Repair Procedures - Boreal W-Series Installation And Service Manual

Hydronic geothermal heat pumps two-stage r410a

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Table Of Contents

Table of Contents

STEP 1

Connect the refrigerant recovery unit to the heat pump service ports via a refrigeration charging manifold

and to a recovery tank as per the instructions in the recovery unit manual. If there was a compressor

burn out, the refrigerant cannot be reused and must be disposed of according to local codes.

STEP 2

All water coil heat exchangers must either have full flow or be completely drained of fluid before recovery

begins. Failure to do so can freeze and rupture the heat exchanger, voiding its warranty. (Note that this

does not apply to double wall domestic hot water exchangers (desuperheater coils)

STEP 3

Ensure all hose connections are properly purged of air. Start the refrigerant recovery as per the instructions

in the recovery unit manual.

STEP 4

Allow the recovery unit suction pressure to reach a vacuum. Once achieved, close the charging manifold

valves. Shut down, purge and disconnect the recovery unit as per the instructions in its manual. Ensure the

recovery tank valve is closed before disconnecting the hose to it.

STEP 5

Connect a nitrogen tank to the charging manifold and add nitrogen to the heat pump until a positive pres-

sure of 5-10PSIG is reached. This prevents air from being sucked into the unit by the vacuum when the

hoses are disconnected.

STEP 6

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.

STEP 1

After completion of repairs and nitrogen pressure testing, the refrigeration circuit is ready for vacuuming.

STEP 2

Release the refrigerant circuit pressure and connect the vacuum pump to the charging manifold. Start the

vacuum pump and open the charging manifold valves. Vacuum until the vacuum gauge remains at less

than 500 microns for at least 1 minute with the vacuum pump valve closed.

STEP 3

Close the charging manifold valves then shut off and disconnect the vacuum pump. Place a refrigerant tank

with the proper refrigerant on a scale and connect it to the charging manifold. Purge the hose to the tank.

STEP 4

Weigh in the appropriate amount of refrigerant through the low pressure (suction) service port. Refer to the

label on the unit or

STEP 5

If the unit will not accept the entire charge, the remainder can be added through the low pressure service

port after the unit has been restarted.

REPLACMENT PROCEDURE FOR A COMPRESSOR BURN-OUT

STEP 1

Pump down the unit as per the Pump Down Procedure above.

STEP 2

Replace the compressor. Replace the liquid line filter-drier.

STEP 3

Vacuum the unit until it remains under 500 microns for several minutes with the vacuum pump valve closed.

STEP 4

Charge the unit and operate it for continuously for 2 hours. Pump down the unit and replace the filter-drier.

Vacuum the unit until it remains under 500 microns for several minutes with the vacuum pump valve closed.

STEP 5

Charge the unit (refrigerant can be re-used) and operate it for 2-3 days. Pump down the unit and replace

the filter-drier.

STEP 6

Charge the unit (refrigerant can be re-used) and operate it for 2 weeks. Pump down the unit and replace

the filter-drier.

STEP 7

Charge the unit a final time. Unit should now be clean and repeated future burn-outs can be avoided.

Boreal Geothermal Inc.