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Maritime Geothermal NORDIC User manual

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Maritime Geothermal Ltd.
P.O. Box 413
Petitcodiac, N.B. E0A 2H0
Maritime
Geothermal Ltd.
NORDIC® models EM (DX) 45-55-65
Direct Expansion
Energy Module Heat Pumps
Refrigerant Filled Copper Heat Exchanger Loop
Hot Water Output
Heat Pump System Requirements ..... 3Safety Controls ………... 14 Trouble Shooting Guide .......... 21
Conceptual Overview ……… 5Starting the Heat Pump ……. 15 Performance Curves ……….. 24
Technology Explanation …….. 7Component Layout ................ 17 Setting the Aquastat ……….. 27
Installing DX linesets .................. 11 Dimensions & Piping Layout 19 Electrical Schematic ..........………. 29
Inside Installation …………………. 12 EM Internal Schematic 20 Electric Block Diagram …... 30
Domestic Hot Water ........................... 13 Min. Circuit Ampacity 20 Warranty ............................………. 31
Table of Contents
Installation
Manual
Revision 1.5 17-Feb-00
Email: [email protected]
www.discribe.ca/nordic
Page .... 2
Maritime Geothermal Ltd.17-Feb-00
A NORDIC® Direct Expansion Heat Pump System
Energy Input:
Solar
Geothermal
Storage System:
Earth’s Mass
Extraction &
Rejection System:
“EM” heat pump
Heat Distribution:
Infloor Heating
Fan Coil Distribution
NORDIC® DX
Energy Module
HEATING COOLING
Infloor Heating
Fan Coil
Ducted
Systems
Page .... 3
Maritime Geothermal Ltd. 17-Feb-00
Horizontal Loop Fields
The successful
application of a
EMDX heat pump
depends on sizing
the machine cor-
rectly for the
home or area to
condition and pro-
viding enough
land area or vol-
ume of earth from
which to extract or
reject heat.
EMDX heat
pumps react with
the earth much
like a conven-
tional reversing
heat pump and closed loop plastic earth heat exchanger.
Heat that is available to the unit must travel through the earth
and therefore the conduction capability of the earth in the lo-
cation of the heat exchanger is very important. A unit used
primarily for heating will have no problem with conduction
and heat transfer since it will be cooling the loop during heat-
ing mode. Cooling the soil draws moisture towards the coils
since they are colder than the surrounding ground. Horizontal
loop fields should be laid out so that the copper coils have
good cross-sectional influence on the minimum areas listed in
Table 1. As a general rule, wider spacing between the loops
so that they do not influence one another, will result in im-
proved performance of the heat pump.
Unless you are sure there will be sufficient moisture pre-
sent in the loop field area during the summer, a soaker hose
is recommended in all horizontal trench systems which will
used for air conditioning purposes.
Vertical Bore Systems
Vertical bores (76 mm x 30 m holes) provide an alter-
nate method of installing a EMDX unit. A high water table in
the borehole area (6 to 9 m) will insure that there is adequate
conduction with the earth and although the loop length per ton
is shorter than the horizontal design, the vertical orientation
and moisture in the boreholes provides very uniform conduc-
tion both winter and summer.
NORDIC® EM (DX) System Prerequisites
There are four specific parts or sub-systems to a EMDX heat pump installation:
1. The source of energy ............................................................... Solar & Geothermal
2. The storage media ................................................................... The Earth’s mass
3. Converting the energy to a useable form ................................... Heat Pump
4. Distributing the heat ..................................................................Hot Water / radiant slab –fan coils
Model # of
Loops Area
Req’d Trench
Layout
EMDX-45 (3) x 106 750 m² 1.3 x 53 m
EMDX-55 (4) x 106 930 m² 1.3 x 53 m
EMDX-65 (5) x 106 1160 m² 1.3 x 53 m
Note: These are minimum loop field requirements
based on an earth temperature of 7° C.
Table 1
Nordic® EMDX-45 will heat up to 140 m²
Nordic® EMDX-55 will heat up to 200 m²
Nordic® EMDX-65 will heat up to 260 m²
Assuming at least R-20 walls and R-40 ceiling
Page .... 4
Maritime Geothermal Ltd.17-Feb-00
NORDIC® EMDX Series Typical Plumbing
Domestic
HOT
Water
Tank
HOT Water OUT to home
DX copper lines to outdoor loops
Check
Valve
Page .... 5
Maritime Geothermal Ltd. 17-Feb-00
Introduction to EMDX Technology
Direct earth coupled heat pump or “EMDX” heat pump is
one that has its refrigerant evaporator / condenser in direct
thermal contact with the earth from which heat is either ex-
tracted from during the heating mode or introduced to during
the cooling mode of operation.
Energy Machine Overview
As a result of direct urging from the engineering community,
Maritime Geothermal Ltd. has developed a unique new heat
pump solution specifically targeted at buildings which employ
infloor heating as the primary energy distribution system in
the building.
The need for an integrated package liquid-to-water or DX®-
to-water heat pump became apparent as mechanical engineers
who were designing the buildings found that the complexity
of setting up a mechanical room with suitable heat pumps,
circulator pumps, storage tanks, aquastats and other controls
seemed to pose a confusing demand on the installation con-
tractors, plumbers and electricians.
This complexity usually required repeated consultations on
site with the designing engineer and various tradesmen in-
volved in carrying out the heat pump installation and with
companies involved in integration of the building manage-
ment system.
To address this situation Maritime Geothermal Ltd. Designed
the "Energy Machine" with all mechanical components re-
quired to mate successfully with an infloor heating system
built into the heat pump enclosure. The plumber need only
connect the supply and return to the floor header system and
the electrician makes a single wiring connection to the unit
for heat pump, circulator pumps and back-up electric heat.
An Energy Machine includes the following components.:
•Compressor
•Earth heat exchanger or provision for DX connection to the
ground.
•Insulated 40 gal. 316 SS distribution tank with integrated
refrigerant condenser and domestic hot water generator.
•Expansion tank, PRV, Boiler feed valve, pressure gauge.
•Electronic 2-stage aquastat.
•12 kw back-up heat
•Floor distribution circulator pump (Standard Taco® 0011 or
you spec head and volume).
•All controls prewired and ready to use.
With a typical water-to-water HPmost of these components
were outside the heat pump and had to be procured and in-
stalled by the plumber.
Energy Machines are superior to a
built-up system in the following ways:
1. Installed first cost is cheaper.
2. Building controls are simpler requiring less control
points.
3. Higher efficiency.
4. Hotter output temperature.
5. Year around domestic hot water capability.
6. Fewer moving parts -less maintenance.
7. Simple integration to an infloor heating system.
8. Back-up heat built in.
9. Stainless Steel storage tank.
10. Accurate temperature regulation.
1. Cost of purchasing the individual components and building
the mechanicals on site are higher than purchasing an inte-
grated package such as the NORDIC® EM.
2. Costs associated with the control points in a building man-
agement system are also reduced since the machine only has
to be put in the "ON" or "OFF" mode requiring 1 point. The
energy machine operates all its internal pumps and circulators
automatically.
3. Because the condenser of the heat pump is built into the
distribution tank, there is no need for an intermediate water
loop and associated pump system. This integration saves the
first cost of the circulation pump and the costs of operating
and maintenance on the pump over the years.
4. The maximum output water temperature can be up to 52°C
(125°F) whereas a conventional water-to-water heat pump
will normally have a maximum output temperature of 46°C
(115°F).
5. A conventional heat pump can only supply hot water dur-
ing regular floor heating cycles unless there is an auxiliary
heat exchanger installed. The EM has a heat exchanger em-
bedded in the tank which can produce domestic hot water
year around.
6. The EMDX has fewer moving parts than a conventional
heat pump and requires no servicing or maintenance of any
kind.
7. A two point connection to the floor header system is all
that is required.
8. External back-up boiler or electric hot water tank is not re-
quired since the EM tank is equipped with 9-15 Kw of back
up electric heat prewired and activated as the second stage of
a 2-stage digital aquastat.
9. The integrated storage tank is fabricated from type 316
Stainless Steel which will last the life of the building.
10. The EM is controlled with a digital 2 stage thermostat
with individually adjustable setpoints and differentials. First
and second stages will not overlap unless set to do so.
Page .... 6
Maritime Geothermal Ltd.17-Feb-00
NORDIC® Vertical EMDX -Typical Loop design
NOTE:
Layout for one borehole shown
below. Actual installation re-
quires one borehole per ton.
(I.E. (3) holes for a EMDX-45,
(4) holes for a EMDX-55 and
(5) for a EMDX-65
NOTES:
•Drill vertical bore to a depth of 30 to 35 m.
•Pre-assemble or construct on site the dual (9 and 13 mm) piping assem-
bly required. Seal both ends and pressurize with 1000 kPa nitrogen for
leak checking. Silver brazing a schrader valve in the end of the 9 mm
line will allow gauge checking for loss of pressure.
•Check for leaks with soap suds. After a minimum 2 hr waiting period,
recheck the line for loss of pressure. If the temperature of the loop
hasn’t changed then the pressure should be same as it was originally.
•Insulate both liquid lines and vapor lines from the heat pump to the well
head unless in separate horizontal trenches. Vapor lines in separate
horizontal trenches need only be insulated from 3 m out in the trench to
the basement wall. Liquid lines must be insulated from the heat pump
to approx. 1 m down the drop pipes in the vertical boreholes.
•Install spacers to keep the pipes separated as far as possible from one
another in the boreholes.
•Install 30 to 35 m of dual tubing (13 mm vapor & 9 mm liquid). Re-
check pressure on lines. Secure pipes through opening in borehole
head. Backfill with pea gravel to 10 m from top. Seal hole with ben-
tonite clay from 10 m to surface.
•Most commercial installations will require tremie grouting of the bore-
hole from bottom to top with bentonite with 28 to 30% solids.
•Install linesets from well heads in horizontal trenches to heat pump in
building. Silver braze all joints with 5% silver solder using dry nitrogen
to purge the system. When all joints are complete, pressurize the entire
system with 1000 kPa nitrogen and recheck for leaks. Vacuum until
system stays below 500 microns for five minutes after vacuum pump
has been shut off.
•Charge the prescribed amount of refrigerant through the high side
schrader valve located on the front of the machine.
Pinch around pipes
and silver braze.
Keep pipes up 13
mm off bottom to
insure good flow.
22 mm Stub Cap (Copper)
NORDIC® DX
“Energy Module”
Heat Pump
Liquid Line
Vapor Line
35 m max.
2 m
Spacers
Insulate liquid line
to here
Trench
Page .... 7
Maritime Geothermal Ltd. 17-Feb-00
Refrigeration Cycle
The general refrigeration cycle of our EMDX machine is
similar in nature to a conventional water-to-air or water-to-
water heat pump in that there exist a compressor, expansion
device, reversing valve, and refrigerant-to-air heat exchanger.
Conventional technology concerned with heat pumps re-
lies upon the transfer of heat from the ground by means of a
secondary heat exchanger system and working fluid, e.g., wa-
ter, which is pumped to the geothermal unit located in the
heated structure. The conventional heat pump has it’s own
internal primary heat exchanger which extracts heat (heating
mode) or rejects heat (cooling mode) from this water, which
is then pumped back to the earth to be reheated or cooled.
EMDX systems similarly use a ground coil system, how-
ever, the working fluid is a refrigerant and the copper ground-
loop is the primary heat exchanger. Such geothermal heat ex-
change is an efficient and effective way of achieving heat ex-
change in heating and air conditioning systems, and especially
heat pump type systems. Since the ground temperature is rela-
tively constant at 7 o. at a depth 2 m below the frost line, the
available heat is constant.
The elimination of the secondary earth heat exchanger
(typically plastic in nature) and its associated working fluid
reduces the temperature difference required between the
ground and the evaporating refrigerant yielding a higher suc-
tion pressure than a conventional system under similar cir-
cumstances and thus a higher efficiency.
Many attempts have been made in the past to develop suc-
cessful direct coupled heat pumps for residential and commer-
cial uses. These attempts have failed adequately to meet a
number of requirements associated with an economically and
functionally viable system. Some of the shortcomings in-
cluded:
1. Inadequate oil return to the compressor primarily in the
heating mode.
2. Inadequate evaporator length and spacing for properly
extracting heat from the earth resulting in low capacity
and low efficiency of the systems.
3. Refrigerant charges in the range of 10 times greater than
a similar capacity conventional geothermal heat pump.
4. Approximately 3 times as much refrigerant required in
the cooling mode as is required in the heating mode.
5. Lack of a proper means to store additional refrigerant re-
quired during the cooling operation but not needed during
the heating mode.
6. Inefficient and ineffective method to account for vastly
varying condenser capability depending on ground tem-
perature.
7. Difficulty in providing an easy to install system of earth
exchanger loops.
The NORDIC® solution has been to start with a clean
new concept and to design a unit from the ground up. We
started by developing an evaporator system that would yield
the best performance to pressure drop factor and which would
impact enough area to maintain a minimum suction pressure
above 276 kPa The current horizontal groundloop comprises
107 m per ton of 13 mm OD copper tubing. A 3 ton system
would have 3 such loops working in parallel during the heat-
ing mode. Refrigerant charge had been determined to be 1.8
kg. of refrigerant per loop. These 13 mm copper loops main-
tain sufficient velocity at all times to insure adequate oil re-
turn. During cooling mode the machine automatically selects
one or more loops based on discharge pressure to act as the
condenser. As the discharge pressure builds to a predeter-
mined point, the on-board computer selects the most appropri-
ate combination of groundloops to dissipate the heat at the
lowest cost to the homeowner. By intelligently controlling the
manner in which the condenser is utilized our total system
charge does not have to be altered nor does an excess charge
have to be stored anywhere.
EMDX Better than Current Technology
There are several advantages of “EMDX” technology
that are superior to conventional geothermal heat pumps of
both the “open loop” and “closed loop” variety. Listed below
are some of the reasons why “EMDX” technology is becom-
ing more attractive to Homeowners, Dealers and Utilities.
More Reliable.
•Fewer parts to the system.
•Does not require a supply and return well.
•Does not require a well pump or circulation pumps.
•No water heat exchanger and associated valving to cor-
rode, freeze and break.
More Efficient
The direct expansion principle allows the refrigerant to
come directly into contact with the earth, separated only by
copper tubing. During winter, maximum heat transfer takes
place at higher temperature than conventional groundloop
technology without the maintenance and electrical cost of cir-
culation pumps.
Less Maintenance
Only a sealed refrigeration circuit to maintain.
More Versatile
“EMDX” systems can be installed in a more confined area
than a conventional groundloop system, primarily because the
heat exchanger coil is much more efficient at transferring heat
Page .... 8
Maritime Geothermal Ltd.17-Feb-00
Piping Layout of Vertical Style DXW Vertical Loop
HOME
Page .... 9
Maritime Geothermal Ltd. 17-Feb-00
to the refrigerant than a plastic earth exchanger. Normal loop
lengths for a “EMDX” machine are nominally 107 m per ton
as opposed to 140 to 150 m per ton for a plastic earth ex-
changer.
Similarly, vertical systems require only a 75 mm borehole
to a normal depth of 30 m per ton.
Easier to sell
Systems can be quoted more accurately and easily since
there is less outside subcontracting involved.
Excavation or drilling contractors know in advance what
is required and can quote definite prices whereas with well
drilling for open loop systems, the well price may eliminate
the sale entirely.
Installation Instructions
Unpacking
When the heat pump reaches it's 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 strongly constructed and every effort has
been made to insure 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 location of liquid-to water heat pump inside the
home should be determined by:
1. The ease at which piping runs can be connected to the
infloor heating headers on the output side of the
unit.
2. Space availability in a mechanical room for the hot
water distribution tank and associated pumps etc.
3. Ease of access to the water well supply and discharge
lines or groundloop lines.
If possible the four main service doors should remain clear
of obstruction for a distance of .6 m so that servicing and gen-
eral maintenance can be carried out with a minimum of diffi-
culty. 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
50 mm Styrofoam covered with 6 mm plywood. The Styro-
foam will smooth out any irregularities in the cement floor
while the plywood will distribute the weight of the NOR-
DIC® unit evenly over the Styrofoam. This process will also
deaden the compressor noise emitted from the bottom of the
cabinet.
As an alternative, several pieces of 50 mm lumber can be
placed under the unit running from the electrical connection
side to the filter rack side of the heat pump. Laying the
wooden pieces in this manner will give the best support since
they will be at right angles with the internal steel compressor
and heat exchanger supports.
Materials
supplied
by NOR-
DIC®
NORDIC® sup-
plies the EMDX
heat pump with
all internal valv-
ing and header-
ing pre-
assembled, pres-
sure tested and
ready to be installed to the customers infloor system and un-
derground copper exchanger loops. The underground coil as-
semblies can be purchased with the unit –pre-tested and
sealed with 700 kPa nitrogen pressure. A EMDX system may
comprise from 2 to 5 underground loops. One loop is required
for each nominal "ton" of compressor capacity. The standard
loops are 13 mm OD type “L” or “K” copper tubing. When
the dealer unpacks the coils the integrity of the loops can eas-
ily be checked by attaching a suitable pressure gauge to the 6
mm schrader valve on the coil assembly. The pressure read at
room temperature should be approx. 700 kPa (+-30 kPa) If a
loop is not within this tolerance, it should be set aside for re-
testing or returned to NORDIC® for replacement. Under no
circumstances should a copper groundloop be used if there is
any question that it may not be pressure tight.
The EMDX heat pump
unit has been high pres-
sure tested for leaks and
has a holding charge of
200 kPa (nitrogen) when
the dealer receives it.
Materials you will
need (inside)
A lineset is required to
connect the heat pump to
the underground coils
which will be installed outside the structure. This lineset con-
sists of one 9 mm liquid line and one 13 mm gas line for each
"ton" or loop installed. The dealer will be required to silver
braze (5% silfos) the required indoor linesets from the point
of entry to the basement or installation area to the heat pump.
Horizontal Trench Requirements
The EMDX heat pump requires one ground coil or "loop"
per nominal ton of capacity.
Trenching for the EMDX heat pump can be best accom-
Page .... 10
Maritime Geothermal Ltd.17-Feb-00
NORDIC® EMDX Horizontal Trench Design