Installation, Operating, and Maintenance Manual

Transcription

1 Engineered Solutions Making Geothermal Easier Installation, Operating, and Maintenance Manual NP Multi Series Multi Circuit Non-Pressurized Flow Centers Part # 4147 Rev. 20DEC2017 Geo-Flo Products Corporation 905 Williams Park Drive Bedford, Indiana 47421, U.S.A Main Number: Toll Free: Fax:

2 Installation, Operating, and Maintenance Manual Rev. 20DEC2017 Table of Contents General Description Model Nomenclature Flow Center Sizing Installation Mounting Flow Center Variable Speed with Zone Valves Constant Speed (Circulators) Flushing and Purging Variable Speed with Zone Valves Constant Speed (Circulators) ,18 Wiring Variable Speed with Zone Valves Constant Speed (Circulators) Start-up Maintenance NOTES: This guide provides the installer with instructions specific to NP Series Multi Circuit Flow Centers. Please refer to your heat pump manufacturer s instructions or IGSHPA guidelines for additional detailed flushing, purging, and installation information. Please review the entire IOM document before proceeding with the installation. Geo-Flo Products Corporation is continually working to improve its products. As a result, the design and specifications of products in this catalog may change without notice and may not be as described herein. For the most up-to-date information, please visit our website, or contact our customer service department. Statements and other information contained in this document are not express warranties and do not form the basis of any bargain between the parties, but are merely Geo-Flo s opinion or commendation of its products.

3 NP MULTI SERIES NON-PRESSURIZED FLOW CENTERS 1 General Description The NP Series Multi Circuit (NPM) is a family of non-pressurized flow centers used for closed-loop geothermal (ground source) heat pump systems, and is specifically designed for applications with three to five geothermal heat pumps sharing a common ground loop. A wide variety of choices within the product family allow for both highly efficient variable speed pumps and zoning with valves (Figure 1, 2, 3), or small circulators dedicated to each heat pump (Figure 4). The NPM can be installed with up to 30 tons of equipment per loop depending on system design and project specific details. Larger systems can be accommodated by installing a dedicated loop for every 30 tons of equipment required. Each NPM flow center consists of a HDPE fluid reservoir (tank) housed in a closed-cell foam-insulated, powder coated steel cabinet. The tank provides water column to deliver the necessary suction head for the circulator pumps and to ensure a flooded pump volute to prevent the pumps from becoming air-locked. In addition, the reservoir s body is sized to create a low fluid velocity region allowing both air and sediment to separate from the fluid. The sealing cap ensures a closed system while providing integrated pressure and vacuum relief to prevent the reservoir from being over-pressurized or dropping below atmospheric pressure. Union ball valves are included on the tank s supply and return connections for ease of installation and tank isolation during startup and/or servicing. A fill and drain ball valve at the base of the tank comes standard for initial filling as well as refilling, draining, and sediment removal. The flexible sight tube is useful for quickly determining the fluid level. Pressure/Vacuum Relief Cap Flushing/Purging Valve To Loop 2 Pipe Connection or 3 Flange Connections Zone Valve 2 or 3 Connections Sight Tube Supply Header Return Header To/From 3, 4, or 5 Heat Pumps From Loop Flushing/Purging Valve Flushing/Purging Valve MAGNA3 Variable Speed Insulated Pump Foam Insulated HDPE Tank; Powder Coated Steel Cabinet Figure 1: Example of NPM5Z-TTTTT-21S-P Drain/Fill Valve Isolation Ball Valves NOTE: Example is a five circuit NP Multi flow center. Three and four circuit versions have the same components, but have one or two less connections to the heat pumps at the manifolds.

4 2 Installation, Operating, and Maintenance Manual Rev. 20DEC2017 Figure 2: Example of NPM5Z-TTTTT-22P-P NOTE: Examples are five circuit NP Multi flow centers. Three and four circuit versions have the same components, but have one or two less connections to the heat pumps at the manifolds. Figure 3: Example of NPM5Z-TTTTT-22S-P

5 NP MULTI SERIES NON-PRESSURIZED FLOW CENTERS 3 Pressure/Vacuum Relief Cap Isolation Ball Valve & Check Valve To Loop 2 Pipe Connection or 3 Flange Connection 2 or 3 Connections From Loop Sight Tube To Heat Pumps Return Header From Heat Pumps Flushing/Purging Valve Foam Insulated HDPE Tank; Powder Coated Steel Cabinet Figure 4: Example of NPM5P NNN-P Drain/ Fill Valve Supply Header Isolation Ball Valves Flushing/Purging Valves NOTE: Example is a five circuit NP Multi flow center. Three and four circuit versions have the same components, but have one or two less connections to the heat pumps at the manifolds.

6 4 Installation, Operating, and Maintenance Manual Rev. 20DEC2017 Model Nomenclature ,13 NPM 3 Z - TTTNN - 2 2P - 14 F NP Multi Ground Loop Connections P = 2" Pipe connection* -- with flush valves Number of Heat Pumps F = 3" ANSI 150# 4-bolt flange -- with flush valves 3 = 3 Circuits * Includes adapters for 2" HDPE pipe & 2" PVC glue 4 = 4 Circuits 5 = 5 Circuits Central Variable Speed Pump NN = N/A (when digit 5 = P) System Type 1S = Single insulated pump P = Circulator(s) for each heat pump 2P = Two insulated pumps in parallel Z = Zone valve for ea. heat pump 2S = Two insulated pumps in series (central variable speed pumping) Central Variable Speed Pump Model System Configuration N = N/A (when digit 5 = P) Digit 6 = Heat Pump #1 1 = Magna variable speed insulated pump Digit 7 = Heat Pump #2 See Central Pumping or (up to 33 ft. of 30 gpm; up to 23 ft. of 60 gpm) Digit 8 = Heat Pump #3 Distributed Pumping, 2 = Magna variable speed insulated pump Digit 9 = Heat Pump #4 below. (up to 50 ft. of 30 gpm; up to 32 ft. of 60 gpm) Digit 10 = Heat Pump #5 Series/Parallel Combinations (Magna3) Central Variable Speed Pumping -- digit 5 = Z Use one of the following choices for digits 6 to 10: in parallel in parallel up to 33 ft. of 60 gpm up to 50 ft. of 60 gpm T = 1" Taco Geo Sentry zone valve (Cv = 8.9) up to 66 ft. of 30 gpm in series B = 1" Belimo zone valve (Cv = 30) up to 46 ft. of 60 gpm R = Remote valve at heat pump (header with isolation valves) up to 100 ft. of 30 gpm in series N = This circuit not used (use in digit 9 and/or 10 for NPM3 or NPM4) up to 64 ft. of 60 gpm NOTE: Circuit field connections are 1" FPT. Distributed Pumping (circulator for heat pump) -- digit 5 = P (Notes 1,3) Use one of the following choices for digits 6 to 10: NOTES: 1 = One UPS Arrange circuits from the the largest to smallest number of 2 = Two UPS26-99 pumps in series. For example, use two pumps in series for 3 = Three UPS26-99 (Note 2) circuit one, two pumps in series for circuit two, and one 4 = One UP pump on circuit three. 5 = Two UP If any circuit has 3 pumps in series, all other circuits must 6 = Three UP (Note 2) have at least two pumps in series. N = This circuit not used (use in digit 9 and/or 10 for NPM3 or NPM4) 3. All pumps must either be UPS26-99 or UP

7 NP MULTI SERIES NON-PRESSURIZED FLOW CENTERS 5 Flow Center Sizing When sizing pumps for a NPM multi-circuit flow center, it is critical that a pressure drop calculation be completed for the entire system when all heat pumps are running. Pump selection must be based upon the required system flow rate and pressure drop with all units running. While this is a relatively straightforward process and calculation for projects with one or two heat pumps, it is increasingly complex for systems with three or more heat pumps particularly when zoning with circulators. The details of this calculation are beyond the scope of this IOM. However, Geo-Flo provides a free online calculator for this product to assist in the design and selection of the proper NPM. Go to select Design Calculators, Pressure Drop Calculators, and Multi Unit (NPM) flow center (see Figure 5). Figure 5: Screen shot of NP Multi Calculator

8 6 Installation, Operating, and Maintenance Manual Rev. 20DEC2017 Installation Mounting the unit: NPM with Central Pump and Zone Valves 1. Determine the location of the tank and pumps. The NPM Series Multi Circuit flow center tank must be mounted on a level surface. The tank can be placed directly on the floor, or on an isolation pad such as a high density rubber pad or piece of expanded polystyrene. Note that the NPM can be mounted with the pump(s) on the right or left side of the tank (See Figures 6a and 6b). Figure 6a: Pump on right of tank Figure 6b: Pump on left of tank 2. Attach the insulated pump to the strut using panel/strut hardware (P/N 4159). Install the hex screw into the strut nut. Then, slide into strut channel. Next, place panel and pump onto the channel and secure with washers and hex nuts (Figures 7 through 9). Figure 7a: Installing strut nut Figure 7b: Strut nut installed Figure 8: Added to channel

9 NP MULTI SERIES NON-PRESSURIZED FLOW CENTERS /4 Figure 9: Pump mounted Figure 10: Board adjustment 3. Insert the suction manifold to the pump. Flo-Link XL fittings seal on the inner diameter with O-rings, and the mechanical retaining nut needs to be hand tight only. Adjust the board s position so that the center line of the suction manifold is approximately 11-1/4 from the base of the strut (Figure 10). 4. Attach the strut to a secure wall. Lag screws are provided to attach the assembly to a wood frame wall. Concrete anchors must be field supplied. TIP: Install the upper screw first in a position that allows for upward adjustment of the pump (i.e. near the bottom of the strut slot -- Figure 11). Once the screw is loosely installed, lift the pump assembly to align the union nut with the valve on the tank (Figure 12). Then, tighten the screw. Ensure that the union nut will thread onto the valve without binding. Next, use a level to ensure the assembly is level and plumb (Figure 13). Finally, install the final lag screw at the top of the slot near the base of the strut (Figure 14) to prevent downward movement of assembly. Figure 11: Install mounting screw with washer near the bottom of the slot to allow for upward adjustment of strut. Figure 12: Ensure the union nut is aligned with the valve. Then, tighten the upper screw.

10 8 Installation, Operating, and Maintenance Manual Rev. 20DEC2017 Install screw and washer at upper side of slot. Figure 13: Ensure the assembly is level and plumb. Figure 14: Install lower screw and connect suction manifold to 2 valve on tank. 5. Tighten the union nut on the suction header onto the ball valve on the tank (Figure 14). 6. Insert the supply header into the pump, and secure with supply header support hardware (P/N 4158 for single pump, P/N 4169 for series and parallel pumps -- Figure 15). Note that the pipe hanger should be installed closest to the end of the header for best support (Figure 16). Supply Header Figure 15: Install supply header into pump. For Single Pump For Series or Parallel Pumps Figure 16: Secure supply header to strut (single pump) or wall (series or parallel pumps). Figure 17: Wall mount hardware

11 NP MULTI SERIES NON-PRESSURIZED FLOW CENTERS 9 7. Install the return header in a convenient location. Two wall brackets, pipe hangers, and hardware are provided (P/N Figure 17). Two 6 pieces of threaded rod are included and can be cut down to any length necessary. 8. Secure the return pipe assembly (Figure 18) with the included pipe hanger kit (P/N Figure 17). The kit includes both a 4-1/8 piece of threaded rod for NPM_Z (central pump/zone valves: NPM3, 4, and 5) and a 3-1/2 piece for NPM_P (individual circulators: NPM3, 4, and 5). Note: If using PVC for interior piping to the ground loop, the supply return piping assembly and fittings (Figure 18) can be replaced with field supplied PVC fittings. The 2 PVC union glue adapter is provided for this purpose (Figure 19). In this case, the provided HDPE assembly can be dismantled to retain the 2 union nut, 1 valve, and cam fitting. PVC union glue adapter Figure 18: Return pipe assembly Figure 19: HDPE loop connections can be changed to PVC in field if desired. 9. Complete plumbing from supply and return headers to each heat pump (Figure 20). 10. Insulate all exposed piping including the sight tube. To HP #5 To Loop From HP #5 From Loop To HP #1* From HP #1* Figure 20: NPM connections/ direction of flow *Connect heat pump with the highest flow rate to circuit 1, the one with the next highest flow rate to circuit 2, and so on. This approach will minimize pressure drop through the header.

12 10 Installation, Operating, and Maintenance Manual Rev. 20DEC2017 Mounting the unit: NPM with Circulators 1. Determine the location of the tank and pumps. The NPM Series Multi Circuit flow center tank must be mounted on a level surface. The tank can be placed directly on the floor, or on an isolation pad such as a high density rubber unit pad or piece of expanded polystyrene. Note that the NPM can be mounted with the pump(s) on the right or left side of the tank (Figure 21) Figure 21: Pumps on the right of tank NOTE: Tank may be rotated 180 degrees, and pump assembly can be installed on the left side of the tank (similar to Figure 6b). 2. Insert hex screws into strut nuts, and slide nuts onto strut channel (Figures 22 through 24). Then, attach the mounting panel to the strut channel using washers and hex nuts (P/N 4160). Figure 22: Installing strut nut Figure 23: Strut nut installed Figure 24: Added to channel 3. Lay out the first row of circulators on the mounting panel. Insert the suction manifold into the pumps. Note that Flo-Link fittings seal on the inner diameter with O-rings, and the mechanical retaining nut needs to be hand tight only. Then, use wood screws to attach the first row of pumps to the panel. Use screws to attach the first row of pumps to the board. Two screws in opposite corners (e.g. bottom left and upper right) of the cabinet is sufficient to hold the pumps in place (Figure 25). Thirty #8 wood screws are provided (P/N 4161) to allow two screws per pump for up to 15 pumps.

13 NP MULTI SERIES NON-PRESSURIZED FLOW CENTERS 11 Figure 25: Attach first row of circulators to the supply manifold. 4. Adjust the board s position so that the center line of the suction header is approximately 11-1/4 from the base of the strut (Figure 26). 5. Attach the struts to a secure wall. Lag screws and washers are provided to attach the assembly to a wood frame wall (Hardware bag P/N 4160). Concrete anchors must be field supplied. TIP: On the strut closest to the tank, install the first screw in a position that allows for upward adjustment of the pump (i.e. near the bottom of the strut slot -- Figure 27). Once the screw is loosely installed, lift the pump assembly to align the union nut with the valve on the tank then tighten the screw (Figure 28). Next, use a level to ensure the assembly is level and plumb (Figure 29), and install a second lag screw at the top of the slot on the other strut (Figure 29). Ensure that the union nut will thread onto the valve without binding (Figure 30). Install the final lag screws and washers near the top of the slots at the base of the strut on both left and right sides (Figure 31). 11-1/4 Figure 26: Board adjustment Figure 27: Install mounting screw with washer near the bottom of the slot to allow for upward adjustment.

14 12 Installation, Operating, and Maintenance Manual Rev. 20DEC2017 Figure 28: Align union nut with tank valve. Figure 29: Ensure the assembly is level and plumb Figure 30: Ensure that the union nut will thread onto the valve without binding. Figure 31: Install the final lag screws and washers near the top of the slots. 6. Tighten the union nut on the suction header onto the ball valve on the tank. 7. Install Flo-Link couplers in the discharge side of the first row of pumps (Figure 32). The nut should be hand-tightened only. O-ring lubricant makes inserting the fittings much easier. NOTE: If using continuous (non-split) insulation, a small piece can be cut and installed at this time (Figure 33). Flo-Link coupler 8. Install the next row of pumps buy sliding the pump onto the Flo-Link coupler and securing the nut (Figure 34). Figure 32: Install Flo-Link couplers in discharge of first row of pumps.

15 NP MULTI SERIES NON-PRESSURIZED FLOW CENTERS 13 Figure 33: Install insulation between pumps Figure 34: Install next row of pumps. 9. Repeat the process in steps 7 and 8 until all pumps have been place. Note that the circuits with the most pumps should be installed closest to the tank (Figure 35). Figure 35: Install circuit(s) with the most pumps closest to the tank. 10. To ensure a neat appearance, align all pumps vertically above the first row by measuring between the mounting board and pump cabinet before attaching cabinets to board with screws. Two screws in opposite corners (e.g. bottom left and upper right) of the cabinet is sufficient (Figure 36). Figure 36: Measure and align all pumps vertically above the first row.

16 14 Installation, Operating, and Maintenance Manual Rev. 20DEC Install valves with installed check valves on the discharge of all pumps (Figure 37). 12. Install the return header in a convenient location. Two wall brackets, pipe hangers, and hardware are pro vided (P/N Figure 17). Two 6 pieces of threaded rod are included and can be cut down to any length necessary. Ball valve with internal check valve 13. Secure the return pipe assembly (Figure 38) with the included pipe hanger kit (P/N 4156). The kit includes both a 4-1/8 piece of threaded rod for NPM_Z (central pump/zone valves: NPM3, 4, and 5) and a 3-1/2 piece for NPM_P (individual circulators: NPM3, 4, and 5). Note: If using PVC for interior piping to the ground loop, the supply return piping assembly and fittings (Figure 38) can be Figure 37: Install ball valves with check valves on top row. replaced with field supplied PVC fittings. The 2 valve PVC union glue adapter is provided for this purpose (Figure 39). In this case, the provided HDPE assembly can be dismantled to retain the 2 union nut, 1 valve, and cam fitting. 14. Complete plumbing from pumps and return headers to each heat pump (Figure 40). PVC union glue adapter Figure 38: Return pipe assembly Figure 39: HDPE loop connections can be changed to PVC in field if desired. To HP #1* To Loop To HP #5 From HP #5 From Loop Figure 40: NPM connections/ direction of flow From HP #1* *Connect heat pump with the highest flow rate to circuit 1, the one with the next highest flow rate to circuit 2, and so on. This approach will minimize pressure drop through the header.

17 NP MULTI SERIES NON-PRESSURIZED FLOW CENTERS 15 Flushing and Purging NOTICE: Using a quality flush cart is the fastest and easiest way to ensure that all air and debris is removed from the ground loop. The flush cart must be able to provide a minimum fluid velocity of 2 ft/s through all piping, provide filtering, and allow power flushing. It is extremely common for construction debris, polyethylene pipe shavings, dirt, sand, rocks, etc. to enter the ground loop piping during installation. The wet rotor circulator pump(s) used during system operation require clean, debris-free fluid to function properly. A small amount of debris in the ground loop could become lodged between the pump s rotor and stator housing causing pump failure a few days to a few years after initial installation. This preventable issue is a common mode of failure for circulators. Although the NP Series flow centers do have the ability to separate air from the loop fluid, its pumps are not powerful enough to guarantee that all air and debris can be flushed from every type of loop during the initial loop installation. Geo-Flo recommends flushing all ground loops with a quality flush cart to ensure that the loop is free of air and debris when the loop installation contractor leaves the job site. NOTE: This installation guide assumes the installer has a solid understanding of how to use a flush cart. Detailed flushing and purging information, as well as detailed flush cart directions, are provided in the Geo-Flo Flush Cart IOM. CAUTION: NEVER DEAD-HEAD THE FLUSH CART PUMP INTO THE FLUID RESERVOIR OF THE NPM. NEVER ATTEMPT TO FLUSH THROUGH THE TANK USING A FLUSH CART PUMP. OVER-PRESSUR- IZATION OF THE FLUID RESERVOIR COULD BE DANGEROUS AND WILL VOID THE WARRANTY. FLUSHING AND PURGING: NPM WITH CENTRAL PUMP AND ZONE VALVES Ground Loop Flushing and Purging 1. Attach flush cart 1 cam fittings on the return loop pipe tee and the return header. The flush cart pump supply/discharge hose should be connected to the loop return, and the cart s return hose should be connected to the return header (Figure 41). Close Valve Remove Cap Close Valves Open Valve Close Valves Open Valves Open Valves Figure 41: Flushing setup

18 16 Installation, Operating, and Maintenance Manual Rev. 20DEC Remove the cap from the NPM Series tank. This step is precautionary and intended to protect the flow center tank from accidental over-pressurization. If the operator places the valves in the incorrect orientation and starts the flush cart, the fluid from the flush cart will quickly fill and overflow the tank. 3. Close 2 valve on the tank and all circuit valves to isolate the NPM tank and heat pumps. Open 1 valves at the flush cart connections and the 2 valve connected to the ground loop on the header (Figure 41). 4. Flush/purge the loop using a high quality flush cart per the Geo-Flo Flush Cart Manual IOM. 5. After flushing is complete, add antifreeze if necessary. Refer to the Pump and Dump method of adding antifreeze in the Geo-Flo Flush Cart Manual IOM. Then, close both 2 valves connected to the ground loop. WARNING: ONLY USE PREMIXED ANTIFREEZE IN A NON-FLAMMABLE STATE. FAILURE TO OBSERVE SAFETY PRECAUTIONS MAY RESULT IN FIRE, INJURY, OR DEATH. 6. Remove the tank s cap. Close the 1 valve connected to the discharge hose of the flush cart; this valve will be used to control the fill speed. Then, open the 2 valve on the return side of the tank, the two 2 valves on the pump suction/discharge, and the 1 flush valve (with cam adapter) at the top of the supply header. Slowly fill the tank and pump stack by starting the flush cart and slightly opening the 1 valve while monitoring the fluid level in the sight tube (Figure 42). When the fluid has reached the top of the sight tube, shut off the 1 flush valve and then turn off the flush cart. Close the 2 valve on the tank. Note that the fluid level in the flush cart tank will drop and must be monitored and filled during this filling process. Filling the NP tank and pump in this manner pushes air from the supply manifold and pump. Care must be taken with the parallel and series version of the NPM since the flush valve/cam adapter on the supply header is lower than the tank. In this case, the flush valve on the supply header should be closed. Remove Cap Close Valve Sight Tube Open Valve Control fill speed using 1 valve Open Valves Figure 42: Filling the tank and manifold stack 7. Close both 1 flush valves at the cam fittings and disconnect the flush cart. Do not pressurize the ground loop. Replace the cap on the tank.

19 NP MULTI SERIES NON-PRESSURIZED FLOW CENTERS 17 Flushing Heat Pump Circuits 1. Close 2 valves to isolate ground loop, tank, and pump. Close 1 flush valve on return pipe (Figure 43). 2. Remove the cap from the NP Series tank. This step is precautionary and intended to protect the flow center from accidental over-pressurization. If the operator places the valves in the incorrect orientation and starts the flush cart, the fluid from the flush cart will quickly fill and overflow the tank. 3. Attach the flush cart to the 1 cam fittings on the supply header and return header. The flush cart pump supply/discharge hose should be connected to the supply header, and the return hose should be connected to the return header (Figure 43). The flush cart hose may need to be supported to prevent excessive stress at the supply header elbow. Remove Cap Support hoses to prevent stress Close Valve Close Valve To HP1 From HP1 Close Valves Open Valves Figure 43: Flushing heat pump circuit 1 4. Flushing direction is the circuit furthest from the flush cart supply hose. Open the first circuit valves on both the supply and return headers to flush the first heat pump circuit. (Figure 43). Flush/purge the first circuit. NOTE: Fluid should not enter the NP Series tank during flushing. If it does, immediately stop the flush cart pump and check to be sure the valves are in the correct orientation. 5. With the cart s pump still running, open the second circuit s valves. Then, close the valves on the first circuit. (Figure 44). Flush/purge the second circuit. 6. Repeat the steps above to flush all circuits. 7. Once all circuits are flushed, close the 1 flush valves and disconnect the flush cart. Replace cap on tank.

20 18 Installation, Operating, and Maintenance Manual Rev. 20DEC2017 Remove Cap Support hoses to prevent stress Close Valve Close Valve To HP2 From HP2 Close Valves Figure 44: Flushing heat pump circuit 2 FLUSHING AND PURGING: NPM WITH CIRCULATORS Ground Loop Flushing and Purging 1. Attach flush cart 1 cam fittings on the return loop pipe tee and the return header. The flush cart pump supply/discharge hose should be connected to the loop return, and the cart s return hose should be connected to the return header (Figure 45). 2. Remove the cap from the NPM Series tank. This step is precautionary and intended to protect the flow center tank from accidental over-pressurization. If the operator places the valves in the incorrect orientation and starts the flush cart, the fluid from the flush cart will quickly fill and overflow the tank. 3. Close 2 valve on the tank and all circuit valves to isolate the NPM tank and heat pumps. Open 1 valves at the flush cart connections and the 2 valve connected to the ground loop on the header (Figure 45). 4. Flush/purge the circuit using a high quality flush cart per the Geo-Flo Flush Cart Manual IOM. 5. After flushing is complete, add antifreeze if necessary. Refer to the Pump and Dump method of adding antifreeze in the Geo-Flo Flush Cart Manual IOM. Then, close both 2 valves connected to the ground loop. WARNING: ONLY USE PREMIXED ANTIFREEZE IN A NON-FLAMMABLE STATE. FAILURE TO OBSERVE SAFETY PRECAUTIONS MAY RESULT IN FIRE, INJURY, OR DEATH. 6. Remove the tank s cap. Close the 1 valve connected to the discharge hose of the flush cart. Open the 2 valve on the return side of the tank. Fill the tank by slowly opening the 1 valve and monitoring the fluid level in the sight tube (Figure 46). When the fluid has reached the top of the sight tube, shut off the 1

21 NP MULTI SERIES NON-PRESSURIZED FLOW CENTERS 19 valve and then turn off the flush cart. Close the 2 valve on the tank. Note that the fluid level in the flush cart tank will drop and must be monitored during this filling process. 7. Close both 1 flush valves at the cam fittings and disconnect the flush cart. Do not pressurize the ground loop. Close Valve Remove Cap Open Valves Open Valves Figure 45: Flushing setup Close Valve CAUTION: NEVER DEAD-HEAD THE FLUSH CART PUMP INTO THE FLUID RESERVOIR OF THE NPM. NEVER ATTEMPT TO FLUSH THROUGH THE TANK USING A FLUSH CART PUMP. OVER-PRESSUR- IZATION OF THE FLUID RESERVOIR COULD BE DANGEROUS AND WILL VOID THE WARRANTY. Remove Cap Sight Tube Close Valve Open Valve Control fill speed using 1 valve Figure 46: Filling the tank Close Valve

22 20 Installation, Operating, and Maintenance Manual Rev. 20DEC2017 Flushing Heat Pump Circuits 1. Close 2 valves to isolate ground loop and tank. Close 1 flush valve on return pipe (Figure 47) and all circuit valves. 2. Remove the cap from the NP Series tank. This step is precautionary and intended to protect the flow center from accidental over-pressurization. If the operator places the valves in the incorrect orientation and starts the flush cart, the fluid from the flush cart will quickly fill and overflow the tank. 3. Attach the flush cart to the 1 cam fittings on the suction manifold and return header. The flush cart pump supply/discharge hose should be connected to the manifold below the pumps, and the return hose should be connected to the return header. Remove Cap To HP1 Close Valve Return Header From HP1 Close Valves Manifold Figure 47: Flushing heat pump circuit 1 Close Valve 4. Flushing direction is the circuit furthest from the flush cart supply hose. Open the first circuit valves to flush the first heat pump circuit (Figure 47). Flush/purge the first circuit. NOTE: Fluid should not enter the NP Series tank during flushing. If it does, immediately stop the flush cart pump and check to be sure the valves are in the correct orientation as shown in Figure With the cart s pump still running, open the second circuit s valves. Then, close the three valves on the first circuit (Figure 48). Flush/purge the first circuit. 6. Repeat the steps above to flush all circuits. 7. Once all circuits are flushed, close the 1 valves on the tops of the pumps. Open all 1 valves on the manifold (bottoms of the pumps). Ensure the 2 valve on NPM tank is closed (Figure 49). Turn on the flush cart pump to pressurize the manifold and each pump stack. Turn each circulator s vent screw a ½ turn counterclockwise until a drop of water appears, then re-tighten the screw. This ensures that the pump s bearings are lubricated and free of air (Figure 50). When all pumps have been vented, turn off the flush cart, close the flush valves, and disconnect the flush cart hoses. NOTE: This step is critical. Opening the vent screw and allowing fluid to drip out ensures that all trapped air has exited the pump motor. Skipping this important step could lead to premature pump failure.

23 NP MULTI SERIES NON-PRESSURIZED FLOW CENTERS 21 Remove Cap To HP2 Close Valve Return Header From HP2 Close Valves Manifold Figure 48: Flushing heat pump circuit 2 Close Valve CAUTION: NEVER DEAD-HEAD THE FLUSH CART PUMP INTO THE FLUID RESERVOIR OF THE NPM. NEVER ATTEMPT TO FLUSH THROUGH THE TANK USING A FLUSH CART PUMP. OVER-PRESSUR- IZATION OF THE FLUID RESERVOIR COULD BE DANGEROUS AND WILL VOID THE WARRANTY. Close 1 Valves Close 2 Valve Figure 49: Pressurize manifold and pump stack Close 2 Valve Close 2 Valve Open 1 Valves

24 22 Installation, Operating, and Maintenance Manual Rev. 20DEC2017 Figure 50: Vent each of the circulators NOTE: This step is critical. Opening the vent screw and allowing fluid to drip out ensures that all trapped air has exited the pump motor. Skipping this important step could lead to premature pump failure. PUMP WIRING: NPM WITH CENTRAL PUMP AND ZONE VALVES Magna3 Wiring WARNING: OPEN THE MAIN POWER SUPPLY DISCONNECT SWITCH AND SECURE IT IN AN OPEN POSITION PRIOR TO PERFORMING ELECTRICAL WORK. VERIFY THAT POWER HAS BEEN DISCONNECTED PRIOR TO WIRING THE PUMP(S). FAILING TO SECURE THE ELEC- TRICAL SUPPLY COULD RESULT IN SERIOUS INJURY OR DEATH. 1. Before attaching power, remove the Start/Stop jumper (remove the entire green plug with the jumper). This will prevent the pump from starting when eventually powered. See Figure Complete high voltage wiring to the pump. Locate the power supply plug and conduit adapter in the box supplied with the pump. Connect wiring from pump disconnect to the pump terminal block as shown in Figure 52. Pump terminals are labeled L, N, and ground (symbol) for both V and 115V pumps. For V pumps, connect L to L1 and N to L2; for 115V pumps, connect L to L and N to N. Wiring must meet all applicable code requirements, including requirements for wire protection, such as conduit. Wire and breaker/fuse size must be determined based upon pump nameplate ratings. Figure 51: Remove Start/Stop jumper WARNING: MAGNA3 PUMPS ARE AVAILABLE IN V AND 115V. VERIFY PUMP NAMEPLATE VOLTAGE BEFORE CONNECTING HIGH VOLTAGE WIRING.

25 See nameplate for correct voltage. 23 If the pump is installed in the return pipe of the system, the built-in temperature sensor can be used. If the constant-temperature control mode has been enabled and the pump is installed in the flow pipe of the system, the sensor must be installed in the return pipe. If the pump is installed in the return pipe of the system, the sensor must be installed in the flow pipe. When the input is used for the heat energy meter, a temperature sensor must be installed in the return pipe. s with 0-10 V or 4-20 ma signal. The analog input can also be used for an external signal for the control from a BMS system or similar control system. See fig. 18. It is possible to use sensor type See fig. 12, pos. 3. The analog input can be used fo r the connection of an external sensor for measuring temperatur e, pressure, flow or other parameter. See fig. 17. Figure 52: High voltage wiring Analog input Select the function of the digita l input on the pump control panel or with the Grundfos GO Remote. Q H M I H M I Q Min. curve Normal duty Min. curve H M A Q Q H M A Max. curve The pump can be forced to operate the digital input. External forced max. or min. curve CAUTION: DO NOT DEADHEAD THE PUMP. USE A PUMP ENABLE RELAY (SEE STEP 3, BELOW) OR PROVIDE A BYPASS ZONE TO AVOID DAMAGING THE PUMP AND/OR PIPING. Max. curve Normal duty on the max. or min. curve via NP MULTI SERIES NON-PRESSURIZED FLOW CENTERS L (L1) N (L2) 3. For systems operating in constant differential pressure mode or constant curve mode, a pump enable relay will leave the pump off unless at least one heat pump is calling for heating or cooling. The pump enable relay (Geo-Flo P/N 3808) may be wired to up to five heat pumps, as shown in Figure 53. Remove the factoryinstalled jumper from terminal block (shown in Figure 54). Then, run two-conductor 18 AWG thermostat wire from the Magna3 pump to the Pump Relay Dry Contacts terminals at the pump enable relay. External start/stop S /S M I (min. 10 A, time lag) M A HP-1 OUT Contact symbol Fuse Digital input Fig. 11 Example of typical connecti on, 1 x 230 V ± 10 %, 50/60 Hz Start/stop PUMP RELAY 24 VAC GFCI HP-1 IN HP-2 IN HP-2 OUT HP-3 OUT Start/stop PUMP RELAY 24 VAC HP-3 IN HP-4 OUT HP-4 IN HP-5 OUT HP-5 IN Connect to heat pumps using 18 AWG thermostat wire (see pump enable I.O.M. for wiring details). External switch PUMP RELAY DRY CONTACTS The pump can be started or stopped via the digital input. Function PUMP RELAY DRY CONTACTS M A M I S/S English (US) Figure 53: Pump enable wiring 5.3 Connection diagram Frame connection S ta rt/s top Min. curve 25 % speed Max. curve 100 % speed On/off timer TM After the heat pumps and Magna3 pump have been wired to the pump enable relay, connect the wall transformer to the pump enable relay. 19 Fig. 14 WARNING: MAKE SURE THAT POWER IS DISAll cables used must be connected in Note CONNECTED BEFORE WIRING PUMP ENABLE accordance with local regulations. External forced max. or min. curve RELAY. pump can be forced to operate on the max. or m 5.4 Connection to external The controllers the digital input. Max. curve M A M A Figure 54: Start/Stop jumper H Norma Q M I S/S M A H Max. c Factory installed jumper Q Min. curve M I Fig. 12 Norma Connection diagram Warning On/off timer H Q M H I outputs Wires connected to supply terminals, NC, NO, C and start/stop input must be separated from each other and from the supply by Min. c Q

26 24 Installation, Operating, and Maintenance Manual Rev. 20DEC2017 Zone Valve Wiring The Taco Geo Sentry and Belimo zone valves includes an end switch, which ensures that the valve is fully open before energizing the compressor to avoid a potential low flow heat pump lock out. Wire the valves to the heat pumps as shown in Figures 55a and 55b. THERMOSTAT HEAT PUMP THERMOSTAT HEAT PUMP R R R R G G G G O O O O Y Jumper C Y Y Jumper C Y C W/Y END SWITCH GEO-SENTRY Figure 55a: Taco zone valve wiring 1 2 S1 S3 C W/Y END SWITCH BELIMO ACTUATOR Figure 55b: Belimo zone valve wiring PUMP WIRING: NPM WITH CIRCULATORS Pump #2 N L UPS26-99 From heat pump fused/circuit breaker protected pump connections Ground L2 L1 N L Pump #1 Constant Speed Pumps L1 Figure 56: Pump field wiring to heat pumps L2 Capacitor UP WARNING: OPEN THE MAIN POWER SUPPLY DISCONNECT SWITCH AND SECURE IT IN AN OPEN POSITION PRIOR TO PERFORMING ELECTRICAL WORK. VERIFY THAT POWER HAS BEEN DISCONNECTED PRIOR TO WIRING THE PUMP(S). FAILING TO SECURE THE ELEC- TRICAL SUPPLY COULD RESULT IN SERIOUS INJURY OR DEATH.

27 NP MULTI SERIES NON-PRESSURIZED FLOW CENTERS 25 Start-Up 1. Open the 2 valves to the tank and the ground loop. Open all 1 valves, except the flush valves (Figure 57). 2. Start flow center pump(s) and allow system to operate for several minutes. Check fluid level adding additional loop fluid, if necessary, while pump(s) are running. 3. Measure and record the flow rate using one of the methods described in the following section of this document. The flow rate through each heat pump must be verified with all heat pumps operating simultaneously. If using a NPM with three speed pumps, the flow can be adjusted by changing the pump(s) speed. The valves on discharge side of the circulators (top) can also be used to balance the flow through each unit. The system should be balanced by starting with the highest flow rate unit and working toward the lowest. The flow rate should be within the range suggested by the heat pump manufacturer (generally gpm) when all units are operating simultaneously. If installing a system with a Magna3 pump, refer to the specific IOM for setup instructions. 4. Verify the performance of the heat pumps per the manufacturer s literature by calculating the heat of extraction and/or rejection (HE-HR). The Geo-Flo website has a free calculator to assist in this calculation. Go to select Design Calculators, then HE-HR Calculator. The HE-HR should be within the range specified by the heat pump manufacturer. 5. To limit condensation, insulate all exposed piping including the sight tube assembly. Open 2 Valve Open 2 Valve Figure 57: Valve positions for startup Open 2 Valve

28 26 Installation, Operating, and Maintenance Manual Rev. 20DEC2017 Measuring System Flow Rate The system flow rate can be determined using two different methods as described below. Method 1: Flow rate from pressure drop 1. Measure the pressure drop across the heat pump s heat exchanger via the PT ports located at the water connections of the unit (Figure 58). Use a single large dial face pressure gauge to allow for more precise measurement. 2. Determine the flow rate using the manufacturer s published tables for pressure drop versus flow (Table 1). If the pressure drop is off the manufacturer s chart, the flow rate can be determined using a free online calculator available on Geo-Flo s website. Go to select Design Calculators then Flow Rate Calculator. Method 2: Direct measurement using a flow meter NOTE: A Geo-Meter flow tool or other flow meter may be field modified for this purpose. However, the flow range for the Geo-Meter s flow meter is 2-20 GPM. Therefore, it is likely that this direct measurement method can only be utilized up to ~7 tons of equipment. Further, additional pressure drop will be introduced by the flow meter and associated piping/hose so the results may not be accurate, particularly at higher flow rates. 1. Attach a flow meter to the flush valve on the return side of the tank. Direct a flexible hose on the other end of the flow meter into the top of the tank. Close the 2 valve on the return side of the tank (Figure 59). 2. Energize the pump(s). 3. Open the flush valve on the return side of the tank. 4. Read the flow rate. Figure 58: Measuring pressure drop EWT F Flow gpm PSI WPD FT FOR REFERENCE ONLY Table 1: Example of heat pump manufacturer s table of pressure drop vs. flow rate

29 NP MULTI SERIES NON-PRESSURIZED FLOW CENTERS 27 Flow Meter Tool Figure 59: Measuring flow rate with flow meter tool

30 28 Installation, Operating, and Maintenance Manual Rev. 20DEC2017 Maintenance There is no regularly scheduled maintenance required for the NPM Series flow center. However, the fluid level in the tank should be monitored particularly during the first several days after installation or service has been performed. Fluid may be added by pouring it into the top of the tank, or by attaching a garden hose to the valve at the base of the tank. The fluid level should remain above the base of the site tube (Figure 60). Lowest recommended fluid level Garden hose connection Figure 60: Filling with garden hose / minimum water level Replacing circulator pump WARNING: OPEN THE MAIN POWER SUPPLY DISCONNECT SWITCH AND SECURE IT IN AN OPEN POSITION PRIOR TO PERFORMING ELECTRICAL WORK. VERIFY THAT POWER HAS BEEN DISCON- NECTED PRIOR TO WIRING THE PUMP(S). FAILING TO SECURE THE ELECTRICAL SUPPLY COULD RESULT IN SERIOUS INJURY OR DEATH. 1. Determine whether the circulator pump needs to be replaced. The pump motor should only be replaced after successfully troubleshooting the system and determining that the pump is not functioning. 2. Close the 1 valves on both sides of the pump stack containing the defective pump (Figure 61). 3. Close all 2 valves to isolate the ground loop and tank. 4. Verify that power has been disconnected from the circulator pump(s) using a multimeter. 5. Disconnect wiring from pump. 6. Remove screws holding pump motor to pump housing (volute), and remove the pump motor. Note that a towel or pan should be used to capture the small amount of water that exits the pumps.

31 NP MULTI SERIES NON-PRESSURIZED FLOW CENTERS Inspect the pump motor and volute for signs that indicate the mode of failure. For example, if debris is present in the pump or volute the ground loop should be re-flushed with a quality flush cart equipped with a filter. 8. Clean the pump seat on the pump housing (volute) with a cloth to remove any debris so that the gasket on the pump will seal properly. Install the new pump motor and reconnect wiring. NOTE: The following steps assume flushing the individual circuit with a garden hose and domestic water supply or transfer pump. If flushing the circuit with a flush cart, see instructions in Flushing section above. 9. Install a hose from a water source to the pump s manifold. Attach a second hose to the return header and direct it to a bucket or floor drain (Figure 61). To HP1 Open Valve Open Valve From HP1 Water supply Open Valve Figure 61: Replacing circulator pump 10. Turn on the water source. Open the lower valve to allow water to flow into the pump stack, and then open the upper valve to allow water to flush the circuit. Continue flushing until all air has been removed from this circuit. 11. With the water source still on, shut off the upper valve then the lower valve. This pressurizes the pump stack. Open the vent screw in the center of the pump motor just installed with a large flat head screwdriver allowing a few drops of fluid to drip out. Then, retighten the vent screw. NOTE: This step is critical. Opening the vent screw and allowing fluid to drip out ensures that all trapped air has exited the pump motor. Skipping this important step could lead to premature pump failure. 12. Turn off the water supply and disconnect the hoses. 13. Open the 1 valves on the pump stack, and 2 loop valves. Re-energize the system.

32 30 Installation, Operating, and Maintenance Manual Rev. 20DEC Verify system performance by checking the flow rate and temperature differential, and comparing the values to the heat pump manufacturer s published data. If installing a UPS26-99, be sure to set the pump speed that provides a flow rate within the manufacturer s recommend range. 15. Fill the tank as needed. Replacing a Zone Valve Actuator WARNING: OPEN THE MAIN POWER SUPPLY DISCONNECT SWITCH AND SECURE IT IN AN OPEN POSITION PRIOR TO PERFORMING ELECTRICAL WORK. VERIFY THAT POWER HAS BEEN DISCON- NECTED PRIOR TO WIRING THE VALVE(S). FAILING TO SECURE THE ELECTRICAL SUPPLY COULD RESULT IN SERIOUS INJURY OR DEATH. 1. Verify that power has been disconnected from the actuator using a multimeter. 2. Mark all wires before disconnecting wiring from valve. 3. Depress spring clip and remove actuator. Note that the clip moves parallel to the piping/valve (Figure 62 and 63). Push this direction Figure 62: Removing actuator Figure 63: Depress spring clip

33 NP MULTI SERIES NON-PRESSURIZED FLOW CENTERS 31 Checking anti-freeze/freeze protection level The loop fluid may contain antifreeze at concentration high enough to achieve a freeze protection level that is generally 10 degrees lower than the lowest expected entering fluid temperature (EWT) to the heat pump. Antifreeze will be used when the loop fluid entering the heat pump (EWT) is expected to drop below 40 degrees F. The freeze protection level depends on the type and concentration of antifreeze. Loop fluid can be removed from the NPM flow center through one of the flush valves, or through the top of the tank. The specific gravity of the fluid can then be measured with an appropriate specific gravity hydrometer. The specific gravity is used to determine the percentage concentration of antifreeze which is then used to determine the freeze protection level. The Residential Pressure Drop calculator available at provides information on percent antifreeze, freeze protection level, and specific gravity for ethanol, methanol, and propylene glycol. Emptying the tank Close both 2 tank isolation ball valves to isolate the NPM flow center from the ground loop and heat pump. The tank can then be emptied through the drain valve at the base of the tank. A discharge hose can be connected to direct the fluid to a drain or catch basin. Note that the NPM Series flow center tank will hold approximately 5 gallons of fluid.

34 Manual Updates Table Date Description of Changes Pages 20DEC2017 Added caution about deadheading the Magna3 pump 23 13JAN2016 Minor changes in verbiage for clarification Various Updated photos of NPM with 2 Magna3 pumps in series to current product layout. 18DEC2015 First published All 2,8

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36 Installation, Operating, and Maintenance Manual NP Multi Series Non-Pressurized Flow Centers Members of... Geo-Flo Products Corporation 905 Williams Park Drive Bedford, Indiana 47421, U.S.A. Main Number: Toll Free: Fax: Geo-Flo Products Corporation is continually working to improve its products. As a result, the design and specifications of products in this catalog may change without notice and may not be as described herein. For the most up-to-date information, please visit our website, or contact our customer service department at jmoan@geo-flo.com. Statements and other information contained in this document are not express warranties and do not form the basis of any bargain between the parties, but are merely Geo-Flo s opinion or commendation of its products. Part # 4147