Econar GeoSource PumpPAK GPP 1S25-1-A User manual

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Installation
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Operating Instructions
GPP-1S25-1-A Thru
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TABLE OF CONTENTS
Title 1
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PumpPAKN Sizing I
PumpPAKltrInstallation " " " 1
SystemPurging ''""''2
SystemstartuP " "4
5
Additional Figures and Tables
Fill and Purge
Valves (2)
Quick Connect/Release
"Fireman" Ports (2)
Pumps
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1" FPT
Connections
Hose Kit
Package
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I. INTRODUCTION TO
ECONAR PumpPAKsrM
ECONAR Energy Systems, Corp. has been producing
geothermal heat pumps in Minnesota for over fifteen
years. The cold winter climate has driven the design of
ECONAR Energy System's heating and cooling
equipment to what is known as a "Cold Climate"
geothermal heat pump. This cold climate technology
focuses on maximizing the energy savings available in
heating dominated regions without sacrificing comfort.
Extremely efficient cooling, dehumidification and
optional domestic hot water heating are also provided in
one neatly packaged system.
Geothermal heat pumps get their name from the transfer
of heat to and from the earth. The earth-coupled heat
exchanger (geothermal loop) supplies the source energy
for heating and absorbs the discharged energy from
cooling. The system uses a compression cycle; much like
your refrigerator, to collect the earth's energy supplied by
the sun and uses it to heat your home. Since the process
only moves energy and does not create it, the efficiencies
are three to four times higher than the most efficient fossil
fuel systems.
This guide discusses ECONAR's line of GeoSource
PumpPAKsrM, which are used to pump the earth loop
fluid in closed loop heat pump applications. PumpPAKsrM
are available in four sizes, and can be sized to fit any
residential and light commercial GeoSource 2000,
Invision3, DualTEK, Ultra, Vara, or Vara 2 Plus heat
pump. (Note: downflow models require to be mounted
remote and connected with an accessory hose kit.)
PumpPAKsrM are completely plumbed and wired at the
factory. To install the PumpPAKrM, simply mount to the
heat pump, connect the wiring, attach the pipes from the
earth loop, and fill and purge the loop system.
Safety and comfort are both inherent to, and designed into
ECONAR Energy System's geothermal heat pumps and
accessories. The best engineering and quality control is
built into every ECONAR heat pump built. Proper
application and correct installation will assure excellent
performance and customer satisfaction.
II. PumpPAKrM SIZING
PumpPAKsrM are available in four sizes, which use from
one to four pumps. Many factors must be taken into
account in order to correctly size the PumpPAKrM;
including heat pump size, earth loop type and size, and
earth loop pressure drop. SCatl your local installer,
disffibutor, or ECONAR's Customer Service for
information regarding PumpPAKrM sizing.
III. INSTALLATION
9Caution - Check ratings in these instructions and on
the product to ensure the product is suitable for the
application.
9WARNING - To prevent personal injury, death, or
property damage, read and follow all instructions and
warnings, including labels shipped with, or attached to,
the unit before operating the equipment.
SWARNING - ELECTRICAL SHOCK CAN CAUSE
PERSONAL INJURY OR DEATH. Disconnect all
power supplies before installing or servicing electrical
devices. Only trained and qualified service personnel
should install, repair or service this equipment.
elmportant - Installer: MOI-INT AND CONNECT the
PumpPAKrM BEFORE ATTACHING the DUCTWORK
to the heat pump because there is minimal clearance.
eNote - Installer: Installation to downflow models
require that PumpPAKsrM be mounted remote and
connected with an available accessory hose kit.
Everything that is needed to mount the PumpPAKrM to
the heat pump is included in the PumpPAKrM assembly.
1. Ensure all power supplies are disconnected.
2. Remove the access panel of the PumpPAKrM, and the
bottom access panel and the electrical box cover from
the heat pump.
3. Thread the fittings provided with the PumpPAKrM
into the heat pump and the PumpPAKrM. Make sure
to thread the P/T ports into the heat pump at 15o from
vertical, and thread the elbows into the PumpPAKrtrr
at 5o from vertical. Wrap the threads of the fittings
with Teflon tape, so the connections will not leak.
SeeFigure 1.
4. Remove the 7/8" electrical knockout on the left side
of the heatpump.
5. Start two of the supplied screws into the top
PurnpPAKrM mounting holes on the left side of the
heat pump. Do not tighten the screws all the way.
6. Set the PumpPAKrM next to the heat pump, and route
the PumpPAKrM wires through the 718" hole and
plastic grommet on the back of the PumpPAKrM, and
through the 718' knockout on the heat pump.
7. Install the supplied hoses between the P/T ports and
the elbows. The top elbow on the PumpPAKru is
connected to the top P/T port on the heat pump with
the longer hose (entering water), and the bottom
elbow is connected to the bottom P/T port with the
shorter hose (leaving water).
8. Hang the PumpPAKru on the two screws while
completing the installation of the hoses. After the
PumpPAKrM is in place, tighten these screws, and
install the remaining two screws. Secure the
connections with the hose clamps.
9. Attach the entering and leaving earth loop pipes to
the connections on the back of the PumpPAKrM. The
1

top connection is for the entering water line' and the
bottom connection is for the leaving water line'
10. Connect the wiring of the PumpPAI(IM to the heat
n *, as shown in ihe wiring diagram supplied on the
Lack of the heat pump's electrical box cover'
11. After the system has been filled and purged' replace -\
all access panels on the heatpump and PumpPAKru' )
ECONAR GeoSource Ileat PumP
Electrical
knockout
ECONARPuTnPPAI(
Front
Figure 1 - Fitting Placement for PumpPAKm and Heat Pump
rV. SYSTEM PURGING
Filling and purging a closed loop system are important
steps to ensure proper heat pump operation. To correctly
fill and purge the system, use the following steps. Also,
refer to the ECONAR GeoSource Heat Pump Handbook,
and the Installation and Operating Instructions included
with the heat pump.
Each loop must be purged with enough water flow to
assure a two feet per second flow rate in each circuit in
the loop. This normally requires a 1-tt2 to 3 HP high
head pump to circulate fluid through the loop to remove
all the air out of the loop and into a purging tank. The
2
P/T Pods (2)
ThroadintoheatPumP at
15 degrees from vertical.
Elbows (2)
Thread into PumpPAK at
5 dogroes from vertical.
pump suction should be from the bottom of a large
container (purge cart). A strainer should be located on the
suction line in order to prevent any debris discharged into
the container to be retumed to the loop system.
Connect the pump discharge hose to the "fireman"
connection on the top fill and purge valve on the
PumpPAKrM. Cormect a return hose to the "fueman"
connection on the bottom fill and purge valve (see Figure
2). This hose returns to the purge cart to discharge water,
air, and debris as the system is flushed. This line should
discharge below the water level in the purge cart, in order
to monitor the air leaving the system.
PumpPAK
mountingholes (4)
I
Side
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Top Fill and Purge Valve
ln (from earth loop)
Bottom Fill and
Puge Valve
Out (to earth loop)
Figure 2 - PumpPAKru Mounted on Heat Pump
Fill the purge cart with water. Rotate the fill and purge
valves on the PumpPAKrM to the positions shown in
Figure 3 to flush the earth loop.
?op EiU and. Surge Vafve
Eallh LooF +- fleat P!aq)
In (to heat pmp)
Out (from heat purp)
Start the pump to circulate the water through the earth
loop. Maintain the level in the purge cart by adding water
to it as the loop fills. If your flushing pump assembly is
equipped with valves to reverse the flow of the water
through the loop system, do so occasionally to help
remove trapped air. Allow the pump to run 10 to 15
minutes after the last air bubbles have been removed.
After the earth loop is completely purged, add the
precalculated amount of antifreeze to the purge cart
reservoir. As the antifreeze is pumped into the loop, the
return hose from the earth loop should be removed from
the reservoir and the initial flow of water returning from
the earth loop should be discarded. After all the antifreeze
has been added, place the return hose back in the purge
cart reservoir and continue until the antifreeze is
uniformly mixed throughout the earth 1oop. Once the
solution is mixed, it should be measured with a
hydrometer, refractometer, or other device to determine
the actual freezing point of the solution. Remember that a
low antifreeze level may result in unit shutdown problems
during cold weather operation due to loop temperatures
falling below the freeze protection ofthe loop solution.
Once the antifreeze solution has been mixed, rotate the fill
and purge valves on the PumpPAKrM to the positions
shown in Figure 4 to purge the heat pump heat exchanger.
Eurge Pq,
Bott@ FiI1 ed turg. ValG
I
Earth Iroop -------> Eeat Pulp
hlEG Cart
j Figure 3 -Earth Loop Purge Setup
J
oo
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hrge Catt
Figure 4-HeatPump Purge Setup
Purge the heat pump with the antifreeze solution using the
same procedure that was used to purge the earth loop.
When the earth loop and heat pump are both purged of air
and debris, and have the correct solution of antifreeze in
them, the system should be pressurized. With the purge
pump running, rotate the fill and purge valves on the
PumpPAKrM to the positions shown in Figure 5.
Top EtIt and hrge va1v.
Earth loop ------+ H.ats Puq)
to 40 psi. Make sure that the system is at this pressure
after the loop pipe has had enough time to stretch. In
order to achieve the 30 to 40 psi static pressure, the loop
may need to be initially pressurized to 60 to 65 psi. This
static pressure will fluctuate from heating to cooling
season, but the pressure should always remain above zero
so the PumpPAKsrM circulation pumps do not cavitate,
and air cannot be pulled into the system.
When the loop system is pressurized, rotate the fill and
purge valves on the PumpPAKrM to the positions shown
in Figure 6, and turn off the purge pump.
Top liu. aad Prgo vdre
Earlh kop
-+ ->
Hcat PurF
turyc Prry)
BotE6 EiIl d tugc Val@
Ealth 1,oop <- +- Heats tuq,
tugc cd
Figure 6 - Normal Operating Setup
V. SYSTEM STARTUP
After the loop system has been completely filled, purged,
and pressurized, return power to the unit and start the
PumpPAKrM circulators to check for proper operation. If
the PumpPAKrM circulators are not operating, turn off the
power to the unit and diaglose the problem.
If the PumpPAKrM is operating correctly, measure the
pressure drop across the heat pump using the P/T ports
where the PumpPAKrM is connected to the heat pump.
Remember to use the same pressure gauge for both
readings, in order to obtain a more accurate reading.
Compare the measured pressure drop with the data
supplied in the heat pump's Installation and Operating
Instructions or ECONAR's Engineering Specifications
manual. If the flow is too low, recheck the sizing of the
PumpPAKrM for sufficient capacity. If the PumpPAKrM
selection is correct, there may be trapped air or some
other restriction in the earth loop, which would cause
decreased flow. This will have to be fixed for proper heat
pump operation.
Top fiu and Purge Valvc
Ea!* loop
E.r& loop
hrqc PW
Botl6 EiU ad hrg€ Va1v.
-----) Heat rlry
<- E6at Dtq
I
Purge PW
BorE6 Ei]l d Purg€ Vafve
Eadh loop +-- <- Beat hq,
Prgc Cart
Figure 5 - Loop Pressurizing Sehrp
Solution flow into the purge cart should stop. The loop
system pressure should rise quickly as the purge pump
forces more solution into the loop. If the water leve1 in the
purge cart falls, air in the loop system is being
compressed and further purging is necessary. The system
should be pressurized to maintain a static pressure of 30
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VI. ADDITIONAL FIGURES AND TABLES
Head ofW
Table 1 - PumpPAKru Performance Data (Flow vs. Head)
'7-t/2" 0.875" Dia. Wiring Hole
Mounting Holes (4)
5-7/8"
5-7 t8"
16" In (ftom erth loop)
Out (to earth loop)
t- 1-'1 t8"
18-1/2"
Figure 7 - PumpPAKru Dimensions
36 35 34 JJ -r-1 32 31 30 29 28 27 27 26 2t 18 15 10
69 67 65 64 63 61 59 57 55 53 52 51 49 39 JJ 27 17
100 97 94 9l 90 88 85 82 79 77 75 73 '71 55 46 3t 22
132 t28 124 121 119 117 113 109 105 101 99 97 94 t-) 6l 49 29
a
o
Grundfos UP26-i 16F 1230 1.8 38s 1t6
Grundfos UP26-1 16F 2230 3.6 770 U3
Grundfos UP26-176F -1 230 5.4 1 155 1/2
Grundfos UP26-116F 4230 7.2 1540
5
Table 2 - PumpPAKru Electrical Data
ry€I*G==reE* 35: .-G *a3.l :i9j:: *tr 3tr ffi *r: *:* @= re ry:
GPP-1S25-1.A
GPP.2S25-1-A
GPP-3S25.1-A
GPP-4S25-1.A
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GPP-1525.1.A
GPP-2S25-1-A
GPP.3S25-1-A
GPP-4S25-1-A

NOTES
I
I

NOTES

NOTES
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GeoSource' 2000, DualTEK, Vara,
Vara 2 Plus*, Invision3 and Ultra Heat Pumps
USA and Canada
Re side ntial and Limite d Commercial Warranty * *
Resid.ential Applicatinns Only: AII Parts - 2 Years
Years 1 and 2, ECONAR Energy Systems Corp. will provide a free replacement part upon prepaid return of all defective parts, F.O.B. Appleton,
MN for any part which fails to frrnction properly due to defective material, or workmanship. * During this period, ECONAR will cover cost of
labor for the.replacement of parts found to be defective: not to exceed ECONAR's published Labor Rate Schedule.
Refrigeration Components - 5 Years
Years 3 through 5, ECONAR will provide a free relacement part upon prepaid return of defective parts, F.O.B. Appleton, MN for any
compressor, or refrigeration components (parts only***) which fails to function properly due to defective material or workmanship.
Heat Exchangers - Lifetime
ECONAR will provide a free replacement intemal heat exchanger (i.e. water to refrigerant, refrigerant to air) upon prepaid retum of defective
part F.O.B. Appleton, MN (parts only) for the lifetime of the heat pump.
Commercial Applications Onlyi AII Parts - 1 Year
**First year, ECONAR will provide a ftee replacement upon prepaid return of all defective parts, F.O.B. Appleton, MN for any part which fails
to function properly due to defective material or workmanship. During this period, ECONAR will cover the cost of labor for the replacement of
parts found to be defective; not to exceed ECONAR's published Labor Schedule.
Refrigeration Components - 5 Years
Years 2 through 5, ECONAR will provide a free replacement part upon prepaid retum F.O.B. Appleton, MN for any compressor, or refrigerant
component (parts only) which fails to function properly due to defective material, or workmanship.
All Applications:
Limitations:
o Begins the date of original purchase as recorded by ECONAR with the retum of the warranty registration card. (If warranty card is not
submitted, warranty begins the date of original manufacture based on serial number).
. Applies to original installation and normal use ofthe heat pump only and does not include any other component ofa system as a whole.
o All ECONAR labeled and manufactured accessories cary a2 year part warranty for residential duty and 1 year for commerical duty. All other
accessories carry the manufacturers warranty only. Labor is excluded on all accessories.
. Service must be performed by an ECONAR authorized service person.
r Replacement parts shall be warranted for 90 days. After the 90 days, the parts will be covered by the remaining warranty of the unit.
. Under no circumstances will ECONAR be liable for incidental, or consequential expenses, losses or damages.
Owners Responsibilites:
r Retum warranty card to activate warranty coverage. See form #90-0147
r Provide normal care and maintenance.
r Make products accessible for service.
Warranty is Void if:
r Datalabelis defaced, orremoved.
. Product has defect, or damage due to product alterations, connection to an improper electric supply, shipping and handling, accident, fire, flood,
lightning, act of God, or other conditions beyond the control of ECONAR.
r Products are not installed in accordance with ECONAR instructions and specifications,
. Products which have defects, or insufficient performance as a result ofinsufficient or incorrect installations, poor water supply, design, or the
improper application of products. (This would include afueezerupture)
. Products are installed, or operate in a corrosive environment causing deterioration ofmetal parts.
Warranty Performance:
o The installing contractor will provide the warranty service for the owner. If the installing contractor is not available, contact:
ECONAR Energy Systems, Corporation Customer Support at: 33 West Veum, Appleton, MN 56208 or call toll free 1-800-4-ECONAR.
*Determination of the defect is the sole discretion of ECONAR Energy Systems, Corp.
**Limited Commercial Wananty covers aLl non-residential applications.
+**Energy Star rated products include parts and labor
This waranty supersedes any and all previously written or implied warranty documentation. OECONAR Energy Systems Corporation O3l2W6

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19230 Evans Street
Elk River, MN 55330
USA
1-800-4-ECONAR
www.econar.com
www.econar.net
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90-1015 Rev 05/2007 Copyright@ECONAR Energy Systems, Corporation All Rights Reserved. Printed in USA.