ClimateMaster Flow Controller 3 Guía

Residential Geothermal Loop,

Single and Two-Pump Modules

Installation, Operation &

Maintenance Instructions

97B0015N01

Revision: 2/9/16

Flow Controller 3

Table of Contents

Model Nomenclature 3

General Information 3

Flow Controller Mounting 4

Piping Installation 5

Electrical Wiring 9

Flushing the Earth Loop 10

Antifreeze Selection 13

Antifreeze Charging 15

Low Temperature Cutout Selection 16

Flow Controller Pump Curves 17

Pump Replacement 18

Geothermal Closed Loop Design 19

Loop Fusion Methods 19

Parallel Loop Design 19-22

Closed Loop Installation 23-24

Pressure Drop Tables 25-30

Building Entry 31

Site Survey Form 31

Warranty 32

Revision History 34

Flow Controller 3

Rev.:Feburary 9,2016

2Geothermal Heat Pump Systems

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Flow Controller 3

Rev.: Feburary 9, 2016

A F C G 2 C 1

1 2 3

567

Accessory Flow Controller

1 = 1 Pump

# of Pumps B = Brass 3-way valve with double O-ring fittings

Valves

Pump Model #

1 = UP26-99

2 = UP26-116 (AFC2B2 only)

3 = UPS32-160

4 = UPS60-150

Vendor/Series

G = Current Series

2 = 2 Pumps

C = Composite 3-way valve with double O-ring fittings

Rev.: 12/07/10

Model Nomenclature

GENERAL INFORMATION

Figure 1a: Flow Controller Dimensions (1 Piece Cabinet)

7.6” [192mm]

(includes pump)

10.2” [259mm]

13.5” [335mm]

5.0” [127mm]

4.7” [119mm]4.7” [119mm] 4.7” [119mm]4.7” [119mm]

Figure 1b: Flow Controller Dimensions (2 Piece Cabinet)

6.9” [174mm]

(includes pump)

10.2” [259mm]

14.9” [378mm]

5.0” [127mm]

4.5” [114mm]4.5” [114mm] 4.5” [114mm]4.5” [114mm]

FLOW CONTROLLER DESCRIPTION

The AFC series Flow Controller is a compact, easy to mount

polystyrene cabinet that contains 3-way valves and pump(s)

with connections for ushing, lling and pumping residential

geothermal closed loop systems. The proven design is foam-

insulated to prevent condensation. Full ow service valves

minimize pressure drop. One or two Grundfos pump models

UP26-99 or UP26-116 are available for a variety of unit ow

rates and loop layouts. Flow Controllers are designed for

systems that require water ow rate of up to 20 U.S. GPM

[1.26 l/s]. Unit and loop connections are designed for double

o-ring adaptor ttings for a variety of connection types

(fusion, threaded, barbed, cam). Pumps are 230VAC, 60Hz.

An attractive gray polystyrene cabinet with black pump(s)

provides an esthetically pleasing enclosure for pump(s) and

valves.

Safety

Warnings, cautions and notices appear throughout this

manual. Read these items carefully before attempting any

installation, service or troubleshooting of the equipment.

DANGER: Indicates an immediate hazardous situation, which

if not avoided will result in death or serious injury.

DANGER labels on unit access panels must be observed.

WARNING: Indicates a potentially hazardous situation, which

if not avoided could result in death or serious injury.

CAUTION: Indicates a potentially hazardous situation or an

unsafe practice, which if not avoided could result in minor or

moderate injury or product or property damage.

NOTICE: Notication of installation, operation or

maintenance information, which is important, but which is

not hazard-related.

Flow Controller 3

Rev.:Feburary 9,2016

4Geothermal Heat Pump Systems

Flow Controller Mounting

CAUTION! Figure 2: Mounting Flow Controller on Stud Wall

Figure 3: Mounting Flow Controller on the Side of Unit

NOTICE! - Flow Controller pumps must be mounted so that

the pump shaft is always in a horizontal position. In other

words, Flow Controller must always be mounted in a vertical

position (not on it’s back or mounted to the ceiling). Pump

damage will occur with pump shaft in a vertical orientation.

General

The Flow Controller should be located as close to the unit

as possible to limit the length of rubber hose kit and thus

its associated pressure drop. In general the Flow Controller

can be mounted in any orientation with the exception of

when the pump shafts are in a vertical position as when it is

laid at on the oor or any similar position. The controller is

typically mounted in one of three locations (see below). Be

certain that there is adequate access to all required ush

ports and valves before mounting.

Stud Wall - Mounting on stud wall with or without drywall

can be accomplished by using the two supplied lag bolts

through the top and bottom center holes directly into the

studs as shown in Figure 2.

Side of Unit - Mounting on the side of the unit can be

accomplished by using the four self-drilling screws directly

into the sheet metal access panels or cabinet as shown in

Figure 3. Be careful not to puncture any internal refrigerant

piping or other components with the screws. It should be

remembered that heat pump access will be limited in this

mounting position.

Concrete wall - Mounting onto a concrete wall can be

accomplished by using 4-1/4” [10.8 cm] ‘Tapcon’ screws

(supplied by others) directly into the concrete wall.

CAUTION! The following instructions represent industry

accepted installation practices for closed loop earth

coupled heat pump systems. Instructions are provided

to assist the contractor in installing trouble free ground

loops. These instructions are recommendations only.

State/provincial and local codes MUST be followed and

installation MUST conform to ALL applicable codes. It is

the responsibility of the installing contractor to determine

and comply with ALL applicable codes and regulations.

Flow Controller 3

Rev.: Feburary 9, 2016

Piping Installation

Figure 4: Double O-Ring Adapters

To Fittings Part #

Polyethylene (PE) Fusion 1-1/4” PE Fusion x Double O-ring AFC6F

PE Fusion 1” PE Fusion x Double O-ring AFC5F

PE Barb 1-1/4” insert barb x Double O-ring1AFC6I

PE/Rubber Hose Barb 1” insert barb x Double O-ring1AFC4I

Cam Adapter Male Cam adapter x Double O-ring2AFC4C

Copper Sweat or PVC Glue 1” MPT x Double O-ring3AFC4T

NOTES:

1. Use two all-stainless hose clamps per connection. One set of 1” insert barb x

Double O-ring adapter ttings is included with AHK5EC hose kit.

2. One set of cam adapters required for connection to ush cart hoses. Cam

connectors should be left with the installed Flow Controller for future service.

Most ush carts will have female cam ttings that will mate to these ttings.

3. Adapters from 1” MPT to copper sweat or PVC glue provided by others.

Table 1: Flow Controller Connection Materials

Piping Material Insulation Description

1” Hose Kit 1-3/8” [34.9 mm] ID - 1/2” [12.7 mm] wall

1” IPS PE 1-1/4” [31.8 mm] ID - 1/2” [12.7 mm] wall

1-1/4” IPS PE 1-5/8” [41.3 mm] ID - 1/2” [12.7 mm] wall

2” IPS PE 2-3/8” [60.3 mm] ID - 1/2” [12.7 mm] wall

Table 2: Typical Piping Insulation Materials

AFC4C

AFC4I

AFC4T

Hose Kit

AHK5EC

AFC5F

AFC6F

Piping Installation

The Flow Controller features Double O-ring ttings for

exible and easy installation. Table 1 illustrates the

connection options available for Flow Controllers with

polystyrene cabinets. Avoid using 3/4” [19.1mm] piping

on ows greater than 6 gpm [0.38 l/s]. Pressure drop in

piping systems should be calculated to insure adequate

ow through unit. All piping should be properly insulated

with closed cell insulation of 1/2” [12.7 mm] wall thickness.

Table 2 shows the insulation requirements for typical piping

materials. Piping insulation should be glued and sealed

to prevent condensation using closed cell insulation glue.

The swivel connectors on the Flow Controller are designed

to be hand tightened only. Connections between the Flow

Controller and adapters are sealed with double o-rings

ttings shown in gure 4.

Loop side piping is typically polyethylene piping directly

into the Flow Controller. Connection to the Flow Controller

Flow Controller 3

Rev.:Feburary 9,2016

6Geothermal Heat Pump Systems

Piping Installation

Figure 5: AHK5EC Hose Kit Typical Detail

Figure 6: Two Units Utilizing One Flow

Controller (One Side Shown)

can be accomplished by a fusion or barbed tting as shown

in Table 1. In multiple Flow Controller systems such as

multifamily housing, PE can also be used on the heat pump

side. Polyethylene is the only acceptable material for pipe

buried in the ground.

Unit side piping is typically connected using the hose

kit (AHK5EC), which contains all ttings necessary for

connection between the Flow Controller and the unit as

shown in Figure 5.

In multiple unit systems, PE piping materials can be used

to ‘tee’ more than one unit into the Flow Controller. It is

recommended that a hose kit still be used at the end of the

PE piping run to facilitate ease of installation and service of

the units as shown in Figure 6. Insulate all exposed piping.

Plastic to metal threads should not be used due to their

leakage potential.

The APSM pump slaving module can be used to allow a

single Flow Controller to be controlled by two heat pumps as

shown in gure 7a.

Flow Controller 3

Rev.: Feburary 9, 2016

Two Units with One Flow Controller

NOTES:

1. Piping is shown schematically

. Actual pipe diameter and layout must be determined before installation.

2. Pressure drop calculation must be made to verify that Flow Controller can deliver design flow rate when both units are oper

ating.

3. Hose kits of longer than 10 ft. (3 meters) one way should not be used. PE pipe or SCH80 PVC should be used for lengths gre

ater than 10 ft. (3 meters).

All units must include P/T ports for flow rate measure and balancing.

5. Use optional field-installed loop pump slaving relay (part #

APSM) to wire both units to the Flow Controller pump(s).

Heat Pump Heat Pump

Flow

Controller

Field-supplied

full-port ball valve

for balancing

Each heat pump

must include P/T

ports to verify flow rates

LWT

EWT

LWT

EWT

Heat Pump Heat Pump

Flow

Controller

Water Out

Water In

Water Out

Water In

Figure 7a: Parallel Unit Piping 1

Piping Installation

Flow Controller 3

Rev.:Feburary 9,2016

8Geothermal Heat Pump Systems

NOTES:

1. Piping is shown schematically. Actual pipe diameter and layout must be determined before installation.

2. Pressure drop calculation must be made to verify that parallel pumping arrangement provides enough head to deliver design flow rate to each unit

when all units are operating.

3. Flow Controller should be mounted close enough to unit to maintain short (approx. 10 ft., 3m) hose kit from Flow Controller to unit.

4. All units must include P/T ports for flow rate measure and balancing.

Multiple Units on Common Loop Field

Parallel Pumping Arrangement

Heat Pump Heat Pump Heat Pump

Field-supplied

full-port ball valve

for balancing

Field-supplied

check valve to

prevent short-cycling

Each heat pump

must include P/T

ports to verify flow rates

Water Out

Water In

Water Out

Water In

LWT

EWT

Flow

Controller

Flow

Controller

Flow

Controller

Heat Pump

Water Out

Water In

Figure 8b: Parallel Unit Piping 2

Piping Installation

Flow Controller 3

Rev.: Feburary 9, 2016

Flow Controller Electrical Wiring

Model Qty Volts Amps HP

UP26-99 1 230 1.07 1/6

UP26-99 2 230 2.14 1/3

UP26-116 2 230 3.50 1/3

Figure 8a: Heat Pump / Circulator Pump

Power Wiring

Figure 8b: Wiring for Two Units Sharing One Flow

Controller (APSM Module)

WARNING! 

CAUTION! 

Power wiring to the Flow Controller should conform to all

applicable codes. Figure 8a illustrates the wiring required

between the heat pump and Flow Controller. Note the Flow

Controller is available only in 230V single phase voltage.

Pumps are fused through a pair of circuit breakers in the

unit control box. See electrical table for Flow Controller

characteristics.

The pump slaving module is designed to allow two units

to share one Flow Controller. The module is mounted in a

NEMA enclosure, which is designed to be mounted on the

Flow Controller or on the outside of the unit. Wire the pumps

and unit as shown in gure 8b.

Electrical Table

WARNING! To avoid possible injury or death due to

electrical shock, open the power supply disconnect switch

and secure it in an open position during installation.

CAUTION! Use only copper conductors for eld installed

electrical wiring. Unit terminals are not designed to accept

other types of conductors.

Flow Controller 3

Rev.:Feburary 9,2016

10 Geothermal Heat Pump Systems

Flushing the Earth Loop

Figure 10a: Valve Position A - Loop Fill

Unit

Garden

Hose

Flow

Controller

Loop

Valve

Position

Flush Cart

Figure 9a: Typical Cleanable Flush

Cart Strainer (100 mesh [0.149mm])

Figure 9b: Cam Fittings for Flush Cart Hoses

Attach

to Flow

Controller

Flush Port

Connect

to Flush

Cart Hose

(1 of 2)

NOTICE: A hydrostatic pressure test is recommended on ALL

piping, especially underground piping before nal backll per

IGSHPA and the pipe manufacturers recommendations.

Front of F.C.

Valve Position

WARNING! 

Once piping is completed between the unit, Flow Controller

and the ground loop, nal purging and charging of the loop

is needed.

A ush cart (at least a 1.5 hp [1.1kW] pump) is needed to

achieve adequate ow velocity in the loop to purge air and

dirt particles from the loop itself. Antifreeze solution is used

in most areas to prevent freezing. All air and debris must be

removed from the earth loop piping system before operation,

Flush the loop with a high volume of water at a high velocity

(2 fps [0.6 m/s] in all piping), both directions using a lter

in the loop return line, of the ush cart to eliminate debris

from the loop system. See charts 6a through 6e for ow rate

required to attain 2fps [0.6 m/s]. The steps below must be

followed for proper ushing.

Fill loop with water from a garden hose through ush cart

before using ush cart pump to ensure an even ll and

increase ushing speed. When water consistently returns

back to the ush reservoir, switch to valve position B.

WARNING! Disconnect electrical power source to prevent

injury or death from electrical shock.

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