Page 1: Table Of Contents
Flow Controller 3 Residential Geothermal Loop, Single and Two-Pump Modules Installation, Operation & Maintenance Instructions 97B0015N01 Revision: 2/9/16 Table of Contents Model Nomenclature Geothermal Closed Loop Design General Information Loop Fusion Methods Flow Controller Mounting Parallel Loop Design 19-22 Piping Installation...
Page 2 Flow Controller 3 R e v. : F e b u r a r y 9 , 2 0 1 6 This page has intentionally been left blank. G e o t h e r m a l H e a t P u m p S y s t e m s...
Page 3: Model Nomenclature
Flow Controller 3 R e v. : F e b u r a r y 9 , 2 0 1 6 Model Nomenclature A F C G 2 C 1 Pump Model # Accessory Flow Controller 1 = UP26-99 2 = UP26-116 (AFC2B2 only)
Page 4: Flow Controller Mounting
Flow Controller 3 R e v. : F e b u r a r y 9 , 2 0 1 6 Flow Controller Mounting Figure 2: Mounting Flow Controller on Stud Wall � CAUTION! � CAUTION! The following instructions represent industry accepted installation practices for closed loop earth coupled heat pump systems.
Page 5: Piping Installation
Flow Controller 3 R e v. : F e b u r a r y 9 , 2 0 1 6 Piping Installation Figure 4: Double O-Ring Adapters Piping Installation The Flow Controller features Double O-ring fittings for flexible and easy installation. Table 1 illustrates the connection options available for Flow Controllers with polystyrene cabinets.
Page 6 Flow Controller 3 R e v. : F e b u r a r y 9 , 2 0 1 6 Piping Installation can be accomplished by a fusion or barbed fitting as shown In multiple unit systems, PE piping materials can be used in Table 1.
Page 7 Flow Controller 3 R e v. : F e b u r a r y 9 , 2 0 1 6 Piping Installation Figure 7a: Parallel Unit Piping 1...
Page 8 Flow Controller 3 R e v. : F e b u r a r y 9 , 2 0 1 6 Piping Installation Figure 8b: Parallel Unit Piping 2 G e o t h e r m a l H e a t P u m p S y s t e m s...
Page 9: Electrical Wiring
Flow Controller 3 R e v. : F e b u r a r y 9 , 2 0 1 6 Flow Controller Electrical Wiring � WARNING! � Electrical Table Model Volts Amps WARNING! To avoid possible injury or death due to UP26-99 1.07...
Page 10: Flushing The Earth Loop
Flow Controller 3 R e v. : F e b u r a r y 9 , 2 0 1 6 Flushing the Earth Loop � WARNING! � Once piping is completed between the unit, Flow Controller and the ground loop, final purging and charging of the loop is needed.
Page 11 Flow Controller 3 R e v. : F e b u r a r y 9 , 2 0 1 6 Flushing the Earth Loop Figure 10b: Valve Position B - Unit Fill If all air is purged from the system, the level will drop only 1 - 2 inches [2.5 - 5 cm] in a 10”...
Page 12 Flow Controller 3 R e v. : F e b u r a r y 9 , 2 0 1 6 Flushing the Earth Loop Figure 10e: Valve Position E - Pressurize and Operation Move valves to position D. By switching both valves to this position, water will flow through the loop and the unit heat exchanger.
Page 13: Antifreeze Selection
Flow Controller 3 R e v. : F e b u r a r y 9 , 2 0 1 6 Antifreeze Selection � WARNING! � General In areas where minimum entering loop temperatures drop below 40°F [4.4°C] or where piping will be routed through WARNING! Always dilute alcohols with water (at least 50% areas subject to freezing, antifreeze is needed.
Page 14 Flow Controller 3 R e v. : F e b u r a r y 9 , 2 0 1 6 Antifreeze Selection Table 4: Antifreeze Percentages by Volume characteristics suffer greatly. Only food grade propylene glycol is recommended to prevent the corrosion inhibitors (often...
Page 15: Antifreeze Charging
Flow Controller 3 R e v. : F e b u r a r y 9 , 2 0 1 6 Antifreeze Charging It his highly recommended to utilize premixed antifreeze fluid proper hydrometer to ensure that the correct amount of where possible to alleviate many installation problems and antifreeze has been added to the system.
Page 16: Low Temperature Cutout Selection
Flow Controller 3 R e v. : F e b u r a r y 9 , 2 0 1 6 Antifreeze Charging Figure 11: Low Temperature Cutout Selection Maximum operating pressure should never exceed 100 psi [689 kPa] under any circumstance.
Page 17: Flow Controller Pump Curves
Flow Controller 3 R e v. : F e b u r a r y 9 , 2 0 1 6 Flow Controller Pump Curves Flow Controller Pump Curves Chart 2: Flow Controller Performance [360] 1-Grundfos 26-99 [290] 2-Grundfos 26-99...
Page 18: Pump Replacement
Flow Controller 3 R e v. : F e b u r a r y 9 , 2 0 1 6 Pump Replacement Procedure NOTICE: Remember this procedure will dilute the antifreeze � WARNING! � mixture by a couple of gallons [7-8 liters]. If performed more...
Page 19: Geothermal Closed Loop Design
Flow Controller 3 R e v. : F e b u r a r y 9 , 2 0 1 6 Geothermal Closed Loop Design use 3/4 inch or 1 inch pipe for loops and 1-1/4 inch, 1-1/2 In general socket fusion loses these advantages in fusion inch or 2 inch pipe for headers and service lines.
Page 20: Parallel Loop Design
Flow Controller 3 R e v. : F e b u r a r y 9 , 2 0 1 6 Geothermal Closed Loop Design In smaller loops of two tons [7 kW] or less, the reasons for most cases. Selecting pumps to attain exactly 3 gpm per using parallel loops as listed above may be less obvious.
Page 21 Flow Controller 3 R e v. : F e b u r a r y 9 , 2 0 1 6 Geothermal Closed Loop Design gpm [36 l/m] to attain 2 fps [0.6 m/s] and since increasing design rules are followed, units of 3 tons [10.6 kW] or less the flow through the last circuit would also require increasing will require only 1 circulating pump (UP26-99).
Page 22 Flow Controller 3 R e v. : F e b u r a r y 9 , 2 0 1 6 Geothermal Closed Loop Design Prior to installation, locate and mark all existing underground and wells. Local codes and ordinances supersede any utilities, piping, etc.
Page 23: Closed Loop Installation
Flow Controller 3 R e v. : F e b u r a r y 9 , 2 0 1 6 Closed Loop Installation � CAUTION! � Seal and protect the entry point of all earth coupling entry points into the building using conduit sleeves hydraulic cement.
Page 24 Flow Controller 3 R e v. : F e b u r a r y 9 , 2 0 1 6 Closed Loop Installation Figure 18: Typical Pond/Lake Loop Configurations Vertical U-Bends and Pond Loop Systems: Test Vertical U-bends and pond loop assemblies prior to installation with a test pressure of at least 100 psi [689 kPa].
Page 25: Pressure Drop Tables
Flow Controller 3 R e v. : F e b u r a r y 9 , 2 0 1 6 Pressure Drop Table 6a: Polyethylene Pressure Drop per 100ft of Pipe Antifreeze (30°F [-1°C] EWT): 17% Methanol by volume solution - freeze protected to 15°F [-9.4°F] 3/4”...
Page 26 Flow Controller 3 R e v. : F e b u r a r y 9 , 2 0 1 6 Pressure Drop Table 6b: Polyethylene Pressure Drop per 100ft of Pipe Antifreeze (30°F [-1°C] EWT): 24% Propylene Glycol by volume solution - freeze protected to 15°F [-9.4°F] 3/4”...
Page 27 Flow Controller 3 R e v. : F e b u r a r y 9 , 2 0 1 6 Pressure Drop Table 6c: Polyethylene Pressure Drop per 100ft of Pipe Antifreeze (30°F [-1°C] EWT): 20% Ethanol by volume solution - freeze protected to 15°F [-9.4°F] 3/4”...
Page 28 Flow Controller 3 R e v. : F e b u r a r y 9 , 2 0 1 6 Pressure Drop Table 6d: Polyethylene Pressure Drop per 100ft of Pipe Antifreeze (30°F [-1°C] EWT): 25% Ethylene by volume solution - freeze protected to 15°F [-9.4°F] 3/4”...
Page 29 Flow Controller 3 R e v. : F e b u r a r y 9 , 2 0 1 6 Pressure Drop Table 6e: Polyethylene Pressure Drop per 100ft of Pipe No Antifreeze (50°F [10°C] EWT): Water 3/4" IPS SDR11 1"...
Page 30 Flow Controller 3 R e v. : F e b u r a r y 9 , 2 0 1 6 Pressure Drop Table 6f: 1” Rubber Hose Pressure Drop per 100ft of Hose No Antifreeze (50°F [10°C] EWT): Water...
Page 31: Building Entry
Flow Controller 3 R e v. : F e b u r a r y 9 , 2 0 1 6 Site Survey Form Client Name: ____________________________________ Date: ____________________________________ Address: ________________________________________ Surveyed by: _____________________________ Phone: __________________________________________ � New construction � Retrofit...
Page 32: Warranty
Flow Controller 3 R e v. : F e b u r a r y 9 , 2 0 1 6 Warranty G e o t h e r m a l H e a t P u m p S y s t e m s...
Page 33 Flow Controller 3 R e v. : F e b u r a r y 9 , 2 0 1 6 Notes...
Page 34: Revision History
97B0015N01 ClimateMaster works continually to improve its products. As a result, the design and specifications of each product at the time for order may be changed without notice and may not be as described herein. Please contact ClimateMaster’s Customer Service Department at 1-405-745-6000 for specific information on the current design and specifications.

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