DIRECT AXXESS Vertical and Diagonal Earth Loops

Transcription

1 DIRECT AXXESS Vertical and Diagonal Earth Loops Quick-Start Instructions VEL-QS (08/16) 2016 EarthLinked Technologies, Inc.

2 Disclaimer Proper installation and servicing of the DIRECT AXXESS Earth Loop System is essential to its reliable performance. All DIRECT AXXESS Earth Loops systems must be installed and serviced by an ETI trained and authorized technician. Installation and service must be made in accordance with the instructions set forth in this manual. Failure to provide installation and service by an ETI trained and authorized technician in a manner consistent with the subject manual will nullify the limited warranty coverage for the EarthLinked Heating and Cooling System or Commercial Water Heating System and the DIRECT AXXESS Earth Loops. Earthlinked Technologies, Inc. shall not be liable for any defect, unsatisfactory performance, damage or loss, whether direct or consequential, relative to the design, manufacture, construction, application or installation of field specified components. Earthlinked Technologies, Inc S. Pipkin Road Lakeland, Florida USA phone: toll-free: General Info: info-question@earthlinked.com CSI # VEL-QS (08/16) Page 2

3 Table of Contents Earth Loop Placement... 4 Manifold Location... 5 Site Preparation and Bore Holes... 8 Earth Loop Installation... 9 Grouting Manifold Assembly Line Set Seal Test Backfilling WARNING! The following Earthlinked Technologies, Inc. Earth Loop Application Policy addresses the restrictions to the application of a copper earth loop system as a component of an EarthLinked Heating and Cooling System or Commercial Water Heating System. 1. DO NOT install an earth loop system in soils with high concentrations of acids, chlorides, sulfides, sulfates, carbon, coal, cinders or ammonia; or organic soils with anaerobic bacteria, or in coastal areas with brackish water marshes, salt water intrusion or acidic peat bogs. Prior to drilling or excavation for the earth loop system, it is the responsibility of the EarthLinked system specifier to determine the presence of these noted concentrations by taking soil samples at appropriate depths below the ground surface and at multiple locations within the intended earth loop field. Further, the soil is to be sampled, analyzed and documented by a licensed soil testing laboratory. 2. DO NOT install an earth loop system within one half (1/2) mile of a salt water sea shore or any tidal body of water. Earth loop systems installed in any of the above conditions will void the EarthLinked Limited Warranties for the copper earth loops, manifolds and all EarthLinked equipment connected to the earth loop system. WARNING! ETI earth loop systems (earth loops, manifolds and earth loop line sets) that are modified in any way will void the EarthLinked Limited Warranties for the earth loop system and all EarthLinked equipment connected to the earth loop system. VEL-QS (08/16) Page 3

4 Earth Loop Placement IMPORTANT WHEN MORE THAN ONE EARTH LOOP SYSTEM IS BEING INSTALLED AT A SITE, THE MINIMUM SEPARATION BETWEEN EACH EARTH LOOP SYSTEM (INCLUDING MANIFOLDS BUT NOT LINE SETS) IS AS FOLLOWS: EARTH LOOP TYPE VERTICAL (ALL) DIAGONAL (ALL) MINIMUM SEPARATION 15 FT. BETWEEN EARTH LOOP SYSTEMS 20 FT. BETWEEN MANIFOLD SETS (ENSURE INDIVIDUAL EARTH LOOPS DO NOT TOUCH) EXAMPLE: THREE (3) VERTICAL EARTH LOOP SYSTEMS INSTALLED TO MAXIMIZE THE HEAT TRANSFER AREA WITH ADJACENT GROUND THAT IS RENEWABLE AS A SOURCE AND SINK FOR HEAT. Figure 1. Multiple Earth Loop System Placement Figure 2. Selected Multiple Vertical Earth Loop System Placement VEL-QS (08/16) Page 4

5 The following guidelines shall be followed when installing multiple vertical earth loop systems as they are shown in Figure 2: All individual earth loops of an earth loop system must be at the same depth. All individual earth loops in an earth loop system must be of equal length. No one earth loop is to contact another. Manifold Location IMPORTANT! FOR ALL EARTH LOOP SYSTEMS, THE LINE SET, MANIFOLDS AND EARTH LOOPS SHALL BE AT LEAST 5 FEET BELOW GRADE OR 1-12/ FEET BELOW THE LOCAL FROST LINE, WHICHEVER IS DEEPER. Manifolds for the earth loops must be located so that: 1. There is adequate space for the selected loop configuration. 2. The total equivalent line set length between the manifolds and the air handler (or cased coil) does not exceed 125 feet. 3. The manifolds are located in the pit in accordance with Figure 3. Be sure manifolds are located in an open area for easy access. 4. Connect earth loops to each manifold, carefully shaping the earth loops to avoid kinking, in a pin wheel fashion as shown in Figure 3. VEL-QS (08/16) Page 5

6 Figure 3. Manifold Pit Detail (Vertical and Diagonal configurations) VEL-QS (08/16) Page 6

7 Using a permanent structure as the basis for measurement, determine and record the distances A and B shown in Figure 4. Figure 4. Manifold Triangulation After locating the manifolds per distances A and B, record this information on the DIRECT AXXESS Warranty Registration (LIT-64) included with this information packet. Provide a copy of this completed form to the owner. VEL-QS (08/16) Page 7

8 Site Preparation and Bore Holes Lay out the bore hole circle and location of each bore hole with spray paint or flag markers, consistent with the selected DIRECT AXXESS Earth Loop System per the appropriate configuration included in this information packet. Diagonal bore hole patterns may be laid out on an 8 feet diameter circle. The space diagrams for diagonal bore hole patterns are based on an 8 feet diameter circle. IMPORTANT Diagonal bore holes are to be drilled on a specific uniform angle from vertical as noted in Figure 5. It is critical that the drilling angle for each bore hole be the same. If not, performance of the system will be negatively impacted, and could result in system failure. Figure 5. Vertical and Diagonal Earth Loops Drill bore holes at least 3 diameter to allow for appropriate grouting operations. Bore holes are to be drilled to a depth consistent with (1) the length of the earth loop and (2) the braze joint connections to the manifolds in the manifold pit. Details of the manifold pit connections are shown in Figure 3. Maintain each earth loop the same length. Do not shorten an earth loop. If it is too long, bend or coil it in a radius no smaller than 1 ft. to take up the extra length. It is critical that each earth loop have the same length to ensure normal system performance. It is recommended that the bore hole angle for diagonal installations not exceed 45 to ensure consistent grout fill. VEL-QS (08/16) Page 8

9 Earth Loop Installation The earth loop bore holes are drilled to a depth appropriate to accept the specified earth loops. The installer should check the earth loop to see that it is sealed, by quickly depressing and releasing the service valve stem at the end of the earth loop liquid (smaller) tube. The rushing sound of escaping nitrogen gas ensures that the earth loop is sealed. The pressurized coiled earth loop is uncoiled and straightened in 4 to 6 ft. lengths (as a minimum), and inserted into the bore hole. As an option, a flexible grouting hose (tremie tube) may be fed into the bore hole with the earth loop, at the same time. If the diameter of the drilled bore hole is large enough, the grouting hose can be inserted after the earth loop has been lowered into place. The method is the installer s choice. After each earth loop is installed in the bore hole and grouted or backfilled as appropriate, the earth loop pressure is checked again to ensure the assembly has maintained its seal during installation. The pressurized nitrogen is not entirely released from each earth loop until the earth loops are ready to be connected to the manifolds. VEL-QS (08/16) Page 9

10 Grouting CAUTION! Grout shall be utilized with all vertical and diagonal DIRECT AXXESS Earth Loop systems and mixed to yield a minimum thermal conductivity of at least 1.0 BTU/H-Ft-F, except where local codes and regulations specify otherwise. Grout shall be installed continuously FROM THE BOTTOM OF THE BORE HOLE UP, to ensure maximum earth contact and to prevent voids. SAND OR BORE HOLE TAILINGS SHALL NOT BE USED FOR GROUTING. Not using a grout previously authorized by EarthLinked Technologies, Inc. (ETI) Technical Services prior to earth loop installation, will void the ETI Limited Warrant on the entire EarthLinked System. If applicable code requirements specify the use of a grout other than those shown in Figures 13a through 13f, the subject grout must be authorized for use in that specific application by ETI Technical Services prior to earth loop installation. CAUTION! Information giving in this section serves as general guidelines only. Installers should FOLLOW THE GROUT MANUFACTURER INSTRUCTIONS. Failure to follow the grout manufacturer instructions will void the ETI Limited Warrant on the entire EarthLinked System. IMPORTANT Do not over-water the grout to facilitate pumping, this is detrimental to thermal conductivity and permeability and will negatively impact the performance of the grout. THERMAL CONDUCTIVITY (BTUH/ft. F) GROUT (50 lb BAG) SILICA SAND (lb) WATER YIELD Barotherm Gold Grout is available from Baroid IDP ( Figure 6a. Barotherm Gold Important mixing procedure for Barotherm Gold: pre-treat mixing water with Soda Ash (sodium carbonate) to reduce total hardness to less than 100 mg/l and to raise ph to VEL-QS (08/16) Page 10

11 THERMAL CONDUCTIVITY (BTUH/ft. F) GROUT (50 lb BAG) SILICA SAND (lb) WATER YIELD High TC Geothermal Grout is available from CETCI ( Figure 6b. High TC THERMAL CONDUCTIVITY (BTUH/ft. F) GROUT (50 lb BAG) WATER YIELD ± ± 0.2 GA-Xtra Grout is available from GEA ( ± 0.2 ga Figure 6c. GA-Xtra THERMAL CONDUCTIVITY (BTUH/ft. F) GROUT (50 lb BAG) WATER YIELD ± ± 0.2 GA-Xtra PLUS Grout is available from GEA ( Figure 6d. GA-Xtra PLUS THERMAL CONDUCTIVITY (BTUH/ft. F) TG Lite (50 lb bag) PowerTECx (lb) Type II Portland Cement (lb) WATER YIELD CG Plus 120 Grout is available from GeoPro, Inc. ( Figure 6e. CG Plus 120 THERMAL CONDUCTIVITY (BTUH/ft. F) TG Select (50 lb bag) PowerTECx (lb) Type II Portland Cement (lb) WATER YIELD CG Plus 120 Grout is available from GeoPro, Inc. ( Figure 6f. CG Plus 120S VEL-QS (08/16) Page 11

12 THERMAL CONDUCTIVITY (BTUH/ft. F) GROUT (50 lb BAG) SILICA SAND (lb) WATER YIELD Therm-Ex Grout is available from WYO-Ben. ( Figure 6g. Therm-X Figure 6h. BNL-111 Thermal grout volume requirements for vertical and diagonal DIRECT AXXESS Earth Loop configurations are listed in Figure 13i. Figure 13i. Grout Volume Requirements VEL-QS (08/16) Page 12

13 Manifold Assembly After earth loops have been inserted and grouted into the bore holes, the terminations of the earth loops are to be connected to the manifolds as shown in Figure 3. The vapor manifold (larger tubes) is to be located above the liquid manifold (smaller tubes) with the vapor manifold earth loop feeders up, the liquid manifold earth loop feeders down, as shown in Figure 3. First, the liquid earth loop tube terminations are cut and cleaned and fit to the liquid manifold connections, also cleaned. The liquid line of the field supplied manifold line set is cleaned and connected to the main port on the liquid manifold, also cleaned. The vapor manifold earth loop terminations and manifold line set connections, are done after the liquid connections are brazed. IMPORTANT! When brazing is completed on all liquid and vapor connections at the manifolds, orient the manifolds and earth loops in the manifold pit as shown in Figure 3, ensuring that the two manifolds are vertical. See Backfilling section. VEL-QS (08/16) Page 13

14 Line Set IMPORTANT! WHEN A LINE SET IS RUN ALONG (PARALLEL TO, NOT THROUGH) A FOUNDATION, THE MINIMUM DISTANCE BETWEEN THE LINE SET AND THE FOUNDATION IS 10 FEET. Manifold/Earth Loop line set sizes are shown in Figure 7. COMPRESSOR LINE SET O.D., INCHES UNIT SIZE LIQUID* VAPOR* 1.5 Tons (-018) 3/8 5/8 2.0 Tons (-024/-025) 3/8 5/8 2.5 Tons (-030) 3/8 3/4 3.0 Tons (-036) 1/2 3/4 3.5 Tons (-042) 1/2 3/4 4.0 Tons (-048) 1/2 7/8 5.0 Tons (-060) 1/2 7/8 6.0 Tons (-072) 1/2 1-1/8 Figure 7. Line Set Sizes Prior to or after brazing the earth loop and line set to the manifolds, the line set should be installed and run to the location of the compressor unit. The methods are shown in Figure 8. Figure 8. Single Trench Line Set VEL-QS (08/16) Page 14

15 IMPORTANT! FOR ALL EARTH LOOP SYSTEMS, THE LINE SET AND MANIFOLDS SHALL BE AT LEAST 5 FEET BELOW GRADE OR 1-1/2 FEET BELOW THE LOCAL FROST LINE, WHICHEVER IS DEEPER. If the compressor unit is to be placed outdoors, the line set is brought up through the ground adjacent to the compressor unit back side (nearest the wall), maintaining separation of the insulated refrigerant lines. If the compressor unit is to be placed indoors, the line set must be run through or under an outer wall to the compressor unit location. The following guidelines are to be used in conjunction with Figure 9, for above ground, slab and crawl space applications. 1. Enter the building above grade, if at all possible. 2. Below grade entry is a source for basement wall leakage. Seal with flexible sealant that maintains a tight seal for temperatures from -40 F to +200 F and adheres to all materials involved. To SEAL AROUND THE OUTSIDE OF THE PVC PIPE at the building entry shown in Figure 9, any one of the following sealants is recommended: Loctite POLYSEAMSEAL Caulk and All Purpose Adhesive Caulk DAP DYNAFLEX 230 Premium Interior/Exterior Latex Sealant 3M Polyurethane Construction Sealant 525 To FOAM THE INSULATED LINE SET TUBES INSIDE THE PVC SLEEVE shown in Figure 9, the following airtight and water proof sealant is recommended: Dow Insulating Foam Sealant ( Great Stuff, # ) IMPORTANT! It is noted that after the insulated vapor and liquid lines enter the building they must continue to be separated by an air space from the point of building entry to the compressor unit. After all brazing has been done on the earth loops/manifolds/line set; the line set compressor unit ends of the tubes are to be prepared as shown in Figure 10, in preparation for the earth loop system seal test. Braze a service valve into the vapor line termination and a cap onto the liquid line termination as shown in Figure 10. VEL-QS (08/16) Page 15

16 Figure 9. Line Set Building Entry Figure 10. Line Set Termination at Compressor End Unit for Seal Test VEL-QS (08/16) Page 16

17 Seal Test WARNING! To avoid personal injury and equipment damage, follow all safety procedures set forth by OSHA, in the handling of high pressure gases. Always use a pressure regulator and hoses that are capable of withstanding the pressures prescribed herein. Do not subject system components OTHER than the earth loop/manifold/line set configuration to 400 PSIG nitrogen. After brazing the earth loop system joints as noted above (includes manifolds, earth loops and earth loop line set, but NOT the compressor unit or any other HVAC refrigeration system component), the complete underground system is to be seal tested with 400 PSIG nitrogen. After connecting a high pressure hose from the regulator on the nitrogen tank to the service valve on the vapor line of the line set, slowly increase the nitrogen pressure to 400 PSIG, checking for any obvious leaks audibly. If no audible leaks are detected, check all joints to ensure they are sealed, by one of the following methods: 1. Ultrasonic Leak Detector or Bubble Solution Leak Detector 2. Electronic Leak Detector (requires a trace amount of refrigerant in the system) IMPORTANT LOOP READINESS Check for leaks by either of these methods or any other reliable method to ensure that there are no leaks and the earth loop system is sealed! It is absolutely necessary that the earth loop/manifold/line set assembly be completely sealed at 400 psig nitrogen. Recheck all leak detector readings. When the Earth Loop System (earth loops, manifolds and line set assembly) has been successfully seal tested, leave 400 psig nitrogen with pressure gauge on the service valve in Figure 10. This indicates the Earth Loop System has been installed; seal checked and is ready for the compressor unit connection. When the line set/manifolds/earth loops are deemed leak free and sealed, valve off the nitrogen source and monitor the pressure on the underground system to ensure that 400psig has been maintained for minimum of 8 hours. Note that there may be slight variations in the pressure reading after 8 hours due to to normal changes in air and/or ground temperatures. Monitor the pressure reading during the backfilling operation to ensure that the earth loop system remains sealed. VEL-QS (08/16) Page 17

18 Backfilling When brazing is completed on all liquid and vapor connections at the manifolds, orient the manifolds and earth loops in the manifold pit as shown in Figure 3, ensuring that the two manifolds are vertical. Carefully pack sand around the manifolds to ensure they are firmly oriented vertically. The sand is added first, then water to compact it. Be sure manifolds and feeder tubes near the manifolds are covered with at least 6 inches of sand to ensure vertical orientation before back-filling. Add water to shored-up area around manifolds and earth loop connections to cover the manifolds. This will ensure firm compaction of the sand that is to be packed around the manifolds and earth loop connections. CAUTION Failure to surround and pack the manifold pit assembly with sand as shown in Figure 3 will negatively impact system performance and may cause a leak in the earth loop. It will void the Earth Loop warranty. Backfill the line set trench with excavated fill if there are no rocks or sharp objects. If the backfill has rocks and/or sharp objects, fill the line set trench with 2 of sand under and over the line set and then carefully backfill the excavated fill. VEL-QS (08/16) Page 18