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Installation, Operating, and Maintenance Manual
Geothermal and Hydronics Specialists
www.geo-flo.com
Flo-Link™ and GPM Series Pressurized Flow Centers
Geo-Flo Products Corporation905 Williams Park DriveBedford, Indiana 47421, U.S.A.
Main Number: 812-275-8513Toll Free: 800-784-8069Fax: 888-477-8829
Part # 2122Rev. 07FEB2014
Installation,Operating,andMaintenanceManual Rev. 07FEB2014
Table of Contents
GeneralDescription . . . . . . . . . . . . . 1FlowCenterSizing . . . . . . . . . . . . . 2Installation . . . . . . . . . . . . . . . . 6FlushingandPurging . . . . . . . . . . . . 8AddingAntifreeze. . . . . . . . . . . . . .16Water Quality . . . . . . . . . . . . . . .21Start-up . . . . . . . . . . . . . . . . . .24Maintenance. . . . . . . . . . . . . . . .26Troubleshooting . . . . . . . . . . . . . .31
NOTES:ThisguideprovidestheinstallerwithinstructionsspecifictopressurizedFlowCenters.Pleaserefertoyourheatpumpmanufacturer’sinstructionsorIGSHPAguidelinesforadditionaldetailedflushing,purging,andinstallationinformation.PleasereviewtheentireIOMdocumentbeforeproceedingwiththeinstallation.Geo-FloProductsCorporationiscontinuallyworkingtoimproveitsproducts.Asaresult,thedesignandspecificationsofproductsinthisdocumentmaychangewithoutnoticeandmaynotbeasdescribedherein.Forthemostup-to-dateinformation,pleasevisitourwebsite,orcontactourcustomerservicedepartment.Statementsandotherinformationcontainedinthisdocumentarenotexpresswarrantiesanddonotformthebasisofanybargainbetweentheparties,butaremerelyGeo-Flo’sopinionorcommendationofitsproducts.
General Description
Geo-Floofferstwotypesofpressurizedflowcenters,Flo-Link™seriesandGPMseries.TheFlo-LinkseriesflowcenterssimplifyinstallationusingFlo-LinkdoubleO-Ringfittingsthateliminatethepossibilityofleaksthatsometimesoccurwiththreadedfittings.Frontflushportsalloweasyaccessduringinstallation.Foaminsulationstopscondensation,andthehighimpactpolystyrenecabinetwillnotrust.Flo-Linkflowcentersareavailablewitheitherdiecastbrassorcompositevalves.Flo-Linkflowcentersofferbothconstantspeedandvariablespeedpumpoptions.
TheGPMseriesflowcentersutilizereliable3-wayvalveswiththesamefeaturesandbenefitsastheFlo-Linkvalves,buthavethreadedFPTconnections.GPMflowcentersareavailableinonetofourpumpconfigurations,andmaybeorderedwithorwithoutthefoamedcabinet.Inaddition,GPMflowcentersareavailablewithiso-lationvalvesforapplicationswheretheflushingvalvesarelocatedundergroundorremotely.
AllGeo-Floflowcentersarefullyassembledandleaktested.Geo-FloutilizesindustrystandardGrundfoscirculators(onetofourpumps).Thecabinetsaredesignedtoallowpumpheadstoberotated,orforupgrad-ing/downgrading(i.e.adding/removingapump).
FLO-LINK&GPMSERIESPRESSURIZEDFLOWCENTERS | 1
Figure1:Flo-LinkFlowCenter(componentsinsidecabinet)
Flush Ports
Ground LoopConnections
Die Cast Brassor Composite3-way Valves
Forged Brass3-way Valves
Double O-ringConnections
BetweenComponents
FlangedConnections
BetweenComponents
Field Upgradable to 2-pump flow center (or add blank-
off kit to convert 2-pump to 1-pump flow center)
Grundfos
Circulator
Heat PumpConnections
Figure2:GPMFlowCenter(componentsinsidecabinet)
Grundfos
CirculatorBlank-off
PlateBlank-off
Plate
NOTE: Geo-Flo manufactures flow centers for some heat pump manufacturers that have the flow rate in the opposite direction of the arrows shown above. Verify direction of flow before connecting to heat pump (see arrows molded or stamped into the cabinet).
2 | Installation,Operating,andMaintenanceManual Rev. 07FEB2014
Flow Center Sizing
Design Notes
Pressurizedflowcenterswithmorethanonepumpareassembledsothatwheninstalled,thepumpsareinseries.Thiscanbethoughtofasa“push-pull”pumpingarrangement.Figures1and2showtransparentviewsofFlo-Link(FL)andGPMflowcenters.
Whensizingpumps,apressuredropcalculationshouldbedonefortheentiresystem.VerifywithonlineCalcu-latorsatwww.geo-flo.com,ortomanuallyselectpumps,usethecurvesbelow.
Performance Curves - FL1 and GPM-1
Flo-LinkFL1andGPM-1flowcentersuseoneUPS26-99(3-speed)oroneUP26-116(singlespeed)ontheleftsideoftheflowcenter.Thecurvesbelowillustrateperformance.OlderFL1andGPM-1flowcentersusedtheUP26-99(singlespeedpump),whichisshownaswell.Usethecurvestodeterminepumpselectionthatmeetsdesignrequirements.
Allpumpcurvesaremanufacturer’sreportedaveragesusingwaterat68°F[20°C]
Flow (U.S. GPM) [l/s]
Grundfos Pump UP and UPS Performance Curves (Single Pump)
Head
(Fee
t) [k
Pa]
[0.32 0.63 0.95 1.26 1.58 1.89 2.21]
[119]
[90]
[60]
[30]
FLO-LINK&GPMSERIESPRESSURIZEDFLOWCENTERS | 3
Performance Curves - FLV1
VariablespeedpumpingisavailableforFlo-Link(FL)seriesflowcenters.One(FLV1)ortwo(FLV2)pumpsareavailable.TheGrundfosMagnaGEOvariablespeedpumpcanoperateanywherebetweentheminimumandmaximumcurves,adjustingbaseduponflowratesettingortemperaturedifference.Forexample,a4tontwo-stagegeothermalheatpumpmightoperateat173Wattsonfullloadand12GPM,butonpartloadat9GPMand77Watts,savingmorethan100Wattsversusaconstantspeedcirculator80%oftime.Geo-FlohasanonlinePumpSizingCalculatoratwww.geo-flo.comthatprovidesoperatingcostcomparisons.
Itisevenmoreimportanttocalculatesystempressuredropforvariablespeedsystems.SincetheMagnaGEOhasbetterperformancethanatypicalconstantspeedpump,itcansometimestaketheplaceoftwoUPS26-99pumps,dependinguponthegroundloopconfiguration.
Flow (U.S. GPM) [l/s]
Grundfos Magna GEO 32-140 Performance Curves (Single Pump)
Head
(Fee
t) [k
Pa]
[0.32 0.63 0.95 1.26 1.58 1.89 2.21 2.52 2.84 3.15]
Pump operates inbetween these curvesto maintain flow rateor temperature diff.
0
5
10
15
20
25
30
35
40
45
50
[134.3]
[14.9]
[29.8]
[44.8]
[59.7]
[74.6]
[89.5]
[104.5]
[119.4]
[149.2]
0 5 10 15 20 25 30 35 40 45 50
Allpumpcurvesaremanufacturer’sreportedaveragesusingwaterat68°F[20°C]
4 | Installation,Operating,andMaintenanceManual Rev. 07FEB2014
Flow (U.S. GPM) [l/s]
Grundfos Pump UP and UPS Performance Curves (Two Pumps in Series)
Head
(Fee
t) [k
Pa]
[0.32 0.63 0.95 1.26 1.58 1.89 2.21]
[239]
[179]
[119]
[60]
40
60
80
20
(two in series) (two in series) (two in series) (two in series) (two in series)
Performance Curves - FLV2
VariablespeedpumpingisavailableforFlo-Link(FL)seriesflowcenters.ThetwopumpvariablespeedflowcenterusesoneGrundfosMagnaGEOvariablespeedpumpandoneUPS26-993-speedpump.Liketheone-pumpflowcenter(FLV1),thecombinationcanoperateanywherebetweentheminimumandmaximumcurves,adjustingbaseduponflowratesettingortemperaturedifference.WhenusedwithaGrundfosUPC-GEOcontroller,thecontrollerwilltrytosatisfytherequirementwiththevariablespeedpumptomaximizeoperat-ingcostsavings.Ifthesetpointcannotbereachedwiththevariablespeedpump,theconstantspeed(UPS26-99)pumpisenergized,andthevariablespeedpumpslowsdowntoadjustsetpoint.Thiscontrolalgorithmachievestwo-pumpvariablespeedoperationwithamuchlowercostthanusingtwovariablespeedpumps.
Performance Curves - FL2 and GPM-2
Flo-LinkFL2andGPM-2flowcentersusetwoUPS26-99(3-speed)ortwoUP26-116(singlespeed)pumps,oneoneachsideoftheflowcenter.Onepumppushes,andonepumppulls,effectivelyplacingthetwopumpsinseries.Thecurvesbelowillustrateperformance.OlderFL1andGPM-1flowcentersusedtheUP26-99(singlespeedpump),whichisshownaswell.Usethecurvestodeterminepumpselectionthatmeetsdesignrequire-ments.
Allpumpcurvesaremanufacturer’sreportedaveragesusingwaterat68°F[20°C]
FLO-LINK&GPMSERIESPRESSURIZEDFLOWCENTERS | 5
Performance Curves - GPM-3 and GPM-4
LiketheGPM-2,thepumpsareinseriesforGPM-3andGPM-4flowcenters.Figure3showsaGPM-3.TheGPM-4hasonemorepumponthelowerrighthandside.Thepumpsontherightpush,andthepump(s)ontheleftpull.Forperformancecurves,usetheFL1andGPM-1curves,andmultiplytheheadbythenumberofpumps.Forexample,aGPM-3flowcenterwithallthreeUPS26-99pumpsonhighspeedcouldproduce14.5GPMat60ft.ofhead(60=3x20).Likewise,aGPM-4withUP26-116pumpscouldproduce15GPMat104ft.ofhead(104=4x26).Geo-FlohasanonlinePumpSizingCalculatoratwww.geo-flo.comtoassistwithselectingpumpcombinations.
Flow (U.S. GPM) [l/s]
Grundfos Magna GEO 32-140 and UPS26-99 (pumps in series)
Pumps operate in seriesbetween these curves*to maintain flow rateor temperature diff.
Magna GEO + UPS26-99 (high speed)
Magna GEO (lowest duty cycle -- highest flow/head)
Magna GEO (highest duty cycle -- lowest flow/head)
*UPS26-99 is a constant speed pump; Magna GEO is a variable speed pump. When both pumps are running, the Magna GEO operates between duty cycles shown below to maintain set flow rate or temperature difference.
[0.32 0.63 0.95 1.26 1.58 1.89 2.21 2.52 2.84 3.15] 0 5 10 15 20 25 30 35 40 45 50
0
101520253035404550556065707580
[134]
[15]
[30]
[45]
[60]
[75]
[90]
[105]
[119]
[149]
[164]
[179]
[194]
[209]
[224]
[239] He
ad (F
eet)
[kPa
]
5
Allpumpcurvesaremanufacturer’sreportedaveragesusingwaterat68°F[20°C]
Figure3:GPM-3FlowCenter
6 | Installation,Operating,andMaintenanceManual Rev. 07FEB2014
Installation
Mounting the Unit
Flo-LinkandGPMSeriesflowcentersaredesignedforindoorinstallationonly,andshouldbemountednearthegroundsourceheatpump.Theunitshouldbesecuredusingthesuppliedhardware.
Theflowcentercanbemountedwiththeflowpathseitherverticalorhorizontal(seeFigure4).However,theflowcentercannotbemountedonitsback,upsidedown,oratanangle,asprematurepumpfailurewilloccurwhenthepumpshaftisnotinthehorizontalposition.
Equallyimportanttopumplongevityisterminalboxorientation.SeeFigure5,6,and7forpropercontrolboxorientation.Thepumpterminalboxmustbelocatedinapositiontoavoidcondensationrunningintothecontrolbox,andalsototakeadvantageofthe“weepholes”designedtodrainanycondensationthatmayhaveformed(Figure6).“Weepholes”arelocatedonthreesidesofthepump.
Figure4:AcceptablemountingpositionsforFlo-LinkandGPMseriesflowcenters
3(1)+""+)3#(%
&2'&X1%Figure5:AcceptableterminalboxlocationsforUPS26-99,UP26-99,andUP26-116pumps.
3(1)+""+)3#(%
&2'&X1%
3(1)+""+)3#(%
&2'&X1%
3(1)+""+)3#(%
&2'&X1%
3(1)+""+)3#(%
&2'&X1%
3(1)+""+)3#(%
&2'&X1%
3(1)+""+)3#(%
&2'&X1%
FLO-LINK&GPMSERIESPRESSURIZEDFLOWCENTERS | 7
3(1)+""+)3#(%
&2'&X1%
3(1)+""+)3#(%
&2'&X1%
Figure6:Example“WeepHole”
Weep Hole
Figure7:CorrectterminalboxlocationforGrundfosMagnaGEOvariable speed pump
Plumbing Options
TheFlo-LinkflowcentercanbeplumbedwithawidevarietyofmaterialsincludingHDPE,copper,PEX,andflexiblehosetoprovidemanyoptionstotheinstaller.Figure8showexamplesofFlo-LinkdoubleO-ringadapt-ersandahosekitspecificallydesignedforthistypeofflowcenter.Thepipingshouldbeproperlysupportedtopreventexcessivestressonthethree-wayvalves.
GPMseriesuse1”FPTconnectionsforthegroundloopandheatpumpconnections.Geo-FlooffersawidevarietyofthreadedadaptersforHDPEfusion,hosebarb,andotherconnectiontypes.Ahosekitisalsoavail-ableforGPMflowcenters.Thepipingshouldbeproperlysupportedtopreventexcessivestressonthethree-way valves.
Figure8:ExampleFlo-LinkDoubleO-ringadaptersets
Flo-Linkx1-1/4”HDPEfusion
Flo-Linkx1”barb
Flo-Linkx1”CAM
HosekitforFlo-Linkflowcenters
8 | Installation,Operating,andMaintenanceManual Rev. 07FEB2014
Flushing and Purging
BeforebeginningthisprocedurecarefullystudytheflushcartdiagraminFigure11tobecomefamiliarwiththevalvesusedthroughouttheprocess.Actualflushingtimewillvarydependingonthesizeandconfigurationoftheloop.However,typicallyflushingwillrequireat least2hoursofcontinuespumpoperation.
1. Positionflushcartneartheflowcenter.Ifflowcenterorpurgevalvesarelocatedinanareadifficulttoaccess(suchasacrawlspace),twoextensionhoses20’longcanbeconnectedtothestandardhosestoprovideadditionalreach.
2. Attach1-1/2”hosesto1-1/2”camfittingsonflushcart.
3. Attachflowcentercamadapterfittingstoflushcarthoses.IfusingaFPTflowcenter,attach1”MPTX1”camfittings,or1”MPTXFlo-Linkfemalefittingstotheflowcenterfirst(Figure9).Thenattachflushcarthoses.The1”MPTXFlo-Linkfemalealongwiththe1”camXFlo-Linkelbowsallowtheflushhosestohangverticallyandprovidearotatingunionconnection.
4. Attachgarden/utilityhoseto1/2”fillvalve(Figure10).Attachotherendofhosetoacceptablemunicipalwatersupplyorpre-mixedantifreezesourceandtransferpump.
WARNING: ONLYUSEPREMIXEDANTIFREEZEINANON-FLAMMABLESTATE.FAILURETOOBSERVESAFETYPRECAUTIONSMAYRESULTINFIRE,INJURY,ORDEATH.
5. Rotate3-wayvalvesonflowcentersothattheheatpumpcircuitisisolatedandfluidisdirectedtowardthegroundlooponly.Figure12showsexamplesofhowthevalvesmaybeoriented.Thiswillvarydependingonthetypeofflowcenterinstalled.
NOTE: Duetothenatureoftheinstallationprocess,thegroundlooptypicallyhasahigheramountofdebristhantheheatpumpcircuit.Therefore,flushingthegroundlooppipingpriortoflushingtheheatpumpandassociatedpipingisrecommended.Thisshouldpreventaccidentlypushingdebristhroughtheheatpump’sheatexchangerand/orthecirculatorpumps.
Figure9:FPTflowcenter(top)andFlo-LinkDoubleO-ringflowcenter(below)flushcartfittings
Figure10:FillValve/TankIsolationValve
1”camxFlo-Link elbow
1”MPTxFlo-Linkfemale
Alternate (non-union)fitting:1”MPTx1”cam
1”camxFlo-Link elbow
1/2”FillValve
2”TankIsolationValve
FLO-LINK&GPMSERIESPRESSURIZEDFLOWCENTERS | 9
Figure11:FlushcartdiagramwithdescriptionsEachflushcartincludestwoflushhoses;thestyledependsontheflushcartpurchased.Twentyfoothoseextensionsarealsoavailable.
Flush Cart Diagram
Switch
1/2”Pump/DumpValve
P/TPlug
1-1/2”DeadHead/Return valve
1-1/2”CamFitting-Return
1-1/2”CamFitting-Supply
1/2”PowerDrainValve
1/4”DrainValves
SightTubewithO-ringMarker
BagFilter(InsideTank)
1-1/2”SupplyValve
2”TankIsolationValve
1/2”FillValve
Garden Hose Swivel
Hosesforflushcart Hosesforflushcartwithballvalves
1”CamFemale
1”CamFemale1-1/2”CamFemale1-1/2”CamFemale
1-1/4”FullPortBallValve(OneperHose)
10 | Installation,Operating,andMaintenanceManual Rev. 07FEB2014
6. InsertpressuregaugewithlargedialfacewithaP/TadapterintoP/Tportonflushcart.Close1/2”pump&dumpvalve(Figure13).
7. EnsurethatthebagfilterisinplaceonthereturnPVCpipe.Geo-Florecommendsloopingthefilterbagstrapoverthetopofthereturnpiping.
8. Close2”tankisolationvalve(Figure10)andopenthe1-1/2”dead-headvalve(Figure14).
9. Open1/2”fillvalve(Figure10)andallowthelooptofill.Watchthefluidlevelinthetankviathesighttube.Whenthetankisnearlyfull,shutoffthe1/2”fillvalveand1-1/2”supplyvalve(Figure14).
10. Openthe2”tankisolationvalve(Figure10)andenergizethepump.Slowlyopenthe1-1/2”supplyvalve(Figure14)approxi-mately1/4to1/2open.Airanddebriswillbepushedthroughthereturnpiping.Debriswillbecapturedinthebagfilterandair will be released to the atmosphere.
NOTE: The100micronbagfiltermustbeinplaceduringflushingtofilterdebrisfromtheloop.Debrisisaleadingcauseofcirculatorpumpfailure.
11. Regulatethefluidlevelinthetankwiththe1/2”fillvalve(Fig-ure10)andthe1-1/2”supplyvalve(Figure14)whilethepumpisrunning.Donotallowthefluidinthetanktodroptooloworairwillbepushedbackintotheloopextendingflushingtime.
NOTE: Whenthepumpisrunninganyairremainingintheloopwillbepressurized.Therefore,ifthepumpispoweredoffduringtheflushingprocessthecompressedairwillexpandpushingtheloopfluidbackinthetank.Thiscouldcausethetanktooverflow.Ifthepumpmustbeshutoffduringtheprocess,closethe1-1/2”supplyvalve(Figure14)andthe1-1/2”dead-head/returnvalve(Figure14)topreventfluidfromreturningtothetank.
12. Whenthefluidlevelremainsrelativelystableensurethatthe1-1/2”supplyvalve(Figure14)isfullyopen.
Figure12:FPTflowcenter(top)andFlo-LinkDoubleO-ringflowcenter(below)valvepositionsforheatpumpisolation
Figure13:1/2”Pump&DumpValve
Horizontal portionofflow“T”toward heat pump
To Flush Cart
To Flush Cart
To Flush Cart
To/FromGround
Loop
To/FromHeat Pump
To/FromGroundLoop
To/FromHeatPump
“OFF”toward heat pump (both valves)
1/2”Pump/DumpValve
P/TPlug
FLO-LINK&GPMSERIESPRESSURIZEDFLOWCENTERS | 11
13. Allowthepumptooperateuntilthefluidreturningtothetankappearsclearandfreeofair.
14. Whilethepumpisrunning,“dead-head”thepumpbyturn-ingoffthedead-head/returnvalve(Figure14).Then,quicklyreopenthevalveallowingthefluidtoreturntothetank.Thisprocessdrivesthelooppressureuptherebycompressinganyairremainingintheloop.Quicklyopeningthevalvecreatesasuddenhighvelocitysurgethathelpsdislodgeairintothefluidstream where it can be returned to the tank.
15. Repeatthedead-headprocess2-3timesoveraperiodof15minutes.Ifnecessary,addmorefluidtothetanksothefluidlevelisvisibleinthesighttube.
16. Withthepumpcontinuingtorun,markthefluidlevelinthetankwiththeO-ringonthesighttube.
17. Closethe1-1/2”dead-headvalve(Figure14)whilewatchingthefluidlevelinthesighttube.Thedead-headprocessdrivesthestaticlooppressuretoapproximately50psi.Sincefluidisincompressiblebutaircanbecompressed,thisprocedureshowswhetherairremainsintheloop.Ingeneral,thefluidshouldnotdropmorethanabout3/8”to3/4”onatypicalresi-dentialsystem.Theslightdropinfluidisduetotheexpansionofthegroundlooppiping,andtheactualdropwilldependontheloopsize(i.e.howmuchtotalpipeisintheloop)andfluidtemperature.
18. Openthe1-1/2”dead-headvalve(Figure14)andallowthefluidtocontinuetocirculate.
NOTE: Iftheprecedingprocedureisunsuccessfulinremovingallairfromtheloop,powerflushingmaybenecessary.Proceedtothesectionofthisdocumententitled“PowerFlushing.”
19. Rotate3-wayvalvesonflowcentersothatthegroundloopisisolatedandfluidisdirectedtowardtheheatpumponly.Figure15showsexamplesofhowthevalvesmaybeoriented.Thiswillvarydependingontheflowcenterandinstallation.
Figure14:FlushCartValvesinflushingsteps
1-1/2”DeadHead/Returnvalve
1/2”PowerDrainValve
1/4”DrainValves
1-1/2”SupplyValve
12 | Installation,Operating,andMaintenanceManual Rev. 07FEB2014
20. RepeatSteps11through17abovetoensurethatallairhasbeenpurgedfromtheheatpumpcircuit.
21. Rotate3-wayvalvesonflowcentersothatthefluidisdirectedtowardboththegroundloopandheatpump.Figure16showsexamplesofhowthevalvesmaybeoriented.Thiswillvarydependingonthetypeofflowcenterinstalled.
22. Repeatsteps11through17abovetoensurethatallairhasbeenpurgedfromthegroundloopandheatpumpsystem.
NOTE:Ifyoususpectthattheloopsystemiscontaminatedwithveryfinesand,silt,orclay,additionalloopfiltrationisnecessary.Proceedtothesectionofthisdocumententitled“FluidFiltering”.
23. Closethe1-1/2”dead-headvalve(Figure14).
24. Closethe1-1/2”supplyvalve(Figure14)totrappressureinthesystem.Turnoffthepump.
25. Usingalargeflatheadscrewdriver,slightlyopentheventscrewonthefaceoftheGrundfospump(s).Afterafewdropsofwaterescapes,retightenthescrew.
NOTE: Thisstepiscritical.Openingtheventscrewandallowingfluidtodripoutensuresthatalltrappedairhasexitedthepumpmotor.Skippingthisimportantstepcouldleadtoprematurepumpfailure.
26. Monitorthepressuregaugefor10-15minutes.Thepressureshouldnotdropsubstantially(typicallynomorethan3-4psi).Theslightpressuredropisduetothelooppiperelaxingandisnormal.Ifthereissubstantialpressuredropthereislikelyaleakinthesystem.Inspectallpipingconnectionsinthemechani-calroomforsignsoffluidandcorrectanyissuesdiscovered.Ifthereisaleakinaflushcartconnectiontheflushcartshouldbeisolatedfromthesystemasshowninstep27.Then,thepres-suregaugecanbeinstalledinaP/Tportattheheatpumptomonitor pressure.
27. Ifinstallingapressurizedsystem,rotatethe3-wayvalvessothattheflushcartisisolatedfromthesystem.Figure17showsanexampleofhowthevalvesmaybeoriented.Thiswillvarydependingonthetypeofflowcenterinstalled.
Horizontal portionofflow“T”toward groundloop
Figure15:FPTflowcenter(top)andFlo-LinkDoubleO-ringflowcenter(below)valvepositionsforgroundloopisolation
“OFF”toward groundloop (both valves)
FLO-LINK&GPMSERIESPRESSURIZEDFLOWCENTERS | 13
Horizontal portionofflow“T”toward middle offlowcenter
“OFF”toward backofflowcen-ter (both valves)
Figure16:FPTflowcenter(top)andFlo-LinkDoubleO-ringflowcenter(below)valvepositionstoallowflowtoboththegroundloopandtheheat pump
28. Openthe1-1/2”SupplyandReturnvalves(Figure14)torelievethepressureinthehoses.
29. Ifusingtheflushcarthoseswith1-1/4”ballvalves,closetheballvalves.
30. Disconnectthehosesfromtheflowcenter.
Horizontal portionofflow“T”toward flushport
“OFF”toward flushport(both valves)
Figure17:FPTflowcenter(top)andFlo-LinkDoubleO-ringflowcenter(below)valvepositionsinoperatingposition
14 | Installation,Operating,andMaintenanceManual Rev. 07FEB2014
Power Flushing
Powerflushingisatechniquethatcanbeutilizedtohelppurgeairfromagroundloopwhenthestandardflushingproceduredoesnoteliminateallairfromtheloop.Thisprocedureutilizestheflushcartpumpandmunicipalwaterpressuretogethertoprovidemaximumsystempressuretocompressandpurgeairpockets.Thefollowingprocedure describes this process and assumes that steps 1-18 in theStandardFlushing/Purgingsectionhavebeencompleted.
1. Besurethereissufficientcapacityinthetanktoaddmorefluid.Ifnecessary,removefluidfromthetankbeforeproceeding.
2. Withthepumprunning,closethe1-1/2”deadheadvalve(Figure18)and2”tankisolationvalve(Figure19),andopenthe1/2”fillvalve(Figure19).
3. Monitorthepressure;itwillquicklyclimbto80-100psig.
4. Whenthepressurereaches80-100psig,closethe1/2”fillvalve(Figure19).Then,openthe1-1/2”deadheadvalve(Figure18)andthe2”tankisolationvalve(Figure19)simultaneously.
5. Repeat steps 1-4 above.
6. Returntostep16oftheStandardFlushing/Purgingsection.
Figure19:FillValve/TankIsolationValve
1/2”FillValve
2”TankIsolationValve
Figure18:FlushCartValvesinflushingsteps
1-1/2”DeadHead/Returnvalve
1/2”PowerDrainValve
1/4”DrainValves
1-1/2”SupplyValve
FLO-LINK&GPMSERIESPRESSURIZEDFLOWCENTERS | 15
Fluid Filtering
Thecirculationpumpsusedinclosedloopgeothermalsystemsrequirecleanfluidtooperateproperlyandreliably.Thestandard100micronfilterprovidedwiththeflushcartisacceptableforcapturingrelativelylargedebrissuchaspipeshavings,gravel,andmediumsandparticles.Incertaininstallationlocationsothersmallermaterialssuchasfinesand,siltandclaymaybepresentinthewatersupplyorintroducedtotheloopsystemduringinstallation.Thesefineparticlescantraveltothecirculationpumpsusedduringsystemoperationpos-siblycausingerosionofthepumphousingand/oralockedrotorandpumpfailure.Debrisintheclosedloopsystemisaleadingfactorinprematurepumpfailure.Therefore,itisgoodpracticetoalwayspreformadditionalfluidfiltrationtoensuretheclearestfluidpossiblebeforecompletingasysteminstallation.Thefollowingpro-cedureassumesthatsteps1-22oftheStandardFlushing/Purgingsectionhavebeencompleted.
NOTE: Priortousingtheonemicronfilter,rinseitthoroughlywithcleanwatertoremoveanyresidualdebrisfromthemanufacturingprocess.
1. Turnoffthepumpanddrainfluidfromthetankuntilthelevelisbelowthebottomofthefilter(makesurethattheleveldoesnotdropbelowthesuctioninlettothepump).Thisstepisnecessarytopreventdebriscapturedinthe100micronfilterbagfrombeingreintroducedintothetank.Ifpossible,capturethefluiddrainedfromthetankinacontainersoitcanbeaddedbacktothetankinstep3.
2. Replacethe100micronfilterwithaonemicronfilter.
3. Replacethefluidremovedinstep1torefillthetanktothelevelitwasbeforefilterreplacement.
4. Rotatethevalvesontheflowcentertodirectthefluidtothegroundlooponly.Figure12showsexamplesofhowthevalvesmaybeoriented.Thiswillvarydependingonthetypeofflowcenterinstalled.
5. Runtheflushcartforatleast30minutes,whilemonitoringthefilter.Thisveryfinefilterwillcatchclay,sandandotherdebris.Ifthefilteroverflowsduringtheprocess,stopthepumpandcleanthefilterasnecessary.Continueuntiltheloopfluidiscompletelyfiltered.Cleanthe100micronfilterwithcleanwaterwhiletheonemirconfilterisbeingused.Rotatethevalvesontheflowcentertodirectthefluidtotheheatpumpandallowthepumptorunforanotherfiveminutes.Figure15showsexamplesofhowthevalvesmaybeoriented.Thiswillvarydependingonthetypeofflowcenterinstalled.
6. Turnoffthepumpanddrainfluidfromthetankuntilthelevelisbelowthebottomofthefilter(makesurethattheleveldoesnotdropbelowthesuctioninlettothepump).Thisstepisnecessarytopreventdebriscapturedintheonemicronfilterbagfrombeingreintroducedintothetank.Ifpossible,capturethefluiddrainedfromthetankinacontainersoitcanbeaddedbacktothetankinstep8.
7. Replacetheonemicronfilterwithaclean100micronfilter.
16 | Installation,Operating,andMaintenanceManual Rev. 07FEB2014
8. Replacethefluidremovedinstep6torefillthetanktothelevelitwasbeforefilterreplacement.
9. Returntostep21oftheStandardFlushing/Purgingsection.
NOTE:Dead-headingthepumptocheckforairintheloopsystemisnotpossiblewiththeonemicronfilterinplace.Thefluidinthetankisdrawndownfromthetankfasterthanitpassesthroughthefilter.Therefore,ifthepumpisdead-headedwiththeonemirconfilterinplace,thefluidlevelinthetankaroundthefilterdropswhilethefluidlevelinthefilterremainsatahigherlevel.Afterfilteringwiththeonemicronfilterandre-installingthe100micronfilter,itisimportanttorepeatthedead-headingproceduredescribedintheStandardFlush/Purgingsectiontoensureairdidnotenterthesystemduringthefilteringprocess.
Adding Antifreeze
Antifreezeisusedinagroundloopsystemwhentheloopfluidenteringtheheatpump(EWT)isexpectedtodropbelow40degreesFahrenheit.Ingeneral,antifreezeisaddedatconcentrationhighenoughtoachieveafreezeprotectionlevelthatis10degreeslowerthanthelowestexpectedenteringfluidtemperature(EWT)totheheatpump.Forexample,ifthelowestdesignorexpectedEWTis35F,antifreezeisaddedtoachieveafreezeprotectionlevelof25F(seetable1).Addingtoomuchantifreezewillresultinreducedloopcapacityandincreasedpumppowerconsumption.Thefreezeprotectionleveldependsonthetypeandconcentrationofantifreeze.Theantifreezetypesmostcommonlyusedaremethanol,ethanol,andpropyleneglycol.Puremethanolandethanolareextremelyflammableandthefumescanignite.Extremecaremustbeexercisedwhenhandlingthesechemicals.
Table2providestheflashpointofethanolandmethanolsolutions.Theflashpointisthelowesttemperaturewherethealcoholwillevaporateenoughtoformacombustibleconcentrationofgas.Therefore,theflammabil-ityofethanolandmethanolantifreezesolutionsdependsonthetemperatureofthemixture.Puremethanolorethanolshouldneverbemixedinanenclosedarea.Sincetheflashpointofpropyleneglycolisabovetheboilingpointofwater,thereislittlefirehazardinstorageorhandling.Geo-Florecommendsusingonlypre-mixedalcoholantifreezesinanon-flammablestateorpropyleneglycolatthejobsite.Somemunicipalitiesrestricttheuseofcertainantifreezesolutionsinthegroundloopsystemsobesuretocheckwithstateandlocalauthorities.
WARNING: ONLYUSEPREMIXEDANTIFREEZEINANON-FLAMMABLESTATE.FAILURETOOBSERVESAFETYPRECAUTIONSMAYRESULTINFIRE,INJURY,ORDEATH.
FLO-LINK&GPMSERIESPRESSURIZEDFLOWCENTERS | 17
Pump and Dump Method of Adding Antifreeze
1. Calculatetheamountofantifreezeneededtoachievethefreezeprotectionrequiredforthesystem.Geo-Floprovidesafreeon-linecalculator(gotoanyofthepressuredropcalculatorsatwww.geo-flo.com)toas-sistindeterminingthequantityandfreezeprotectionleveloftheantifreezechosenforaparticularinstalla-tion.Table1providesfreezeprotectionlevelsforethanol,methanol,andpropyleneglycol.
2. Attachahosetothe1/2”pump&dumpvalve(Figure20).Directtheoppositeendofthehosetoanappro-priate drain.
3. Rotatetheflushvalvesontheflowcentertodirectfluidtothegroundlooponly(Figure12).Sincemostoftheloopfluidisinthegroundloop,mostoftheantifreezewouldlikelydumpdownthedrainifantifreezewere introduced toward the heat pump.
4. Openthe1-1/2”supplyvalve(Figure20).
5. Closethe1-1/2”deadheadvalve(Figure20).Thispreventsfluidfromreturningtothetank.
6. Slightlyopenthe1/2”pump&dumpvalve(Figure20).
7. Energizethepump.Thewaterfromthetank/loopispumpedtothedrain.Closelymonitorthefluidlevelinthetankandturnoffthepumpbeforethefluidleveldropsbelowthesuctionpipesoairisnotdrawnintothesystem.Ifairisdrawnintothesystem,theflushingproceduredescribedabovemustberepeated.
Table 1: Freeze protection and specific gravity for common ground loop antifreeze mixtures (source:Geo-FloCalculatorapps,www.geo-flo.com)
Table 2: Flash point* for ethanol and methanol mixtures (source:engineeringtoolbox.com)*Theflashpointofachemicalisthelowest temperature where it will evapo-rateenoughfluidtoformacombustibleconcentrationofgas.Theflashpointisanindicationofhoweasyachemicalmayburn.
18 | Installation,Operating,andMaintenanceManual Rev. 07FEB2014
8. Carefullyaddtheantifreezefluidtothetank.Propylenegly-colcanbepoureddirectlyintothetopofthetank.However,methanolandethanolshouldbehandledwithextremecau-tion.Thesechemicalsshouldneverbepoureddirectlyintothetopoftheflushcarttankwhentheflushcartislocatedinan enclosed space such as a home or mechanical room. Pure methanolandethanolareextremelyflammableandthefumescanignite.Always pre-mix alcohols before taking them to the job site. Forexample,ifthedesiredconcentrationofmethanolis12.5%(16.2deg.Ffreezeprotection),bringa25%mixturetothejobsite,andsimplyusefourtimesasmuchofthemixturevs.puremethanol.Extremecaremustbeexercised,especiallyinhotweather,as25%methanolbyvolumehasaflashpointofabout100deg.F.
9. Energizethepump.Thewaterfromthetank/loopispumpedtothedrainwhiletheantifreezeispumpedtothegroundloop.Closelymonitorthefluidlevelinthetankandturnoffthepumpbeforethefluidleveldropsbelowthesuctionpipesoairisnotdrawnintothesystem.Ifairisdrawnintothesystem,theflushingproceduredescribedabovemustberepeated.
10. Repeatsteps8and9untiltherequiredantifreezehasbeenadded to the loop.
11. Closethe1/2”pumpanddumpvalve(Figure20).
12. Openthe1-1/2”supplyvalve(Figure20)andenergizethepumptomixtheantifreezewiththewaterintheloop.
13. Rotatetheflushvalvesontheflowcentertodirectthefluidtoboththeheatpumpandthegroundlooptoallowtheantifreezetomix.Allowthepumptorununtilthefluidisthoroughlymixed.Ifinstallingapressurizedflowcenter,pres-surizethesystemasdescribedintheStandardFlushing/PurgingProceduresectionofthisdocument.
Figure20:FlushCartValvesinaddingantifreezesteps
1/2”Pump/DumpValve
P/TPlug
1-1/2”DeadHead/Returnvalve
1/2”PowerDrainValve
1/4”DrainValves
1-1/2”SupplyValve
WARNING: ONLYUSEPREMIXEDANTIFREEZEINANON-FLAMMABLE
STATE.FAILURETOOBSERVESAFETYPRECAUTIONSMAYRESULTINFIRE,INJURY,ORDEATH.
FLO-LINK&GPMSERIESPRESSURIZEDFLOWCENTERS | 19
Verifying Antifreeze Concentration/ Freeze Protection
Theantifreezeconcentrationischeckedusingaspecificgravityhydrometerorrefractometer.Besuretousetheproperspecificgravityhydrometerfortheantifreezetypeused.Table1andFigures21through24providespecificgravityversusfreezeprotectionformethanol,ethanol,andpropyleneglycol.
1.000
0.99
0.98
0.97
0.96
0.95
Figure21:Typicalhydrometer(above);readingahydrometer(below).Intheexample,thishydrometerwouldbereadas0.975,approximately25%ethanolbyvolume.NOTE:Therearetwotypesofhydrometers,oneforfluidslighterthanwater(ethanolandmethanol);andoneforfluidsheavierthanwater(propyleneglycol).
20 | Installation,Operating,andMaintenanceManual Rev. 07FEB2014
Free
ze P
rote
ctio
n, d
eg. F
Antifreeze Mixture, % by Volume
Freeze Protection, deg. F
Spec
i�c
Gra
vity
Freeze Protection, deg. F
Spec
i�c
Gra
vity
Figure22:Freezeprotectionforcommongroundloopantifreezemixtures(source:Geo-FloCalcu-latorapps,www.geo-flo.com)
Figure23:Specificgravityforalcohol-basedantifreezesoverarangeoffreezeprotectiontem-peratures(source:Geo-FloCalcu-latorapps,www.geo-flo.com)
Figure24:Specificgravityforpropyleneglycoloverarangeoffreezeprotectiontemperatures(source:Geo-FloCalculatorapps,www.geo-flo.com)
FLO-LINK&GPMSERIESPRESSURIZEDFLOWCENTERS | 21
Water Quality
Unfortunatelyforsomesystemowners,waterqualityisnotconsideredforclosedloopsystems.Oneoftheleadingcausesofprematurepumpfailureispoorwaterquality.Waterqualityrelatedtopumporsystemcom-ponentfailuremaybecategorizedintofourareasofconcern,namely:
• Suspended Solids:Suspendedsolidscanincludedirt,silt,sand,biologicalgrowth,insolubleorganicmatter,and iron. Suspended solids act like sandpaper in the system. It is common to see examples of suspended solids in pump tear-down analyses of warranty returns.
• System Insufficiently Purged of Air:Oxygeninthesystemattacksferrousmaterials(castironvolutes,steelpipingincommercialbuildings,etc.).
• pH level:AsthepHofthesystemwaterincreases(movestowardthealkalinesideofthescale),thecor-rosivenessofthewaterdecreases.However,asthepHofthewaterincreases,theformationofscaleincreases.LowpHisacidic;highpHisalkaline.Accordingthe2011 ASHRAE Handbook -- HVAC Applications,normalsystempHshouldbeinthe6.5to9.0range.
• Hardness:Asthehardnessofthesystemwaterincreases,thecorrosivenessofthewaterdecreases.How-ever,asthehardnessofthesystemwaterincreases,theformationofscaleincreases.
Poorwaterqualitycanaffectpumpsandsystemcomponentsinanumberofways.HeatpumpheatexchangerfailureorpumpvolutecorrosionistypicallyaresultoflowsystempHlevel.However,waterhardnessisalsoaproblemwithregardtopumpbearingfailure,pluggingofvalves/orifices,andcoatingofsystemsurfaces(de-creasedheatexchange).
Determiningwaterqualityrequirestestingasample.Inmostcases,contractorsonlyneedtodotwotothreewaterqualityteststogetageneralfeelforthewaterqualityinthearea.Forexample,ifmostofthegeother-malapplicationsareina30mileradius,theremayonlybetwotothreemunicipalwatersystemsintheservicearea.
Table3provideswaterqualityguidelinestohelpprotectthelooppump(s)fromprematurefailure,assumingthatalldebrisisfilteredfromthesystemfluid.However,followingtheseguidelineswillalsohelpprotecttheheatpumpheatexchangerandothersystemcomponents.
ItisimportanttochooseatestingcompanythatcanprovideawaterqualityanalysisthatispertinenttoHVACapplications.Figure25showsanexamplereportfromRockyResearchinBoulderCity,Nevada(http://rockyresearch.com,702-293-0851).
IncertainpartsofNorthAmerica,bronzeorstainlesssteelvolutesarepopular.Inmostcases,watertreat-mentortheuseofantifreeze(withcorrosioninhibitors)atstartupissignificantlylessexpensiveovertimethaninstallingamorecorrosion-resistantmaterial,evenifantifreezeisnotneededforfreezeprotection(Southernclimates).Selectionofbronzeorstainlesssteelwillprolongtheservicelifeofthepumpvolute,butthereareothercomponentsinthesystemthatwillbeattackedbytheharshsystemwater.
22 | Installation,Operating,andMaintenanceManual Rev. 07FEB2014
Forthemostpart,therearetwosolutionstoprovidinggoodsystemwaterquality,namely:1)treatmentoflocalwater;or2)transportationofwatertothejobsite.Infact,mostantifreezemanufacturersrequirede-ionizedordistilledwateraspartoftheirwarrantypolicy.
Treatmentoflocalwatercanbedifficult,especiallyifthelocalwaterqualityispoor.Althoughwatertreatmentsystemsmayberentedorpurchased,theexpenseisoftenhigh.Transportingwaterorusingapre-mixanti-freezemaybeabettersolution,especiallyconsideringtheadvantages.Forexample,puremethanoldoesnotincludecorrosioninhibitors.Purchaseofapre-mixantifreezecouldsignificantlyimprovesystemreliabilityifthewaterqualityiscontrolledandthereareadditivesinthemixturetoinhibitcorrosion.TherearemanyexamplesofsuchfluidsonthemarkettodaysuchasDowfrost™GEO(pre-mixpropyleneglycol),Environol™1000(pre-mixethanol),andothers.
Whenusingapre-mixwater/antifreezesolution,extremecaremustbeexercisedtokeepdirtanddebrisoutofthesystem.Sincethefluidthatwillbeusedtofill/flushthegroundloopwillbethefinalsystemfluid,everyattemptshouldmadetocappipesandkeepdebrisoutofthesystemduringloopinstallation.Notethatthestandard100micronfilterontheGeo-Floflushcartisacceptableforcapturingrelativelylargedebrissuchaspipeshavings,gravel,andmediumsandparticlesbutisnotcapableofcatchingverysmallparticles.Geo-Floprovidesaonemicronfilterfortheflushcartthatmaybeusedforfinalclean-uponceairispurgedfromtheloop(see“FluidFiltering”section).Table4providesparticlesizeofvarioussoiltypes,showingthevalueofutilizingaonemicronfilter.
Ifparticulatematterisaconcern,itmaybeadvantageoustouselocalwaterforpurgingairandfilteringdebrisfromthesystem,andthenusethe“pumpanddump”methodforreplacingthepurgingwaterwiththepre-mixantifreezesolution.Considerationofwaterqualitycaneliminatemanysystemfailuresandhelpmaintainsatis-fiedcustomers.
Table 3: Water quality guidelinesTable 4: Grain size
Installation Tip:Considerapre-mixantifreezesolutiontocontrolsystemwaterquality.
FLO-LINK&GPMSERIESPRESSURIZEDFLOWCENTERS | 23
Sulfate 231 ppmS04 <25 ppm ppm mg mg/
Chloride 24 ppmCl <25 Total Hardness 788 mgCaC03/L <75
Nitrite 0 mg/L 250- 1000 Bicarbonate Alkalinity 270.9 as mg CaC03/L
Carbonate Alkalinity 0 as mg CaC03/L Hydroxide Alkalinity 0 as mg CaC03/L
Total Alkalinity 271 as mg CaC03/L pH 7.9 8.5-9.5
Total Dissolved Solids 667 ppm <1000 ppm
Closed Loop Water Analysis
Customer Name Job Name JobiD Manufacturer Model Number Serial Number Equipment Name Equipment ID
Heat Pumps ‘R Us GF3000000 None None None 0 Closed Loop Cooling Water GF650001
Sample Number Customer Sample No. Collection Date Collected By Receive Date Analysis Date
ABC123 131 5/30/2013 Service Tech 5/30/2013 5/31/2013
Sample Data Limits
S04 Cl
CaC03/L L
MAINTENANCE RECOMMENDATIONS: The sulfate level is above 25 ppm, which will contribute to corrosion. Total Hardness is above the limit, which will cause scale in the system. The pH is low, corrosion protection may be compromised. No corrosion inhibitors were detected. Replace the charge with distilled or deionized water to remove contaminants. A water treatment program with corrosion inhibitors and pH buffers is highly recommended.
Customer Comments: None
This report is based on a single sample. Sampling regularly and tracking the data provides the clearest insight to the solution chemistry of your unit. A large change in any result may make a resample advisable.
Figure25:Samplewaterqualityreport(courtesyofRockyResearch)
24 | Installation,Operating,andMaintenanceManual Rev. 07FEB2014
Start-Up
WARNING: OPEN THE MAIN POWER SUPPLY DISCONNECT SWITCH AND SECURE IT IN AN OPEN POSITION PRIOR TO PERFORMING ELECTRICAL WORK. VERIFY THAT POWER HAS BEEN DISCONNECTED PRIOR TO WIRING THE PUMP(S). FAILING TO SECURE THE ELECTRICAL SUPPLY COULD RESULT IN SERIOUS INJURY OR DEATH.
Preparing Flow Center for Start-Up
1. WirethecirculatorpumpstotheheatpumpsasshowninFigure26.Followallelectricalandlocalcodesforwiringandfuse/breakersizing.
2. Opentheventscrewinthecenterofeachpumpmotorwithalargeflatheadscrewdriverallowingafewdropsoffluidtodripout.Then,retightentheventscrew.
NOTE:Step#2iscritical.Openingtheventscrewandallowingfluidtodripoutensuresthatalltrappedairhasexitedthepumpmotor.Skippingthisimportantstepcouldleadtoprematurepumpfailure.
From heat pump #1fused/circuit breaker
protected pumpconnections
N
L
Ground
L2
L1
N
L
Wiring forNPD3 and NPD4
(2nd pump onLH side)
N
L
N
L
Wiring forNPD4 (2nd pump
on RH side)
From heat pump #2fused/circuit breaker
protected pumpconnections
Pump #3 Pump #4
Pump #1 Pump #2
Capacitor
Speed Switch
Terminal Strip
Ground
L2
L1
Figure26:Pumpfieldwiring.ToppictureshowsUPS26-99controlbox;bottompictureshowsUP26-116controlbox.
From heat pumpfused/circuit breaker
protected pumpconnections
Ground
L2
L1N
L
N
L
Pump #2
Pump #1
Speed Switch
Terminal Strip
From heat pump #1fused/circuit breaker
protected pumpconnections
Ground
L2
L1
Wiring forNPD3 and NPD4
(2nd pump onLH side)
L2
L1
L2
L1
L2
L1
L2
L1
Wiring forNPD4 (2nd pump
on RH side)
From heat pump #2fused/circuit breaker
protected pumpconnections
Pump #3 Pump #4
Pump #1 Pump #2
Capacitor
Ground
L2
L1
L2
L1
FLO-LINK&GPMSERIESPRESSURIZEDFLOWCENTERS | 25
3. Startallflowcenterpumpsandallowsystemtooperateforseveralminutes.
4. Measureandrecordtheflowrateusingthemethodsdescribedinthefollowingsectionofthisdocument.IfusingUPS26-99threespeedpump(s),theflowcanbeadjustedbychangingthepump(s)speed.Theflowrateshouldbewithintherangesuggestedbytheheatpumpmanufacturer.
5. Verifytheperformanceoftheheatpumpsperthemanufacturer’sliteraturebycalculatingtheheatofextractionand/orrejection(HE-HR).TheGeo-Flowebsitehasafreecalculatortoassistinthiscalculation.Gotowww.geo-flo.com,selectDesignCalculatorsthenHE-HRCalculator.TheHE-HRshouldbewithintherangespecifiedbytheheatpumpmanufacturer.
6. Installallvalvefacecoversandflushportcaps/plugsincludedinthehardwarebag.
Measuring System Flow Rate -- Flow Rate from Pressure Drop
Thesystemflowratecanbedeterminedbaseduponthepressuredropacrosstheheatpump’sheatexchanger.
1. Measurethepressuredropacrosstheheatpump’sheatexchangerviatheP/Tportslocatedatthewaterconnectionsoftheunit(Figure27).Useasinglelargedialfacepressuregaugetoallowformoreprecisemeasurement.
2. Determinetheflowrateusingthemanufacturer’spublishedtablesforpressuredropversusflow(Table5).Ifthepressuredropisoffthemanufacturer’schart,theflowratecanbedeterminedusingafreeonlinecalculatoravailableonGeo-Flo’swebsite.Gotowww.geo-flo.com,selectDesignCalculatorsthenFlowRateCalculator.
Figure27:Measuring pressure drop
WPD
PSI FT
3.0 0.9 2.24.5 1.8 4.26.0 2.9 6.83.0 0.9 2.14.5 1.7 4.06.0 2.8 6.63.0 0.9 2.04.5 1.7 3.96.0 2.8 6.43.0 0.9 2.04.5 1.6 3.86.0 2.7 6.2
20
EWT °F
Flow gpm
50
40
30
Table5:Exampleofheatpumpmanufacturer’stableofpressuredropvs.flowrate
Example O
nly
26 | Installation,Operating,andMaintenanceManual Rev. 07FEB2014
Maintenance
ThereisnoregularlyscheduledmaintenancerequiredforFlo-LinkandGPMSeriesflowcenters.However,thereismaintenanceassociatedwiththegroundloopthatcouldaffectpumplongevity.The“LoopPressurization”sectionbelowaddressesgroundlooppressurechanges.Ifthepumpdoesneedtobereplacedatsomepointintime,Geo-Flooffersapumpheadreplacement.Thevoluteisfoamedintotheflowcenter,andwouldnottypi-cally be replaced.
Loop Pressurization
Groundlooptemperaturesinsomeclimatescanswingasmuchas70to75deg.F,whichcausesthegroundlooppipingtoexpandandcontract.Insummer,thepipeexpands,causingthepressuretodecreaseinapres-surizedsystem;inwinterthepipecontracts,increasingthelooppressure.Foryearstheindustryrecommendedagainstexpansiontanks,insistingthatthePEpipehadenoughexpansioncapability.Inareaswherelooptemperaturesaremilder,itispossiblethatanexpansiontankwouldnotbeneeded.InmostareasofNorthAmerica,experiencehasshownthatexpansiontanksareneeded.Geo-Flo recommends either a Pressure Bat-tery (polyethylene expansion tank) or a Geo-Prime tank on all pressurized systems(seeFigures28and29)asamethodofalleviatingconcernswithlooppressurization.TheGeo-Primetankactsasanexpansiontankandairseparator,effectivelyturningapressurizedsystemintoahybridsystem(pressurizedflowcenterwithnon-pressurizedcharacteristics).
Tank Volume = 0.75 U.S. gallons (2.8 liters)
7-1/8”(181mm)
13-1/4”(337 mm)
14-3/8”(365 mm)
8”(203 mm)
Tank halves are butt fusedin controlled factoryenvironment for a leakproof tank
Figure28:PressureBatteryExpansionTank
Figure29:Geo-PrimeTank(left)andtypicalGeo-Primeinstallationwithpressurizedflowcenter(right)
FLO-LINK&GPMSERIESPRESSURIZEDFLOWCENTERS | 27
SystemswithoutaPressureBatteryorGeo-PrimeTankmayneedtoberepressurizedwithagardenhoseifthesystemfallsbelow10to15psig.Otherwise,thetemperatureswing,andresultingpressurechangecouldcauseprematurepumpfailureifthesystempressuregoestozero.Anyairinthesystemwillexacerbatetheproblem.Grundfoscirculatorsarecooledandlubricatedbythefluidflowingthroughthepump.Figure30showsatypical“LoopGooser”thatallowsthepressureinthegroundlooptobeincreasedbydomesticwaterpressureviaagardenhosethroughtheheatpumpP/Tport.Itisimportanttobleedairoutofthegardenhosebeforeat-temptingtopressurizetheloop.Theballvalveshouldbeopenedsothatasmallstreamiscomingfromtheendofthe“LoopGooser”beforeinsertingitintotheP/Tporttoavoidintroducingairintothesystem.
Figure30:LoopGooser assembly (allowsgardenhoseattachmentforincreasinglooppressure)
Replacing Circulator Pump
WARNING: OPEN THE MAIN POWER SUPPLY DISCON-NECT SWITCH AND SECURE IT IN AN OPEN POSITION PRIOR TO PERFORMING ELECTRICAL WORK. VERIFY THAT POWER HAS BEEN DISCONNECTED PRIOR TO WIR-ING THE PUMP(S). FAILING TO SECURE THE ELECTRICAL SUPPLY COULD RESULT IN SERIOUS INJURY OR DEATH.
1. Determine whether the circulator pump needs to be replaced. The pumpmotorshouldonlybereplacedaftersuccessfullytrouble-shootingthesystemanddeterminingthatthepumpisnotfunction-ing.SeeTroubleshootingsectionofthisdocumentformoreinfor-mation.
2. Rotatebothvalvestoisolatethegroundloop.(Figure31).• Important (GPM series):Rotatetheleftvalveclockwise,and
therightvalvecounter-clockwisetoavoidreintroducingairintotheloopfromtheflushport.
• Important (Flo-Link series): Rotatetheleftvalvecounter-clock-wise,andtherightvalveclockwisetoavoidreintroducingairintotheloopfromtheflushport.
3. Verifythatpowerhasbeendisconnectedfromthecirculatorpump(s)usingamulti-meter.
4. Disconnectwiringfrompump.
5. Removescrewsholdingpumpmotortopumphousing(volute),andremovethepumpmotor.Positionabucketunderneaththepumptocatchthefluidbetweenthe3-wayvalveandthepumpvolute.
Horizontal portionofflow“T”toward groundloop
Figure31:GPM(FPT)flowcenter(top)andFlo-LinkDoubleO-ringflowcenter(below)valvepositionsforgroundloopisolation
“OFF”toward groundloop (both valves)
Flo-Link Adapter
28 | Installation,Operating,andMaintenanceManual Rev. 07FEB2014
6. Inspectthepumpmotorandvoluteforsignsthatindicatethemodeoffailure.Forexample,ifdebrisispresentinthepumporvolute,thegroundloopshouldbere-flushedwithaqualityflushcartequippedwithafilter.
7. Cleanthepumpseatonthepumphousing(volute)withaclothtoremoveanydebrissothatthegasketonthepumpwillsealproperly.Installthenewpumpmotorandreconnectwiring.Makesurethattheterminalboxisinthe12o’clock,3o’clock,or9o’clockpositiontoavoidpotentialmotorfailureduetocondensationbuild-upinsidetherotorcan.See“MountingtheUnit”(InstallationSection)formoreinformation.
Figure32:Geo-FloFlushKit
Flo-Link adapter (use forGPMflowcenters;notneededforFlo-Linkflowcenters)
Flo-Linkxgardenhose adapter
Flo-LinkxCAMadapter (used withflushcart)
8. ForGPMseries,threadontheFlo-Linkadapter(Figures31&32),whichprovidesaunionconnectionandeasierinstallation/removalofthegardenhose adapter. This step is not neces-saryforFlo-Linkflowcenters.Figure32showsthefittingsincludedwiththeloopflushingkit.Thiskitprovidesalloftheadaptersneededwhenoriginallyflushingtheloop,aswellasthefittingsneededwhenreplacingapump.
9. ConnecttheFlo-Linkxgardenhoseadapterstotheflowcenter.Usingtwogardenhoses,connectonehosetoeachsideoftheflowcenter.Connectthelefthosetoanearbywaterspigot;runtherighthosetoadrain.Donotturnthe3-wayvalves.Whenchangingapump,theflowcenter,heatpump,andconnectingpipingcanbepurgedofairwithagardenhoseunlessthereisanexcessiveamountofpipebetweentheheatpumpandtheflowcenter.Inmostcases,ahosekitwillbeinstalledbetweentheflowcenterandtheheat pump.
10. Turnonthewaterandletthewaterrunthroughthepipinguntilallairhasbeenpurgedfromthepiping.
11. Turntherightvalvetonormaloperatingpositiontoturnoffhosegoingtodrain.IMPORTANT: Do not turn off the water to the left hose in this step.• GPMSeries(FPTfittings):Rotatetherightvalveclockwisetoturnofftheflushportconnectedtothe
righthose(Figure33).NOTE: It is very important to turn the valve clockwise. Otherwise,aircouldbereintroducedintotheloopthroughtheflushport.
• Flo-LinkSeries(doubleO-ringfittings):Rotatetherightvalvecounter-clockwisetoturnofftheflushportconnectedtotherighthose(Figure33).NOTE: It is very important to turn the valve counter-clockwise.Otherwise,aircouldbereintroducedintotheloopthroughtheflushport.
12. Withthespigottothelefthosestillon,pressurizethegroundlooptothedesiredpressure(typically30to50psig).
13. Usingalargeflatheadscrewdriver,slightlyopentheventscrewonthefaceoftheGrundfospump(s).Afterafewdropsofwaterescapes,retightenthescrew.
NOTE: Step#13iscritical.Openingtheventscrewandallowingfluidtodripoutensuresthatalltrappedairhasexitedthepumpmotor.Skippingthisimportantstepcouldleadtoprematurepumpfailure.
FLO-LINK&GPMSERIESPRESSURIZEDFLOWCENTERS | 29
Figure33:GPM(FPT)flowcenter(top)andFlo-LinkDoubleO-ringflowcenter(below)valvepositionsforpressurization
“OFF”toward flushport(rightsideonly).DONOTmoveleftvalve.
Turnoffflushport(rightsideonly).DONOTmoveleftvalve.
Horizontal portionofflow“T”toward flushport
“OFF”toward flushport(both sides)
Figure34:GPM(FPT)flowcenter(top)andFlo-LinkDoubleO-ringflowcenter(below)valvepositionsfornormaloperation
OFF
“OFF”towardgroundloop(leftsideonly).DONOTmovethisvalve.
30 | Installation,Operating,andMaintenanceManual Rev. 07FEB2014
14. Rotatetheleftvalvebacktotheoperatingposition(Figure34).Turnoffthespigottothelefthose,andremovehosesandfittingsfromflowcenter.
15. Verifysystemperformancebycheckingtheflowrateandtemperaturedifferential,andcomparingthevaluestotheheatpumpmanufacturer’spublisheddata.IfinstallingaUPS26-99(3-speed)pump,besuretosetthepumpspeedthatprovidesaflowratewithinthemanufacturer’srecommendrange.
16. Replacevalvefacecoversandflushportplugsorcaps.
Converting From GPM-1/FL1 to GPM-2/FL2
FollowprocedureforReplacingCirculatorPump,exceptremovetheblankplateinsteadofthepumpmotor.Besuretoremovethegasket(Figure35).
Gasket
Cover Plate
RubberCover
Figure35:Removingcoverplate
FLO-LINK&GPMSERIESPRESSURIZEDFLOWCENTERS | 31
Troubleshooting
Problem Possible Cause Checks/SolutionNoflow/lackofflow(alwayscheck pressure drop across coaxtoverifyflow)
Valve(s)inwrongposition Rotatevalve(s)tooperatingposition
Pumpnotoperating Ensureproperpower/voltageatpumpmotorNo power at pump Ensureheatpumpcontactsareoperating
Resetfuse/breakerinheatpumpStuck/lockedimpeller Removeventscrew;rotateshaftwithsmallflathead
screwdriver;ifshaftwillnotrotate,replacepumpmotor.
Frozenheatexchanger Thawheatexchanger;check/correctantifreezelevel.Power at pump but not operat-ing
Removeventscrewandrotateshaftwithasmallscrew-driver.Replaceventscrewandre-energizepump.Replace pump power head
No/lowsystempressure
Pipeexpansion Noproblem;bumpsystempressuretoacceptablelevel.Addexpansiontankand/orantifreezemakeupsystem
Pipeexpansion+Airinloop Flushsystem;pressurize.Leak Find and repair leak
AddantifreezemakeupsystemNoise Mechanicalvibrationdueto
pump motor resonanceProvidevibrationisolationbetween:1)pipingandflowcenter2)flowcenterandunit3)flowcenter&mountinglocation(wall,heatpump,etc.)
Air/debrisinsystem Flush loopAddair/dirtseparatorandexpansiontankand/oranti-freezemakeupsystem
Highvelocitywater:pumpover-sizedorpipingundersized
1) Usesmallerpump2) Turnpumpspeeddown3) Removeoneoftwopumps4) Addflowrestriction(ballvalve)5) Increasepipesize
Pumpcavitation IncreasepumpsuctionpressurePumpmotornoise-squealing 1) Ventpump;ensurenotdryrunning.
2) Bearingfailure:replacepumpValveLeak Debris in valve Rotatevalve360degreestodislodgedebris
Removevalvespool;cleanvalvebodyandspool;re-placeO-ring(s)onvalvespoolifnecessary.
Sideloadingvalvespoolwhenrotatingwith3/8”drivetool
Rotate valve spool so that no side load is placed on spool
Pinched/twistedO-ring Rotatevalve360degreestoreseatO-ringFluid leaks out valveface
CutO-ring ReplaceO-ring;kitsandinstructionsareavailable.Pinched/twistedO-ring Rotatevalve360degreestoreseatO-ring
Troubleshooting continues on next page
32 | Installation,Operating,andMaintenanceManual Rev. 07FEB2014
Troubleshooting (Con’d)
Problem Possible Cause Checks/SolutionFluid drips around adapt-er/fittings
Incorrectfittingused(i.e.threadedfittinginsteadofFlo-LinkdoubleO-ringfitting)
Replaceincorrectfittings
Poorfusionjoint ReplacejointCondensation InsulatepipingO-ringsealfailure(Flo-Linkfittings)
Removefitting;cleanvalveportandfittings;replaceO-ringsifnecessary.
Pipemisalignment;side-loadingO-rings(Flo-Linkfittings)
Removefittings;checkO-ringsandreplaceifnecessary;alignandsupportpiping
Leakatthreaded(MPT)fitting TightenMPTadapter(ifpossible)Replacefitting
Fluid leaks out “HeatPump”endofflowcenter
Condensation Insulatepiping/fittingsCrackedflange:overtighteningMPTfitting(flangedFPTflowcenter)
Replaceflowcenter
Leakfromabovedrippingdownthroughflowcenterandoutbottomholes
Investigatefurther;seeotherfluidleaktroubleshootingitemsinthissection.
Internalleak-volutecorrosion/erosion due to poor water quality
Replaceflowcenter
Internalleak-sealfailureduetohightemperature
Replaceflowcenter;checkwiringtobesurepumpisnotpoweredcontinuously.
Fluid leaks out “GroundLoop”endofflowcenter
Seeabovefor“HeatPump”leak(exceptcrackedflange)
Seeabovefor“HeatPump”leak
Fluid leaks out ofcabinet(outback,aroundvalve,aroundpump,etc.)
Leakfromabovedrippingdownthroughflowcenterandoutpathofleastresistance
Investigatefurther;seeotherfluidleaktroubleshootingitemsinthissection.
Manual Updates Table
Date Description of Changes Pages07FEB2014 Completere-write;addedFlo-Linkflowcenters All
OCT2008 Updatesforproductchanges Various
1998 First published All
Installation, Operating, and Maintenance ManualFlo-Link™ and GPM Series Pressurized Flow Centers
Part # 2122
Geo-Flo Products Corporation905 Williams Park DriveBedford, Indiana 47421, U.S.A.
Main Number: 812-275-8513Toll Free: 800-784-8069Fax: 888-477-8829
www.geo-flo.com
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