Single Stage Packaged Geothermal Heat Pump Installation & Operating Instructions Model: (RA-VE*) Application Forced air Geo source installation Equipped for optional AUX EL strip heat (controller included) Dual Heat – combine this geothermal unit with standby gas or oil furnace LMC (Load management control) ready Tested to UL Standards 1995 and CSA Standards C22.2 Domestic Water Heater, Desuperheater Energy Star promotes the desuperheater and it is standard with this series.
Table of Contents Introduction 1 Product Configurator (NC028) 2 Mechanical Specifications 3 Electrical Data 4 Product Dimensions 5 Installation Requirements 6 Mechanical Installation Overview 7 Mechanical Installation Source Water 8 Flushing and Filling Procedure 10 Converting to Right Hand Return 14 Desuperheater, Domestic Hot Water 16 Preventative Maintenance 18 Electrical Hookup 20 EZGEO Controller 21 Additional Hookup or Special Equipment Concerns 25 Field Setup or Programm
Introduction When used and controlled properly, geothermal heat pumps can save hundreds of dollars in heating and cooling costs per year. Northern Heat Pump NorthStar Series geothermal heat pumps are designed to provide maximum efficiency, comfort, and reliability. Solid and simple electric controls allow for low maintenance and built in safety protection. This is a prewired package system with the necessary controls for various forced air heating applications.
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Mechanical Specifications – R410A Single Stage Compressor MODEL Coax & Piping Water Volume – gal Source Temperature °F (min/max) Nominal source differential* °F (H/C) Factory Charge R410A Static Pressure – Nominal Static Pressure – Design Air Filter Weight– Packaged (lbs) RA-VE-041 (3 ton) .65 20°/120° 9/11° 4 lbs. 8 oz. 0.3 0.5 7/8 X 28 7/8 X 27 1/2 460 RA-VE-053 (4 ton) 1.1 20°/120° 6/11° 6 lbs. 4 oz. 0.3 0.5 7/8 X 27 1/2 X 37 7/8 480 RA-VE-061 (5 ton) 1.1 20°/120° 6/10° 6 lbs. 4 oz. 0.3 0.
Electrical Data – Single Phase Model 041 053 061 (60 Hz) RLA LRA FLA FLA Loop Pump (Ext) FLA 208/230-1 208/230-1 208/230-1 17.9 26.4 28.3 112 134 178 6.1 6.1 7.3 .15 .15 .15 4.4 4.4 4.4 Voltage Compressor Blower Desup. Pump Total Min. FLA Ampac. Max. Fuse/ HACR 28.6 37.5 40.2 33.0 43.5 47.2 50 70 70 Total Min. FLA Ampac. Max. Fuse/ HACR 24.2 31.1 32.4 27.5 36.2 37.
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Installation Requirements 1. All installation work must be performed by trained, qualified contractors or technicians. Northern Heat Pump sponsors installation and service schools to assist the installer. Visit our Website at www.northernheatpump.com for upcoming service schools. WARNING ALL ELECTRICAL WIRING MUST BE IN ACCORDANCE WITH NATIONAL ELECTRIC CODE AND LOCAL ELECTRIC CODES, ORDINANCES, AND REGULATIONS. WARNING OBSERVE ELECTRIC POLARITY AND WIRING COLORS.
Mechanical Installation Overview This NorthStar Series unit cannot correct airflow problems inherent within the duct work system. The following items should be carefully considered and properly followed for all installations: Examination of the existing forced air furnace – Prior to starting this installation, examine the total furnace system and make necessary comments or recommendations to the homeowner.
Mechanical Installation Source Water WARNING LOOP DESIGN IS EXTREMELY IMPORTANT FOR PROPER HEAT PUMP OPERATION. INCORRECT LOOP DESIGN WILL REDUCE HEAT PUMP EFFICIENCY, CAUSE POOR PERFORMANCE OR MAY RENDER THE SYSTEM UNUSABLE. CONTACT AN IGSHPA OR CGC CERTIFIED GEOTHERMAL LOOP CONTRACTOR FOR PROPER INSTALLATIONS.
Figure 4 – Pressurized Closed Loop with Flow Center – Typical piping arrangement. Figure 5 – Non-Pressurized Closed Loop with Flow Center – Typical piping diagram.
Flushing and Filling the System Using 3-Way Valves Step 1 Use water and a high volume head circulator pump to flush air and debris and to fill the loop system. • Refer to recommendations provided by IGSHPA or CGC when choosing a pump for the flushing process. • It is recommended that pump suction be from the bottom of a large volume container. Use a suction line strainer to prevent debris discharged into the container from being recycled to the system.
versus the pressure drop table (Table#3) and determine the actual flow rate. If the flow rate is low, recheck the selection of the loop pump module model for sufficient capacity. If the model is correct, there is likely trapped air or a restriction in the flow circuit. System pressure should increase rapidly as the flush pump works to force more water into the system. Additional flushing of the loop is needed if the water level in the loop falls. This shows that there is air in the system.
Open Loop Well to Well – An open system gets its name from the open discharge of water after it has been used by the heat pump. A well must be available that can supply all of the water requirements of the heat pump along with any other water requirements drawing off that same well. The well must be capable of supplying the heat pumps required flow rated for up to 24 hours per day for the coldest winter day. Figure 6 shows the necessary components for water piping of an open system.
Figure 6: Open Loop Well to Well – Typical piping diagram. Open Loop Freeze Protection Switch – Heat pump installations on open loop systems, using a non-antifreeze protected water source during the heating mode require the use of a water coil freeze protection switch. If the water supply to the heat pump is interrupted for any reason, continued operation of the compressor will cause the water remaining in the water-to-refrigerant heat exchanger to freeze and rupture.
Converting to Right Hand Return One of the unique features of your NorthStar Series Heat Pump is the ability to quickly and easily convert the unit from the factory-shipped left-hand return air configuration to a configuration where return air enters the unit from the right-hand side. This is accomplished by moving the access doors and EZGEO control box from the front of the cabinet to the rear of the cabinet and rotating the heat pump 180°. 1.
Built-in Electric Strip Heat (AUX EL) Electric Resistance Heat (optional) –NHP NorthStar Series heat pumps may be ordered with optional electric resistance heat. This feature is installed for various reasons. Most commonly, particularly in northern climates where extremely low temperatures are found, geothermal heat pumps are often intentionally undersized for the coldest days of the year.
Desuperheater, Domestic Hot Water General NHP NorthStar Series units are equipped with a desuperheater and an integrated circulating pump (can be a price deduct) that can provide Supplemental Domestic hot Water (SDW). This is done by stripping heat from the superheated gas leaving the compressor. Fuses – 3-amp fuses are installed in series with the desuperheater pump. The fuses are located in the line voltage control box, upper right.
Figure 7 – Desuperheater Piping, Buffer Tank This arrangement is the most effective and efficient and the recommended installation. The buffer tank need not be as big as the standard water heater; 40-gallon size can be very effective. With this two tank system the desuperheater will always act as a city/well water pre-heater and the standard water heater (electric elements or gas) only requires tempering energy which is a very small percentage of domestic water heater energy required.
Preventive Maintenance Air Filter Maintenance – The air filter in your Northern Heat Pump is designed for optimum performance and long life. However, a dirty filter will result in lower efficiency and performance. Periodically, the filter should be thoroughly pressure washed in the opposite direction of airflow. Under normal operating conditions, a monthly cleaning should be satisfactory. Water Coil Maintenance –In closed loop systems, water coil maintenance is generally not needed.
Condensate Drain In the cooling season, condensation is collected in a drip pan and exits the heat pump through the labeled hole outfitted with a ¾” NPT fitting. The condensation drain is trapped internally, so generally, no external p-trap is required. A drain vent in the condensate line is required to ensure proper water flow. Terminate the condensation line into a nearby floor drain. If a floor drain is not nearby, a condensate drain pump may be used.
Electrical Hookup WARNING DISCONNECT ALL ELECTRICAL POWER BEFORE ELECTRICALLY CONNECTING OR SERVICING THE UNIT. FAILURE TO DISCONNECT THE ELECTRICAL POWER BEFORE WORKING ON THIS PRODUCT CAN CREATE A HAZARD LEADING TO PERSONAL INJURY OR DEATH. Line Voltage The nameplate and/or Installation and Operating Manual specification page provides RLA, LRA, and total amps requirement. Select the proper wire size to comply with your type of wire routing and NEC field wiring requirements.
EZGEO Controller EZGEO Features Review attached HC112 HELPS document which lists the various characteristics and capability of this controller product. Application The EZGEO controller is standard on all Northern Heat Pump models. For this model, the controller is designed to run under 1 of 3 different operating “modes”.
Utility Load Control Bottom 2-screw terminal block marked blue and blu/wht. Remove the jumper and extend the two wires to the utility furnished control device. For electric energy operation (off-peak) the two blue wires represent contact closure as shipped. Do not apply external voltage or external power to the blue wires, they are simply looking for a closed contact during off-peak. • The maximum “AC noise” on the blue wire is 5 volts, peak to peak.
Visual example only – the exact connections will depend upon operating mode. Review previous section – EZGEO Controller.
Temperature Sensors WARNING BOTH MUST BE INSTALLED ON ALL MODELS. Outdoor Sensor (OT) – extend sensor to an outdoor location properly sampling the outdoor temperature. Select a location away from direct sunlight and where the sensor will not pick up false temperature from the heat pump outdoor unit, refrigerant line sets, dryer vent, reflection off of steel siding, etc. Do not install the sensor in any type of enclosure, as this will falsely trap and pick up radiant sun temperature.
Additional Hookup or Special System Equipment Concerns Additional Room Thermostat Connection Points On the EZGEO board, upper left, are two optional control tabs – W2 and E-GAS. These can be used for troubleshooting or emergency full output energy or with a conventional 2H/2C room thermostat. If the Geo system has been sized to meet 100% of the heating load, it may be desirable to control the strip heat (if equipped) at the thermostat.
Field Setup Overview Your EZGEO-equipped Northern Heat Pump can be set up at your location to fit most any requirements and conditions. This is accomplished with the use of the various dials and switches located on the EZGEO board. It is extremely important the installer properly goes through this section and sets up the various switches to match the installation. Again, refer to HC112 Helps – EZGEO Controller section for further details on these setups.
Switchover Temperature (SW OVER) This switch is shipped from the factory with a square “GAS” label. This label should be removed ONLY if a secondary furnace is present and active in the system. The installer should remove the label and adjust this switch only after reading this manual and understanding the operation of the switch. Select the OT temperature to interrupt the compressor and transfer to the sequence shown on applicable mode Figures 2, 3, 4. This only applies when a gas furnace is connected.
Gas Furnace CFM See previous page on gas furnace hookup for proper programming of ECM motor for the required CFM output. Outdoor Temp (OT) Factory Default Settings Default 90° F (32° C) 70° F (21° C) 20° F (-6° C) 90° F (32° C) ST target temp Dead compressor ST OT temp, heating – HI > OT temp, cooling – HI > EZGEO Board Dial Configurations Below is a list of different configurations the EZGEO system can be adapted to and the matching appropriate EZGEO board settings.
Undersized geothermal heat pump with fossil fuel furnace. • Mode Dial: C • SW Over Dial: 1=-15°F/ 2=-10°F/ 3=0°F/ 4=5°F/ 5=10°F/ 6=20°F/ 7=30°F • AUX EL: 0 • SOT Dial: 0=30min 1=90min 2=180min 3=270min • Thermostat type: Conventional 1H/2C Geothermal heat pump with fossil fuel furnace.
Override Switch – the front panel slide switch (very similar to standard Electro-Mate DFC) is a direct hardware disabling of the HP-Y1 and electric elements functions. The room thermostat heat call wire or function is directly controlling the fossil fuel or gas furnace. This function can also be on a remote switch, see previous statement for “SBSW” tab. WARNING THIS FRONT PANEL MANUAL OVERRIDE SWITCH IS A HARDWARE DIRECT TO GAS FURNACE FUNCTION. THUS THERE ARE NO BLOWER PURGE CYCLES.
Power On, Startup Before applying power to the heat pump, check the following items: 1. Water supply plumbing to the heat pump is complete and operational. 2. Low voltage wiring of the thermostat and any additional control wiring is complete. 3. Set thermostat to the OFF position. 4. All high voltage wiring is correct including fuses, breakers, and wire sizes. 5. The heat pump is located in a warm area above 50°F [10°C]. Starting the system with low ambient temperature conditions is more difficult. 6.
Operational Tips ICM Board – The ICM board performs the functions controlling the compressor operation: system lockout, compressor anti-short cycle, and a five minute delay after power is applied. The control will begin the 5-minute time delay upon a Y call from the thermostat. After the time delay expires, the compressor contactor will be energized as long as the high and low pressure switches are closed. If either switch is open after the delay expires, the compressor will not energize.
Unit Operating Conditions – Heat Blower AMPS CFM Discharge pressure at 68 deg A-RT Discharge temp 11.2-13.2 12.4-14.4 13.7-15.7 1.9 2.0 2.0 1170-1210 1170-1210 1200-1250 305-325 351-371 395-415 160-166 160-166 161-167 10.4-14.4 11.9-15.9 11.3-15.3 25-30 32-37 39-44 16.4-18.4 18.0-20.0 19.7-21.7 3.2 3.3 3.2 1590-1630 1590-1630 1530-1570 317-337 358-378 402-422 158-164 155-161 153-159 15 15 15 26-31 32-37 40-45 18.9-20.9 20.7-22.7 22.8-24.8 3.8 3.9 4.
Unit Operating Conditions – Cool Model Source Temp Source temp ∆ RA-VE-041 50 59 77 86 Discharge pressure at Nominal CFM 80 deg ART Suction temp at bulb Super-heat at bulb 119-129 124-134 127-137 123-133 55-61 57-63 57-63 55-61 14.5-18.5 13.8-17.8 12.8-16.8 12.1-16.1 6.3-10.3 7.7-11.7 7.6-11.6 8.8-12.8 130-140 131-141 133-143 135-145 57-63 57-63 58-64 59-65 12.0-16.0 11.8-15.8 11.4-15.4 11.2-15.2 122-128 127-133 145-151 156-162 7.0-11.0 7.0-11.0 9.5-13.5 7.2-11.
Troubleshooting – EZGEO Control Sensor Temperature Calibration – both remote sensors are digital electronic and factory calibrated. Normally these do not require field calibration or verification. However, if sensor temperature error is determined, use special PC software disc and PC serial port cable.
Troubleshooting/Repair Helps 1. This EZGEO controller contains several interference suppression components, but as an electronic logic product, unpredictable and unusual transients or interferences may sometimes cause strange results. If the EZGEO controller is “acting strange”, one immediate step would be power down reset. Simply turn off the 24volt source power (probably furnace or air handler circuit breaker), when the green LED goes out, count to 10, and re-energize power supply. 2.
EZGEO Bypass Behind the front panel hinged door the various wires from the EZGEO board terminate on a Geo standard terminology terminal block. If necessary to prevent building freeze-up, etc. the wires from the EZGEO board can be disconnected from this terminal block and the room thermostat (or another heat pump type roomstat) can be transferred to this terminal block to run the compressor/heat pump in an emergency mode. - R to Y1 – compressor on and blower at full airflow.
Compressor bypass – initial installation or special requirement to heat with AUX EL only. Special configuration, mode B and SW OVER = 0 only. 1. Pull yellow wire at ICM Y tab, or configure stat to 2H/1C or 2H/2C and follow wiring instructions on NH401. 2. Jumper stat W to W2 tab. 3. Stat W will set blower to high, AUX EL steps on to full (may take time between stages, especially first time on) but no compressor. 4.
Accessories/Options NHP GEO Alarm Fuse – source loop pump, 10A Fuse – desuperheater pump, 3A Secure/Soft Start Kit for 1ph NHP Digital 4-Wire Thermostat (pre-programmed) Open loop, freeze limit, 39° F (4° C), pipe mounted Internal Strip Heater Sound vibration pad Return air filter 21-⅞ x 27-½ 28-⅞ x 27-½ 37-⅞ x 27-½ Part Number R-AL-FD-1 UFUSE1799 UFUSE1796 R-SS-1 5021 6047 KN-*-1-Z R-PAD-2735-1 5864 5865 5863 *5, 10, 15, AND 20 kW models available.
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