Boreal ACDX-45 Installation Manual Download Page 3

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2005 Boreal Geothermal Inc.

www.boreal-geothermal.com

Table of Contents

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Heat Pump System Requirements

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Optimum Placement

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Installing ACDX line sets

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Vacuuming & Charging

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Built-in refrigerant safety controls

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Theory of Operation

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Vertical Case Dimensions

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Horizontal Dimensions

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Electrical Requirements

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Component Layout

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Performance Ratings

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CFM available

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Trouble Shooting Guide

•

Electrical Schematic

•

Installer Wiring

•

Plenum Heater Wiring

•

Duct sizing Guide

•

Warranty

Section

Page

•

Electronic Control Board

Summary of Contents for ACDX-45

Page 1: ...ermal com Installation Manual ACDX 45 55 65 High Efficiency Direct Expansion Geothermal Heat Pumps Energy Efficient Solutions Tel 514 886 0682 Fax 514 221 3448 Email info boreal geothermal com Web www boreal geothermal com Boreal GEOTHERMAL Inc ...

Page 2: ...ged from this unit must be recovered WITHOUT EXCEPTION Technicians must follow industry accepted guidelines and all local state and federal statutes for the recovery and disposal of refrigerants If a compressor is removed from this unit refrigerant circuit oil will remain in the compressor To avoid leakage of the compressor oil refrigerant lines of the compressor must be sealed after it is removed...

Page 3: ...11 Built in refrigerant safety controls 13 Theory of Operation 15 Vertical Case Dimensions 18 Horizontal Dimensions 19 20 Electrical Requirements Component Layout 21 Performance Ratings 22 CFM available 23 Trouble Shooting Guide 24 Electrical Schematic 27 Installer Wiring 28 Plenum Heater Wiring 29 Duct sizing Guide 30 Warranty 35 Section Page Electronic Control Board 31 ...

Page 4: ...ll be sufficient moisture present in the loop field area during the summer a soaker hose is recommended in all hori zontal trench systems which will used for air condi tioning purposes Vertical Bore Systems Vertical bores 3 x 100 ft holes provide an alternate method of installing a ACDX unit A high water table in the borehole area 20 to 30 ft will insure that there is adequate conduction with the ...

Page 5: ...e installed to prevent the build up of pressure which may result in bursting of the circulator pump housing if the unit is operated while both valves are shut See point A marked above Boreal ACDX All Models Hot water lines are 1 2 ID copper Insulate both hot lines and all refrigerant lines Use ball or gate valves on hot water lines Set hot water thermostats in tank to 120 F Use flexible duct colla...

Page 6: ...or residential and commer cial uses These attempts have failed adequately to meet a num ber of requirements associated with an economically and func tionally viable system Some of the shortcomings included I Inadequate oil return to the compressor primarily in the heating mode II Inadequate evaporator length and spacing for properly ex tracting heat from the earth resulting in low capacity and low...

Page 7: ...should be same as it was originally Insulate both liquid lines and vapor lines from the heat pump to the well head unless in separate horizontal trenches Vapor lines in separate horizontal trenches need only be insulated from 10 ft out in the trench to the basement wall Liquid lines must be insulated from the heat pump to approx 6 ft down the drop pipes in the vertical boreholes Install spacers to...

Page 8: ...wood The styrofoam will smooth out any irregularities in the cement floor while the plywood will distribute the weight of the BOREAL unit evenly over the styrofoam This process will also deaden the compressor noise emitted from the bottom of the cabinet As an alternative several pieces of 2 x 4 lumber can be placed under the unit running from the electrical connection side to the filter rack side ...

Page 9: ...9 2005 Boreal Geothermal Inc www boreal geothermal com Piping Layout of a BOREAL Vertical ACDX Heat Pump System ...

Page 10: ...making a 90 degree turn above ground and entering the dwelling between the floor joists just below the first floor These pipes should be insu lated with a minimum of 3 4 of closed cell weatherproof insulation There will be two 1 2 OD copper tubes for each nominal ton of capacity of the heat pump being installed For example a 3 ton unit would have 3 groundloops and thus 6 ends to go through the con...

Page 11: ...11 2005 Boreal Geothermal Inc www boreal geothermal com BOREAL ACDX Horizontal Trench Design ...

Page 12: ...uuming the system with a leak will be impossible and attempting to do so will introduce moisture to the system making the process take much longer to vacuum after the leak has been found and re paired vacuum the system until the reading on an electronic vacuum gauge stays below 500 microns for a period of 5 minutes after the vacuum pump is shut off and the system sealed Charging system Once the sy...

Page 13: ...13 2005 Boreal Geothermal Inc www boreal geothermal com BOREAL Horizontal ACDX Heat Pump System Plan View ...

Page 14: ... of water total Return ducts should ide ally be placed in every room and be sized 50 larger than corresponding supplies In some instances the number of floor diffusers will actually double when compared to the number that would normally be used for a warm air oil fired furnace Starting the Heat Pump BEFORE starting the heat pump the following areas should be rechecked to assure proper operation 1 ...

Page 15: ... of 1 2 copper tubing The pit could be a excavated area or an existing area which needs to be filled as part of general excavation Loops should be buried approxi mately 6 ft underground for best performance Example Boreal ACDX 45 should have 3 loops as shown at left a ACDX 55 4 loops and a ACDX 65 5 loops Other configurations would work as well such as a 50 ft x 50 ft pattern or a 60 ft x 45 ft et...

Page 16: ...oop by virtue of the sensing bulbs being attached to each respective return vapor line and all the equalizer lines con nected to the common suction inlet line The sensing bulb of each TX valve is located just below the connection to the 3 way valves on the gas line header assembly The liquid refrigerant coming in contact with the warm earth vaporizes to a gas and flows back to the heat pump via th...

Page 17: ...itch from heating to cooling mode without shut off on it s low pressure control since refrigerant pressure is supplied to the intake of the com pressor by the idle loops while the refrigerant is being repositioned to operate in another loop or loops Once the refrigerant enters the ground loop s it con denses giving up its heat and returns to its liquid state Oil and liquid refrigerant are swept al...

Page 18: ...18 2005 Boreal Geothermal Inc www boreal geothermal com BOREAL Series ACDX 45 55 65 Engineering and Performance Data ...

Page 19: ... acoustic material Supply Return Duct Sizes Basic cabinet design is the same for all ACDX mod els 45 55 65 Cold air return measures 27 x 30 5 Hot air plenum can be attached to any point on top of the unit except within 6 of the filter rack To pro tect the air coil below See the line marked A at left Filter rack is removable to facilitate easy entry to the building and is reversible so that the fil...

Page 20: ...ng 13 5 x 15 5 14 00 3 19 2 00 16 15 BLOWER DOOR FRONT VIEW FRONT DOOR SIZE 28 W x 31 H 1 25 1 00 31 00 1 00 4 22 4 00 3 50 3 50 4 50 7 50 5 00 5 00 33 00 17 13 6 99ø RIGHT SIDE DOOR 26 07 2 50 BACK SIDE Return Air Side 19 00 Electric Box 1 00 18 00 DOOR Filter rack area Refrigerant Air Coil 33 00 29 00 52 00 27 00 33 00 Direct Expansion to Air Heat Pumps Cabinet Piping Layout horizontal ...

Page 21: ...Size 40 40 50 Max breaker size 40 40 50 Thermostat wire size 18 18 18 Thermostat conductors 8 8 8 Domestic Hot Water Generator Specifications Temperature IN F Temperature OUT F Temperature Rise F of Total ACDX 45 Igal hr ACDX 55 Igal hr ACDX 65 Igal hr 40 150 110 20 10 11 8 14 5 45 150 105 18 9 4 11 1 13 7 50 150 100 15 8 33 9 8 12 1 60 150 90 12 7 33 8 6 10 6 75 150 75 10 7 33 8 6 10 6 90 150 60 ...

Page 22: ...elt drive blower with ball bearings Non sticking reversing valve High efficiency ball bearing PSC style motor Galvanized drip tray Sight glass optional Suction accumulator Bi flow filter driers Thermostatic expansion valve Front Plumbing side Back Electrical Box Side Baked enamel cabinet with satin galvanized condensate tray and floor Components accessible from three sides Heavy duty electrical co...

Page 23: ...ip BM HE 33 Marathon G 10 Blower 2 row 6 circuit air coil 1 2 x 210 ft loops 41 Heating Voltage 230 1 60 Entering Air 70DB 60WB CFM 1550 External Static 15 WC 1 2 x 210 ft loops 77 Cooling Capacity Data Model ACDX 55 HAC nominal 4 ton Heating Ground Temp Heat of Absorption EAT LAT Diff Btu s Out Comp Amps Comp Watts Blower Amps Blower Watts Total Watts COP Suct Disc Pres 70 60745 70 111 4 41 6 708...

Page 24: ... 14 41 9 207 2 30 30341 70 96 7 26 7 49725 22 2 4491 4 2 412 4903 2 97 38 8 203 5 Ground EAT LAT Diff Sens Latent Total Comp Comp Blower Blower Total EER Suct Disc 50 79 9 56 7 23 15 42405 22950 65355 25 9 4342 4 5 415 4757 13 7 66 7 185 7 60 79 9 58 1 21 79 39878 23849 63727 27 4 4415 4 4 420 4835 13 2 70 0 211 6 70 79 5 58 2 21 20 38940 19443 58383 28 4 4515 4 3 415 4930 11 8 69 8 234 8 77 80 1 ...

Page 25: ... power company Burned out motor Ohmmeter shows no resistance be tween common and run terminals or between common and start terminals Note Be sure compressor overload has had a chance to reset If comp is hot this may take several hours Determine cause and replace motor Thermal overload on com pressor tripped Ohmmeter shows reading when placed across R and S terminals and infinity between C R or C S...

Page 26: ...arily until room comes up to temperature Faulty low pressure ctrl Refrigerant pressure control should open on drop at approx 20 psig Control should reset automatically Heat pump can then be restarted by resetting the lock out relay Turn power off then back on Replace faulty control if it will not reset Low refrigerant charge Check return air temp Normal suc tion is 40 60 psig Add refrigerant slowl...

Page 27: ...ter heat exchanger Check water flow and power to pump Check water lines for obstruc tion Remove obstruction in water lines Acid treat the domestic hot water coil Thermostat limit is open Check contact operation Should close at 120 F and open at 140 F Replace thermostat if faulty Disconnect switch open or fuse blown in electrical sup ply to hot water tank Check both line and load sides of fuses If ...

Page 28: ...28 2005 Boreal Geothermal Inc www boreal geothermal com BOREAL ACDX Series Schematic Wiring Diagram Package Unit Schematic Shown ...

Page 29: ...t on off Hot Water Circulator Special Instructions Note If heat pump is to be operated without the hot water circulator connected to the water tank and flooded with water remove the wire marked with RED tape located here This pump is water lubricated and must not be run dry 230 115v 1 60 connections Wire to lugs on compressor relay Connect L3 to Black Connect L2 to White neutral Connect L1 to Red ...

Page 30: ...ng the remaining 2 conductors connect F and F in the heat pump s electrical box to F and F in the plenum heater Thermostat Operation The BOREAL heat pump comes supplied with a 2 stage heating 1 stage cooling auto change over digital thermostat The heat pump is already prewired for this stat and requires only the connections mentioned above for full operation The thermostat operates the heat pump a...

Page 31: ...x 40 10 x 30 12 x 24 14 x 20 16 x 17 16 5 x 16 5 20 1750 2000 18 8 x 40 10 x 30 12 x 24 14 x 20 16 x 17 16 5 x 16 5 22 2000 2250 20 10 x 38 12 x 30 14 x 26 16 x 22 18 x 19 18 5 x 18 5 22 2250 2600 20 10 x 38 12 x 30 14 x 26 16 x 22 18 x 19 18 5 x 18 5 24 2600 2900 22 12 x 36 14 x 30 16 x 26 18 x 23 20 x 20 24 2900 3400 22 12 x 36 14 x 30 16 x 26 18 x 23 20 x 20 26 3400 3600 24 14 x 38 16 x 32 18 x...

Page 32: ... etc In our system direct connection to the stat could put loads on the stat which would shorten it s life With the 24v signal we send only a few milli amps of current are required 2 It is impossible to for the installer to short anything during the installation of the thermostat Crossed connections some erratic manner but would not damage the controller board The BCB has all the time delay functi...

Page 33: ...s RS232 Communication Port Activates loop 1 through 5 Cooling loop solenoids Soaker Hose E Emergency Heat O Reversing Valve G Blower Y Compressor R 24v Hot C Common 24vAC Low Pres Ctrl High Pres Ctrl Short Pins to Reset Selects the No of loops that The board controls 2 5 High Pres Lockout LED Low Pres Lockout LED Working Properly LED Loop Switch Activating LED Diagram A 1 ...

Page 34: ...puts of the controller board are optically coupled to solid state switches so that the worst malfunction in wiring etc would produce only minor damage if at all to the output section of the control board There are 12 output connections at the bottom of the BCB located on 2 two 6 terminal connectors Terminal designa tions are as follows Left to Right Left Block 1 Cooling Loop 1 2 Cooling Loop 2 3 C...

Page 35: ... OPEN liquid line solenoid and 1 ground loop will activate followed by the blower If the system has been in the HEAT mode there will be a delay as the MODE switch timer keeps the compressor OFF for 5 minutes adjustable The compressor will start and be gin to cool using only 1 of the possible loops available MODE 1 The controller board keeps track of the actual run time hours and stores this inform...

Page 36: ...36 2005 Boreal Geothermal Inc www boreal geothermal com ...

Page 37: ...llation Data Sheet have it endorsed by the owner and return it to MANUFACTURER within 21 days after the installation of the unit 3 It is the responsibility of the building or general contractor to supply temporary heat to the structure prior to occupancy These heat pumps are designed to provide heat only to the completely finished and insulated structure Start up of the unit shall not be scheduled...

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