ClimateMaster Flow Controller 3 Leitfaden
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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3
Flow Controller 3
Rev.: Feburary 9, 2016
A F C G 2 C 1
1 2 3
4
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: Notication 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.
5
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.
7
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).
4.
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
9
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 backll 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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