Boreal W-Series Manual

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

Page 2Boreal Geothermal Inc. 02 JULY 2009
SAFETY PRECAUTIONS
WARNING: Ensure all access panels are in place and properly secured before applying power to the unit.
Failure to do so may cause risk of electrical shock.
WARNING: Before performing service or maintenance on the heat pump system, ensure all power sources
are DISCONNECTED. Electrical shock can cause serious personal injury or death.
WARNING: Heat pump systems contain refrigerant under high pressure and as such can be hazardous to
work on. Only qualified service personnel should install, repair, or service the heat pump.
CAUTION: Safety glasses and work gloves should be worn at all times whenever a heat pump is serviced. A
fire extinguisher and proper ventilation should be present whenever brazing is performed.
CAUTION: Venting refrigerant to atmosphere is illegal. A proper refrigerant recovery system must be
employed whenever repairs require removal of refrigerant from the heat pump.
! !
Series:
W = Liquid to water (Hydronic)
MODEL NOMENCLATURE
Nominal Size:
25 = 2 Ton
45 = 3 Ton
55 = 4 Ton
65 = 5 Ton
75 = 6 Ton
Functions:
H = Heating
AC = Active Cooling
W = Domestic Hot Water
Refrigerant:
P = R410a
Voltage Code:
1 = 230-1-60 VAC
2 = 208-3-60 VAC
4 = 460-3-60 VAC
5 = 575-3-60 VAC
6 = 220-1-50 VAC
7 = 380-3-50 VAC
Compressor Stages*:
S = 1 Stage
T = 2 Stage
* 2 stage unless unavailable
due to voltage code, refer to
the Electrical Tables.
Outdoor Loop Exchanger:
C = Copper
Z = Cupro-Nickel (CuNi)
Indoor Loop Exchanger:
C = Copper
Z = Cupro-Nickel (CuNi)
Revision:
01, 02 etc.
W—65—HACW—P—1T—CC—xx

02 JULY 2009 Page 3 Boreal Geothermal Inc.
APPLICATION TABLE (continued)
SIZE FUNCTION REFRIGERANT VOLTAGE STAGES OUTDOOR COIL REVISIONSINDOOR COIL
25
HAC
P
1 T
C or Z
04
C or Z
2 S 04
4 S 04
6 S 04
7 S 04
HACW
1 T 04
2 S 04
4 S 04
6 S 04
7 S 04
45
HAC
P
1 T
C or Z
04
C or Z
2 T 04
4 T 04
5 S 04
6 S 04
7 T 04
HACW
1 T 04
2 T 04
4 T 04
5 S 04
6 S 04
7 T 04
55
HAC
P
1 T
C or Z
04
C or Z
2 T 04
4 T 04
5 T 04
6 S 04
7 T 04
HACW
1 T 04
2 T 04
4 T 04
5 T 04
6 S 04
7 T 04
65
HAC
P
1 T
C or Z
04
C or Z
2 T 04
4 T 04
5 T 04
6 S 04
7 T 04
HACW
1 T 04
2 T 04
4 T 04
5 T 04
6 S 04
7 T 04
75
HAC
P
1 T
C or Z
04
C or Z
2 S 04
4 S 04
5 S 04
6 S 04
7 S 04
HACW
1 T 04
2 S 04
4 S 04
5 S 04
6 S 04
7 S 04
This manual applies only to the models and revisions listed in this table

Page 4Boreal Geothermal Inc. 02 JULY 2009
INSTALLATION INFORMATION: ……………………...……….……………………………………………………………… PAGE 6
Unit description: …………………………………………………………………………………………………..…... Page 6
Unpacking the unit: …………………………………………………………………………………………………... Page 6
Optimum Placement: …………………………………………………………………………………………………. Page 6
Electrical Provisions: ………………………………………………………………………………………………… Page 6
Circulator Pump Module Wiring (Ground Loop Only): …………………………………………………………. Page 6
Indoor Loop Circulator Wiring: …………………………………………………………………………………….. Page 6
Control Requirements: ……………………………………………………………………………………………..... Page 6
Control Transformer : ……..…………………...……………………….…………………………………………… Page 7
Safety Controls: ………………………………………………………………………………………………………. Page 7
Domestic Hot Water Connections (HW and HACW only): …………..………………………………………… Page 8
SIZING AND HYDRONIC INFORMATION: ………….………………………………………………………………………… PAGE 12
Heat Pump Sizing: …………………………………….………………………………………………………………. Page 12
Hydronic Applications General: ………………...…………………………………………………………………. Page 12
GROUND WATER SYSTEM INFORMATION: ………………………………………………………………………………… PAGE 15
General Requirements: …………………….………………………………………………………………………… Page 15
Plumbing the Heat Pump: ……………………………………………………………………………………………. Page 15
Pipe Insulation: ………………………………………………………………………………………………………… Page 15
Water Discharge Methods: …………………………………………………………………………………………… Page 15
GROUND LOOP SYSTEM INFORMATION: ………………………………………………………………………………….. PAGE 18
Circulator Pump Module: ……………………………………………………………………………………………. Page 18
Flushing & Purging the Ground Loop: ……………………………………………………………………………. Page 18
Adding Antifreeze Solution: ………………………………………………………………………………………… Page 19
Initial Pressurization: ………………………………………………………………………………………………… Page 19
Pipe Insulation: ……………………………………………………………………………………………………….. Page 19
STARTUP PROCEDURE: ………………………………………………………………………………………………………. Page 21
Pre-start Inspection: …………………………………………………………………………………………………. Page 21
Unit Startup: …………..………………………………………………………………………………………………. Page 22
Startup Record: ……………….………………………………………………………………………………………. Page 23
GENERAL MAINTENANCE: ……………...…………………….……………………………………………………………… PAGE 24
TROUBLESHOOTING GUIDE: ………………………………….……………………………………………………………… PAGE 25
Repair Procedures: …………………………………………………………………………………………………… Page 32
Refrigeration Circuit Diagrams: ……………………………………………………………………………………. Page 33
MODEL SPECIFIC INFORMATION: ……………………..….…………………………………………………………………. PAGE 35
Refrigerant Charge Chart: …………………………………………………………………………………………… Page 35
Standard Capacity Ratings: …………………………………………………………………………………………. Page 35
Capacity Ratings: ………………………………….…………………………………………………………………. Page 37
Electrical Tables: ……………………………………………………………………………………………………… Page 42
Electrical Diagrams (230-1-60): ………..…………………………………………………………………………… Page 43
Case Details: ………………………...………………………………………………………………………………… Page 45
APPENDIX A: Control Board Specifications: ……………………………………………………………………………… PAGE 46
APPENDIX B: Installation Example: …………………………………………………………………………………………. PAGE 47
WARRANTY INFORMATION: ………………………………………………………………………………………………….. PAGE 52
Table of Contents

02 JULY 2009 Page 5 Boreal Geothermal Inc.
Tables, Diagrams and Drawings
TABLES
Table 1 - Control Signal Description: …….………………………………………………………………..…….... Page 6
Table 2 - Typical Aquastat Settings: ……………….……………………………………………………………... Page 7
Table 3 - Control Board Fault Codes: ……..……………………………………………………………………... Page 8
Table 4 - Heat Pump Size vs. Heated Area for Ground Loop Systems: …..………………………………... Page 12
Table 5 - Heat Pump Size vs. Heated Area for Ground Water Systems: ….………………………………... Page 12
Table 6 - Required Flow and Air Tank Sizing: …..……………………………………………….……………... Page 15
Table 7 - Antifreeze Percentages by Volume: ………………………………..………………………….……... Page 19
Table 8 - Volume of Fluid per 100ft. Of Pipe: …..………………………………….…………………….….…... Page 19
Table 9 - Refrigerant Charge Chart: …..………………………..………………….….………………………... Page 35
Table 10 - Standard Capacity Ratings - Ground Loop Heating 60Hz: ………….………………………..…... Page 35
Table 11 - Standard Capacity Ratings - Ground Water Heating 60Hz: ……………………………………... Page 35
Table 12 - Standard Capacity Ratings - Ground Loop Cooling 60Hz: …...………………………….….…... Page 36
Table 13 - Standard Capacity Ratings - Ground Water Cooling 60Hz: …..……....…….…………………... Page 36
Table 14 - Heat Pump Electrical Information (230-1-60): …..…………………….……………………….…... Page 42
Table 15 - Heat Pump Electrical Information (208-3-60): …..…………………….……………………….…... Page 42
Table 16 - Heat Pump Electrical Information (460-1-60): …..…………………….……………………….…... Page 42
Table 17 - Heat Pump Electrical Information (575-3-60): …..…………………….……………………….…... Page 42
Table 18 - Heat Pump Electrical Information (220-1-50): …..…………………….……………………….…... Page 42
Table 19 - Heat Pump Electrical Information (380-3-50): …..…………………….……………………….…... Page 42
DIAGRAMS
Diagram A - Typical P/T (Pete’s) Plug & Thermometer Stem: …….……………………….…………..…….. Page 18
Diagram B - Typical Purge Cart: …………………………………………………………………………………… Page 18
Case Details: ……………………..…………………….………………………………………………………….….. Page 45
DRAWINGS
000575CDG - Typical Two-Stage Hydronic Heating Only Control and Zone Wiring: ….…………...…….. Page 9
000576CDG - Typical Two-Stage Hydronic Heating & Cooling Control and Zone Wiring: ….….……….. Page 10
000484PDG - Single Unit Connection to DHW Pre-Heat Tank: ……………………………………………….. Page 11
000533PDG - Typical Piping Configuration - Four Port Tank: …………………..……………………………. Page 13
000530PDG - Typical Zone Types for Hydronic Applications: …..……………..……………………………. Page 14
000529CDG - Typical Ground Water Installation for Size 25-75 Heat Pumps: …………………………….. Page 16
000619INF - Ground Water Disposal Methods: ………………………………………………………………… Page 17
000610CDG - Geo-Flo Circulator Pump Module Installation: ………………………………………………… Page 20
000210RCD - W-Series (25-75) Refrigeration Circuit Diagram—Heating Mode: …….………………….… Page 33
000211RCD - W-Series (25-75) Refrigeration Circuit Diagram—Cooling Mode: …….………………….… Page 34
000683SCH - W-**-HAC*-*-1T-** Schematic Diagram: …………………..………...…………..…………..…… Page 43
000684ELB - W-**-HAC*-*-1T-** Electrical Box Diagram: ……………………...……..………………..……… Page 44

Page 6Boreal Geothermal Inc. 02 JULY 2009
UNIT DESCRIPTION
The W-Series unit is a high efficiency two-stage geother-
mal heat pump with R410a refrigerant. Two-stage units offer a
significant efficiency increase over single stage units when oper-
ating in the reduced capacity mode (stage 1).
The unit has several key features that are described in the
specifications document for the particular heat pump. Please
request a copy if desired or visit www.boreal-geothermal.com
UNPACKING THE UNIT
When the heat pump reaches its destination it should be
unpacked to determine if any damage has occurred during
shipment. Any visible damage should be noted on the carrier's
freight bill and a suitable claim filed at once.
The heat pump is well constructed and every effort has been
made to ensure that it will arrive intact, however it is in the
customer's best interest to examine the unit thoroughly when it
arrives.
OPTIMUM PLACEMENT
The placement of a hydronic unit has negligible effects on
the operation of the system. For ground water systems, the unit
can be placed near the well water system, ground loop system
units can be place near where the header pipes enter the struc-
ture to keep the ground loop piping, heat pump and circulator
pump module in one location. The hydronic layout may make a
particular location ideal for the unit installation.
If possible the access panels should remain clear of
obstruction for a distance of two feet to facilitate servicing and
general maintenance. DO NOT STACK UNITS ON TOP OF
EACH OTHER. The cases are not designed to hold the weight
of another unit. Stacking should only be done with a proper rack
system able to hold a minimum of 2x the weight of the unit.
Raising the heat pump off the floor a few inches is
generally a good practice since this will prevent unnecessary
rusting of the bottom panel of the unit. We recommend that the
heat pump be placed on a piece of 2'' Styrofoam covered with
1/4'' plywood. The Styrofoam will smooth out any irregularities in
the cement floor while the plywood will distribute the weight of
the unit evenly over the Styrofoam. This process will also
deaden the compressor noise emitted from the bottom of the
cabinet.
ELECTRICAL PROVISIONS
The heat pump has a concentric 1.093” / 0.875” knockout
for power supply connection to the electrical box. There are
also two other 0.875” knockouts: one for connections to the in-
door circulator; the other for connections to the circulator pump
module for ground loop applications. There are three 1/2” open-
ings with plastic grommets (grommet hole is 3/8”) in the upper
section of the electrical box for connections to the controls.
A schematic diagram and electrical box layout diagram
(ELB) can be found inside the electrical box cover of the unit as
well as in the Model Specific section of this manual. The Electri-
cal Tables in the Model Specific section and the ELB diagram
contain information about the size of wire for the connections, as
well as the recommended breaker size.
A properly qualified electrician should be retained to
make the connections to the heat pump and associated
controls. The connections to the heat pump MUST CON-
FORM TO LOCAL CODES.
CIRCULATOR PUMP MODULE WIRING
(GROUND LOOP ONLY)
The heat pump has provisions for connecting the circulator
pump module so that the pumps will be turned on whenever the
compressor operates. Connect the circulator pump module to
the appropriate two terminals of the terminal strip marked
OUTDOOR - INDOOR CIRCULATORS in the heat pump, as
per the voltage of the circulator pump module. Ensure that the
total current draw of all circulators connected to the terminal
strip does not exceed the value indicated on the label in the heat
pump electrical box. Refer to the electrical box drawing on the
electrical box cover for more information.
INDOOR LOOP CIRCULATOR WIRING
The Indoor Loop circulator provides flow between the heat
pump and the buffer tank. The heat pump has provisions for
connecting the Indoor Circulator so that it will be turned on
whenever the compressor operates. Connect the Indoor Loop
circulator to the appropriate two terminals of the terminal strip
marked OUTDOOR - INDOOR CIRCULATORS in the heat
pump, as per the voltage of the circulator pump module. Ensure
that the total current draw of all pumps connected to the terminal
strip does not exceed the value indicated on the label in the heat
pump electrical box. Refer to the electrical box drawing on the
electrical box cover for more information.
CONTROL REQUIREMENTS
The heat pump requires a two-stage heating (and two
stage cooling for reversing units) control system for proper op-
eration. The stages are S1 = Stage 1 compressor, and S2 =
Stage 2 compressor.
Two-stage aquastats can be purchased with the unit, or
other system controllers with dry contacts may be used. This
manual covers operation of the heat pump with aquastats.
The electrical box diagram on the electrical box cover pro-
vides a description of the signal connections in the heat pump.
They are also listed in TABLE 1 below.
NOTE: Some models are not available in two-stage at the pre-
sent time (see Electrical Tables). The Y2 signal is not used for
these units.
The aquastat(s) can be placed anywhere within the range
of the probe cable. The probe(s) should be inserted into a dry
well in or near the top of the tank for optimal operation (refer to
drawing 000533PDG) . If a dry well is not available, it may be
possible to fix the probe to the tank inside the insulation.
TABLE 1 - Control Signal Description
Signal Description
C 24VAC Common (Ground)
R 24VAC Hot
Y1Heat Pump Stage 1
O Cooling Mode (reversing valve)
Y2Heat Pump Stage 2 (if applicable to unit)
Installation Information

02 JULY 2009 Page 7 Boreal Geothermal Inc.
The aquastat connections and system wiring differ for
heating only and heating/cooling systems. Heating only sys-
tems only require one aquastat, while heating/cooling system
require two, one for heating and one for cooling. Heating/
cooling systems require extra relays to provide an isolated cool-
ing signal to the heat pump and to disable radiant in-floor heat-
ing zones while in cooling mode. Drawing 000575CDG show a
typical wiring diagram for a heating only setup, while drawing
000576CDG depicts a heating/ cooling wiring diagram. These
drawings represent a basic system, in which heating is the de-
fault mode and cooling has priority. It is recommended that the
system be designed by a qualified system designer to ensure
proper functionality.
TABLE 2 shows typical settings for the aquastats. With
these settings, Stage 1 will activate when the tank temperature
reaches the activation point. If the load is too great, the tank
temperature will continue to drop when heating (rise when cool-
ing) until Stage 2 is activated. As the tank temperature stops
dropping and begins to increase when heating (decrease when
cooling) , Stage 2 will turn off before Stage 1, rather than at the
same time as Stage 1. There are three main advantages to this:
 Less aquastat probe lag leading to reduced overshoot as the
tank temperature rate of change is reduced when only
Stage 1 is active.
 Prolonged Stage 1 runtime leads to increased overall effi-
ciency as Stage 1 has a higher COP than Stage 2.
 Reduced number of compressor starts.
The settings may be changed as desired; however Stage 1
setpoint for heating should not exceed 120°F (49°C); Stage 1
cooling setpoint should not be set below 43°F (6°C). Exceeding
these setpoint limits will cause the heat pump operating pres-
sures to approach the safety control settings, possibly causing
nuisance shut downs.
NOTE:If only floor zones are being heated, it is highly rec-
ommended to drop each of the heating setpoints by 15°F
(8°C) for increased efficiency.
It is recommended that a buffer tank with electric elements
be selected to provide auxiliary / backup heat. The tank ele-
ment thermostat can be set to maximum, allowing the electric
elements to be controlled by an external contactor placed in the
power supply connections. The contactor can be connected to
Stage 2 of the heating aquastat via a 0-2hour timer. Refer to
drawing 000575CDG or drawing 000576CDG.
CONTROL TRANSFORMER
The low voltage controls for all model voltage codes ex-
cept code 5 (575-3-60) are powered by a 75VA class II trans-
former. The transformer has a resettable breaker on the secon-
dary side for circuit protection. Should the breaker trip, locate
and correct the problem and then reset the breaker by pressing
in on it. 575-3-60 units have a 100VA transformer with primary
and secondary fuses for circuit protection.
SAFETY CONTROLS
The heat pump has two built in safety controls which are
designed to protect the unit from situations which could damage
it should the operation of the refrigeration circuit fall outside the
allowable operating range.
A. Low Pressure Control
The low pressure control monitors the compressor suction
pressure and will shut the compressor down if the refrigerant
evaporating pressure becomes too low, risking the danger of
freezing conditions in the evaporator.
There are (3) main reasons why this control would activate
in response to the operating conditions of the unit while operat-
ing in heating mode:
1. Low or no outdoor loop flow.
2. Low Outdoor loop entering liquid temperature.
3. Dirty or fouled Outdoor loop heat exchanger.
B. High Pressure Control
The high pressure safety control monitors the compressor
discharge pressure and will shut the compressor down if the
condensing pressure becomes too high.
There are (3) main reasons why this control would activate
in response to the operating conditions of the unit while operat-
ing in heating mode:
1. Low or no Indoor loop flow.
2. High Indoor loop entering liquid temperature.
3. Dirty or fouled Indoor loop heat exchanger.
The unit contains a control board that monitors the safety
controls and operates the compressor accordingly. Refer to
APPENDIX A for control board specifications. The low pressure
control is connected to LP1 and LP2. The high pressure control
is connected to HP1 and HP2.
The control board also has provisions for a flow switch.
The flow switch is unused from the factory and a jumper wire is
placed across the FLOW SWITCH terminals. If a flow switch is
desired, the jumper can be removed and the two leads from the
flow switch can be connected to the FLOW SWITCH terminals
on the safety board. The flow switch is ignored for 30 seconds
on compressor startup to allow time for flow to be established.
The high and low pressure controls are monitored at all times,
the compressor will not be able to start if either of them has a
fault.
TABLE 2 - Typical Aquastat Settings
HEATING AQUASTAT
Stage 1 Stage 2
Item °F °C °F °C
Setpoint 115 46 105 41
Delta 5 3 5 3
Activation * 110 43 100 38
COOLING AQUASTAT
Stage 1 Stage 2
Item °F °C °F °C
Setpoint 45 7 50 10
Delta 5 3 5 3
Activation * 50 10 55 13
*Activation is indirectly set by the Setpoint and Delta
values

Page 8Boreal Geothermal Inc. 02 JULY 2009
The control board has an on-board LED and a FAULT
pin with a 24VAC output. An external indicator or relay can be
connected across the FAULT pin and ground if external signal-
ing is desired. Should a fault occur, the LED will flash the code
of the fault condition while the safety control in question is open
The codes are shown in TABLE 3. The control board will lock
out the compressor for five minutes when a fault occurs. Three
retries per fault condition are allowed within a 60 minute period.
If the fault condition occurs a fourth time the control board will
permanently lock out the compressor and energize the FAULT
pin. This can only be reset by powering down the unit. The
LED will flash the fault code until the unit is reset.
If the control board enters permanent lockout mode there
is a serious problem with the system and it must be rectified if
the unit is to maintain good service.
WARNING: REPEATED RESETS OF A LOW PRES-
SURE LOCKOUT COULD CAUSE THE HEAT EX-
CHANGER TO FREEZE AND RUPTURE, DESTROY-
ING THE HEAT PUMP AND VOIDING THE WAR-
RANTY.
DOMESTIC HOT WATER
CONNECTIONS (HW & HACW only)
A typical piping diagram for a pre-heat tank configuration
can be found in drawing 000484PDG at the end of this section.
Be sure to note the position of the check valve and the direction
of water flow. Other configurations are possible, and there may
be multiple units tied together in larger buildings.
WARNING: USE ONLY COPPER LINES TO
CONNECT THE DESUPERHEATER. TEMPERA-
TURES COULD REACH 200F SHOULD THE DHW
CUTOUT SWITCH FAIL, POTENTIALLY RUPTURING
PEX PIPING.
Ensure the tank is filled with water and under pressure
before activating the heat pump. Slightly loosen the boiler drain
on the DHW Out pipe to allow air to escape from the system
before the unit is started. This step will make certain that the
domestic hot water circulator in the unit is flooded with water
when it is started.
CAUTION: the domestic hot water pump is water lu-
bricated; damage will occur to the pump if it is run
dry for even a short period of time.
Connect the brown wire with the blue insulated terminal
to L1 of the compressor contactor (fuse terminal for 575-3-60
units). Ensure the power is off when connecting the wire.
The DHW loop may have to be purged of air several times
before good circulation is obtained. A temperature difference
between the DHW In and DHW Out can be felt by hand when
the circulator pump is operating properly.
For the pre-heat tank setup, the final tank should be set to
140°F(60°C), unless local code requires a higher setting. The
pre-heat tank does not require electric elements. This setup
takes full advantage of the desuperheater as it is the sole heat
provider to the pre-heat tank. The desuperheater remains active
during the compressor runtime until the pre-heat tank has been
completely heated by the desuperheater alone. This setup is
more energy efficient than a single tank setup.
CAUTION: If two (2) shut-off valves are located on the
domestic hot water ines as shown in the diagram, a
pressure relief valve must be installed to prevent possible
damage to the domestic hot water circulator pump should
both valves be closed.
TABLE 3 - Control Board Fault Codes
Fault Code
High Pressure 1
Low Pressure 2
Flow 3
!
!
!

02 JULY 2009 Page 9 Boreal Geothermal Inc.

Page 10Boreal Geothermal Inc. 02 JULY 2009

02 JULY 2009 Page 11 Boreal Geothermal Inc.

Page 12Boreal Geothermal Inc. 02 JULY 2009
Once the total heat loss has been calculated, the unit can
be sized using the performance tables (from the specifications
document) in conjunction with the minimum expected entering
liquid temperature of the ground loop (well water temperature for
ground water system). The heat pump output must be able to
match the total heat loss at the selected entering water tempera-
ture in order to provide a comfortable environment with minimal
auxiliary heat.
HYDRONIC SYSTEMS - GENERAL
Hydronic systems typically provide heat through two different
types of media:
 radiant in-floor heating
 forced air heating via fan coil units
One of the benefits of hydronic systems is the flexibility in
setting up the heating system. Whereas a typical forced air sys-
tem has one central thermostat controlling the entire heating
system, the home may be sectioned into several areas called
zones with a hydronic system. Each zone has its own thermo-
stat, allowing simple separate temperature control of the individ-
ual areas in the home.
There are other uses for hydronic systems, the two most com-
mon being on-demand domestic hot water and pool/spa heat-
ing. Drawing 000530PDG shows the most common types of
zones. A typical system consists of the heat pump, the buffer
tank and the zones. The heat pump’s sole purpose is to main-
tain the buffer tank set point. Its operation is independent of the
zone operation.
Drawing 000533PDG shows a typical piping configuration for
a single unit with a buffer tank. This is a guideline for a simple
installation. There are many other configurations, such as sepa-
rate heating and cooling buffer tanks, multiple units connected
to one buffer tank, etc. It is recommended that the hydronic
system be designed by a qualified system designer to ensure
proper functionality.
Fan coils can be used to provide heating and/or cooling for
areas that do not have radiant in-floor heating. They provide a
means of air heating/cooling with minimal or no ductwork. Note
that the buffer tank temperature should be set for 115°F (46°C)
if there are fan coils in the system.
Two port fan coils are recommended for connection to the
system if a single buffer tank is used for heating and cooling.
For systems with separate hot and cold buffer tanks, two port
fan coils are recommended for zones that provide only one func-
tion (heating or cooling), while four port fan coils are recom-
mended for zones that heat and cool. These are simply sugges-
tions, the fan coil selection will depend on the final system de-
sign.
It is recommended that all piping be insulated with 3/8” thick
closed cell pipe insulation. This is a MUST for any piping that is
used for cooling to prevent dripping onto floors and walls. Care
should be taking when wiring the system to ensure that radiant
in-floor heating zones are disabled whenever the heat pump is
switched to cooling mode.
HEAT PUMP SIZING
TABLE 4 depicts a rough guideline as to the size of home
each heat pump size can handle for ground loop installations.
TABLE 5 depicts a rough guideline as to the size of home
each heat pump size can handle for ground water installations.
THE TABLES ABOVE ARE FOR INFORMATION ONLY,
THEY SHOULD NOT BE USED TO SELECT A UNIT SIZE.
They simply show on average what size unit is required for a
typical two-level home (main level and below grade basement)
with R-20 walls, R-40 ceiling and average size and number of
windows. The Heated Area is the area of the main level, The
tables account for a basement the same size as the heated
area.
BOREAL GEOTHERMAL INC. HIGHLY RECOMMENDS
THAT A PROPER HEAT LOSS/GAIN ANALYSIS BE PER-
FORMEDE BY A PROFESSIONAL INSTALLER WITH CSA
APPROVED SOFTWARE BEFORE SELECTING THE SIZE OF
UNIT REQUIRED FOR THE APPLICATION. For heating
dominant areas, we recommend sizing the unit to 100% of
the heating design load for maximum long term efficiency
with minimal supplementary heat. The unit should be in-
stalled as per CSA 448.2-02. For ground loop applications,
the ground exchanger should be designed using suitable
software with a multi-year analysis.
There are many factors to consider when sizing the heat
pump. Some of these factors include the number of levels, the
size of the windows, the orientation of the home, attached ga-
rage, bonus rooms, walk-in basement, coldest outdoor tempera-
ture, etc. The heat loss program will take all of these factors
into consideration in its calculations. An undersized installation
will require not be as efficient and will required expensive sup-
plemental heat to maintain a comfortable temperature in the
home, and the cost savings of having a geothermal heat pump
are greatly reduced.
TABLE 4 - Heat Pump Size vs. Heated Area
for a Ground Loop System
Model Size (tons) Sq.ft. Sq.m.
25 2 800 75
45 3 1,400 130
55 4 2,000 185
65 5 2,600 240
75 6 3,100 290
TABLE 5 - Heat Pump Size vs. Heated Area
for a Ground Water System
Model Size (tons) Sq.ft. Sq.m.
25 2 1,000 95
45 3 1,800 165
55 4 2,500 230
65 5 3,200 295
75 6 3,800 355
Sizing and Hydronic Information

02 JULY 2009 Page 13 Boreal Geothermal Inc.

Page 14Boreal Geothermal Inc. 02 JULY 2009

02 JULY 2009 Page 15 Boreal Geothermal Inc.
Ground Water System Information
Water flow to the heat pump can be controlled very
accurately by the installation of a reverse action refrigeration
pressure valve in the discharge line of the unit.
Another more common method of regulating the flow is by
the use of a DOLE Valve. This valve will automatically control
the amount of water flowing through it by varying the diameter of
a flexible rubber orifice through which the water passes. This
minimizes the water usage of the unit and also prevents a re-
versing unit from running excessively low discharge pressure
when in cooling mode. Dole valves can be noisy, it is recom-
mended that they be installed outside if possible.
Optionally a water flow meter can be installed in the dis-
charge line so that the exact amount of water flowing can be
determined at a glance. It should be placed between the Out-
door OUT (Supply OUT) pipe of the heat pump and the water
valve.
With proper flow, there should be 5-7°F (3-4°C) delta T
between the IN and OUT water temperatures of the heat pump
when operating in the heating mode.
All water line valves on both the supply and discharge lines
should be either BALL or GATE valves. GLOBE valves have a
higher pressure drop, meaning more pumping power to maintain
the required flow to the heat pump.
PIPE INSULATION
All ground water piping to and from the Outdoor Loop
ports on the heat pump should be insulated with 3/8” closed cell
pipe insulation, to prevent condensation and dripping onto floors
or walls.
WATER DISCHARGE METHODS
Water disposal methods vary from area to area. However,
some consideration should be made to prevent the cooled
discharge water from immediately coming in contact with the
supply source. Attempting to return the water to the source well
will eventually cool the water so much that the heat pump will
shut off on its low pressure safety control.
Acceptable methods for disposing of the waste water are
listed below. The waste water is clean, the heat pump has no
other effect than reducing the temperature of the water. Refer
to drawing 000619INF for typical disposal method diagrams.
 Second well (return well)
 Percolation (Drain, ditch, leaching field)
 Pond, river or stream.
ENSURE SELECTED METHOD CONFORMS TO LOCAL CODES.
GENERAL REQUIREMENTS
1. The temperature of the well water should be a minimum
of 39°F (4°C), and should normally be 45+°F (7°C)
2. The well system must be able to supply the required
water flow as listed under the Total Flow column in
TABLE 6.
PLUMBING THE HEAT PUMP
Plumbing lines, both supply and discharge, must be of
adequate size to handle the water flow necessary for the heat
pump. A 1” copper or plastic line should be run to the Outdoor
IN (Supply IN) pipe of the heat pump. Similarly, a 1”' line should
be run from the Outdoor OUT (Supply Out) pipe to the method
of disposal. P/T plugs should be installed at each port. See
Diagram A in the Ground Loop section for a description of P/T
plugs. The water valve should be installed in the discharge line.
Refer to drawing 000529CDG at the end of this section for
the recommended setup. Placing the water valve in the dis-
charge line ensures that the heat exchanger inside the heat
pump remains full of water when the unit is not running. Unions
or some other form of disconnect should be used so that the
coaxial heat exchanger may be accessed should it required
cleaning.
The heat pump has an electrical connector for the water
valve just inside the case. After the water valve is installed, run
the valve harness into the case through the hole provided. Re-
move the jumper plug from the Valve Connector and connect
the harness in its place.
Ideally there will be water flow available in excess of the
requirement of the heat pump. In such a situation the proper
pump can be selected to maintain a pressure of 30 to 40 psig.
on the lines when the heat pump is operating. However in some
cases a well can supply a heat pump only if the minimum
requirement for water is used.
TABLE 6 - Required Flow and Air Tank Sizing
Heat
Pump
Model
Size
Heat
Pump
Flow*
IGPM
(USGPM)
Home
Flow
IGPM
(USGPM)
Total
Flow
IGPM
(USGPM)
Minimum Air
Bladder
Tank**
IGal
(USgal)
25 6 (7.2) 3 (3.6) 9 (10.8) 18(22)
45 8 (9.6) 3 (3.6) 11(13.2) 22(26)
55 10 (12.0) 3 (3.6) 13(15.6) 26(31)
65 12 (14.4) 3 (3.6) 15(18.0) 30(36)
7514 (16.8) 3 (3.6) 17(20.4) 34(41)
* These are minimum water requirements based on an
entering water temperature of 46° F.
**Based on two-minute well pump run time. Use next size
larger tank if there is not a match for the value indicated.

Page 16Boreal Geothermal Inc. 02 JULY 2009
When snow comes it will usually cover the entire process
much like a small spring. It is recommended that the pipe be
below the frost line when possible for maximum freeze protec-
tion.
When discharging into a river or stream, or above the surface
of a pond, the same guidelines should be followed as described
in the paragraph above for the percolation method.
When discharging the waste water below the surface of a
pond, the discharge pipe should be placed below the frost line
to prevent the pipe from freezing. As opposed to the percola-
tion method, water will remain in the end of the pipe. It is rec-
ommended that the surface of the pond be lower than the instal-
lation location of the heat pump where practical. This reduces
the back pressure generated by the weight of the water in the
pond.
A return well should be a minimum of 80 ft. from the supply
well for residential applications. The water returned to the well
will not necessarily be pumped into the same aquifer, depend-
ing on underground conditions. The return must be able to sup-
ply at least the same quantity of water as the amount you wish
to recharge into it. If the static level (level when not being
pumped) of a well is high (10 to 20 ft. from the surface) it may
be necessary to place a well cap on the well to keep the return
water from flowing out the top of the well. This cap is commonly
required since a certain amount of pressure is needed to force
the return water back down the well if the static level is high.
Water discharged by percolation will generally soak into the
ground within a distance of 50 to 100 ft. If suitable care is taken
to ensure that the drain pipe runs downhill and the end of the
pipe is protected by a bale of hay or spruce bows etc. the end of
the pipe will not freeze as the pipe will empty out when the heat
pump shuts off and the water valve closes.

02 JULY 2009 Page 17 Boreal Geothermal Inc.
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Page 18Boreal Geothermal Inc. 02 JULY 2009
Once the ground loop has been pressure tested and the header
pipes have been connected to the circulator pump module, the
heat pump can be connected to the circulator pump module.
CIRCULATOR PUMP MODULE
Boreal Geothermal Inc. has compact pump modules with
built in three way valves to facilitate filling and purging the
ground loop. Refer to drawing 000610CDG at the end of this
section. Alternatively, Grundfoss® Model UPS 26-99 or Taco®
Model 0011 pumps or other brands with similar pumping
capability may be used. The single pump module will typically
handle systems up to 3 tons (model sizes 25 - 45); the two
pump module will typically handle 4 to 6 ton systems (model
sizes 55, 65, 75). This is based on a typical parallel system with
one circuit per ton.
Boreal Geothermal Inc. recommends calculating the total
pressure drop of the ground loop (including headers, indoor
piping and heat pump exchanger drop) based on the antifreeze
type and concentration at the desired minimum loop
temperature. A pump module that can deliver the flow required
for the unit at the calculated total pressure drop should be
selected. Refer to the Model Specific Information section for
unit flow requirements.
Loop pressure drops can be calculated using software such
as those mentioned in the Horizontal Ground loops section, or
can be calculated in a spreadsheet using the pipe
manufacturer’s pressure drop tables for pipe diameter and
fittings.
The circulator pump module must be connected to the heat
pump Outdoor Loop ports with a lineset suitable for the flow
required with minimum pressure drop. 1” rubber or plastic lines
should be used. The installation of P/T plugs (pressure /
temperature, pronounced “Pete’s plugs” ) is recommended on
both the entering and leaving lines at the heat pump (see
Diagram A).
The P/T plug will allow the installer or homeowner to check
water flow through the loop by measuring the pressure
difference through the heat exchanger and comparing it to that
listed in the Model Specific Information section, or the
specifications document. Optional fittings with P/T ports are
available for the circulator pump modules sold by Boreal
Geothermal Inc..
FLUSHING & PURGING THE GROUND
LOOP
Once the groundloop has been installed and all connections
are completed between the heat pump, circulator pump module
and ground loop, the entire ground loop system should be
pressure tested with air to 100 PSIG to make sure there are
no leaks on any of the inside fittings. Soap all joints and observe
that the pressure remains constant for 1 hour.
When satisfied that all connections are leak free, release the
air pressure and connect a purge cart (see Diagram B ) to the
flushing access ports at the pump module (refer to drawing
000610CDG).A temporary flushing system can alternately be
constructed using a 45 gal. barrel and a pump with sufficient
volume and head capability to circulate fluid at a velocity of at
least 2 ft./min. through all parts of the loop.
Adjust the circulator pump module valves to connect the
purge cart to the ground loop. Begin pumping water through the
ground loop, ensuring that the intake of the pump stays
submerged at all times by continuously adding water. Water
flowing back from the return line should be directed below the
water level in the barrel or flush tank to prevent air being mixed
with the outgoing water.
Ground Loop System Information
DIAGRAM A - Typical P/T –―Pete’s‖
Plug & Thermometer Stems
DIAGRAM B - Typical Purge Cart

02 JULY 2009 Page 19 Boreal Geothermal Inc.
Once the lines have been filled and no more air bubbles are
appearing in the line, adjust the circulator pump module valves
to circulate water through the heat pump using the same
technique as described above. When all air is removed reverse
the flow of water through the lines by interchanging the flush
cart lines and purge again. You will be able to visibly tell when
all air is removed.
ADDING ANTIFREEZE SOLUTION
In most mid and northern areas of the US and in all of
Canada it is necessary to condition the loop fluid by the addition
of some type of antifreeze solution so that it will not freeze
during operation in the winter months. This antifreeze is required
because the loop fluid will normally reach a low entering
temperature of 28°F to 32°F (-2°C to 0°C) and refrigerant
temperatures inside the heat pump’s heat exchanger may be as
low as 20°F (11°C) cooler. See TABLE 7 for details of freeze
protection provided by different concentrations.
NOTE: Add enough antifreeze to allow for a temperature
20°F (11°C) lower than the expected lowest loop fluid
temperature entering the heat pump.
Although many different antifreeze solutions have been
employed in geothermal systems, the alcohols such as
methanol or ethanol have the most desirable characteristics for
groundloop applications. The overall heat transfer
characteristics of these fluids remain high although care must be
taken when handling pure alcohols since they are extremely
flammable. Once mixed in a typical 25% by volume ratio with
water the solution is not flammable. In situations where alcohols
are not allowed as a loop fluid due to local regulations then
propylene glycol is a non-toxic alternative which can be
substituted . Propylene glycol should only be used in cases
where alcohols are not permitted since the heat transfer
characteristics are less desirable and it becomes more viscous
at low temperatures, increasing pumping power.
The volume of fluid that your loop system holds can be
closely estimated by totaling the number of ft. of each size pipe
in the system and referencing TABLE 8 the for approximate
volume per 100 ft.
When the volume of the loop has been calculated and the
appropriate amount of antifreeze is ready for addition by
referencing TABLE 7 , drain the equivalent amount of water
from the flush cart or mixing barrel and replace it with the
antifreeze.
When using alcohols, be sure to inject below the water
line to reduce initial volatility of the pure antifreeze. If the
loop is large it may be necessary to refill the tank with antifreeze
several times to get all the antifreeze into the loop. Pump the
loop for 5 to 10 minutes longer to ensure the remaining fluid has
been well mixed.
INITIAL PRESSURIZATION
At this point open all valves in the flow circuit and slowly close
off the supply and return flush cart valves in a manner that
leaves about 20-30 psig. on the system. If an air bladder
expansion tank is used it should be charged to the above
pressure before actual water pressure is put on the system .
Systems without an expansion tank will experience greater
fluctuations in pressure between the heating and cooling
seasons, causing pressure gauges to have different values as
the loop temperature changes. This fluctuation is normal since
expansion and contraction of the loop fluid must be handled by
the elasticity of the plastic loop.
 Pressurize the loop to a static pressure of 45 psig. when
installing a system in the fall going into the heating season.
 Pressurize the loop to a static pressure of 25 psig. when
installing a system in the spring or summer going into the
cooling season.
After operating the heat pump for a period of time, any
residual air in the system should be bled off and the static
pressure should be verified and adjusted if necessary. Add
additional water / antifreeze mix with the purge cart to bring the
pressure back to the original setting if required.
PIPE INSULATION
All ground loop piping inside the structure (between the
structure entry point and the heat pump) should be insulated
with 3/8” thick closed cell pipe insulation to prevent
condensation and dripping onto floors or walls.
TABLE 8 - Volume of fluid per 100 ft. of pipe
Volume /100ft.
Type of Pipe Diameter Igal USgal L
Copper 1” 3.4 4.1 15.5
1-1/4” 5.3 6.4 24.2
1-1/2” 7.7 9.2 34.8
Rubber Hose 1” 3.2 3.9 14.8
Polyethylene 3/4” IPS SDR11 2.3 2.8 10.6
1” IPS SDR11 3.7 4.5 17.0
1-1/4” IPS SDR11 6.7 8.0 30.3
1-1/2” IPS SDR11 9.1 10.9 41.3
2” IPS SDR11 15.0 18.0 68.1
Other Item Volumes
Heat Exchanger Average 1.2 1.5 5.7
Purge Cart Tank See cart manual TBD
TABLE 7 - Antifreeze Percentages
BY VOLUME
Protection to: 10°F 15°F 20°F 25°F
Methanol 25% 21% 16% 10%
Propylene Glycol 38% 30% 22% 15%
BY WEIGHT
Protection to: 10°F 15°F 20°F 25°F
Methanol 16.8% 13.6% 10% 6.3%
Propylene Glycol 30% 23.5% 18.3% 12.9%

Page 20Boreal Geothermal Inc. 02 JULY 2009
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