Models GF and EF
Contents
1. Heat Upon receiving a G and Y1 signal from the thermostat the compressor will be energized and the reversing valve de energized On two stage units with ECM the first stage of the compressor will be energized and the blower will provide the first stage airflow The compressor will be limited by a timer that will provide short cycle protection When a subsequent Y2 signal is received the second stage of the compressor will be energized and the blower will provide the second stage airflow two stage units with ECM only Open Loop Systems An optional valve can be fitted to stop water flow when the compressor is not energized This allows the variable pumping system to work more efficiently Supplemental Electric Heat Field Installed Accessory Upon receiving a W1 signal from the thermostat the first stage of the auxiliary electric heat is energized Upon receiving a W2 E signal from the thermostat the second stage of auxiliary electric heat is energized Table 18 1 Water Pressure Drop psi Based on Entering Water Temperature Table 18 2 Antifreeze Pressure Drop Corrections Antifreeze Solution Antifreeze Type Percent by Weight 15 1 12 Correction Factor Ethylene Glycol Propylene Glycol Ethanol Methanol 18 GEO16 500 3 START UP PROCEDURE Equation 19 1 Coaxial Coil Pressure Drop2. MODINE sid n ds MovINE 9 S ICI CICO i WARNING Improper installation adjustment alteration service or maintenance can cause property damage injury or death and could cause exposure to substances which have been determined by various state agencies to cause cancer birth defects or other reproductive harm sales representative Read the installation operating and maintenance 2 Check rating plate on unit to verify that power supply meets instructions thoroughly before installing or servicing this equipment August 2015 INSTALLATION AND SERVICE MANUAL forced air ground source heat pumps models GF and EF C US LISTED NOTE Energy Star only Intertek E eue A WARNING This unit contains R 410A high pressure refrigerant Hazards exist that could result in personal injury or death Installation maintenance and service must only be performed by an HVAC technician qualified in R 410A refrigerant and using proper tools and equipment Due to much higher pressure of R 410A refrigerant DO NOT USE service equipment or tools designed for refrigerants other than R 410A IMPORTANT 1 The use of this manual is specifically intended for a qualified installation and service agency A qualified installation and service agency must perform all installation and service of these appliances 2 GF EF units contain the refrigerant R 410A Review the R 410A Material Safety Dat
3. 5H0835090000 12 300 16 300 5H0835100000 24 600 32 700 5H0835110000 j 24 600 32 700 5H0835120000 36 900 49 100 5 0835130000 49 200 65 500 Table 16 3 Auxiliary Heater Data Vertical Nominal Part Number Rating kW 5H0835040000 5H0835050000 5H0835060000 5H0835070000 5H0835080000 Table 16 4 Auxiliary Heater Data Horizontal Nominal Part Number Rating kW 5H0835090000 5H0835100000 5H0835110000 5H0835120000 5H0835130000 NOTE refer to Auxilliary Heat Installation Manual for installation instructions 16 GEO16 500 3 START UP PROCEDURE START UP PROCEDURE IMPORTANT Start up and adjustment procedures must be performed by a qualified service agency The unit has been factory tested and set for proper operation but a full unit start up is recommended NOTE if any abnormal operation occurs during the startup procedure refer to the Troubleshooting section NOTE Always start the system in heating mode Pre Start Checks Before applying power to heat pump use the following checklist to ensure a complete and proper installation Check that the supply voltage matches the unit supply voltage listed on the Unit Serial Plate Verify that all wiring is secure and properly protected All high voltage wiring is correct including fuse
4. Thermostat Installation The thermostat should be located on an interior wall in a larger room approximately 54 off the floor and away from supply duct drafts DO NOT locate the thermostat in areas subject to sunlight drafts or on external walls Auxiliary Heat Wiring Refer to the auxiliary heat installation manual provided with auxiliary heat assembly and the wiring diagram for details The auxiliary heat assembly is mounted internally on vertical units and externally on horizontal units The auxiliary heat assembly is powered separately from the unit Open Loop Control Valve Wiring Always maintain water pressure in the heat exchanger by placing water control valves at the outlet of the unit to prevent mineral precipitation during the off cycle Pilot operated slow closing valves are recommended to reduce water hammer If water hammer persists an expansion tank can be mounted on the piping to help absorb the excess hammer shock Slow closing valve must have an end switch that enables disables the compressor See Figure 14 2 for proper wiring Figure 14 2 Optional Open Loop Valve Wiring WHITE CC LOW CC GND 1 Existing wire do not remove 2 Remove WHITE wire from CC LOW terminal on printed circuit board and splice to terminal 3 on valve 3 Wire CC LOW terminal to terminal 2 on valve 4 Wire Contactor to terminal 1 on valve Figure 14 3 Thermostat Terminals 24VAC Common 24VAC Hot Fan C
5. materials 8 If the unit is installed in a crawl space the bottom of the unit must be at least 4 above grade to prevent flooding during heavy rainfalls 9 Provide a clear physical path to the unit Adequate space should be provided to allow removal of the unit if necessary 10 Some residential applications require the installation of horizontal units on an attic floor In this case the unit should be set in a full size secondary drain pan on top of a vibration absorbing pad The secondary drain pan prevents possible condensate overflow or water leakage damage to the ceiling The secondary drain pan is usually placed on top of plywood resting on the ceiling joists The use of a secondary drain pan overflow switch is recommended The switch should be tied into the overflow alarm switch circuit in the unit control panel Terminals are provided in the control panel for easy tie in of secondary overflow switch Refer to unit wiring diagram Ducting a 4 10 IMPORTANT In order to ensure efficient operation of system the ductwork should be designed and installed per current industry guidelines and procedures A flexible connector is recommended for discharge and return air duct connections on metal duct systems to eliminate the transfer of vibration to the duct system Duct should be insulated with a minimum of 1 duct insulation Uninsulated duct work in an unconditioned space is not recommended as un
6. Table 12 1 DHW Pipe Sizes COLD WATER IN AIR VENT HOT HOT Maximum pipe length one way to MUS achieve optimum flow DHW Flow 1 2 Copper gpm 0 6 50 0 8 50 1 2 50 TANK 1 HEATING SOURCE DISABLED 1 6 45 2 0 25 2 4 10 DRAIN CONNECTION DRAIN VALVE 12 GEO16 500 3 INSTALLATION Wiring A WARNING Disconnect power supply before making wiring connections to prevent electrical shock and equipment damage All appliances must be wired strictly in accordance with the wiring diagram furnished with the appliance Any wiring different from the wiring diagram could result in a hazard to persons and property Any original factory wiring that requires replacement must be replaced with wiring material having a temperature rating of at least 105 C Ensure that the supply voltage to the appliance as indicated on the serial plate is not 5 greater than rated voltage A CAUTION Ensure that the supply voltage to the appliance as indicated on the serial plate is not 5 less than the rated voltage Installation of wiring must conform with local building codes or in the absence of local codes with the National Electric Code ANSI NFPA 70 Latest Edition Unit must be electrically grounded in conformance to this code In Canada wiring must comply with CSA C22 1 Part 1 Electrical Code Electric wiring must be sized to
7. repairs or any other work done This warranty does not apply to any equipment which shall have been repaired or altered outside the factory of Seller in any way so as in the judgment of Seller to affect its stability nor which has been subjected to misuse negligence or operating conditions in excess of those for which such equipment was designed This warranty does not cover the effects of physical or chemical properties of water or steam or other liquids or gases used in the equipment BUYER AGREES THAT SELLER S WARRANTY OF ITS PRODUCTS TO BE FREE FROM DEFECT IN MATERIAL AND WORKMANSHIP AS LIMITED HEREIN SHALL BE IN LIEU OF AND EXCLUSIVE OF ALL OTHER WARRANTIES EITHER EXPRESS OR IMPLIED WHETHER ARISING FROM LAW COURSE OF DEALING USAGE OF TRADE OR OTHERWISE THERE ARE NO OTHER WARRANTIES INCLUDING WARRANTY OF MERCHANTABILITY OR FITNESS FOR PURPOSE WHICH EXTEND BEYOND THE PRODUCT DESCRIPTION CONFIRMED BY BUYER AND SELLER AS OF THE DATE OF FINAL AGREEMENT This warranty is void if the input to the product exceeds the rated input as indicated on the product serial plate by more than 596 on gas fired and oil fired units or if the product in the judgment of SELLER has been installed in a corrosive atmosphere or subjected to corrosive fluids or gases been subjected to misuse negligence accident excessive thermal shock excessive humidity physical damage impact abrasion unauthorized alterations or operation contrary to SELLER S
8. 55 21 55 21 16 09 16 09 16 11 14 52 12 27 12 27 13 73 13 73 12 43 11 90 14 66 14 66 11 76 11 76 10 43 9 40 12 16 12 16 2 12 2 12 2 14 2 14 2 14 2 14 4 87 4 87 4 82 4 63 7 27 Ter 7 24 7 24 7 19 7 15 9 96 9 96 11 12 11 12 12 23 14 28 14 35 14 35 17 08 17 08 18 99 17 49 20 25 20 25 4 87 4 87 11 59 11 67 16 00 16 00 27 54 27 54 29 92 31 83 35 57 35 57 24 63 24 63 27 43 29 39 29 39 29 39 10 39 10 39 10 39 13 82 13 82 13 82 Z m oo mm ooo ms gt 9 21 9 21 10 89 9 69 9 69 9 69 9 37 9 37 9 37 13 24 13 24 13 24 Filter Size 27 0x29 5x2 0 27 0x29 5x2 0 27 0x29 5x2 0 27 0x29 5x2 0 31 5x33 8x2 0 27 0x29 5x2 0 Approx Shipping Weight Ibs 324 329 388 465 544 546 Coil Con nection Size Female Swivel 1 NPT 1 NPT NOTE Right Return shown Left Return is mirror image 4 1 NPT 1 NPT GEO16 500 3 1 NPT 1 NPT UNIT DIMENSIONS Figure 5 1 Dimensional Drawings Vertical Bottom Discharge AUXILIARY HEAT POWER CONDENSATE DRAIN Table 5 1 Dimensions inches Vertical Bottom Discharge 53 89 53 89
9. 56 04 58 04 62 04 62 04 25 65 25 65 25 65 25 65 25 65 25 65 27 79 27 79 31 14 32 62 32 62 32 62 25 66 25 66 27 66 29 67 33 67 33 67 47 40 47 40 48 34 49 43 55 98 55 98 45 04 45 04 45 72 46 80 53 17 53 17 43 07 43 07 43 22 44 30 50 67 50 67 32 88 32 88 34 87 37 01 40 87 40 87 1 62 1 62 1 62 1 62 1 71 1 71 37 99 37 99 40 05 42 05 46 05 46 05 41 88 41 88 47 14 49 15 53 15 53 15 47 84 47 84 51 49 52 37 60 12 60 12 42 32 42 32 44 47 46 48 50 48 50 48 27 54 27 54 29 92 31 83 35 57 35 57 24 63 24 63 27 43 29 39 29 39 29 39 10 39 10 39 10 39 13 82 13 82 13 82 21 i 0 oo m gt 9 21 9 21 10 89 9 69 9 69 9 69 9 37 9 37 9 37 13 27 13 24 13 24 Filter Size 27 0x29 5x2 0 27 0x29 5x2 0 30 0x32 0x2 0 31 5x33 8x2 0 31 5x33 8x2 0 31 5x33 8x2 0 Approx Shipping Weight Ibs 324 329 388 465 544 546 Coil Con nection Size Female Swivel NOTE Right Return shown Left Return is mirror image GEO16 500 3 UNIT DIMENSIONS Figure 6 1 Dimensional Drawings Horizontal End Discharge Table 6 1
10. Antifreeze Correction To find actual pressure drop through either coaxial coil when the unit is operated with an antifreeze solution rather than water WPD WPD x ACF Where WPD Water Pressure Drop at Actual Conditions WPD Water Pressure Drop at Standard Conditions water from Table 18 1 ACF Antifreeze Correction Factor from Table 18 2 Table 19 1 Typical Operating Conditions Heating No Desuperheater Entering Water Temperature CF 30 Suction Discharge Water Air Pressure waqan E Temperature Temperature psig psig en Drop F Rise F 1 5 68 76 285 310 8 12 5 7 15 21 3 0 72 80 290 315 8 12 3 5 17 23 1 5 100 110 315 345 9 13 7 9 22 28 3 0 104 114 320 350 9 13 5 7 24 30 1 5 134 144 355 395 10 14 9 11 30 36 3 0 138 148 360 390 10 14 7 9 32 38 Heating No Desuperheater Suction Discharge Water Air Pressure Pressure Temperature Temperature psig psig Drop F Rise F 122 130 220 235 120 128 190 210 127 136 210 280 125 134 250 270 132 144 360 380 130 142 330 350 Water Flow gpm ton 50 70 Entering Water Temperature CF Water Flow gpm ton Table 19 2 Operating Limits 2222 NOTE Limits acceptable for start up conditions only Operating Limits Cooling CF Heating Cr Min max limits are intended for bringing the space up down Min Ambient 45 45 to normal temperatures U
11. Dimensions inches Horizontal End Discharge 23 13 23 13 23 13 23 13 25 65 25 65 25 65 25 65 61 80 42 41 79 91 79 91 NA NA NA NA 17 08 14 52 17 08 17 08 14 26 11 90 14 26 14 26 11 76 9 40 11 76 11 76 1 97 2 10 1 97 1 97 1 46 1 46 1 46 1 46 7 15 7 15 7 15 7 15 14 24 14 24 14 24 14 24 21 21 17 46 21 21 21 21 11 57 11 57 11 57 11 57 20 65 20 65 20 65 20 65 30 42 40 73 45 53 45 53 9 38 13 24 13 24 13 24 6 39 4 28 4 28 4 28 0 5 25 rX Zi Goo nm oo ms gt 10 36 13 82 13 82 13 82 o 11 02 7 16 7 16 7 16 Filter Size 22 5x32 5x2 0 22 5 32 5 2 0 22 5x38 5x2 0 22 5 42 5 2 0 22 5 48 0 2 0 22 5 48 0 2 0 Shipping Weight Ibs 324 465 544 546 Coil Con nection Size Female Swivel 1 NPT 1 NPT 1 NPT NOTE Right Return shown Left Return is mirror image 1 NPT GEO16 500 3 1 NPT 1 NPT UNIT DIMENSIONS Figure 7 1 Dimensional Drawings Horizontal Side Discharge Table 7 1 Dimensions inches Horizontal Side Discharge 23 13 23 13 23 13 23 13 25 65 25 65 25 65 25 65 61 80 61 80 67 50 76 91 NA NA NA NA 17 08 17 08 15 45 17 08 14 26 14
12. Dual Capacity GEO16 500 3 21 MAINTENANCE MAINTENANCE A WARNING When servicing or repairing this equipment use only factory approved service replacement parts A complete replacement parts list may be obtained by contacting Modine Manufacturing Company Refer to the rating plate on the appliance for complete appliance model number serial number and company address Any substitution of parts or controls not approved by the factory will be at the owner s risk A CAUTION Do not attempt to reuse any mechanical or electrical component which has been wet Such component must be replaced Air coil fin edges are sharp take necessary precautions IMPORTANT To check most of the Possible Remedies in the troubleshooting guide listed in Tables 26 1 28 1 refer to the applicable sections of the manual The routine care and maintenance of this unit will increase longevity provide for the proper operational performance and reduce the probability of failure Once the unit is operational it will be necessary to perform certain routine maintenance service checks Following is a Maintenance Schedule with the recommended checks If your unit is equipped with special features there may be additional checks that are required Consult Modine for assistance The use of torque screwdrivers on panel cover or component mounting screws is not recommended Hand start all screws If electric drills are used se
13. PCB Compressor Check piping slope away from unit and toward outlet Check venting Cycle power to system using an amp meter verify amperage draw Replace printed circuit board Check 24VAC voltage signals to the auxiliary heater printed circuit board Make sure the compressor is not in direct contact with the base or sides of the cabinet Cold surroundings can cause liquid slugging increase ambient temperature Replace printed circuit board Remove compressor mounting bolts Rattles and vibrates Check for loose screws panels or internal components Tighten and secure Piping could be hitting the metal surfaces Add insulation between the contact Air flow is noisy Undersized duct work will cause high airflow velocities and noisy operation Pump cavitation Purge air from closed loop system GEO16 500 3 START UP TROUBLESHOOTING FORM Customer Name Date Address Loop Type Model Serial Antifreeze Startup Troubleshooting Complaint COOLING CYCLE ANALYSIS PSIG SAT F F UNITTOTALAMPDRAW AIR COMPRESSOR AMP DRAW COIL LINE VOLTAGE 0 6 AR COMPRESSOR FILTER EXPANSION DRIER VALVE DISCHARGE PSIG SAT F oF F F F F F P3 FS SUPERHEAT F GPM FD LIQ EXIT FLASH GAS LIQUID LINE SUBCOOLING SOURCE FLOW HEAT OF REJECTION SOURCE FLOW G
14. TEN YEARS FROM DATE OF RESALE BY BUYER IN ANY UNCHANGED CONDITION OR WITHIN ONE HUNDRED TWENTY SIX MONTHS FROM DATE OF SHIPMENT FROM SELLER WHICHEVER OCCURS FIRST Heat Exchangers Low Intensity Infrared Units Compressors Condensing Units for Cassettes FIVE YEARS FROM DATE OF FIRST BENEFICIAL USE BY BUYER OR ANY OTHER USER WITHIN FIVE YEARS FROM DATE OF RESALE BY BUYER OR ANY OTHER USER WITHIN FIVE YEARS FROM DATE OF RESALE BY BUYER IN ANY UNCHANGED CONDITION OR WITHIN SIXTY SIX MONTHS FROM DATE OF SHIPMENT FROM SELLER WHICHEVER OCCURS FIRST Burners Low Intensity Infrared Units TWO YEARS FROM DATE OF FIRST BENEFICIAL USE BY BUYER OR ANY OTHER USER WITHIN Other TWO YEARS FROM DATE OF RESALE BY BUYER IN ANY UNCHANGED CONDITION OR WITHIN Components excluding Heat Exchangers Coils Condensers Burners Sheet Metal THIRTY MONTHS FROM DATE OF SHIPMENT FROM SELLER WHICHEVER OCCURS FIRST Heat Exchangers Coils Indoor and Outdoor Duct Furnaces and System Units Steam Hot Water Units Oil Fired Units Electric Units Cassettes Vertical Unit Ventilators Geothermal Units Compressors Vertical Unit Ventilators Geothermal Units Burners High Intensity Infrared Units Sheet Metal Parts All Products ONE YEAR FROM DATE OF FIRST BENEFICIAL USE BY BUYER OR ANY OTHER USER WITHIN ONE YEAR FROM DATE OF RESALE BY BUYER IN ANY UNCHANGED CONDITION OR WITHIN EIGHTEEN MONTHS FROM DATE OF SHIPMENT FROM SELLER WHICHEVER O
15. carry the full load amp draw of the motor starter and any controls that are used with the unit See Tables 15 1 16 1 for electrical data Any damage to or failure of units caused by incorrect wiring of the units is not covered by warranty Terminal Strip Connections The terminal strip connections are designed to clamp down on the wires To properly connect the wires to the terminal strip 1 Push a small flat head screwdriver into the square hole on the terminal Press firmly until the screwdriver hits the back stop and opens the terminal see Figure 13 1 2 Remove approximately 3 8 of insulation from the end of the wire and push the stripped wire into the oval hole in the terminal 3 Remove the screwdriver Pull on the wire to make sure that it is securely clamped in the terminal 4 Make sure that the terminal clamp is in contact with bare wire insulation removed Figure 13 1 Terminal Strip Unit Power Connection Refer to the unit serial plate for unit voltage and phase Available power must be the same as indicated on serial plate Remove access panel and electrical box cover Using Unit Power knockout route power lines through unit and into main electrical panel Connect line voltage wires to the L1 and L2 amp L3 if three phase voltage lugs of the contactor Consult the unit electrical data on the serial plate for correct overcurrent protection sizing Connect ground wire to ground lug in electrical
16. inlet and outlet pipes to the heat pump make it possible for debris build up and completely stop the flow of water to and from the desuperheater All components should be located in a conditioned space that is maintained above 50 F at all times N 10 11 Turn off power or fuel supply to the water heater Close cold water supply valve to heater Drain and flush the tank then remove the drain valve Inspect the water heater cold water inlet pipe for a check valve and remove if present Failure to do so will result in damage to the unit Use a tee to connect the cold water supply pipe to the DHW In connection on the unit Be sure to install a check valve rated for at least 1 2 PSI and a shutoff valve on the Cold Water Inlet pipe Also install a shutoff valve on the supply line to the unit as well as an air vent at the highest point of the system Run DHW piping using a minimum of 1 2 OD copper tubing See Table 12 1 for recommended line sizes Use a tee to connect the unit DHW Out Connection to the water heater drain connection Be sure to install a shutoff valve on the pipe as near to the water heater as possible Reinstall the drain valve on one side of the tee Open all valves except the system drain valve and fill the System with water Bleed all air and check for leaks Insulate all piping with 3 8 closed cell insulation Refer to Start Up Procedure for DHW setup and start up
17. not install units with a common trap and or vent All connections must be made in accordance with local plumbing codes Condensate Piping Vertical Bottom Discharge Units and Horizontal Units 1 On vertical bottom discharge and horizontal units a stainless steel 3 4 FPT fitting is provided for condensate drain piping connection 2 An external trap is required see Figure 10 1 As a general rule the minimum trap depth is 1 1 2 Figure 10 1 Bottom Discharge and Horizontal Condensate Piping lt 3 4 PVC Coupling Vent if needed 3 4 PVC 1 8 per foot c If a vent is necessary an open pipe stand may be applied to a tee in the field installed condensate piping Each unit must be installed with its own individual trap and connection to the condensate line or riser Provide a means to flush or blow out the condensate line DO NOT install units with a common trap and or vent Always vent the condensate line when dirt or air can collect in the line or a long horizontal drain line is required Also vent when large units are working against higher external static pressure than other units connected to the same condensate main since this may cause poor drainage for all units on the line When a vent is installed in the drain line it must be located after the trap in the direction of the condensate flow All connections must be made in accordance with local p
18. panel Replace electrical box cover and access panel prior to unit startup Hot Water Generator Pump Wiring The domestic hot water pump is not wired in the factory to prevent pump burnout in case the unit is powered before the domestic hot water tank is plumbed or full of water Refer to the control manual and wiring diagram for instructions on enabling the pump Transformer Wiring The system supplies the power to the controller via a 24V transformer On 208V systems the transformer is factory wired and is ready for operation On 208 230V systems the transformer comes factory wired for 230V operation If the unit is to be powered with 208V the transformer must be wired for 208V A terminal strip with a jumper is provided for easy field configuration see Figure 14 1 Refer to the wiring diagram provided with the unit for details GEO16 500 3 13 INSTALLATION Figure 14 1 208 230V Transformer Wiring TRANSFORMER VOLTAGE JUMPER YELLOW 22 EJ ORANGE 1 EJ RED 4 BLACK COM YELLOW Flow Center Wiring The flow center must be connected to the terminal blocks in the electrical box The pumps will automatically be cycled as required by the unit Be sure to wire the flow center prior to turning the system on Thermostat Wiring The thermostat wires must be connected to the appropriate terminal blocks in the electrical box Refer to the the unit wiring diagram or control manual for details
19. 22 5H1038033022 5H1038034022 5H1038035122 5H1038036022 Motor Type E Blower Motor 5H1006770006 5H1006770006 5H1006770006 5H1006770006 5H1006770008 5H1006770008 All Models Water Line Fitting Gasket Spacer Kit 3H0387930000 Condensate Overflow Switch 5H1011780000 High Pressure Switch 5H0834070001 Low Pressure Switch 5H0834070002 24 GEO16 500 3 TROUBLESHOOTING General When encountering a unit with operational faults complete these preliminary system checks before utilizing the troubleshooting charts In order to maintain system integrity performance and efficiency do not install service gauges unless unit operation appears abnormal and all other diagnostic checks are normal Verify water and air side temperatures changes against Typical Operating Data If the performance is within the ranges in the table and the air and water flows have been verified then gauges may be installed in order to check subcooling and superheat 1 Verify that the unit and flow center power supplies are on 2 Verify that all fuses or disconnects switches are intact 3 Inspect unit for obvious defects e g leaking connections loose or damaged wiring etc 4 Verify field inputs and outputs refer to wiring diagram a Thermostat inputs Thermostat inputs are 24VAC signals and can be verified using a volt meter between C and Y G O W b Outputs Compressor and reversing valve output
20. 24VAC on compressor contactor coil when 24VAC is present at controller and controller fuse is intact Replace controller Defective run capacitor Defective thermostat Measure resitance across capacitor terminals If shorts exist capacitor is defective Verify operation of thermostat Replace if faulty Replace if defective Thermostat wiring Verify thermostat wiring at unit Repair wiring if needed Loss of power to motor 208 240V units Verify voltage across 240VAC L1 IN amp L2 IN If no voltage on L1 and L2 check wiring repair wiring as needed Defective ECM motor Verify line voltage at motor GEO16 500 3 If power at motor verify control signals from thermostat TROUBLESHOOTING Table 27 1 Troubleshooting Unit short cycles Low pressure cutout High pressure cutout Possible Cause Unit is oversized Verify load calculations and unit selection Action Dirty Air Filter Check air filter Replace if necessary Thermostat location Defective compressor overloads Check to see if thermostat is installed near a supply air grill Ensure that compressor is cool and overload has had sufficient time to reset Ohmmeter shows a resistance across R amp S terminals and OPEN or infinite resistance between C amp R or C amp S terminals Relocate if necessary If windings are open or overload is faulty replace comp
21. 26 12 82 14 26 11 76 11 76 10 32 11 76 1 97 1 97 1 97 1 97 1 46 1 46 1 46 1 46 7 15 7 15 7 15 7 15 14 24 14 24 14 24 14 24 21 21 21 21 18 59 21 21 11 57 11 57 11 57 11 57 20 65 20 65 20 65 20 65 30 42 30 42 36 12 45 53 9 38 9 38 9 38 13 24 6 39 6 39 6 39 4 28 10 36 10 36 10 36 13 82 11 02 11 02 11 02 7 16 u O z Z r x o Filter Size 22 5 32 5 2 0 22 5 32 5 2 0 22 5 38 5 2 0 22 5 42 5 2 0 22 5x48 0x2 0 22 5 48 0 2 0 Approx Shipping 324 329 388 546 Weight Ibs Coil Connection Size Female Swivel NOTE Right Return shown Left Return is mirror image GEO16 500 3 UNIT LOCATION INSTALLATION Table 8 1 SI Metric Conversion Factors Multiply By To Obtain Multiply By To Obtain 0 24 kPa CFH 1 699 m min 6 893 kPa Btu ft 0 0374 mJ m F 32 x 0 555 C pound 0 453 kg inches 25 4 mm Btu hr 0 000293 kW hr feet 0 305 meters gallons 3 785 liters CFM 0 028 m min psig 27 7 W C UNIT LOCATION DANGER Appliances must not be installed where they may be exposed to potentially explosive or flammable atmosphere Handling Each unit will be shipped to the site on a wood skid Whenever possible all lifting and handling of the unit should be done with the packing and skid in position When slinging or using a forklift to lift the unit the support
22. CCURS FIRST As Modine Manufacturing Company has a continuous product improvement program it reserves the right to change design and specifications without notice PT MODINE Modine Manufacturing Company 2015 Modine Manufacturing Company 1500 DeKoven Avenue Racine WI 53403 Phone 1 877 679 4436 4GEO www modinehvac com
23. PM X AT F X 500 FOR WATER 485 ANTIFREEZE BTU HR HEATING CYCLE ANALYSIS PSIG SAT F F UNIT TOTAL AMP DRAW COMPRESSOR AMP DRAW LINE VOLTAGE COMPRESSOR FILTER EXPANSION DRIER VALVE DISCHARGE PSIG SAT F F U F F F SUPERHEAT GPM LIQUID LINE FD EXIT FLASH GAS SUBCOOLING SOURCE FLOW HEAT OF EXTRACTION SOURCE FLOW GPM X AT F X 500 FOR WATER 485 ANTIFREEZE BTU HR Note In order to maintain optimal performance DO NOT hook up pressure gauges during start up procedures When troubleshooting conduct water side analysis first If water side performance is poor use of pressure gauge and refrigerant side analysis may be required Technician Notes GEO16 500 3 29 30 THIS PAGE LEFT BLANK INTENTIONALLY GEO16 500 3 THIS PAGE LEFT BLANK INTENTIONALLY GEO16 500 3 31 COMMERCIAL WARRANTY For Residential Warranty see GEO16 510 Seller warrants its products to be free from defects in material and workmanship EXCLUSIVE HOWEVER of failures attributable to the use of materials substituted under emergency conditions for materials normally employed This warranty covers replacement of any parts furnished from the factory of Seller but does not cover labor of any kind and materials not furnished by Seller or any charges for any such labor or materials whether such labor materials or charges thereon are due to replacement of parts adjustments
24. a Sheet MSDS for hazards and first aid measures 3 Refrigerant charging should only be carried out by an EPA certified air conditioning contractor Inspection On Arrival 1 Inspect unit upon arrival In case of damage report it immediately to transportation company and your local factory available electric power at point of installation 3 Inspect unit received for conformance with description of product ordered including specifications where applicable THIS MANUAL IS THE PROPERTY OF THE OWNER PLEASE BE SURE TO LEAVE IT WITH THE OWNER WHEN YOU LEAVE THE JOB SPECIAL PRECAUTIONS SPECIAL PRECAUTIONS THE INSTALLATION AND MAINTENANCE INSTRUCTIONS IN THIS MANUAL MUST BE FOLLOWED TO PROVIDE SAFE EFFICIENT AND TROUBLE FREE OPERATION IN ADDITION PARTICULAR CARE MUST BE EXERCISED REGARDING THE SPECIAL PRECAUTIONS LISTED BELOW FAILURE TO PROPERLY ADDRESS THESE CRITICAL AREAS COULD RESULT IN PROPERTY DAMAGE OR LOSS PERSONAL INJURY OR DEATH THESE INSTRUCTIONS ARE SUBJECT TO ANY MORE RESTRICTIVE LOCAL OR NATIONAL CODES HAZARD INTENSITY LEVELS 1 DANGER Indicates an imminently hazardous situation which if not avoided WILL result in death or serious injury 2 WARNING Indicates a potentially hazardous situation which if not avoided COULD result in death or serious injury 3 CAUTION Indicates a potentially hazardous situation which if not avoided MAY result in minor or moderate injury 4 IMPORTANT Indicates
25. a situation which if not avoided MAY result in a potential safety concern DANGER 1 Appliances must not be installed where they may be exposed to potentially explosive or flammable atmosphere 2 Water temperatures over 125 F can cause severe burns instantly resulting in severe injury or death Feel water before showering or bathing Ensure that the primary water heating Source setpoints are higher than the heat pump water discharge temperature of 120 F A WARNING Disconnect power supply before making wiring connections to prevent electrical shock and equipment damage All appliances must be wired strictly in accordance with the wiring diagram furnished with the appliance Any wiring different from the wiring diagram could result in a hazard to persons and property Any original factory wiring that requires replacement must be replaced with wiring material having a temperature CAUTION Ensure that the supply voltage to the appliance as indicated on the serial plate is not 5 less than the rated voltage Do not use these units to heat or cool the building during construction Mechanical components can quickly become clogged with debris System damage may result Do not overcharge the refrigeration system This can lead to elevated compressor discharge pressure and possibly flooding the compressor with liquid Do not attempt to reuse any mechanical or electrical component which has been wet Such co
26. d recharge to factory recommended charge Scaled or plugged coaxial coil Check temperature drop across coaxial coil Clean if necessary Reduced water flow Check flow center operation Troubleshoot flow center Manually open water valve and measure water flow Adjust to proper flow rate Plugged water strainer or filter Replace or clean if dirty Water supply too hot Verify GEO IN with temperature probe Verify loop sizing bring water temperature within design parameters Reduced water flow Check flow center operation Troubleshoot flow center Manually open water valve and measure water flow Adjust to proper flow rate Plugged water strainer or filter Replace or clean if dirty Water supply too cold Verify GEO IN with temperature probe Verify loop sizing bring water temperature within design parameters Restricted TXV Verify superheat and subcooling values Replace if necessary Compressor Troubleshoot compressor operation If discharge pressure is too low and suction pressure too high compressor is not pumping properly Replace compressor Non condensables in system Blocked drain Verify superheat and subcooling values Check for blockage and clean drain Evacuate and recharge to factory recommended charge Improper trap Check trap dimensions and location Poor drainage Defective auxiliary heater
27. ective low pressure switch Reduced water flow Monitor suction pressure while operating verify low pressure cut out pressure 25 5 psig Check flow center operation Replace if defective Troubleshoot flow center Manually open water valve and measure water flow Adjust to proper flow rate Plugged water strainer or filter Clean or replace Water supply too hot Verify GEO IN with temperature probe Verify loop sizing bring water temperature within design parameters Scaled or plugged coaxial coil Check temperature drop across coaxial coil Clean if necessary Reduced or no air flow in heating Verify blower operation Troubleshoot blower operation Check air filter Replace or clean if dirty Check for airflow restrictions in ducting system Address any ductwork airflow restrictions Check external static Check external static against blower table Air temperature out of range Measure return air should be below 95 F Bring return air temperature within design parameters Defective high pressure switch Monitor discharge pressure while operating verify high pressure cut out pressure 600 25 psig Replace if defective Overcharged with refrigerant Verify superheat and subcooling values Evacuate and recharge to factory recommended charge Restricted TXV Verify superheat and subcooling values Replace if nece
28. er Flow Cooling Low Low Low Normal High Low Low Source Water Flow Heating Low Low Low High High Low Source Water Flow Cooling High High High Low High High Air Flow Load Water Flow Heating Low Low Low High Normal High High Air Flow Load Water Flow Cooling Normal High Normal High High Low Normal High High Source Water Flow Heating Normal High Normal High High Low Normal Low High Source Water Flow Cooling Low Low Low High Low Low Indoor Air Load Water Temp Heating Low Low Low Normal High Normal High Low Indoor Air Load Water Temp Cooling Low Low Low Normal High Low High Indoor Air Load Water Temp Heating High High Normal High Low Normal Low High Indoor Air Load Water Temp Cooling High High High Low High Restricted TXV TXV Bulb Failure Loss of Charge High Low Normal Low High High High Low Restricted Filter Drier Low Normal High Inefficient Compressor Low High Scaled Fouled Load Heat Exchanger Heating High High Scaled Fouled Load Heat Exchanger Cooling Low Low Low Normal Low Normal Scaled Fouled Source Heat Exchanger Heating Scaled Fouled Source Heat Exchanger Cooling High High H
29. er rinse Figure 11 1 Water Connection Breakdown Hot Water Generator Desuperheater Installation If Equipped DANGER Water temperatures over 125 F can cause severe burns instantly resulting in severe injury or death Feel water before showering or bathing Ensure that the primary water heating Source setpoints are higher than the heat pump water discharge temperature of 120 F IMPORTANT All piping and connections must be made in accordance with local plumbing codes A minimum 50 gallon water heater is recommended with the Desuperheater DHW option Higher demand applications may use either one 80 gallon water heater or two 50 gallon water heaters piped in series The hot water tank should be allowed to stratify by lowering the bottom element setpoint to 100 F and setting the top element setpoint to 125 F Control of the DHW pump is via electro mechanical temperature switches The pump is energized whenever the unit is running a conditioning cycle the DWH supply temperature water leaving the desuperheater coil is lt 120 F and the compressor discharge temperature is gt 100 F The desuperheater pump is disabled on delivery from the factory It must be enabled by wiring the pump in the unit control panel after the DHW piping has been completed and purged This is a safety feature to prevent the domestic hot water pump from running before the DHW tank is piped to the heat pump DHW option must not be enab
30. ery three months to minimize the problem It may be necessary to clean the condensate pan periodically to insure indoor air quality The condensate drain can pick up lint and dirt especially with dirty filters Inspect twice a year to avoid the possibility of overflow Compressor Conduct annual amperage checks to insure that amp draw is no more than 1096 greater than indicated on the operating data Blower Motors All units have lubricated fan motors Do not lubricate unless obvious dry operation is inspected Periodic oiling is not required may lead to excessive dirt buildup amp motor failure Check the operation amperage annually to ensure the amp draw is not greater than 1096 of data indicated on the name plate ECM fan motors need NO oiling 22 GEO16 500 3 MAINTENANCE Air Coil The air coil should be cleaned annually to retain maximum performance Inspect once a year under normal operating conditions If the air coil shows dirt or debris use a vacuum with a gentle end or a rag to clean the debris from the air coil The fins are easily damaged so take care when cleaning Cabinet If a flood occurs try to expel water as soon as possible Water contact for any duration will cause corrosion on the cabinet finish All units mounted on the ground should be installed on an absorption pad This also helps prevent water from entering the cabinet If the cabinet is dirty do not spray with water use a damp rag with mild detergent a
31. h piping conduit or other materials 8 Provide a clear physical path to the unit Adequate space should be provided to allow removal of the unit if necessary Horizontal Unit Field Discharge Air Conversion Horizontal units can be field converted from a side to end supply discharge and vice versa NOTE Horizontal units can not be converted from left to right hand return or vice versa NOTE Unit conversion must take place on the ground and prior to hanging End to Side Supply Conversion see Figure 9 1 Remove side access panel Disconnect blower wiring Remove end blower panel fasteners Carefully install blower panel in side supply position Reconnect blower wiring Check blower wiring routing and connections for tension and contact with sheet metal edges Reroute wiring as required 7 Manually rotate the blower wheel to verify that the wheel is not obstructed 8 Reinstall access panel Side to End Supply Conversion The process is the same as above with the exception of the location of the blower and access panels Note that the blower panel may need to be rotated 180 in order to prevent interference with condensate pan when installed in the end position Figure 9 1 End to Side Discharge Conversion SIDE ACCESS PANEL END BLOWER PANEL Horizontal Unit Installation Horizontal units are available in side or end discharge with left or right hand ret
32. hese warranties for any labor allowance or field labor participation Seller will not honor any expenses incurred in its behalf with regard to repairs to any of Seller s products No credit shall be issued for any defective part returned without proper written authorization including but not limited to model number serial number date of failure etc and freight prepaid OPTIONAL SUPPLEMENTAL WARRANTY Provided a supplemental warranty has been purchased Seller extends the warranty herein for an additional four 4 years on certain compressors Provided a supplemental warranty has been purchased Seller extends the warranty herein for an additional four 4 years or nine 9 years on certain heat exchangers EXCLUSION OF CONSUMABLES amp CONDITIONS BEYOND SELLER S CONTROL This warranty shall not be applicable to any of the following items refrigerant gas belts filters fuses and other items consumed or worn out by normal wear and tear or conditions beyond Seller s control including without limitation as to generality polluted or contaminated or foreign matter contained in the air or water utilized for heat exchanger condenser cooling or if the failure of the part is caused by improper air or water supply or improper or incorrect sizing of power supply APPLICABLE WARRANTY PERIOD TEN YEARS FROM DATE OF FIRST BENEFICIAL USE BY BUYER OR ANY OTHER USER WITHIN TEN YEARS FROM DATE OF RESALE BY BUYER OR ANY OTHER USER WITHIN
33. igh Restricted filter drier will have symptoms similar to restricted TXV Check temperature drop across filter driver to verify a restriction 20 GEO16 500 3 PHYSICAL DATA Table 21 1 Physical Data Copeland Scroll Compressor Factory Charge R 410A oz No HWG 46 Copeland Ultratech 67 Copeland Ultratech 73 Copeland Ultratech 97 Copeland Ultratech 140 Copeland Ultratech 140 Factory Charge R 410A oz wHWG 49 71 76 101 144 144 ECM Variable Speed Blower Motor Type Speeds ECM Variable Speed ECM Variable Speed ECM Variable Speed ECM Variable Speed ECM Variable Speed Blower Motor hp 1 8 1 2 1 2 1 2 1 1 Blower Wheel Size in 9 7 Max ESP in W C 9 7 9 7 0 75 11 10 11 10 11 10 Vertical Air Coil Dims HxW in 30x23 5 Vertical Air Coil Face Area ft 4 9 Horizontal Air Coil Dims HxW in 20x36 Horizontal Air Coil Face Area ft 5 0 Air Coil Tube Diameter in 3 8 Air Coil Number of Rows Table 21 2 Blower Data CFM 3 Max ESP Cooling Heating Mode in W C Blower Motor Type Fan Only Stage 1 Stage 2 ECM Var Speed Single Capacity ECM Var Speed Dual Capacity Dual Capacity ECM Var Speed ECM Var Speed Dual Capacity Dual Capacity ECM Var Speed ECM Var Speed
34. ing must be capable of carrying the maximum current load under no fault conditions at the stipulated voltages Care should be taken to avoid significant voltage drops A knockout for power connection is provided on the access side of the unit See unit dimensions INSTALLATION IMPORTANT 1 The ground heat exchanger open or closed loop or water source to be connected to the unit must be designed constructed and prepared in accordance with industry guidelines IGSHPA ASHRAE NGWA etc and best practices and any more restrictive local codes and regulations by a qualified service agency Failure to properly size install or prepare the source could result in reduced performance a reduction in the normal life of the units and a hazard to persons and property Units selected for open loop ground source applications should have a cupronickel source coaxial heat exchanger to reduce mineral buildup and scaling Open loop systems should have the source coaxial coil flushed periodically to maintain peak performance Installation of these units is to be INDOORS only The instructions detailed below are for the Installation of a Standard unit Accommodations and adjustments will be required for the usage of additional unit accessories Should assistance be required for the installation of these additional items consult Modine at the phone number listed on the back cover of this manual GEO16 500 3 INSTALLATION Vertical Uni
35. ior to engaging the compressor Freezing of the coax or water lines can permanently damage the heat pump A CAUTION To avoid equipment damage DO NOT leave system filled in a building without heat during the winter unless antifreeze is added to the water loop Heat exchangers never fully drain by themselves and will freeze unless winterized with antifreeze Controller Setup GF EF systems are pre programed from the factory for easy installation no installer setup is required for the unit to function The DHW pump is not wired from the factory on all units This is done to protect the pump during installation and startup If a DHW pump is in the system it must be wired IMPORTANT Ensure that the freeze protection setpoint is properly set approximately 10 F above the fluid freeze point for the type and percentage of fluid used in the ground loop Table 17 1 Freeze Point of Pure Antifreeze Solutions F Propylene 5 0 All values are typical refer to antifreeze manufacturer data sheets for actual values 17 START UP PROCEDURE Unit Startup Procedure The Startup Troubleshooting form found on page 29 of this manual may be used to assist during unit startup 1 Put thermostat in standby or off mode 2 Turn on line power to heat pump 3 Turn thermostat fan position to ON and verify blower operation 4 Put thermostat in heating mode 5 Slowly raise the ther
36. it performance will be adversely affected If the unit is connected to existing duct work check the duct system to ensure that it has the capacity to accommodate the air flow cfm required for the unit application If the duct is too small as in the replacement of heating only systems larger duct work should be installed All existing duct work should be checked for leaks and repaired if necessary The duct system should be sized to handle the design airflow quietly and efficiently To maximize sound attenuation of the unit blower the supply and return plenums should include an internal duct liner of fiberglass or constructed of ductboard for the first few feet When fitting the supply ducting to the unit be sure to use screws that are no longer than 1 2 Long radius return transitions are recommended Condensate Piping Vertical Top Discharge Units 1 On vertical top discharge units the condensate drain is internally trapped external P trap is not required and consists of a flexible drain tube connected to the pan and a 3 4 PVC female adapter The female adapter exits the front of the unit and should be glued to the field installed PVC condensate piping The condensate pan is slightly tilted for proper drainage Ensure level mounting of the system for proper drainage Each unit must be installed with its own individual vent where necessary and a means to flush or blow out the condensate drain line Do
37. ival u u a i eese 1 Ensure that the supply voltage to the appliance as Special Precautions 2 indicated on the serial plate is not 5 greater than rated Model Serial Number Designations 3 voltage Unit Dimensions 4 This unit contains R 410A high pressure refrigerant Unit 19 18 00 he PR amends 8 Hazards exist that could result in personal injury or HP 8 death Installation maintenance and service must only SI Metric Conversion Factors 8 be performed by an HVAC technician qualified in R 410A Vertical UME se iced rade be ae ee Ro eee snl 9 refrigerant and using proper tools and equipment Due horizontal sr bo aa ro PR Lae 9 to much higher pressure of R 410A refrigerant DO NOT DUGCHING TEES 10 USE service equipment or tools designed for refrigerants Water Connections 11 other than R 410A WIFIDQ erm te s e edet e bo debeo 13 When servicing or repairing this equipment use only Electrical Specifications 15 factory approved service replacement parts A complete Start Up Procedure 2 23 n u mee teet t xni 17 replacement parts list may be obtained by contacting Physical Data eE 21 Modine Manufacturing Company Refer to the rating plate Maintenances u u l 22484402 cc brass 22 on the a
38. led until all piping is complete and the DHW loop has been purged and bled or damage can occur Factory installed Snap ring in this groove Swivel adaptor hand tighten D XXX OOO OOOO Xd Brass snap ring 4 Brass spacer m 4 Rubber gasket Swivel adaptor lt hand tighten P T Port access for temperature and pressure GEO16 500 3 11 INSTALLATION Poor domestic water quality may result in debris buildup in the system A water softener is recommended with hard water greater than 10 grains or 170 total hardness Extreme hard water will require additional maintenance and should be considered with the DHW option as maintenance costs may outweigh potential savings Make sure all local electrical and plumbing codes are met for installing a hot water generator The installing contractor is responsible for performing the installation accordingly Figure 12 1 Typical DHW Piping Diagram with One Tank COLD HOT WATER WATER IN OUT AIR VENT DHW IN L bd eS OUT gt DRAIN CONNECTION DRAIN VALVE Figure 12 2 Typical DHW Piping Diagram with Two Tanks Water piping lengths must be kept at a minimum DO NOT use a one way length greater than 50 Coaxial drain tees that provide an inlet and outlet to the heat pump from the drain connection are not recommended The decreased diameter of the
39. lumbing codes GEO16 500 3 INSTALLATION Water Connections 1 All units utilize swivel pipe fittings for water connections that are rated for 150 psi 2 The connections have a rubber gasket seal similar to a garden hose gasket which when mated to the flush end of most 1 threaded male pipe fittings MPT provides a leak free seal without the need for thread sealing tape or joint compound 3 The water piping system should include pressure temperature taps for serviceability 4 Install the brass spacer and rubber gasket in swivel connector prior to attempting any connection as shown in Figure 11 1 rubber gasket and brass spacer kits are shipped with unit To make the connection mate the field supplied male pipe thread fitting against the rubber gasket in the swivel connector and thread the female locking ring onto the pipe threads while maintaining the brass elbow in the desired direction Tighten the connectors by hand and then gently snug the fitting with pliers to provide a leak proof joint 5 DO NOT OVERTIGHTEN as leaks may occur 6 NOTE Never use flexible hose smaller than 1 inside diameter on the unit Limit the length to 10 per connection in one direction Check carefully for leaks Air Coil To ensure maximum performance it is recommended that the air coil be cleaned before startup A solution of 1096 dishwasher detergent and water is recommended Spray both sides of the coil followed by a thorough clean wat
40. ly Compressor Amps 208V 10 60Hz 10 48i Supply Motor FLC Amps 4 2n 1 2 Factory Charge 3 1 Lbs 1 4 Kg Design Pressure High 450psi Low 150psi COMMON REPLACEMENT PARTS Compressor 5H102804 1611 Supply Motor 9F050090 Supply Blower 5H0834250001 Air Coil 5H0834010006 Source Coil 5H0834080016 Control Board 5H0B835950001 Control Display 5H0835950002 DHW Pump 5H0834230001 Wiring Diagram SHO834743001 KI 37717 CERTIFIED TO CAN CSA STD C22 2 NO 236 thosa GEO16 500 3 23 REPLACEMENT PARTS Table 24 1 Common Replacement Parts o 0 Mods 024 036 048 oso 066 Configuration MERV 13 Pleated Air Filter 5H1042680006 5H1042680006j1 Electrostatic Air Filter Compressor Code Compressor 5H1028041611 Compressor Run Capacitor 5H1036890009 Compressor _ 5H1038032021 5H1038033021 5H1038034021 5H1038035121 5H1038036021 Compressor Run Capacitor 5H1036890001 5H1036890002 5H1036890009 5H1036890012 5H1036890012 03 04 Soft Start 5H0834140002 Motor Type E Blower Motor 5H1006770006 5H1006770006 5H1006770006 5H1006770006 5H1006770008 5H1006770008 Hot Water Generator 1 Desuperheater DHW Pump 5H0834230001 o o z Control Transformer 5H0749490001 Contactor 5H0834310001 Compressor Code 01 03 Compressor 5H1028041611 _ _ _ 02 04 Compressor 5H10380320
41. mostat set point until a heating call is generated and the compressor energizes 6 After a few minutes check the supply air and verify warm air delivery 7 Verify water flow by comparing pressure drop across the coaxial coil to values in Table 18 1 8 Monitor ground water supply GWI and return GWO temperatures If temperature drop is within expected operating range as shown in Table 19 1 continue with testing 9 If temperature drop is outside of expected operating range check refrigerant pressures and compare to values in Table 19 1 10 Check air temperature rise across the coil Air temperature rise should be between 20 F and 30 F 11 Check for vibration noise and leaks 12 Lower thermostat set point below room temperature and verify that compressor and flow center deactivate 13 Initiate a control signal to place the unit in the cooling mode Cooling set point must be set below room temperature 14 Cooling will energize after a time delay 15 Be sure that the compressor and flow center are activated 16 Monitor ground water supply GWI and return GWO temperatures If temperature rise is within expected operating range in Table 19 1 continue with testing 17 If temperature drop is outside of expected operating range check refrigerant pressures and compare to Table 19 1 18 Check for an air temperature drop of 15 F to 25 F across the air coil 19 Check for vibration noise and leaks 20 Adjust the co
42. mponent must be replaced IMPORTANT Start up and adjustment procedures must be performed by a qualified service agency All refrigeration checks must be made by a qualified R 410A refrigeration technician Do not release refrigerant to the atmosphere When adding or removing refrigerant all national state province and local laws must be followed The ground heat exchanger open or closed loop or water source to be connected to the unit must be designed constructed and prepared in accordance with industry guidelines IGSHPA ASHRAE NGWA etc and best practices and any more restrictive local codes and regulations by a qualified service agency Failure to properly size install or prepare the source could result In reduced performance a reduction in the normal life of the units and a hazard to persons and property Units selected for open loop ground source applications should have a cupronickel source coaxial heat exchanger to reduce mineral buildup and scaling Open loop systems should have the source coaxial coil flushed periodically to maintain peak performance All piping and connections must be made in accordance with local plumbing codes To check most of the Possible Remedies in the troubleshooting guide listed in Tables 26 1 28 1 refer to the applicable sections of the manual Table of Contents 2 General Information ponit ye d 1 rating of at least 105 C Inspection on Arr
43. nd wipe the system clean Refrigerant System The refrigerant circuit is sealed service gauges should not be used unless the system is not operating correctly The operational charts show correct pressures flow and temperature Before servicing the refrigerant circuit ensure that the water and air flow are correct Replacement Parts For ease of identification when ordering replacement parts or contacting the factory about your unit please provide the complete model number and unit serial number This information can be found on the serial plate attached to your unit see Figure 23 1 When a component part fails a replacement part should be obtained by contacting your local distributor or Modine Sales Representative Your sales representative can assist with Return Material Authorizations RMAs and potential warranty claims The following details are required to process parts orders and warranty claims 1 Full description of part required including unit s model number 2 The complete unit s serial number 3 Completed Return Material Authorization RMA 4 An appropriate purchase order number For further information email modinegeothermal ccsportal com or call 1 877 679 4436 4GEO Figure 23 1 Serial Plate EXAMPLE Modi ne 1500 DeKoven Avenue Racine WI 53403 2552 Phone 1 866 823 1631 MODINE lt WADE IN U S A Sarral Number 111111 04020114212 1234 Hoge GFV018B1023RNX1ETL Power Supp
44. nits are not designed to operate at the min max conditions on a continual or regular basis The Rated Ambient operating limits are dependant upon three primary factors 1 water temperature 2 return air temperature and 3 ambient Max Ambient temperature When any of the factors are at the minimum or maximum levels the other two factors must be at the normal Min Entering Air 59 level for proper and reliable unit operation Rated Entering Air db wb 80 6 66 2 Max Entering Air db wb 110 83 Min Entering Water 30 Normal Entering Water Max Entering Water GEO16 500 3 19 START UP PROCEDURE Table 20 1 Compressor Winding Resistance Compressor ZP16K5E PFV Cto S ZPS20K5E PFV ZPS26K5E PFV ZPS35K5E PFV ZPS49K5E PFV ZPS51K5E PFV ZPS60K5E PFV Table 20 2 Refrigerant Circuit Malfunctions and Probable Causes The following chart will assist in troubleshooting and diagnosing causes of a problematic unit The chart provides general guidance for system measurements relative to typical operating conditions Undercharged System Symptom Head Press Low Comp Amp Draw Low Superheat High Subcool Low Air Temp Diff Water Source Temp Diff Low Overcharged System High High Normal High Normal Low Air Flow Load Water Flow Heating High High High Low Low Low Air Flow Load Wat
45. oling set point above the room temperature and verify that the compressor and flow center deactivate 21 If unit fails to operate as described see troubleshooting section If the unit still does not operate properly contact Modine at the number listed on the back of this manual 22 When testing is complete set system to normal operating mode DHW Startup Procedure 1 If the DHW was wired the DHW pump will run whenever the heat pump is running and the DHW Supply temperature is below 120 F and the discharge temperature is above 100 F 2 To verify operation of the DHW pump ensure that the heat pump is running and the DHW temperature is below 120 F and the discharge temperature is above 100 F 3 The temperature rise across the desuperheater should be 5 10 F Sequence of Operation The unit s controller will monitor calls for heat or cooling by thermostat Blower The blower will cycle with a call for cooling or heating Cool Upon receiving a G Y1 and O signal from the thermostat the compressor and reversing valve will be energized On two stage units with ECM the first stage of the compressor will be energized and the blower will provide the first stage airflow The compressor will be limited by a timer that will provide anti cycle protection When a subsequent Y2 signal is received the second stage of the compressor will be energized and the blower will provide the second stage airflow two stage units with ECM only
46. ompressor Stage 1 Compressor Stage 2 Reversing Valve Thermostat Terminals Alarm Signal Control Panel Terminals Aux Ht Stg 1 Aux Ht Stg 2 Em Ht 14 GEO16 500 3 ELECTRICAL SPECIFICATIONS Table 15 1 Electrical Ratings Digits 9 amp 10 Power Code Rated Voltage 208 230 60 1 208 230 60 1 Voltage min max 197 253 197 253 Digit 8 Compressor Code Compressor RLA LRA Total Unit MCA MOP 208 230 60 8 208 230 60 1 197 258 197 258 208 230 60 8 208 230 60 1 197 258 197 258 208 230 60 8 208 230 60 1 197 258 197 253 208 230 60 3 208 230 60 1 197 253 197 253 208 230 60 3 197 253 GEO16 500 3 15 ELECTRICAL SPECIFICATIONS Table 16 1 Auxiliary Heater Ratings Vertical Nominal Actual Rating Actual Rating Minimum Part Number Rating kw Circuits Btu Hr Airflow kW 208V 240V 208V 240v 5H0835040000 12 300 16 300 5H0835050000 24 600 32 700 5H0835060000 24 600 32 700 5H0835070000 36 900 49 100 5H0835080000 49 200 65 500 Table 16 2 Auxiliary Heater Ratings Horizontal Nominal Actual Rating Actual Rating Minimum Part Number Rating kW Circuits Btu Hr Airflow KW 208v 240V 208V 240v
47. points should be sufficiently apart to give stability when lifting Unless otherwise noted the lifting points should be equidistant from the centerline Extreme care should be taken not to drop the unit Considerable damage can occur to the unit during positioning in particular to the paneling and exterior paint Use an adequate number of personnel and the correct tools when moving the unit The unit is designed to remain upright so care should be taken when lifting the unit up steps The use of torque screwdrivers on panel cover or component mounting screws is not recommended Hand start all screws If electric drills are used set at the lowest possible torque Storage Equipment should be stored in clean dry area and in its original packaging Do not store or install units in corrosive environments or in locations subject to temperature or humidity extremes Performance reliability and service life can be significantly reduced Transport and store units in an upright position Tilting units greater than 60 beyond horizontal may result in damage to the compressor If the unit is tilted past 60 do not energize the compressor until the unit has been upright for a minimum of 6 hours to prevent compressor damage Unit Protection To prevent damage keep the unit in its original packaging or cover with an equivalent protective covering while on the job site Cover open water connections to prevent debris from entering the sy
48. ppliance for complete appliance model number Replacement lt 23 serial number and company address Any substitution of Serial Plate 23 parts or controls not approved by the factory will be at the Troubleshooting pem uyantapas i ees aan 25 owner s risk Start Up Troubleshooting Form 29 Wanay PEMEX Back Page GEO16 500 3 MODEL NOMENCLATURE Figure 3 1 Model Number Designations 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 MT UC MBH DS CC SV CT AC GM HM HWG MT SA RA 1 2 Model Type MT GF Residential Forced Air Unit EF Commercial Forced Air Unit 3 Unit Configuration UC V Vertical H Horizontal 4 5 6 Nominal Cooling Capacity MBH 018 18 000 Btu hr 024 24 000 Btu hr 036 36 000 Btu hr 048 48 000 Btu hr 060 60 000 Btu hr 066 66 000 Btu hr 7 Development Sequence Designation DS C Current 8 Compressor Configuration CC 1 Single Stage 2 Two Stage 3 Single Stage with Soft Start 4 Two Stage with Soft Start 9 10 Supply Voltage SV 02 208 60 1 03 208 230 60 1 04 208 60 3 05 208 230 60 3 Figure 3 2 Serial Number Designations 11 Controls Type CT 4 Modine Controls System 12 Air Coil AC R Round Tube Plate Fin RTPF R 410A 13 Geo Source Coaxial Coil Material GM C Copper N Cu
49. printed instructions or if the serial number has been altered defaced or removed BUYER AGREES THAT IN NO EVENT WILL SELLER BE LIABLE FOR COSTS OF PROCESSING LOST PROFITS INJURY TO GOODWILL OR ANY OTHER CONSEQUENTIAL OR INCIDENTAL DAMAGES OF ANY KIND RESULTING FROM THE ORDER OR USE OF ITS PRODUCT WHETHER ARISING FROM BREACH OF WARRANTY NONCONFORMITY TO ORDERED SPECIFICATIONS DELAY IN DELIVERY OR ANY LOSS SUSTAINED BY THE BUYER Component Applicable Models Heat Exchangers Gas Fired Units BUYER S REMEDY FOR BREACH OF WARRANTY EXCLUSIVE OF ALL OTHER REMEDIES PROVIDED BY LAW IS LIMITED TO REPAIR OR REPLACEMENT AT THE FACTORY OF SELLER ANY COMPONENT WHICH SHALL WITHIN THE APPLICABLE WARRANTY PERIOD DEFINED HEREIN AND UPON PRIOR WRITTEN APPROVAL BE RETURNED TO SELLER WITH TRANSPORTATION CHARGES PREPAID AND WHICH THE EXAMINATION OF SELLER SHALL DISCLOSE TO HAVE BEEN DEFECTIVE EXCEPT THAT WHEN THE PRODUCT IS TO BE USED BY BUYER AS A COMPONENT PART OF EQUIPMENT MANUFACTURED BY BUYER BUYER S REMEDY FOR BREACH AS LIMITED HEREIN SHALL BE LIMITED TO ONE YEAR FROM DATE OF SHIPMENT FROM SELLER FOR GAS FIRED PRODUCTS INSTALLED IN HIGH HUMIDITY APPLICATIONS AND UTILIZING STAINLESS STEEL HEAT EXCHANGERS BUYER S REMEDY FOR BREACH AS LIMITED HEREIN SHALL BE LIMITED TO TEN YEARS FROM DATE OF SHIPMENT FROM SELLER These warranties are issued only to the original owner user and cannot be transferred or assigned No provision is made in t
50. pronickel 14 Hydronic Load Coaxial Coil Material HM X None 15 Hot Water Generator or Desuperheater HWG 0 None 1 HWG with Factory Installed Pump 16 Motor Type MT E ECM 17 Supply Air Configuration SA 18 Return Air Configuration RA L Left R Right WARRANTY TERM 1 1 Years Parts Commercial 2 10 Years Parts 5 Years Labor Residential 3 10 Years Parts 10 Years Labor Extended Residential Serial Number S 0 40 20 1 SPO MODEL STACKED UNIT 0 Standard 1 Stacked BLOWER SUPPLIER 20 Morrison 00 None MOTOR SUPPLIER 40 AO Smith 51 Genteq 00 None COMPRESSOR 1 Copeland YEAR OF SPO MANUFACTURE NUMBER 11 14 1234 12345 SEQUENTIAL NUMBER Number varies from 0000 to 9999 Each unit within the same week of manufacture is to have unique number WEEK OF MANUFACTURE GEO16 500 3 UNIT DIMENSIONS Figure 4 1 Dimensional Drawings Vertical Top Discharge AUXILIARY HEAT POWER 268 UNIT POWER PUMP POWER FRONT VIEW GEO SOURCE OUT DHW OUT CONDENSATE DRAIN GEO SOURCE IN Table 4 1 Dimensions inches Vertical Top Discharge 48 50 48 50 53 20 54 61 61 14 61 14 25 65 25 65 25 65 25 65 25 65 25 65 27 79 27 79 31 14 32 62 32 62 32 62 42 60 42 60 47 20 48 66
51. relays are 24VAC and can be verified using a voltmeter The fan flow center and DHW pump are powered through 240V relays Operation can be verified using a voltmeter or clamp on ammeter 5 After completing these checks refer to the troubleshooting tables on the next pages GEO16 500 3 25 TROUBLESHOOTING Table 26 1 Troubleshooting No power to unit Compressor not operating 26 Possible Cause Power Failure No voltage at line side of compressor contactor Action Check disconnect switch and power distribution panel Open disconnect switch At heat pump disconnect voltmeter shows voltage on the line side but not on the load side Determine why the disconnect switch was opened Close disconnect if safe to do so Blown fuse circuit breaker tripped Check fuses and circuit breaker Reset circuit breaker or replace fuses with proper size and type Verify total load on system and proper fuse circuit breaker sizing Low supply voltage Thermostat position Voltmeter shows abnormally low voltage at heat pump disconnect switch below 9596 of serial plate voltage Verify that thermostat is in heating or cooling position Call power company Test operation of thermostat Defective thermostat Verify operation of thermostat verify thermostat signals at unit Replace if defective Thermostat wiring Verify thermostat wiring at unit and signals at unit Repair wi
52. ressor Wiring and controls Reduced water flow Examine all wiring points Check flow center operation Manually open water valve and measure water flow Tighten all wiring points Troubleshoot flow center Adjust to proper flow rate Plugged water strainer or filter Replace or clean if dirty Scaled or plugged coaxial coil Check temperature drop across coaxial coil Clean if necessary Water supply too cold Verify GEO IN with temperature probe Verify loop sizing verify that all air has been purged from ground heat exchanger bring water temperature within design parameters Entering air too cold Measure return air should be above 60 F Bring return air temperature within design parameters Reduced air flow Verify blower operation Troubleshoot blower operation Check air filter Replace or clean if dirty Check for airflow restrictions in ducting system Address any ductwork airflow restrictions Check external static Check external static against blower table Low refrigerant charge Check for refrigerant leaks If leaks found evacuate repair and recharge to factory recommended charge Plugged bi flow filter drier Verify that low pressure cut out occurs in heating mode and not in cooling mode Replace filter if necessary Restricted TXV Verify superheat and subcooling values Replace if necessary Def
53. ring if needed Transformer Check primary and secondary transformer voltages If no primary verify wiring If no or low secondary check transformer wiring If wiring ok replace transformer Check transformer secondary voltage circuit breaker Reset breaker if tripped Power wiring defect Check for loose or broken wires at compressor contactor and capacitor Repair wiring if needed Locked out on safety controls Check for fault Address lockout and cycle power to unit to reset controller Defective compressor overload Ensure that compressor is cool and overload has had sufficient time to reset Ohmmeter shows a resistance across R amp S terminals and OPEN or infinite resistance between C amp R or C amp S terminals If windings are open or overload is faulty replace compressor Compressor motor burn out or open windings Ohmmeter shows no resistance or OPEN between common and run terminals NOTE Make sure the compressor is rested Troubleshoot cause and replace motor Defective compressor contactor Voltage on line side and contactor pulled in but no voltage on one or both terminals on the load side Points damaged Replace contactor Voltage on line side 24VAC across contactor coil and no voltage on load side Bad coil replace contactor Loss of compressor run signal Voltage on line side of contactor verified and contactor won t pull in No
54. s breakers and wire sizes Trace circuits to insure that the unit has been wired according to the wiring diagram Check that the unit has no visible damage and that all the components are secure Check that all field electrical and mechanical work has been performed according to all applicable Federal State and Local codes Check the supply voltage to the unit is within 596 of the voltage on the unit serial plate Low voltage wiring for thermostat control wiring and the freeze protection setpoint completed Transformer wiring is correct Water supply to heat pump is completed Piping completed water system cleaned and flushed of debris Air and debris are purged from a ground loop Antifreeze added to ground loop as required Isolation valves are open water control valves or loop pumps wired DHW piping is complete all air purged from system and charged with water IMPORTANT Ensure all valves in the DHW circuit are fully open and pump is wired correctly Condensate line is open condensate drain line is correctly pitched Blower rotates freely Check air coil for cleanliness Filter is clean and in position Clean all debris from the ducting system Service access panels are in place Entering air and water temperatures are within operating limits in Table 19 1 GEO16 500 3 A CAUTION Verify that ALL water control valves are open and allow water flow pr
55. ssary Non condensables in system Verify superheat and subcooling values GEO16 500 3 Evacuate and recharge to factory recommended charge 27 TROUBLESHOOTING Table 28 1 Troubleshooting Unit will not operate in cooling mode Insufficient cooling or heating Condensate overflow Auxiliary heater is always ON Noisy unit 28 Possible Cause Loss of control signal In cooling mode verify 24VAC at RV coil and at REV terminals Action If 24VAC exists troubleshoot RV and coil If no contrrol signal troubleshoot thermostat signals Defective reversing valve Verify operation of reversing valve and solenoid coil Replace if defective When it is necessary to replace the reversing valve wrap it with a wet cloth and direct the heat away Excessive heat can damage the valve Thermostat setup wiring Verify thermostat setup and wiring Repair wiring if needed Thermostat operation Verify proper thermostat signals to unit Replace if necessary No water flow high pressure cutout Dirty Air Filter Check flow with flow meter Check air filter Check pump operation Replace or clean if dirty Unit undersized Verify load calculations and unit selection If excessive it may possible to rectify with shading and insulation Thermostat location Check to see if thermostat is installed near a supply air grill Reloca
56. stem Take extra precautions to protect the unit from damage or contamination when in an area where spraying plastering and or painting has not been completed Physical damage or contamination from foreign debris may prevent proper start up and costly equipment clean up Examine all fittings valves or pipes and remove all dirt or debris before installing unit Preparation 1 Before installation ensure that the correct electrical power supplies are available for the unit 2 Each unit requires an independently fused and isolated power supply 3 Check to make sure that the units will have adequate installation clearance for easy access to remove all panels and access all internal components Provide ample area to access external components in and around the unit and System including water valves fittings and all electrical connections 4 Remove any Accessory Kits and shipping support material from the mechanical and fan blower compartments 5 Check Refrigerant Piping for dents or kinks 6 Inspect all electrical connections Connections must be clean and tight at the terminal Electrical Electrical wiring should be done in accordance with all applicable national and local codes It is the responsibility of the electrical contractor to adhere to such codes The warranty will be voided if wiring is not in accordance with the specifications of the unit Modine recommends using copper conductors only All power supply wir
57. t Installation Vertical units are available in top or bottom discharge with left or right hand return air configurations 1 Top discharge units should be mounted on a vibration absorbing pad slightly larger than the base of the unit See Table 9 1 below for Modine vibration pad part numbers If the unit isn t mounted on a vibration absorbing pad it must be raised off the floor to prevent damage due to accidental flooding It is not necessary to anchor the unit to the floor Table 9 1 Vibration Absorbing Pads High Density Plastic PadSize 5H0835220000 018 036 5H0835230000 048 066 2 Bottom discharge units should be mounted level and sealed well to the floor to prevent air leakage Bottom discharge units require the supply air opening to be cut at least 1 2 larger than the unit s air outlet Protect the edges of combustible flooring with sheet metal or other non combustible materials 3 Check to ensure that the unit is level in both directions and also plumb If adjustment is necessary Modine recommends the placement of metal shims in the outermost corners of the base 4 Provide adequate clearance for all access panels 5 Provide easy access for air filter replacement drain pan cleaning fan and fan motor maintenance and for servicing water valves fittings compressor and air coil 6 Provide access to the controller and all electrical connections 7 Do not block air filter access wit
58. t at the lowest possible torque Coaxial Coil Maintenance Ground Water Applications If the system is installed in an area with a known high mineral content 125 P P M or greater best practice is to establish a periodic maintenance schedule with the owner so the coil can be checked on a regular basis Should periodic coil cleaning be necessary use coil cleaning procedures that are compatible with the heat exchanger material and copper water lines Generally with greater the water flow rates the likelihood of scaling reduces Therefore the recommended minimum water flow is 1 5 gpm per ton Recommended minimum flow rate for entering water temperatures below 50 F is 2 0 gpm per ton Keep all air out of the water An open loop system should be checked to ensure that the well head is not allowing air to infiltrate the water line Lines should always be airtight Keep the system under pressure at all times It is recommended in open loop systems that the water control valve be placed in the discharge line to prevent loss of pressure during off cycles Closed loop systems must have positive static pressure Coaxial Coil Maintenance Ground Loop Applications Generally coaxial coil maintenance is not needed for closed loop systems However if the piping is known to have high dirt or debris content best practice is to establish a periodic maintenance schedule with the owner so the coil can be checked on a regular basis Dirty installa
59. te if necessary Defective lreversing valve Verify operation of reversing valve and solenoid coil Defective reversing valve creating bypass of refrigerant from discharge to suction side of compressor Replace if defective When it is necessary to replace the reversing valve wrap it with a wet cloth and direct the heat away Excessive heat can damage the valve Reduced or no air flow in heating Verify blower operation Troubleshoot blower operation Check air filter Replace or clean if dirty Check for airflow restrictions in ducting system Address any ductwork airflow restrictions Check external static Check external static against blower table Reduced air flow in cooling Verify blower operation Troubleshoot blower operation Check air filter Replace or clean if dirty Check for airflow restrictions in ducting system Address any ductwork airflow restrictions Check external static Check external static against blower table Duct losses Check supply and return air temperatures at heat pump and at furthest registers If difference is significant duct losses are occuring Repair duct losses Ambient losses Check for losses gains due to ambient air infiltration through doors and windows Address issue Low refrigerant charge Check superheat and subcooling values Check for refrigerant leaks If leaks found evacuate repair an
60. tions are typically the result of deterioration of iron or galvanized piping or components in the system Open cooling towers requiring heavy chemical treatment and mineral buildup through water use can also contribute to higher maintenance Should periodic coil cleaning be necessary use standard coil cleaning procedures that are compatible with the heat exchanger material and copper water lines Generally with greater the water flow rates the likelihood of scaling reduces However flow rates over 3 gpm per ton can produce water or debris velocities that can erode the heat exchanger wall and ultimately produce leaks Desuperheater Coils If potable water is hard or not chemically softened the high temperature of the desuperheater can lead to scaling This results in more scheduled maintenance A buffer tank may be installed to help prevent scaling Extreme hard water conditions should not use the desuperheater option Should periodic coil cleaning be necessary use coil cleaning procedures that are compatible with the heat exchanger material and copper water lines Air Filters Filters must be clean to obtain maximum performance They should be inspected monthly under normal operating conditions and be replaced when necessary Units should never be operated without a filter Condensate Drain In areas where airborne bacteria produce slime in the drain pan it may be necessary to treat chemically with an algaecide approximately ev
61. urn air configurations 1 Horizontal units may be installed on any level surface that is capable of supporting the weight of the unit s 2 Horizontal units are typically installed above false ceilings and are normally suspended from a ceiling by 3 8 diameter thread rod see Figure 9 2 Rods are usually attached to units by hanger brackets furnished with each unit Accessory bracket kits to allow for horizontal suspension of units are available from Modine model sizes 018 036 use part number 3H0388190001 and model sizes 042 066 use 3H0388190002 Figure 9 2 Horizontal Hanger Kit 3 8 DIA THREADED ROD SUPPLIED BY OTHERS 1 4 20 X 1 SM SCREW SUPPLIED IN KIT RUBBER ISOLATOR SUPPLIED IN KIT m d MOUNTING BRACKET SUPPLIED IN KIT WASHER SUPPLIED IN KIT 3 8 DOUBLE HEX NUT SUPPLIED BY OTHERS 3 Pitch the unit toward the drain connection as shown in Figure 9 3 Figure 9 3 Horizontal Pitch for Condensate Drain Water and drain connections Pitch E 3 4 drain connection GEO16 500 3 9 INSTALLATION 4 Provide adequate clearance for all access panels 5 Provide easy access for air filter replacement drain pan cleaning fan and fan motor maintenance and for servicing hanger hardware water valves fittings compressor and air coil 6 Provide access to the controller and all electrical connections 7 Do not block air filter access with piping conduit or other
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