ClimateMaster Flow Controller 3 Installation, Operation & Maintenance Instructions Manual Download Page 23

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Flow Controller 3 

R e v. :   F e b u r a r y   9 ,   2 0 1 6

Closed Loop Installation

home. Actual area can be 1500-3000 sq. ft. per ton [39.6 to 

79.2 sq. meters per kW] of cooling. In the north, an ice cover 

is required during the heating season to allow the pond 

to reach an average 39°F [3.9°C] just below the ice cap. 

Winter aeration or excessive wave action can lower the pond 

temperature preventing ice caps from forming and freezing, 

adversely affecting operation of the geothermal loop. Direct 

use of pond, lake, or river water is discouraged because of 

the potential problems of heat exchanger fouling and pump 

suction lift. Heat exchanger may be constructed of either 

multiple 300 ft. [92 meter] coils of pipe or slinky style loops 

as shown in Figure 18. In northern applications the slinky or 

matt style is recommended due to its superior performance 

in heating. Due to pipe and antifreeze buoyancy, pond heat 

exchangers will need weight added to the piping to prevent 

floating. 300 foot [92 meter] coils require two 4” x 8” x 16” 

[102 x 203 x 406 mm] blocks (19 lbs. [8.6 kg] each) or 8-10 

bricks (4.5 lbs [2.1 kg] each) and every 20 ft [6 meters] of 

1-1/4” supply/return piping requires 1 three-hole block. 

Pond Coils should be supported off of the bottom by the 

concrete blocks. The supply/return trenching should begin at 

the structure and work toward the pond. Near the pond the 

trench should be halted and back filled most of the way. A 

new trench should be started from the pond back toward the 

partially backfilled first trench to prevent pond from flooding 

back to the structure.

� 

CAUTION! 

CAUTION!

 This manual is not intended for commercial 

loop design.

Figure 16: Typical Horizontal Loop Configurations

Seal and protect the entry point of all earth coupling  

entry points into the building using conduit sleeves 

hydraulic cement.

Slab on Grade Construction

New Construction: When possible, position the pipe in the 

proper location prior to pouring the slab. To prevent wear as 

the pipe expands and contracts protect the pipe as shown 

in Figure 19. When the slab is poured prior to installation, 

create a chase through the slab for the service lines with 4 

inch [102 mm] PVC street elbows and sleeves. 

Retrofit Construction: Trench as close as possible to the 

footing. Bring the loop pipe up along the outside wall of 

the footing until it is higher than the slab. Enter the building 

as close to the slab as the construction allows. Shield and 

insulate the pipe to protect it from damage and the elements 

as shown in Figure 20.

Pier and Beam (Crawl Space)

New and Retrofit Construction: Bury the pipe beneath the 

footing and between piers to the point that it is directly 

below the point of entry into the building. Bring the pipe 

up into the building. Shield and insulate piping as shown in 

Figure 21 to protect it from damage.

Below Grade Entry

New and Retrofit Construction: Bring the pipe through the 

wall as shown in Figure 22. For applications in which loop 

temperature may fall below freezing, insulate pipes at least 4 

feet [1.2 meters] into the trench to prevent ice forming near 

the wall.

Pressure Testing

Upon completion of the ground loop piping, hydrostatic 

pressure test the loop to assure a leak free system.

Horizontal Systems: Test individual loops as installed. 

Test entire system when all loops are assembled before 

backfilling and pipe burial.

Figure 17: Typical Vertical Loop Configurations

Summary of Contents for Flow Controller 3

Page 1: ...Mounting 4 Piping Installation 5 Electrical Wiring 9 Flushing the Earth Loop 10 Antifreeze Selection 13 Antifreeze Charging 15 Low Temperature Cutout Selection 16 Flow Controller Pump Curves 17 Pump...

Page 2: ...Flow Controller 3 R ev F e bu rary 9 2016 2 Geothermal Heat Pump Systems This page has intentionally been left blank...

Page 3: ...or two Grundfos pump models UP26 99 or UP26 116 are available for a variety of unit flow rates and loop layouts Flow Controllers are designed for systems that require water flow rate of up to 20 U S G...

Page 4: ...ting Stud Wall Mounting on stud wall with or without drywall can be accomplished by using the two supplied lag bolts through the top and bottom center holes directly into the studs as shown in Figure...

Page 5: ...D 1 2 12 7 mm wall 1 IPS PE 1 1 4 31 8 mm ID 1 2 12 7 mm wall 1 1 4 IPS PE 1 5 8 41 3 mm ID 1 2 12 7 mm wall 2 IPS PE 2 3 8 60 3 mm ID 1 2 12 7 mm wall Table 2 Typical Piping Insulation Materials AFC4...

Page 6: ...s typically connected using the hose kit AHK5EC which contains all fittings necessary for connection between the Flow Controller and the unit as shown in Figure 5 In multiple unit systems PE piping ma...

Page 7: ...should not be used PE pipe or SCH80 PVC should be used for lengths greater than 10 ft 3 meters 4 All units must include P T ports for flow rate measure and balancing 5 Use optional field installed lo...

Page 8: ...lose enough to unit to maintain short approx 10 ft 3m hose kit from Flow Controller to unit 4 All units must include P T ports for flow rate measure and balancing Multiple Units on Common Loop Field P...

Page 9: ...e phase voltage Pumps are fused through a pair of circuit breakers in the unit control box See electrical table for Flow Controller characteristics The pump slaving module is designed to allow two uni...

Page 10: ...least a 1 5 hp 1 1kW pump is needed to achieve adequate flow velocity in the loop to purge air and dirt particles from the loop itself Antifreeze solution is used in most areas to prevent freezing All...

Page 11: ...uously mixed back into the fluid Surges of 50 psi 345 kPa can be used to help purge air pockets by simply shutting off the return valve going into the flush cart reservoir This process dead heads the...

Page 12: ...seasons and pressures will be higher in the winter months than during the cooling season This fluctuation is normal and should be considered when charging the system initially Unhook the flush cart fr...

Page 13: ...imum entering loop temperatures drop below 40 F 4 4 C or where piping will be routed through areas subject to freezing antifreeze is needed Alcohols and glycols are commonly used as antifreeze solutio...

Page 14: ...anol is not recommended because of the unknown denaturants included in the solution and their possible toxicity and damage resulting to polyethylene piping systems Denaturing agents that are petroleum...

Page 15: ...through both the unit and the loop and flush until fluid is homogenous and mixed It is recommended to run the unit in the heating and cooling mode for 15 20 minutes each to temper the fluid temperatur...

Page 16: ...ent internal damage to the port Use same gauge and thermometer to determine the differential in pressure and temperature Earth Loop Pressure The earth loop must have a slight positive pressure to oper...

Page 17: ...6 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Flow Rate Head ft kPa 1 Grundfos 26 99 2 Grundfos 26 99 2 Grundfos 26 116 3 Grundfos 26 99 0 06 0 13 0 19 0 25 0 32 0 38 0 44 0 50 0 57 0 63 0 69 0 76 0 82...

Page 18: ...e with new pump insuring no foreign material has been introduced and evenly install the four Allen head mounting bolts 5 Place garden hose supply and return on flush ports as shown in Figure 12 and op...

Page 19: ...to be more forgiving of operator skill Joints are frequently required in difficult trench connections and the smaller socket fusion iron is more mobile Operators will have less of a tendency to cut co...

Page 20: ...per kW minimum In larger systems 2 5 to 2 7 gpm per ton 2 41 to 2 90 l m per kW is adequate in most cases Selecting pumps to attain exactly 3 gpm per ton 3 23 l m per kW is generally not cost effectiv...

Page 21: ...uce pressure drop problems In general 2 feet of head 6 kPa pressure drop is allowed for all earth loop fittings which would include 10 12 elbows for inside piping to the Flow Controller This allows a...

Page 22: ...ails common loop cross sections used in horizontal loops Actual number of circuits used in each trench will vary depending upon property size Use GeoDesigner software to determine the best layout Vert...

Page 23: ...is not intended for commercial loop design Figure 16 Typical Horizontal Loop Configurations Seal and protect the entry point of all earth coupling entry points into the building using conduit sleeves...

Page 24: ...when all loops are assembled before backfilling and pipe burial Closed Loop Installation Figure 18 Typical Pond Lake Loop Configurations Building Entry Figure 19 Slab on Grade Entry Detail Figure 20 R...

Page 25: ...1 40 1 86 7434 0 49 1 19 5946 12 26 82 6 63 14655 9 22 4 23 11702 3 08 2 66 9281 1 63 2 03 8110 0 57 1 30 6486 13 30 84 7 18 15876 10 60 4 58 12677 3 54 2 88 10054 1 87 2 20 8786 0 65 1 41 7027 14 12...

Page 26: ...9 22 3 87 6287 3 10 2 44 4986 1 64 1 86 4357 0 58 1 19 3485 12 30 94 6 63 8588 10 70 4 23 6858 3 59 2 66 5439 1 91 2 03 4753 0 67 1 30 3801 13 35 51 7 18 9304 12 27 4 58 7430 4 11 2 88 5892 2 18 2 20...

Page 27: ...2 44 5272 1 62 1 86 4607 0 57 1 19 3685 12 30 46 6 63 9082 10 53 4 23 7252 3 53 2 66 5752 1 87 2 03 5026 0 66 1 30 4020 13 34 97 7 18 9839 12 08 4 58 7857 4 05 2 88 6231 2 15 2 20 5445 0 75 1 41 4355...

Page 28: ...01 1 47 1 86 6380 0 51 1 19 5103 12 27 90 6 63 12577 9 61 4 23 10043 3 21 2 66 7965 1 70 2 03 6960 0 59 1 30 5567 13 32 07 7 18 13625 11 04 4 58 10880 3 69 2 88 8629 1 95 2 20 7540 0 68 1 41 6031 14 1...

Page 29: ...5 3 4 6 5 0 2 0 1 6 1 3 2 7 9 1 3 6 1 1 5 0 0 4 6 5 2 8 6 2 8 6 1 3 0 3 9 2 5 6 3 9 4 3 1 9 0 8 3 9 9 5 4 3 1 1 7 1 3 8 8 0 2 2 7 1 7 5 0 8 4 1 7 2 4 8 2 6 8 1 6 2 0 1 3 6 8 3 6 8 3 1 3 3 0 4 4 3 6 3...

Page 30: ...5 99 3 17 7308 5 79 3 17 8363 10 7 02 3 52 8997 8 09 3 52 5095 7 20 3 52 8115 6 96 3 52 9286 11 8 29 3 87 9892 9 56 3 87 5602 8 51 3 87 8922 8 23 3 87 10210 12 9 65 4 23 10812 11 13 4 23 6123 9 91 4 2...

Page 31: ..._____________________________________________________________________________________ Permit number _______________ Owner s preference on location of loop __________________________ __________________...

Page 32: ...ls or rating labels have been removed or defaced 5 Products on which payment to CM or to the owner s seller or installing contractor is in default 6 Products which have not been installed and maintain...

Page 33: ...33 Flow Controller 3 Rev Febur ary 9 2 0 1 6 Notes...

Page 34: ...s and do not form the basis of any bargain between the parties but are merely ClimateMaster s opinion or commendation of its products ClimateMaster Inc 2006 97B0015N01 7300 S W 44th Street Oklahoma Ci...

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