if either of these test methods does

not show the desired results.

Summary of Contents for GW024

Page 1: ...eaters or in marine applications MIS 3159 Earth Loop Fluid Temperatures 25 110 F Ground Water Temperatures 45 75 Manual 2100 583G Supersedes 2100 583F Date 5 17 18 BMC Inc Bryan Ohio 43506 INSTALLATION INSTRUCTIONS WATER TO WATER GEOTHERMAL HEAT PUMP Models GW024 GW036 GW048 GW060 GW070 ...

Page 2: ... Logic Control 29 High Low Pressure Switch 30 Flow Switch 30 Over Under Voltage Protection 30 Intelligent Reset 30 Alarm Output 30 Pressure Service Ports 30 Checking Refrigerant Quantity 30 Refrigerant Charge General 31 R 410A Topping Off System Charge 31 Safety Practices 31 Troubleshooting Table 45 Service Hints Unbrazing System Components Compressor Solenoid 46 Ground Source HP Perf Report Check...

Page 3: ...ky Installation Guide Radiant Systems Design RPA IAMPO ASSE FOR MORE INFORMATION CONTACT THESE PUBLISHERS ACCA Air Conditioning Contractors of America 1712 New Hampshire Avenue Washington DC 20009 Telephone 202 483 9370 Fax 202 234 4721 ANSI American National Standards Institute 11 West Street 13th Floor New York NY 10036 Telephone 212 642 4900 Fax 212 302 1286 ASHRAE American Society of Heating R...

Page 4: ...W 048 1 S 1 A X R C C X No of Compressors Compressor Type S Step Capacity Water to Water Geothermal Options X None Voltage A 230 208 60 1 Capacity MBTUH 024 036 048 060 070 Revision Level Hot Water Generator Option X No HWG 1 HWG Pump Reversible Option H Heating Only Phase 2 Release R Reversible Phase 1 Release Source Coax C Copper closed loop N Cupronickel open loop Load Coax C Copper Loop circul...

Page 5: ...24 1 29 32 Branch Circuit Selection Current 11 7 15 3 21 2 27 1 29 7 Locked Rotor Amps 230 208 58 3 83 0 104 0 152 9 179 2 Flow Center Based upon DORFC 2 Volts 208 230 60 1 Amps 2 14 Desuperheat Pump Motor Volts 208 230 60 1 Amps 0 15 Model GPM GW024 GW036 GW048 GW060 GW070 PSID Ft Hd PSID Ft Hd PSID Ft Hd PSID Ft Hd PSID Ft Hd 4 93 2 15 5 1 55 3 58 1 57 3 62 6 2 17 5 01 2 19 5 05 1 63 3 75 7 2 79...

Page 6: ...5 5 8 F MIS 3160 UNIT A B C D E F GW024 19 1 2 3 1 2 5 3 8 5 1 2 19 7 16 3 9 16 GW036 19 1 2 3 1 2 5 3 8 5 1 2 19 7 16 3 1 2 GW048 20 5 16 3 1 2 5 5 16 5 7 16 20 5 16 3 11 16 GW060 21 3 8 2 3 4 5 1 4 5 1 8 21 3 8 3 GW070 24 1 8 2 3 4 5 1 8 5 24 1 16 2 5 8 HIGH VOLTAGE ENTRANCES LOW VOLTAGE ENTRANCES 19 044 1 357 19 044 20 763 1 357 20 763 28 296 FIGURE 1 UNIT DIMENSIONS ...

Page 7: ... the unit consider ease of piping and electrical connections for the unit Also for units which will be used with a desuperheater consider the proximity of the unit to the water heater or storage tank Place the unit on a solid base preferably concrete to minimize undesirable noise and vibration DO NOT elevate the base pan on rubber or cork vibration eliminator pads as this will permit the unit base...

Page 8: ...jury The signal word DANGER is to be limited to the most extreme situations DANGER signs should not be used for property damage hazards unless personal injury risk appropriate to these levels is also involved WARNING color ORANGE Indicate s a hazardous situation which if not avoided could result in death or serious injury WARNING signs should not be used for property damage hazards unless personal...

Page 9: ...CONTROL WIRING HIGH VOLTAGE LINE SUPPLY Supplied with the unit is an adequate length of liquid tite conduit and fittings to run internally within the sheet metal chassis from the control panel to one of four 4 1 holes in the chassis sides front rear corners for line voltage wires to be ran through See Figures 2 4 LOW VOLTAGE CONTROL WIRES Supplied with the unit is an adequate length of plastic con...

Page 10: ...tory shipped where the control panel is located on the same side of the unit the water connections are located NOTE the control panel can be moved to the rear of the unit opposite to where the water connections are located See Figure 3 1 Remove both front and rear service panels 2 Remove control panel cover 3 Remove four 4 screws securing control panel to unit base 4 Lift and turn control panel si...

Page 11: ...different ways to utilize this 1 Select an Aquastat with an outdoor temperature sensor and program the Aquastat to only energize the Y2 signal when outdoor temperatures fall below a certain level 2 Program a length of time to offset Stage 2 being energized following Stage 1 call This will increase system run time thermal consistency and minimize the start stop cycles on the compressor and minimize...

Page 12: ...PHASE EQUIPMENT DUAL PRIMARY VOLTAGE TRANSFORMERS All Equipment leaves the factory wired on 240 Volt transformer tap For 208 Volt operation reconnect from 240 Volt to 208 Volt tap The acceptable operating voltage range for the 240V and 208V transformer taps are as noted in Table 4 For low voltage connections between the Aquastat and the geothermal heat pump a low voltage terminal strip is factory ...

Page 13: ...ing fitting with a retainer nut that secures it in place It is the same style of fitting used for the flow center connection on ground loop applications Various fittings are available so you may then connect to the unit with various materials and methods These methods include 1 barbed fitting straight and 90 1 MPT straight and 90 and 1 hot fusion fitting straight only See Product Specification She...

Page 14: ...e tanks volume and the wide the operating temperature differential the longer the heat source cycle length The following fomula can be used to calculate the volume necessary when given a specified minimum heat source on time tank operating differential and rate of heat transfer Where v required volume of the buffer tank gallons t desired duration of the heat source s on cycle minutes Qheatsource h...

Page 15: ...STAT OUTDOOR TO FROM OTHER TEMPERATURE SEPARATOR CIRCULATOR SENSOR AIR CIRCULATOR PURGE VALVE VALVE PURGE TANK GEOTHERMAL HEAT PUMP EXPANSION PURGE PRESSURE REDUCING VALVE W BACKFLOW PREVENTER NOTE REQUIRES PRESSURE TEMPERATURE RELIEF VALVE WITH TYPICAL 30 PSIG SETPOINT MAY VARY BY LOCAL CODE CONSULT LOCAL CODES FOR INSTALL REQUIREMENTS FIGURE 5 A TYPICAL LOAD SIDE HYDRONIC SYSTEM ...

Page 16: ...ump systems The design eliminates most causes of system failure The heat pump itself is rarely the cause Most problems occur because designers and installers forget that a ground loop earth coupled heat pump system is NOT like a household plumbing system Most household water systems have more than enough water pressure either from the well pump or the municipal water system to overcome the pressur...

Page 17: ...g cap Barbed 90 adapter MIS 2622 A NOTE Slide retaining cap back to expose double o rings Apply petroleum jelly to o rings to prevent damage and aid in insertion with guage adaptor Dial face pressure guage Thermometer P T Manual 2100 545 Page 18 of 38 0 10 20 30 40 50 60 70 0 5 10 15 20 25 30 35 Flow GPM Head Feet FIGURE 9 PERFORMANCE MODEL DORFC 2 FLOW CENTER 0 5 10 15 20 25 30 35 0 5 10 15 20 25...

Page 18: ...ve the water flow direction indicated by the arrow on the side of the valve body Strainer 8 installed upstream of water coil inlet to collect foreign material which would clog the flow valve orifice The figure shows the use of shutoff valves 4 and 5 on the in and out water lines to permit isoation of the unit from the plumbing system should future service work require this Globe valves should not ...

Page 19: ...ter flow rate through the pipe The worksheet included in Manual 2100 078 should guarantee the well pump has enough capacity It should also ensure that the piping is not undersized which would create too much pressure due to friction loss High pressure losses due to undersized pipe will reduce efficiency and require larger pumps and could also create water noise problems GROUND WATER WELL SYSTEM AP...

Page 20: ...aking if the water is not offensive for drinking purposes it should pose no problem for the heat pump The well driller or local water softening company can perform tests which will determine the chemical properties of the water Water quality problems will show up in the heat pump in one or more of the following ways Decrease in water flow through the unit Decreased heat transfer of the water coil ...

Page 21: ...aned with a solution of Phosphoric Acid food grade acid Follow the manufacturer s directions for mixing use storage etc Refer to the Cleaning Water Coil Figure 9 The acid solution can be introduced in the heat pump coil through the hose bib A Be sure the isolation valves are closed to prevent contamination of the rest of the system by the coil The acid should be pumped from a bucket into the hose ...

Page 22: ...more electrical energy than similarly sized submersible pumps Pipe the unit the same as a water well system D Size the pump to provide necessary GPM for the ground water heat pump A 12 GPM or greater water flow rate is required on all models when used on this type system E A pressure tank should be installed in dwelling to be heated adjacent to the the ground water heat pump A pressure switch shou...

Page 23: ...that a second water storage tank be installed in addition to the main water heater Fossil Fuel fired water heaters must be a two tank installation Tanks specifically intended for hot water storage are available from water heater manufacturers solar hot water storage tanks A well insulated electric water heater without the electric heating elements will also make a suitable storage tank The size of...

Page 24: ... leaving water temperatures and will shut down the pump accordingly START UP AND CHECK OUT Be sure all shut off valves are open and all power supplies are on Open a hot water faucet to permit any air to bleed from the plumbing NOTE The inherent design of this pump for maximum efficiency means this pump is not self priming It is imperative to check the air has been adequately bled from the system T...

Page 25: ...IS 2844 A LINE POWER 208 230 60 1 FROM GEOTHERMAL LOGIC CONTROL PUMP CONTROL BLACK BLACK RED RED BLACK RED COMPRESSOR CONTACTOR SIGNAL RED DESUPERHEATER TEMPERATURE MOTOR RED BLACK THERMISTOR THERMISTOR BLACK BLACK LIMIT BLACK PUMP LOW VOLTAGE TERMINAL STRIP R C BI METAL DESUPERHEATER PUMP PLUG FIGURE 10 DESUPERHEATER WIRING DIAGRAM DESUPERHEATER POTABLE HOT WATER ASSIST ...

Page 26: ...ING WATER HEATER WATER SOURCE UNIT RELIEF VALVE HIGH PRESSURE TO HOUSE VALVES COLD WATER IN INSTALLED HIGH PRESSURE RELIEF VALVE HOT WATER STRAINER DRAIN OUT IN IN OUT L P GAS OIL ELECTRIC ALL PLUMBING MUST CONFORM TO LOCAL CODES NOTES DO NOT OPERATE PUMP WITHOUT WATER LINES CONNECTED AND WATER IN SYSTEM WITH SHUT OFF VALVES OPEN OPTIONAL CHECK VALVE PER CODES MIS 3169 B OPTIONAL EXPANSTION TANK F...

Page 27: ...N VERTICAL OUT DRAIN CHECK VALVE RELIEF VALVES SHUTOFF VALVES INSTALLED AT BOTTOM AS SHOWN EXISTING WATER HEATER ALL PLUMBING MUST CONFORM TO LOCAL CODES IN OUT NOTES DO NOT OPERATE PUMP WITHOUT WATER LINES CONNECTED AND WATER IN SYSTEM WITH SHUT OFF VALVES OPEN ADDITIONAL HOT WATER STORAGE TANK NOT ELECTRICALLY CONNECTED OPTIONAL EXPANSION TANK MIS 3170 B DESUPERHEATER PUMP SHIPPED DISCONNECTED F...

Page 28: ...control board A It will constantly monitor inputs from two temperature sensors Inlet Outlet water sensors B It will constantly monitor the CC Compressor Contactor Signal only energized when compressor is operating C Upon acknowledgement of CC signal and following two minutes the control board will energize the pump relay D After 1 minutes based upon temperature difference between Outlet Inlet sens...

Page 29: ... or energizes the water solenoid Ground Water Water Loop Applications Following 10 seconds of the A terminal energization the compressor contactor is energized SEQUENCE OF OPERATION FULL LOAD HEATING The unit should already be operating in Part Load Heating operation prior to Full Load Cooling being energized see previous Additionally what occurs the thermostat completes a circuit from R to Y2 Thi...

Page 30: ...nal voltage All four 4 LED fault lights will flash when an under or over voltage condition occurs NOTE The over voltage protection can be disabled by removing the O V jumper on the Geothermal Logic Control Board INTELLIGENT RESET The Geothermal Logic Control has an intelligent reset feature after a safety control is activated The controller locks out the unit for 5 minutes at the end of this perio...

Page 31: ...lizing the charging charts on the service door of the unit or this manual as a guideline REMEMBER When adding R 410A refrigerant it must come out of the charging cylinder tank as a liquid to avoid any fractionation and to ensure optimal system performance Refer to instructions for the cylinder that is being utilized for proper method of liquid extraction SAFETY PRACTICES 1 Never mix R 410A with ot...

Page 32: ...RHEATER SWITCH LOW PRESSURE SWITCH EXPANSION UNIT HIGH VOLTAGE MIS 3172 CONTROL BOARD PLUG TERMINAL STRIP DESUPERHEATER LOGIC BOARD GROUND TERMINALS TRANSFORMER COMPRESSOR RELAY CAPACITOR RELAY GEOTHERMAL SOLID STATE FLOW CENTER CIRCUIT BREAKERS COMPRESSOR CONTACTOR FLOW CENTER POWER CONNECTION FIGURE 14 SYSTEM COMPONENT LOCATIONS FIGURE 15 ELECTRICAL CONTROL LOCATIONS COMPONENT LOCATION ...

Page 33: ...Manual 2100 583G Page 33 of 48 FIGURE 16 COOLING CYCLE DIAGRAM REFRIGERATION SYSTEM DIAGRAMS ...

Page 34: ...Manual 2100 583G Page 34 of 48 FIGURE 17 HEATING CYCLE DIAGRAM REFRIGERATION SYSTEM DIAGRAMS ...

Page 35: ...418 427 437 7 50 70 90 121 162 195 413 422 432 8 50 70 90 204 163 196 427 418 427 SOURCE LOAD SYSTEMS REFRIGERANT PRESSURES EWT F GPM EWT F GPM Suction PSIG Discharge PSIG 50 5 50 70 90 7 123 148 149 175 181 181 6 50 70 90 120 145 145 172 178 179 7 50 70 90 118 143 144 168 174 175 8 50 70 90 164 139 140 178 172 172 60 5 50 70 90 7 124 154 162 210 217 219 6 50 70 90 121 151 160 206 213 215 7 50 70 ...

Page 36: ...339 481 7 60 90 120 146 179 190 221 340 482 8 60 90 120 212 179 191 459 340 483 SOURCE LOAD SYSTEMS REFRIGERANT PRESSURES EWT F GPM EWT F GPM Suction PSIG Discharge PSIG 20 5 60 90 120 7 66 68 70 190 296 435 6 60 90 120 66 69 71 190 296 436 7 60 90 120 67 70 72 190 296 436 8 60 90 120 72 69 72 402 296 436 30 5 60 90 120 7 83 86 89 194 300 441 6 60 90 120 84 87 90 194 301 441 7 60 90 120 85 88 91 1...

Page 37: ...441 9 50 70 90 115 140 149 419 428 431 11 50 70 90 164 139 148 430 422 425 SOURCE LOAD SYSTEMS REFRIGERANT PRESSURES EWT F GPM EWT F GPM Suction PSIG Discharge PSIG 50 6 50 70 90 9 119 120 123 182 181 182 7 50 70 90 116 117 120 184 183 183 9 50 70 90 113 114 118 175 174 174 11 50 70 90 115 114 117 169 170 170 60 6 50 70 90 9 120 132 137 218 220 221 7 50 70 90 118 129 134 217 219 220 9 50 70 90 115...

Page 38: ...7 491 9 60 90 120 114 142 157 230 348 492 11 60 90 120 170 143 157 466 348 492 SOURCE LOAD SYSTEMS REFRIGERANT PRESSURES EWT F GPM EWT F GPM Suction PSIG Discharge PSIG 20 6 60 90 120 9 63 66 69 193 300 442 7 60 90 120 64 66 69 193 300 442 9 60 90 120 65 67 70 193 300 443 11 60 90 120 70 67 71 407 300 443 30 6 60 90 120 9 79 82 86 198 305 447 7 60 90 120 80 83 87 198 305 448 9 60 90 120 82 85 88 1...

Page 39: ... 452 462 11 50 70 90 111 150 169 429 442 453 13 50 70 90 189 150 169 449 437 447 SOURCE LOAD SYSTEMS REFRIGERANT PRESSURES EWT F GPM EWT F GPM Suction PSIG Discharge PSIG 50 7 50 70 90 11 120 128 132 195 195 194 9 50 70 90 114 122 125 187 187 186 11 50 70 90 111 119 122 183 183 182 13 50 70 90 125 117 120 183 183 182 60 7 50 70 90 11 120 138 144 229 233 234 9 50 70 90 115 133 139 220 224 226 11 50...

Page 40: ... 511 11 60 90 120 131 164 182 246 366 512 13 60 90 120 198 165 184 489 368 514 SOURCE LOAD SYSTEMS REFRIGERANT PRESSURES EWT F GPM EWT F GPM Suction PSIG Discharge PSIG 20 7 60 90 120 11 63 66 70 201 309 451 9 60 90 120 64 66 71 201 309 451 11 60 90 120 64 67 71 202 310 452 13 60 90 120 70 67 72 419 310 452 30 7 60 90 120 11 78 82 87 205 314 457 9 60 90 120 80 83 88 206 315 457 11 60 90 120 81 84 ...

Page 41: ...8 451 462 13 50 70 90 110 149 172 430 442 453 15 50 70 90 187 148 171 449 437 449 SOURCE LOAD SYSTEMS REFRIGERANT PRESSURES EWT F GPM EWT F GPM Suction PSIG Discharge PSIG 50 9 50 70 90 13 115 137 137 192 200 200 11 50 70 90 111 133 133 184 193 193 13 50 70 90 108 130 130 179 188 188 15 50 70 90 149 127 128 193 184 184 60 9 50 70 90 13 115 142 149 226 236 238 11 50 70 90 112 139 146 219 229 231 13...

Page 42: ...504 13 60 90 120 123 154 168 242 361 504 15 60 90 120 185 155 169 481 362 505 SOURCE LOAD SYSTEMS REFRIGERANT PRESSURES EWT F GPM EWT F GPM Suction PSIG Discharge PSIG 20 9 60 90 120 13 61 63 67 203 309 452 11 60 90 120 62 64 68 203 309 452 13 60 90 120 62 65 69 204 309 453 15 60 90 120 67 65 69 415 309 453 30 9 60 90 120 13 77 80 84 207 314 457 11 60 90 120 78 81 86 207 314 457 13 60 90 120 79 82...

Page 43: ...3 466 475 15 50 70 90 111 143 162 447 461 469 17 50 70 90 173 142 161 469 456 465 SOURCE LOAD SYSTEMS REFRIGERANT PRESSURES EWT F GPM EWT F GPM Suction PSIG Discharge PSIG 50 11 50 70 90 16 111 140 150 200 213 217 13 50 70 90 109 138 148 196 208 212 15 50 70 90 107 136 146 193 206 209 17 50 70 90 163 134 144 216 203 207 60 11 50 70 90 16 113 145 160 236 250 256 13 50 70 90 111 143 158 231 245 250 ...

Page 44: ... 515 15 60 90 120 122 144 151 255 371 515 17 60 90 120 166 145 152 488 372 515 SOURCE LOAD SYSTEMS REFRIGERANT PRESSURES EWT F GPM EWT F GPM Suction PSIG Discharge PSIG 20 11 60 90 120 16 61 64 68 207 316 457 13 60 90 120 62 65 69 207 317 457 15 60 90 120 62 65 69 208 317 458 17 60 90 120 69 66 70 427 317 458 30 11 60 90 120 16 76 80 85 214 323 464 13 60 90 120 77 81 86 214 323 465 15 60 90 120 78...

Page 45: ...t Sequence Not Timed Out Loose Terminals Control Tranformer has circuit breaker Voltage Transformer has 208 240V Taps Geothermal Logic Control has over under voltage protection Thermostat Contactor Coil High Pressure Trip Green Diagnostic Light Low Pressure Trip Orange Diagnostic Light Flow Switch Trip Red Diagnostic Light Bad Compressor Capacitor Compressor Internal Thermal Overload Open Bearings...

Page 46: ...ion is made with a molded plug assembly This plug contains a full wave rectifier to supply direct current dc volts to the unloader coil COMPRESSOR SOLENOID TEST PROCEDURE If it is suspected that the unloader is not working the following methods may be used to verify operation 1 Operate the system and measure compressor amperage Cycle the compressor solenoid on and off at 10 second intervals The co...

Page 47: ..._________________________________________________ WATER SYSTEM INFORMATION 6 Open Loop System Water Well _____________ Closed Loop System ________________ A If Open Loop where is water discharged ____________________________________________________ 7 The following questions are for Closed Loop systems only A Closed Loop system designed by ______________________________________________________ B Ty...

Page 48: ...19 Amperage draw of compressor common wire 20 Suction line temperature 6 from compressor 21 Superheat at compressor 22 Liquid line temperature at metering device 23 Coil subcooling LOAD SIDE DATA 24 Entering fluid temperature 25 Entering fluid pressure 26 Leaving fluid temperature 27 Leaving fluid temperature 28 Pressure drop through coil 29 Gallons per minutes through water coil 30 Fluid temperat...

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