Boreal W-Series Installation And Service Manual
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Boreal W-Series Installation And Service Manual

Hydronic geothermal heat pumps two-stage r410a
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Installation and Service Manual
Boreal® W-Series (HW)
Two-Stage R410a
Model Sizes 25-75 (2-6 Ton)
Hydronic
Geothermal Heat Pumps
Email: info@boreal-geothermal.com
Boreal Geothermal Inc.
Web: www.boreal-geothermal.com
Phone : 450-534-0203
Document Number: 000620MAN-02
Fax : 450-534-1864
REVISION DATE : 02 JULY 2009
02 JULY 2009
Page 1
Boreal Geothermal Inc.

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  • Page 1 Installation and Service Manual Boreal® W-Series (HW) Two-Stage R410a Model Sizes 25-75 (2-6 Ton) Hydronic Geothermal Heat Pumps Email: info@boreal-geothermal.com Boreal Geothermal Inc. Web: www.boreal-geothermal.com Phone : 450-534-0203 Document Number: 000620MAN-02 Fax : 450-534-1864 REVISION DATE : 02 JULY 2009...

  • Page 2: Safety Precautions

    Electrical Tables. Refrigerant: P = R410a Voltage Code: 1 = 230-1-60 VAC 2 = 208-3-60 VAC 4 = 460-3-60 VAC 5 = 575-3-60 VAC 6 = 220-1-50 VAC 7 = 380-3-50 VAC Boreal Geothermal Inc. Page 2 02 JULY 2009...
  • Page 3 C or Z C or Z HACW C or Z C or Z HACW C or Z C or Z HACW This manual applies only to the models and revisions listed in this table 02 JULY 2009 Page 3 Boreal Geothermal Inc.

  • Page 4: Table Of Contents

    Electrical Tables: ……………………………………………………………………………………………………… Page 42 Electrical Diagrams (230-1-60): ………..…………………………………………………………………………… Page 43 Case Details: ………………………...………………………………………………………………………………… Page 45 APPENDIX A: Control Board Specifications: ……………………………………………………………………………… PAGE 46 APPENDIX B: Installation Example: …………………………………………………………………………………………. PAGE 47 WARRANTY INFORMATION: ………………………………………………………………………………………………….. PAGE 52 Boreal Geothermal Inc. Page 4 02 JULY 2009...
  • Page 5 000619INF - Ground Water Disposal Methods: ………………………………………………………………… Page 17 000610CDG - Geo-Flo Circulator Pump Module Installation: ………………………………………………… Page 20 000210RCD - W-Series (25-75) Refrigeration Circuit Diagram—Heating Mode: …….………………….… Page 33 000211RCD - W-Series (25-75) Refrigeration Circuit Diagram—Cooling Mode: …….………………….… Page 34 000683SCH - W-**-HAC*-*-1T-** Schematic Diagram: …………………..………...…………..…………..……...

  • Page 6: Installation Information

    A properly qualified electrician should be retained to UNIT DESCRIPTION make the connections to the heat pump and associated The W-Series unit is a high efficiency two-stage geother- controls. The connections to the heat pump MUST CON- mal heat pump with R410a refrigerant. Two-stage units offer a FORM TO LOCAL CODES.

  • Page 7: Control Transformer

    The high and low pressure controls are monitored at all times, the compressor will not be able to start if either of them has a fault. 02 JULY 2009 Page 7 Boreal Geothermal Inc.

  • Page 8: Domestic Hot Water Connections (Hw And Hacw Only)

    The DHW loop may have to be purged of air several times before good circulation is obtained. A temperature difference between the DHW In and DHW Out can be felt by hand when the circulator pump is operating properly. Boreal Geothermal Inc. Page 8 02 JULY 2009...
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  • Page 10 Boreal Geothermal Inc. Page 10 02 JULY 2009...
  • Page 11 02 JULY 2009 Page 11 Boreal Geothermal Inc.

  • Page 12: Sizing And Hydronic Information

    Fan coils can be used to provide heating and/or cooling for BOREAL GEOTHERMAL INC. HIGHLY RECOMMENDS areas that do not have radiant in-floor heating. They provide a THAT A PROPER HEAT LOSS/GAIN ANALYSIS BE PER- means of air heating/cooling with minimal or no ductwork. Note...
  • Page 13 02 JULY 2009 Page 13 Boreal Geothermal Inc.
  • Page 14 Boreal Geothermal Inc. Page 14 02 JULY 2009...

  • Page 15: Ground Water System Information

    30 to 40 psig. on the lines when the heat pump is operating. However in some cases a well can supply a heat pump only if the minimum requirement for water is used. 02 JULY 2009 Page 15 Boreal Geothermal Inc.
  • Page 16 Boreal Geothermal Inc. Page 16 02 JULY 2009...
  • Page 17 Boreal Boreal Boreal 02 JULY 2009 Page 17 Boreal Geothermal Inc.

  • Page 18: Ground Loop System Information

    Optional fittings with P/T ports are CIRCULATOR PUMP MODULE available for the circulator pump modules sold by Boreal Geothermal Inc.. Boreal Geothermal Inc. has compact pump modules with built in three way valves to facilitate filling and purging the FLUSHING &...

  • Page 19: Adding Antifreeze Solution

    3/8” thick closed cell pipe insulation to prevent condensation and dripping onto floors or walls. 02 JULY 2009 Page 19 Boreal Geothermal Inc.
  • Page 20 Boreal Geothermal Inc., BOREAL Boreal Geothermal Inc. Page 20 02 JULY 2009...

  • Page 21: Startup Procedure

    The following steps describe how to perform the startup procedure of the geothermal heat pump. The W-Series Two-Stage R410a Startup Record located in this manual is used in conjunction with this startup procedure to pro- vide a detailed record of the installation. A completed copy should be left on site, a copy kept on file by the installer and a copy should be sent to Boreal Geothermal Inc.

  • Page 22: Unit Startup

    3. Do a final check for leaks in the ground water / ground loop system and ensure the area is clean. 4. Leave a copy of the Startup Record at the installation site, send a copy to Boreal Geothermal Inc. and keep the final copy.

  • Page 23: Startup Record

    Startup Record Sheet—W-Series Size 25-75 Two-Stage R410a Installation Site Startup Date Installer City Company Province Check boxes unless Model asked to record data. Country Serial # Circle data units. PRE-START INSPECTION Indoor Loop All shut-off valve are open (full flow available)

  • Page 24: General Maintenance

    Disconnect the purge cart and set the pump module valves back to the original positions. STEP 10 Operate the system and check for improved performance. *Depending on the plumbing, there should be either unions or boiler drains for to access the heat exchanger. Boreal Geothermal Inc. Page 24 02 JULY 2009...

  • Page 25: Troubleshooting Guide

    Correct the wiring. heat pump and aquastats. and COM at the top of the aquastat. Faulty aquastat. 24VAC is present across 24V Replace aquastat. and COM of the aquastat but there is no display. 02 JULY 2009 Page 25 Boreal Geothermal Inc.
  • Page 26 Faulty control board. 24VAC is present across each Replace control board. FLOW SWITCH terminal and C, but not voltage is present across CC on the control board and C. Boreal Geothermal Inc. Page 26 02 JULY 2009...

  • Page 27: Compressor Troubleshooting

    Verify if 24VAC is present across Replace module if signal is pre- Stage 2 will not Y2 and C of the terminal strip. sent. Check wiring if signal is not activate present. 02 JULY 2009 Page 27 Boreal Geothermal Inc.
  • Page 28 Faulty compressor, not Pressures change only slightly from Replace compressor. pumping. static values when compressor is started. Boreal Geothermal Inc. Page 28 02 JULY 2009...
  • Page 29 Disconnect the water lines and Have a qualified service technician heat exchanger. check the inside of the pipes for backflush the coaxial exchanger. (typically for ground water, scale deposits. unlikely for ground loop) 02 JULY 2009 Page 29 Boreal Geothermal Inc.
  • Page 30 (does not occur pressor to run when it shouldn’t, tripping the low pressure control. while there) Intermittent Indoor circula- Verify wiring is good Correct the wiring or replace the tor. circulator. Boreal Geothermal Inc. Page 30 02 JULY 2009...
  • Page 31 15 psig or as high as 125 psi. The Voltmeter / controlling mechanism consists of a flexible Digital orifice that varies its area inversely with In-line Flowmeter pressure so that a constant flow is maintained. 02 JULY 2009 Page 31 Boreal Geothermal Inc.

  • Page 32: Repair Procedures

    The heat pump is now ready for repairs. Always ensure nitrogen is flowing through the system during any soldering procedures to prevent soot buildup inside the pipes. Boreal Geothermal Inc. recommends replac- ing the liquid line filter-drier anytime the refrigeration system has been exposed to the atmosphere.

  • Page 33: Refrigeration Circuit Diagrams

    REFRIGERATION CIRCUIT DIAGRAMS 02 JULY 2009 Page 33 Boreal Geothermal Inc.
  • Page 34 REFRIGERATION CIRCUIT DIAGRAMS (continued) Boreal Geothermal Inc. Page 34 02 JULY 2009...

  • Page 35: Model Specific Information

    14.6 3.94 Stage 1 3,325 42,700 12.5 3.77 14.4 0.91 31.2 Stage 2 4,765 59,400 17.4 3.65 Stage 1 4,190 50,900 14.9 3.56 16.8 1.06 33.5 Stage 2 5,380 66,700 19.6 3.63 02 JULY 2009 Page 35 Boreal Geothermal Inc.

  • Page 36: Table 12 - Standard Capacity Ratings - Ground Loop Cooling 60Hz

    14.3 6.21 Stage 1 1,795 43,400 12.7 7.08 14.4 0.91 26.9 Stage 2 2,915 57,100 16.7 5.74 Stage 1 2,520 51,000 14.9 5.93 16.8 1.06 29.6 Stage 2 3,595 63,400 18.6 5.17 Boreal Geothermal Inc. Page 36 02 JULY 2009...

  • Page 37: Capacity Ratings

    21,079 1,443 1,511 14.0 89.2 26,005 12.0 27.1 6,176 4.09 37.8 27.1 31.8 7,619 53.6 47.6 1,544 1,612 94.1 25,681 20,412 12.7 12.0 27.1 40.6 27.1 34.5 7,525 5,981 3.71 Compressor: ZPS20K4E-PFV 02 JULY 2009 Page 37 Boreal Geothermal Inc.
  • Page 38 1,944 2,077 89.1 38,941 32,307 15.6 12.0 36.2 9,466 4.56 37.8 36.2 31.7 11,410 53.6 47.1 31,332 2,073 2,206 14.2 94.0 38,407 12.0 36.2 9,180 4.16 40.6 36.2 34.4 11,253 Compressor: ZPS30K4E-PFV Boreal Geothermal Inc. Page 38 02 JULY 2009...
  • Page 39 12.0 86.2 51,746 12.0 54.2 37.8 54.2 30.1 15,161 12,554 4.47 53.6 12.0 47.8 2,761 13.0 2,960 12.0 91.1 50,936 41,512 14.0 12.0 54.2 40.6 54.2 32.8 14,924 12,163 4.11 Compressor: ZPS40K4E-PFV 02 JULY 2009 Page 39 Boreal Geothermal Inc.
  • Page 40 60,037 48,409 13.5 12.0 54.2 37.8 54.2 31.9 17,591 14,184 3.96 53.6 12.0 46.7 3,630 16.5 3,802 12.0 94.2 59,358 46,968 12.4 12.0 54.2 13,762 3.62 40.6 54.2 34.6 17,392 Compressor: ZPS51K4E-PFV Boreal Geothermal Inc. Page 40 02 JULY 2009...
  • Page 41 14.0 85.4 70,456 12.0 63.3 37.8 63.3 29.7 20,643 16,655 3.93 53.6 14.0 47.0 4,217 19.2 4,466 14.0 90.3 69,515 55,124 12.3 12.0 63.3 40.6 63.3 32.4 20,368 16,151 3.62 Compressor: ZPS60K4E-PFV 02 JULY 2009 Page 41 Boreal Geothermal Inc.

  • Page 42: Electrical Tables

    #8-2 14.9 16.7 #12-4 17.7 25.5 29.9 #6-2 10.0 17.8 20.3 #10-4 27.3 35.1 41.9 #6-2 10.9 18.7 21.4 #10-4 32.9 40.7 48.9 #4-2 * Single Stage unit * Single Stage unit Boreal Geothermal Inc. Page 42 02 JULY 2009...

  • Page 43: Electrical Diagrams (230-1-60)

    ELECTRICAL DIAGRAMS (230-1-60) 02 JULY 2009 Page 43 Boreal Geothermal Inc.
  • Page 44 ELECTRICAL DIAGRAMS (230-1-60) - continued Boreal Geothermal Inc. Page 44 02 JULY 2009...

  • Page 45: Case Details

    CASE DETAILS Back View Front View Left Side View Right Side View 02 JULY 2009 Page 45 Boreal Geothermal Inc.

  • Page 46: Appendix A: Control Board Specifications

    APPENDIX A - Control Board Specifications Boreal Geothermal Inc. Page 46 02 JULY 2009...

  • Page 47: Appendix B: Installation Example

    Pumping unit bentonite grout. The grout is Bentonite grout seals the geothermal wells introduced into the geothermal wells from and ensured the best possible thermal the bottom and going up to the surface. conductivity. 02 JULY 2009 Page 47 Boreal Geothermal Inc.
  • Page 48 The geothermal heat pump is connected through a pumping module to ground loops that has previously been purged of air and filled with a suitable antifreeze. The unit is ready to operate Boreal Geothermal Inc. Page 48 02 JULY 2009...
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  • Page 52: Warranty Information

    This warranty covers all internal components of the heat pump. BOREAL GEOTHERMAL INC. shall, at its option, repair or replace any part covered by this warranty. Defective parts shall be returned to BOREAL GEOTHERMAL INC., transportation charges prepaid.

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