Heat Pumps Refrigeration Troubleshooting Manual

P.O.
Box 245
Syracuse, NY 13211
www.roth-america.com
888-266-7684
Refrigeration/Troubleshooting
Manual
Table of Contents:
Section 1: Geothermal Refrigeration
Circuits
Overview ................................................................ 2
Water-to-Air Refrigerant Circuit ........................... 3
Refrig. Ckt. Component Operation .................... 3
Water-to-Water Refrigerant Circuit ..................... 5
Heating Operation ................................................ 6
Cooling Operation ................................................ 6
Summary ................................................................ 8
Section 2: Heat of Extraction/Heat of
Rejection
Overview ................................................................ 9
Performance Data ................................................ 9
Formulas ............................................................... 10
Examples .............................................................. 12
Section 3: Superheat/Subcooling
Overview .............................................................. 14
Defnitions ............................................................. 14
Checking Superheat and Subcooling .............. 14
Putting It All Together .......................................... 15
Pressure/Temperature Chart R-410A ................ 16
Pressure/Temperature Chart R-22 ..................... 17
Superheat/Subcooling Measurements ............ 18
Superheat/Subcooling Tables ........................... 19
Examples .............................................................. 20
Section 4: Desuperheater Operation
Overview .............................................................. 22
Desuperheater Cut-Away .................................. 22
Appendix A: Troubleshooting Form
P/N: 2300100910
Guide Revision Table:
Date By Page Note
August, 2010 KT All First published
2 Roth Refrigeration/Troubleshooting Guide,
August, 2010
exchanger (water-to-water and water-
to-air units) is connected to the ground
loop or open loop (well water) system. The
load heat exchanger is connected to the
hydronic load (for example, radiant foor
heating) for water-to-water units. The load
heat exchanger in a water-to-air unit is the
air coil, which is connected to duct work.
Overview
Geothermal heat pumps are available in a
variety of confgurations to provide fexibility
for installation in new construction or
retroft applications. Most common in North
America are packaged water-to-air heat
pumps, which provide forced air heating
and cooling. Packaged units (see fgure 1)
have the compressor section and the air
handler section in the same cabinet. There
are also other types of geothermal heat
pumps, such as water-to-water, which are
used for radiant foor heating.
Water-to-water heat pumps heat or chill
water instead of heating or cooling the air
(see fgure 5). The difference between a
water-to-air and water-to-water heat pump
is the load heat exchanger. A second
water-to-refrigerant coil is substituted for
the air to refrigerant coil. The source heat
Figure 1: Water-to-Air Refrigeration Circuit
Section 1: Geothermal Refrigeration Circuits
To suction line bulb
To suction line
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Discharge
Heating
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Discharge
Cooling
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Liquid line (heating)
Liquid line (cooling)
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TXV
Filter Drier
Reversing
Valve
Source
Coax
Optional desuperheater
installed in discharge line
(always disconnect during
troubleshooting)
Condenser (heating)
Evaporator (cooling)
Condenser (cooling)
Evaporator (heating)
Suction
Discharge
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3
2
4
5
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3 Refrigeration/Troubleshooting Guide
August, 2010
Roth
Water-to-Air Refrigerant Circuit
The water-to-air geothermal heat pump
refrigerant circuit is very simple compared
to air source heat pumps. Defrost cycle
is not required, and all components are
indoors in a single cabinet. The main
components shown in fgure 1 are the
compressor (1), the air coil (2), the coaxial
heat exchanger (3), the reversing valve (4),
the TXV or thermal expansion valve (5), and
the flter drier (6).
Compressor: The compressor (1) is the
heart of the system. The compressor
pumps refrigerant through the circuit, and
increases the pressure of the refrigerant.
Since pressure and temperature are directly
related, when the pressure is increased, the
temperature is also increased. When the
temperature of the refrigerant is raised to a
higher temperature than the temperature
of the air fowing through the air coil (2)
in heating, heat is released to the air to
heat the building. Likewise, when the
refrigerant temperature is raised to a higher
temperature than the water fowing through
the coaxial heat exchanger (3) in cooling,
heat is released to the water.
Roth uses Copeland Scroll compressors.
A scroll is an involute spiral which, when
matched with a mating spiral scroll form
as shown in fgure 2, generates a series of
crescent-shaped gas pockets between the
two members. Scroll compressors work by
moving one spiral element inside another
stationary spiral to create a series of gas
pockets that become smaller and increase
the pressure of the gas.
The largest openings are at the outside
of the scroll where the gas enters on the
suction side. As these gas pockets are
closed off by the moving spiral they move
towards the center of the spirals and
become smaller and smaller. This increases
the pressure on the gas until it reaches
the center of the spiral and is discharged
through a port near the center of the scroll.
Both the suction process (outer portion of
the scroll members) and the discharge
process (inner portion) are continuous.
The moving scroll moves in an orbiting
path within the stationary (fxed) scroll as
it creates the series of gas pockets. During
compression, several pockets are being
compressed simultaneously, resulting in
Figure 2: Scroll Operation
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5
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Compression in the
scroll is created by the
interaction of an orbiting
spiral and a stationary
spiral. Gas enters the
outer openings as one
of the spirals orbits.
The open passages
are sealed of as gas is
drawn into the spiral.
As the spiral continues
to orbit, the gas is
compressed into
two increasingly
smaller pockets.
By the time the gas
arrives at the center
port, discharge pressure
has been reached.
Actually, during
operation, all six gas
passages are in various
stages of compression
at all times, resulting
in nearly continuous
suction and discharge.
August, 2010
a very smooth process. By maintaining
an even number (six in a Copeland Scroll
compressor) of balanced gas pockets on
opposite sides, the compression forces
inside the scroll work to balance each other
and reduce vibration inside the compressor.
Single speed and two-stage (UltraTech)
scroll compressors are used in Roths
product line. The two-stage scroll works
exactly like the single speed scroll shown in
fgure 2, but it has additional components,
a solenoid valve, and bypass ports in the
scroll mechanism. When the solenoid valve
opens the bypass ports as shown in fgure 3,
the capacity is reduced to 67%, since part
of the scroll is bypassed.
67% - PORTS OPEN 100% PORTS CLOSED
Figure 3: UltraTech Operation
Air Coil: The air coil (2), a refrigerant-to-air
heat exchanger servers as the condenser in
heating, and the evaporator in cooling.
Coaxial Heat Exchanger: The coaxial heat
exchanger (3), a water-to-refrigerant heat
exchanger, serves as the evaporator in
heating, and the condenser in cooling.
Reversing Valve: The reversing valve (4)
provides the ability to switch functions
of the two heat exchangers, above. As
shown in fgure 1, the discharge line from
the compressor is always connected to the
bottom of the reversing valve. The center
connection at the top is always connected
to the suction line from the compressor.
The other two connections allow the heat
pump to switch from heating to cooling.
The normal (non-energized) mode is
heating. Therefore, the discharge gas from
the compressor fows to the air coil in the
non-energized mode. When the reversing
valve solenoid is energized in cooling, the
valve switches to allow the discharge gas
from the compressor to fow to the coaxial
heat exchanger.
The reversing valve is a pilot-operated
valve, which means that the solenoid
opens a small port, connecting the
copper tubing from the bottom port
(discharge line from the compressor) to the
valve chamber. The high pressure of the
discharge line forces the valve to switch
from one mode to the other.
Thermal Expansion Valve (TXV): The TXV (5)
meters refrigerant to make sure that the
proper amount of refrigerant is being fed to
the heat exchangers in order to maximize
the condensing and evaporating functions.
The TXV is also important in keeping liquid
refrigerant from reaching the suction line of
the compressor, which could damage the
compressor. The TXV is designed to operate
bi-directionally in packaged water-to-air
and water-to-water heat pumps.
Diaphram
Valve Seat
Pin
4
4 = Liquid Pressure
(opening force)
Figure 4: TXV Operation
August, 2010
Roth
Figure 4 shows the operation of the TXV, and
the four forces that affect the operation.
The TXV has two copper fttings for
connection to the air coil and coaxial heat
exchanger, as well as two smaller copper
lines that are used for metering. One line
is connected to a bulb that is attached to
the suction line of the compressor. The bulb
is flled with refrigerant. As the suction line
temperature changes, the bulb pressure
changes. The other line is connected
directly to the suction line. The bulb pressure
(force 1) pushes down on the diaphragm
as the bulb pressure increases (suction line
temperature increases). When the pressure
pushes down on the diaphragm, the pin
(which is attached to the diaphragm) is
pushed away from the valve seat, which
opens the valve.
The other line, connected directly to the
suction line uses suction pressure (force 2) to
push up on the diaphragm as the pressure
increases. As the diaphragm is pushed up,
the pin is pushed into the valve seat, closing
To suction line
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Heating
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Discharge
Cooling
Mode
Load
Coax
TXV
Filter Drier
Reversing
Valve
Source
Coax
troubleshooting)
Condenser (heating)
Condenser (cooling)
Suction
Discharge
Figure 5: Water-to-Water Refrigerant Circuit
the valve. This relationship of temperature
(bulb pressure) and pressure (suction line)
creates a balancing effect, which causes
the valve to meter at 0F superheat (see
section 3 for explanation of superheat).
Since it is important to make sure that liquid
is not returning to the compressor, the valve
spring (force 3) is adjusted to fool the
valve into balancing at a higher superheat
(usually 10 to 12F). Force 4 (liquid pressure)
is an opening force.
Filter Drier: The flter drier (6) functions
exactly as its name implies. It flters any
particles from the refrigerant system,
and it pulls moisture from the system. It is
extremely important that the flter drier is
changed any time the refrigerant circuit
is open for a component replacement or
repair, especially for systems with R-410A
refrigerant. R-410A uses P.O.E. oil, which
is hygroscopic (tendency of a material
to absorb moisture from the air). Moisture
contaminates the refrigerant circuit over
time, and must be avoided.
August, 2010
Water-to-Water Refrigerant Circuit
The water-to-water heat pump refrigerant
circuit, as shown in fgure 5, functions
exactly the same as the the water-to-air
refrigerant circuit with one exception. The
air coil is replaced by a second coaxial
heat exchanger. The source coax is
the same as the water-to-air unit coax.
However, the load coax heats or chills
water instead of heating or cooling the air.
Heating Operation
For the purposes of discussing the refrigerant
circuit operation in heating and cooling
modes, the water-to-air circuit will be used.
The other confgurations directly apply with
minor terminology/component changes.
In heating mode (see fgure 7), the
reversing valve is not energized. The high
temperature, high pressure refrigerant gas
from the compressor fows to the air coil. As
the air moves through the air coil, the cool
(typically 70F) air causes the hot refrigerant
(typically 130 to 180F) to condense into a
liquid. Thus, the air coil is the condenser in
the heating mode.
After leaving the air coil (condenser),
the refrigerant is approximately the
temperature of the leaving air. The
refrigerant is within a few psi of being at the
same pressure as it was at the compressor
discharge line. This is the heating liquid line.
The liquid line of a packaged unit changes
location, depending upon the mode of
operation. It is always located between
the TXV and the condenser. However,
since a geothermal unit is a heat pump,
the condenser can either be the air coil
(heating) or coaxial water coil (cooling).
At the TXV, the refrigerant is forced through
a very small opening, which causes a
large pressure drop. As mentioned earlier,
pressure and temperature are directly
related, so the temperature also drops after
the TXV. At this point, the refrigerant is a
low temperature liquid (typically 15 to 50F,
depending upon loop temperature).
The warm water (or water/antifreeze
solution) fowing through the coaxial heat
exchanger (typically 30 to 60F) causes the
cold refrigerant to boil off (evaporate)
into a gas or vapor. Thus, the coax is the
evaporator in heating.
After leaving the coax (evaporator), the
refrigerant is now approximately the same
temperature as the water entering the
heat pump. This low pressure gas enters the
compressor, and the cycle starts all
over again.
Proper refrigerant metering will insure that
no liquid is returned to the compressor.
Section 3 discusses superheat and
subcooling, which allow the technician
to evaluate how well the condenser and
evaporator are operating.
Cooling Operation
In cooling mode (see fgure 8), the
reversing valve must be energized. The high
temperature, high pressure refrigerant gas
from the compressor fows to the coaxial
heat exchanger. As the water (or water/
antifreeze solution) fows through the coax,
the cool (typically 50 to 100F) water causes
the hot refrigerant (typically 130 to 180F) to
condense into a liquid. Thus, the coax is the
condenser in the cooling mode.
After leaving the coax (condenser),
the refrigerant is approximately the
temperature of the water leaving the
coax. The refrigerant is within a few psi of
the compressor discharge line pressure.
This is the cooling liquid line. The liquid line
of a packaged unit changes location,
August, 2010
Roth
To suction line
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TXV
Filter Drier
Reversing
Valve
Source
Coax
troubleshooting)
Condenser (heating)
Condenser (cooling)
Suction
Discharge
Figure 7: Heating Mode
Figure 8: Cooling Mode
To suction line
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TXV
Filter Drier
Reversing
Valve
Source
Coax
troubleshooting)
Condenser (heating)
Condenser (cooling)
Suction
Discharge
August, 2010
depending upon the mode of operation. It
is always located between the TXV and the
condenser. However, since a geothermal
unit is a heat pump, the condenser can
either be the air coil (heating) or coaxial
water coil (cooling).
At the TXV, the refrigerant is forced through
a very small opening, which causes a large
pressure drop. Once again, since pressure
and temperature are directly related, the
temperature also drops after the TXV. At this
point, the refrigerant is a low temperature
liquid (typically 35 to 45F, depending upon
return air temperature and air fow).
The warm air fowing through the air coil
(typically 70 to 80F) causes the cold
refrigerant to boil off (evaporate) into
a gas or vapor. Thus, the air coil is the
evaporator in cooling.
After leaving the air coil (evaporator), the
refrigerant is now approximately the same
temperature as the air entering the heat
pump. This low pressure gas enters the
compressor, and the cycle starts all
over again.
Summary
To summarize, refrigerant circuits in
geothermal heat pumps can be confgured
for packaged water-to-air, water-to-water,
split systems or combination water-to-air
and water-to-water units. All circuits utilize
a Copeland scroll (single or two-stage)
compressor, one or two water-to-refrigerant
coaxial coils, an air-to-refrigerant coil, a
reversing valve, a bi-directional TXV, and
a flter drier. Combination units include a
direction valve and a 3-way valve to switch
condenser operation.
The air coil operates as the condenser in
heating, and the evaporator in cooling.
The source (loop) coax operates as the
condenser in cooling and the evaporator in
heating. Water-to-water units use a second
coax instead of the air coil.
The reversing valve is energized in the cooling
mode. The non-energized mode is heating.
August, 2010
Roth
Section 2: Heat of Extraction/Heat of Rejection
Overview
As mentioned in section 1, most geothermal
heat pumps are packaged water-to-air
heat pumps. Therefore, the refrigerant
circuit is evacuated and charged at the
factory, and there is no need to connect
refrigerant gauges unless the technician
has verifed that there is a refrigerant
circuit problem. Since connecting gauges
can cause a loss of charge and affect
performance, Roth recommends against
connecting refrigerant gauges at startup.
There are a number of checks that can
be made at startup to verify performance
without connecting refrigerant gauges.
Heat of extraction is a calculation of the
amount of heat that is being extracted or
absorbed from the water or water/anti-
freeze solution by the evaporator (coaxial
heat exchanger) in the heating mode.
Heat of rejection is the amount of heat
that is being rejected to the water by the
condenser (coaxial heat exchanger) in the
cooling mode. In addition to measuring the
temperature rise or drop across the air coil,
calculating heat of extraction or heat of
rejection allows the technician to verify that
the heat pump is performing according to
specifcations. If the calculation shows that
the heat pump is performing poorly, then
refrigeration gauges may be required to
further troubleshoot the problem.
Performance Data
Before discussing heat of extraction (HE)
/ heat of rejection (HR) calculations, the
technician should understand how to use
the performance data in the catalog to
compare the unit specifcations to actual
calculations.
Figures 9 and 10 show performance data
for a typical 3 ton geothermal water-to-
air heat pump. the highlighted columns
indicate HE and HR. In fgure 9, HE is the
amount of heat that is being extracted
from the water (for example, ground loop)
by the refrigerant circuit. The compressor
and fan power (kW column) is used to
operate the refrigerant circuit. The heat
delivered to the space (HC column) equals
the HE from the water plus the waste heat
of the power used for compressor and fan.
If the kW is converted to Btuh, and added
to the HE, the sum should equal HC.
For example, in fgure 9, at 30F EWT, 9.0
GPM and 70F EAT, the heating capacity
is 30,700 Btuh. HE is 21,800 Btuh. If the kW
(2.63) is converted to Btuh (2.63 x 3.412 =
8.97 MBtuh or 8,970 Btuh), and added to
HE, the result is HC. Therefore, if HE is within,
10-15% of catalog performance, HC should
also be within specifcations. There is no
need to connect refrigerant gauges if HE is
within specifcations.
In fgure 10, HR is the amount of heat that is
being rejected to the water (for example,
ground loop) by the refrigerant circuit. The
compressor and fan power (kW column) is
used to operate the refrigerant circuit. The
heat rejected from the space (HR column)
equals the heat from the air (TC column --
amount of cooling) plus the waste heat of
the power used for compressor and fan. If
the kW is converted to Btuh, and added to
the TC, the sum should equal HR.
For example, in fgure 10, at 90F EWT, 9.0
GPM and 75F DB/63F WB (50% RH), HR
is 43,400 Btuh. TC is 34,400 Btuh. If the kW
(2.73) is converted to Btuh (2.73 x 3.412 =
9.31 MBtuh or 9310 Btuh), and added to
TC, the result is HR. Thefore, if HR is within,
10-15% of catalog performance, TC should
also be within specifcations. There is no
need to connect refrigerant gauges if HR is
within specifcations.
August, 2010
Formulas
The formula is the same for HE and HR.
The amount of heat being extracted
or rejected can be calculated if the
temperature difference between water
entering and leaving the coaxial heat
exchanger (TD) is known, and the water
fow (GPM) is measured. The only other item
needed is the type of antifreeze. A fuid
factor is used to represent the specifc heat
of the water/antifreeze solution, as well as
to convert the units (GPM and F) to Btuh.
HE or HR (Btuh) = GPM x TD x Fluid Factor
Where: GPM = Flow rate in U.S. gallons per
minute TD = Temp. diff. (between water in
& out) Fluid Factor = 500 for water; 485 for
most antifreezes
Figures 11 and 12 show the tools required
for checking HE and HR. All technicians
installing and servicing geothermal heat
pumps should have at least one set of
these tools.
Flow rate can be determined by measuring
the pressure drop across the coaxial heat
exchanger. The pressure gauge and adapter
should be inserted into the P/T (pressure/
temperature) port of the Water IN
connection. Record the reading. Next, insert
the gauge into the Water OUT port, and
record the reading. The difference between
the IN and OUT is the pressure drop.
Once the pressure drop of the heat
exchanger is known, the fow rate can be
determined by consulting the performance
data for the particular unit.
Example:
In heating mode, model 036 has EWT of
50F, water pressure IN of 40 psi, and water
pressure OUT of 35 psi. The pressure drop,
therefore is 5 psi. Figure 10 shows three
water pressure drop values and three water
fow rates. At 50F, if the pressure drop is 1.7
psi, the fow rate would be 5.0 GPM; if the
pressure drop is 3.1 psi, the fow rate would
be 7.0 GPM; and if the pressure drop is 5.0
psi, the fow rate would be 9.0 GPM. The fow
rate in this example is 9.0 GPM. Rarely are
the temperature and pressure drop exactly
as shown in the tables, so there will be some
interpolation required (for example, 52F EWT
and 4.7 psi pressure drop).
NOTE: A large gauge face is preferred,
since it will be easier to read pressures to
the nearest 0.5 psi. ALWAYS use the same
gauge in the IN and OUT connections.
The use of two gauges could cause false
readings, since they could both be out of
calibration in opposite directions. Never
force the gauge adapter into the P/T port.
The gauge adapter could break off in the
P/T port, or the force could cause the ring
holding the P/T port bladder to become
dislodged, potentially ending up in a
pump impeller.
Once the fow rate is determined, the
pocket thermometer can be used to obtain
TD. Insert the thermometer into the Water
IN P/T port. Record the temperature. Insert
the thermometer into the Water OUT
port, and record the temperature. The
difference between the IN and OUT
is the TD. In heating, EWT (entering water
temperature) will be warmer than LWT
(leaving water temperature); in cooling it
will be just the opposite.
The last item needed is the type of fuid
circulating through the heat pump. As
mentioned earlier, 500 should be used for
pure water (open loop/well water systems).
Use 485 for most antifreeze solutions (see
Flow Center and Loop Application Manual
for details on antifreeze solutions).
August, 2010
Roth
036 Performance Data:
3.0 Ton, 1200 CFM, Heating
EWT GPM
r e t a e h r e p u s e D h t i w g n i t a e H g n i t a e H D P W
PSI FT EAT HC HE LAT KW COP HC HE LAT KW DH COP
30
5.0 1.8 4.2
60 30.2 21.7 83.3 2.47 3.58 26.5 21.7 80.4 2.45 3.8 3.62
70 29.4 20.4 92.7 2.61 3.30 25.5 20.5 89.7 2.56 3.9 3.36
80 28.4 19.2 101.9 2.73 3.05 24.4 19.3 98.9 2.68 4.0 3.11
7.0 3.4 7.8
60 31.1 22.6 84.0 2.50 3.65 27.3 22.7 81.0 2.45 3.9 3.73
70 30.3 21.3 93.4 2.63 3.37 26.3 21.4 90.3 2.58 4.0 3.44
80 29.4 20.0 102.7 2.77 3.12 25.3 20.1 99.5 2.7 4.1 3.19
9.0 5.4 12.5
60 31.5 23.0 84.3 2.50 3.70 27.6 23.2 81.3 2.44 3.9 3.78
70 30.7 21.8 93.7 2.63 3.42 26.6 18.7 90.6 2.58 4.1 3.49
80 29.9 20.4 103.1 2.76 3.17 25.7 20.5 99.8 2.71 4.2 3.23
50
5.0 1.7 3.9
60 39.1 30.3 90.2 2.59 4.42 34.2 30.6 86.4 2.51 4.9 4.57
70 37.9 28.5 99.3 2.73 4.07 32.9 28.8 95.4 2.65 5.0 4.20
80 36.6 26.8 108.3 2.86 3.75 31.5 27.1 104.3 2.78 5.1 3.86
7.0 3.1 7.2
60 40.7 31.7 91.4 2.64 4.52 35.7 32.1 87.5 2.56 5.1 4.67
70 39.4 30.0 100.4 2.78 4.15 34.2 30.2 96.4 2.69 5.2 4.29
80 38.1 28.1 109.4 2.93 3.82 32.8 28.4 105.3 2.83 5.4 3.95
9.0 5.0 11.6
60 41.6 32.6 92.1 2.65 4.59 36.4 32.8 88.1 2.56 5.2 4.76
70 40.2 30.7 101.1 2.79 4.22 34.9 31.1 96.9 2.70 5.3 4.36
80 38.9 28.9 110 2.94 3.88 33.4 29.2 105.8 2.84 5.5 4.01
Entering
Water
Temp (F)
Flow
Rate
(U.S. GPM)
Water
Press. Drop
(PSI & Ft. of Head)
Entering
Air
Temp (F)
Heating
Capacity
(MBtuh)
Heat of
Extraction
(MBtuh)
Leaving
Air
Temp (F)
Input
Power (kW)
Coefficient
of
Performance
Desuperheater
Capacity
(MBtuh)
Figure 9: Typical Performance Data - Heating Mode
036 Performance Data:
3.0 Ton, 1200 CFM, Cooling
EWT GPM
WPD EAT
DB/
WB
r e t a e h r e p u s e D h t i w g n i l o o C g n i l o o C
PSI FT TC SC HR KW EER TC SC HR KW DH EER
70
5.0 1.7 3.9
75/63 36.7 26.8 44.8 2.41 15.2 36.9 26.9 44.9 2.35 4.7 15.7
80/67 39.8 27.9 47.6 2.47 16.1 40.0 28.0 47.7 2.40 4.9 16.7
85/71 43.0 29.0 50.5 2.51 17.2 43.3 29.1 50.6 2.46 5.1 17.6
7.0 3.0 6.9
75/63 37.2 27.1 45.0 2.29 16.2 37.4 27.2 45.1 2.26 4.6 16.6
80/67 40.5 28.2 47.9 2.34 17.3 40.4 28.3 48.0 2.31 4.7 17.6
85/71 43.7 29.3 50.8 2.39 18.3 43.9 29.5 50.9 2.34 4.8 18.7
9.0 4.8 11.1
75/63 37.6 27.1 45.2 2.22 16.9 37.8 27.2 45.4 2.21 4.3 17.1
80/67 40.9 28.2 48.1 2.27 18.0 41.1 28.3 48.3 2.26 4.5 18.2
85/71 44.1 29.3 50.9 2.32 19.0 44.3 29.5 51.2 2.30 4.7 19.3
90
5.0 1.6 3.6
75/63 33.4 25.7 43.1 2.98 11.2 33.7 25.9 43.3 2.89 6.3 11.7
80/67 36.3 26.8 45.9 3.04 11.9 36.6 27.0 46.0 2.95 6.4 12.4
85/71 39.2 27.9 48.7 3.09 12.7 39.5 28.0 48.8 3.01 6.6 13.2
7.0 2.8 6.4
75/63 34.0 26.0 43.4 2.81 12.1 34.3 26.2 43.6 2.75 6.0 12.5
80/67 37.0 27.1 46.1 2.87 12.9 37.3 27.2 46.3 2.80 6.2 13.3
85/71 40.0 28.1 48.8 2.92 13.7 40.4 28.3 49.2 2.87 6.3 14.1
9.0 4.5 10.3
75/63 34.4 26.0 43.4 2.73 12.6 34.7 26.2 43.8 2.70 5.8 12.9
80/67 37.4 27.1 46.2 2.78 13.4 37.8 27.2 46.6 2.75 5.9 13.7
85/71 40.4 28.1 49.0 2.85 14.2 40.8 28.3 49.4 2.80 6.1 14.5
Total Cooling, (MBtuh)
= SC + LC (Latent Cap)
Sensible Cooling
(MBtuh)
Heat of
Rejection
(MBtuh)
Input
Power (kW)
Energy
Efficiency
Ratio
Figure 10: Typical Performance Data - Cooling Mode
August, 2010
Figure 13 includes an example water-to-air
heat pump in heating mode; fgure 14 shows
the same heat pump in cooling. Following
are two examples based upon these fgures,
which are shown on the next page.
Example 1: Model 036, ground loop system
with ProCool (ethanol) antifreeze solution,
heating mode.
1) Fluid factor = 485
2) EWT = 30.0F LWT = 23.5F TD = 6.5F
3) Pressure IN = 40 psi
Pressure OUT = 36.6 psi
Pressure drop = 3.4 psi
From performance data, GPM = 7.0
4) HE = GPM x TD x Fluid Factor
HE = 7.0 x 6.5 x 485 = 22,067 Btuh
Catalog HE = 21,300 Btuh. Therefore, unit is
Pressure Gauge
(P/N TSPG-GC or equivalent)
Gauge Adapter
(P/N TSPTN)
Adapter
Protector
Pocket Thermometer
P/N TSDT or equivalent
Figure 11: Pressure Gauge with Adapter
performing better than specifcations.
Example 2: Model 036, ground loop system
with ProCool (ethanol) antifreeze solution,
cooling mode.
1) Fluid factor = 485
2) EWT = 90.0F LWT = 101.2F TD = 11.2F
3) Pressure IN = 40 psi
Pressure OUT = 36.3 psi
Pressure drop = 3.7 psi
From performance data, GPM = 8.0
4) HR = GPM x TD x Fluid Factor
HR = 8.0 x 11.2 x 485 = 43,456 Btuh
Catalog HR = 43,400 Btuh. Therefore, unit is
performing better than specifcations.
NOTE: HE and HR should be within 10-15% of
catalog values.
Figure 12: Pocket Thermometer
August, 2010
Roth
To suction line
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Discharge
Heating
Mode
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C
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Discharge
Cooling
Mode
F
F
Discharge Line
psi
(saturation)
F
Suction Line
psi
(saturation)
F
Suction temp
F
For water-to-water units
substitute a second coaxial
heat exchanger for the air coil.
Load
Coax
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C
o
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TXV
Filter Drier
Reversing
Valve
Source
Coax
troubleshooting)
Source (loop) IN
Source (loop) OUT
F
psi
F
psi
Load IN
F
psi
Load OUT
F
psi
Return Air
F
Supply Air
F
GPM
GPM
101.2
36.3
90.0
40.0
75.0 55.0
To suction line
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Discharge
Heating
Mode
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Discharge
Cooling
Mode
F
F
Discharge Line
psi
(saturation)
F
Suction Line
psi
(saturation)
F
Suction temp
F
Load
Coax
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C
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TXV
Filter Drier
Reversing
Valve
Source
Coax
troubleshooting)
Source (loop) IN
Source (loop) OUT
F
psi
F
psi
Load IN
F
psi
Load OUT
F
psi
Return Air
F
Supply Air
F
GPM
GPM
23.5
36.6
30.0
40.0
70.0 93.4
Figure 13: Heating Operation Example
Figure 14: Cooling Operation Example
August, 2010
Overview
Superheat and subcooling are used to
determine if the heat pump has the proper
refrigerant charge, as well as for verifying
that the condenser and evaporator
are performing properly. Superheat
and subcooling can even be used to
troubleshoot refrigerant circuit blockages or
a bad TXV.
Defnitions
Saturation Temperature: Saturation
temperature, sometimes called boiling
point, is the temperature at which a
refrigerant changes state. For example,
Table 1 shows that refrigerant R-410A has
a saturation temperature of 32F at 100
psi. Therefore, the refrigerant at 100 psi is a
liquid if it is below 32F, and a gas (vapor) if
it is above 32F.
Superheat: Superheat is defned as the
number of degrees above the saturation
temperature of a refrigerant. For example,
if the temperature of refrigerant R-410A is
40F at 100 psi, it has 8F of superheat, since
the saturation temperature is 32F.
Subcooling: Subcooling is defned as the
number of degrees below the saturation
temperature of a refrigerant. For example,
if the temperature of refrigerant R-410A
is 28F at 100 psi, it has 4F of subcooling,
since the saturation temperature is 32F.
Checking Superheat and Subcooling
Superheat and subcooling should only be
checked after the heat of extraction or
heat of rejection calculations (see section
2) indicate that the unit is performing
poorly. Connecting refrigerant gauges
should be done as a last resort.
Checking superheat and subcooling requires
a refrigeration gauge set with manifold and
hoses, plus a digital thermocouple type
thermometer. Heat pumps produced by
Roth have two schrader ports for service
connections, one at the discharge line of
the compressor, and one at the suction line
of the compressor. When these pressures
are used in conjunction with the suction line
temperature and liquid line temperature,
superheat and subcooling can be
calculated. Insulation should be removed
from the suction line and liquid line, and the
copper should be free from insulation glue,
so that the thermocouple makes a good
connection at the copper line.
Figures 15a and 15b illustrate the locations
for taking pressure and temperature
measurements. Notice that the two areas
for temperature measurement are suction
line and liquid line. In order to check
superheat and subcooling, the saturation
temperature must be determined, which
requires the pressure of the refrigerant and
the actual temperature of the refrigerant
at the same location. However, the only
location where both temperature and
pressure are easily obtained is at the
suction line. In section 1, temperatures
and pressures were discussed in relation
to components, both before and after
the components. It was also mentioned
that the discharge pressure and the
liquid line pressure are within a few psi
of each other. Most manufacturers of
packaged equipment adjust their service
data to allow the technician to use the
discharge pressure as the liquid line
pressure. Therefore, for checking superheat
and subcooling, use discharge pressure
with liquid line temperature, and suction
pressure with suction temperature.
Although superheat and subcooling can
be calculated anywhere in the refrigeration
August, 2010
Roth
circuit, there are two points that are most
useful for troubleshooting purposes. First of
all, it is imperative that liquid is not returned
to the compressor. Liquid refrigerant
will wash some of the compressor oil
away from critical internal parts, causing
premature compressor failure. Plus, the
compressor is designed to pump gas, not
liquid, and will be operating under adverse
conditions. Checking for superheat at the
suction line of the compressor insures that
the state of the refrigerant at this point is
a gas (vapor). The amount of superheat
at the suction line determines how well
the evaporator (coax in heating, air coil in
cooling) is working. Superheat is normally
in the 8 to 12F range, but the installation
manual will provide specifc information for
the unit being serviced. NOTE: Check the
temperature of the suction line near the
TXV bulb, especially on split systems.
The other location to check is the liquid
line. Since the liquid line is located after
the condenser (air coil in heating, coax
in heating), the amount of subcooling
determines how well the condenser is
working. In most cases subcooling is in the
4 to 10F range, but the installation manual
will provide specifc information for the unit
being serviced.
Putting It All Together
In section 1, TXV operation was discussed.
Since the TXV spring has been adjusted
to maintain 8 to 12F of superheat, it will
close down when necessary to maintain
the predetermined superheat setting.
Therefore, subcooling plays a crucial part in
evaluating the units refrigeration charge. In
other words, if the unit is overcharged, the
TXV will close down to maintain superheat,
backing up liquid refrigerant in the
condenser. If only superheat is measured,
the technician would not know that the unit
is overcharged. If subcooling is measured,
the high value would indicate that there
is a problem with the refrigeration charge.
Table 3 lists the conditions associated with
high or low superheat and subcooling.
Table 4 is an example of typical data found
in the installation manual.
Figures 16 through 18 illustrate examples
of a normally charged system, an
undercharged system, and an
overcharged system.
August, 2010
Saturation Saturation Saturation
Pressure Temp (F) Pressure Temp (F) Pressure Temp (F)
PSIG R-410A PSIG R-410A PSIG R-410A
0 -60 125 43 370 111
2 -58 130 45 375 112
4 -54 135 47 380 113
6 -50 140 49 385 114
8 -46 145 51 390 115
10 -42 150 53 395 116
12 -39 155 55 400 117
14 -36 160 57 405 118
16 -33 165 59 410 119
18 -30 170 60 415 120
20 -28 175 62 420 121
22 -26 180 64 425 122
24 -24 185 66 430 122
26 -20 190 67 435 123
28 -18 195 69 440 124
30 -16 200 70 445 125
32 -14 205 72 450 126
34 -12 210 73 455 127
36 -10 215 75 460 128
38 -8 220 76 465 129
40 -6 225 78 470 130
42 -4 230 79 475 130
44 -3 235 80 480 131
46 -2 240 82 485 132
48 0 245 83 490 133
50 1 250 84 495 134
52 3 255 85 500 134
54 4 260 87 505 135
56 6 265 88 510 136
58 7 270 89 515 137
60 8 275 90 520 138
62 10 280 91 525 138
64 11 285 92 530 139
66 13 290 94 535 140
68 14 295 95 540 141
70 15 300 96 545 142
72 16 305 97 550 142
74 17 310 98 555 143
76 19 315 99 560 144
78 20 320 100 565 145
80 21 325 101 570 146
85 24 330 102 575 146
90 26 335 104 580 147
95 29 340 105 585 148
100 32 345 106 590 149
105 34 350 108 595 149
110 36 355 108 600 149
115 39 360 109 650 154
120 41 365 110 700 159
Table 1: Pressure/Temperature Chart, R-410A Refrigerant
August, 2010
Roth
Saturation Saturation Saturation
Pressure Temp (F) Pressure Temp (F) Pressure Temp (F)
PSIG R-22 PSIG R-22 PSIG R-22
0 -41 90 54 300 132
2 -37 95 56 305 133
4 -32 100 59 310 134
6 -28 105 62 315 135
8 -24 110 64 320 136
10 -20 115 67 325 137
12 -17 120 69 330 138
14 -14 125 72 335 140
16 -11 130 74 340 141
18 -8 135 76 345 142
20 -5 140 78 350 144
22 -3 145 81 355 144
24 0 150 83 360 145
26 2 155 85 365 146
28 5 160 87 370 147
30 7 165 89 375 148
32 9 170 91 380 149
34 11 175 93 385 151
36 13 180 94 390 152
38 15 185 96 395 153
40 17 190 98 400 155
42 19 195 100 405 155
44 21 200 101 410 156
46 23 205 103 415 158
48 24 210 105 420 159
50 26 215 107 425 160
52 28 220 108 430 160
54 29 225 110 435 161
56 31 230 112 440 162
58 32 235 113 445 163
60 34 240 115 450 164
62 35 245 116 455 165
64 37 250 118 460 167
66 38 255 119 465 168
68 40 260 120 470 169
70 41 265 121 475 169
72 42 270 123 480 170
74 44 275 124 485 171
76 45 280 126 490 172
78 46 285 127 495 173
80 48 290 129 500 173
85 51 295 130
Table 2: Pressure/Temperature Chart, R-22 Refrigerant
August, 2010
F
To suction line
F
F
Discharge Line
psi
(saturation)
Suction Line
psi
(saturation)
F
Suction temp
F
Load
Coax
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TXV
Filter Drier
Reversing
Valve
Source
Coax
troubleshooting)
Source (loop) IN
Source (loop) OUT
F
psi
F
psi
Load IN
F
psi
Load OUT
F
psi
Return Air
F
Supply Air
F
GPM
GPM
R-410A Manifold/Gauge Set
Suction Discharge
F
Thermometer
1
2
2 1
To suction line
F
F
Discharge Line
psi
(saturation)
F
Suction Line
psi
(saturation)
F
Suction temp
F
Load
Coax
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C
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TXV
Filter Drier
Reversing
Valve
Source
Coax
troubleshooting)
Source (loop) IN
Source (loop) OUT
F
psi
F
psi
Load IN
F
psi
Load OUT
F
psi
Return Air
F
Supply Air
F
GPM
GPM
R-410A Manifold/Gauge Set
Suction Discharge
F
Thermometer
1
2
2 1
Figure 15a: Superheat/Subcooling Measurement - Heating
Figure 15b: Superheat/Subcooling Measurement - Cooling
August, 2010
Roth
Superheat Subcooling Condition
Normal Normal Normal operation
Normal High Overcharged
High Low Undercharged
High High Restriction or TXV is stuck almost closed
Low Low TXV is stuck open
Heating - Without Desuperheater
EWT GPM
Per Ton
Discharge
Pressure
(PSIG)
Suction
Pressure
(PSIG)
Sub
Cooling
Super
Heat
Air
Temperature
Rise (F-DB)
Water
Temperature
Drop (F)
30
1.5
3
285-310
290-315
68-76
70-80
4-10
4-10
8-12
8-12
14-20
16-22
5-8
3-6
50
1.5
3
315-345
320-350
100-110
105-115
6-12
6-12
9-14
9-14
22-28
24-30
7-10
5-8
70
1.5
3
355-395
360-390
135-145
140-150
7-12
7-12
10-15
10-15
30-36
32-38
9-12
7-10
Cooling - Without Desuperheater
EWT GPM
Per Ton
Discharge
Pressure
(PSIG)
Suction
Pressure
(PSIG)
Sub
Cooling
Super
Heat
Air
Temperature
Drop (F-DB)
Water
Temperature
Rise (F)
50
1.5
3
220-235
190-210
120-130
120-130
10-16
10-16
12-20
12-20
20-26
20-26
19-23
9-12
70
1.5
3
280-300
250-270
125-135
125-135
8-14
8-14
10-16
10-16
19-24
19-24
18-22
9-12
Table 3: Superheat/Subcooling Conditions
Table 4: Typical R-410A Unit Superheat/Subcooling Values
August, 2010
Figure 16: Normally-Charged System, Heating Mode
Figure 17: Under-Charged System, Heating Mode
To suction line
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Discharge
Heating
Mode
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Discharge
Cooling
Mode
F
F
Discharge Line
psi
(saturation)
F
Suction Line
psi
(saturation)
F
Suction temp
F
Load
Coax
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C
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TXV
Filter Drier
Reversing
Valve
Source
Coax
troubleshooting)
Source (loop) IN
Source (loop) OUT
F
psi
F
psi
Load IN
F
psi
Load OUT
F
psi
Return Air
F
Supply Air
F
GPM
GPM
30.0
40.0
7.0
23.5
36.6
76 19
300
29
90.0
70.0
Superheat =
29 - 19 = 10F
Subcooling =
96 - 90 = 6F
To suction line
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Discharge
Heating
Mode
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C
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Discharge
Cooling
Mode
F
F
Discharge Line
psi
(saturation)
F
Suction Line
psi
(saturation)
F
Suction temp
F
Load
Coax
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C
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TXV
Filter Drier
Reversing
Valve
Source
Coax
troubleshooting)
Source (loop) IN
Source (loop) OUT
F
psi
F
psi
Load IN
F
psi
Load OUT
F
psi
Return Air
F
Supply Air
F
GPM
GPM
30.0
40.0
7.0
26.5
36.6
68 14
260 87
29
87.0
70.0 90.0
Superheat =
29 - 14 = 15F
Subcooling =
87 - 87 = 0F
August, 2010
Roth
Figure 18: Over-Charged System, Heating Mode
To suction line
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Discharge
Heating
Mode
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Discharge
Cooling
Mode
F
F
Discharge Line
psi
(saturation)
F
Suction Line
psi
(saturation)
F
Suction temp
F
Load
Coax
A
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C
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TXV
Filter Drier
Reversing
Valve
Source
Coax
troubleshooting)
Source (loop) IN
Source (loop) OUT
F
psi
F
psi
Load IN
F
psi
Load OUT
F
psi
Return Air
F
Supply Air
F
GPM
GPM
30.0
40.0
26.5
36.6
85 24
325 101
34
85.0
70.0 90.0
Superheat =
34 - 24 = 10F
Subcooling =
101 - 85 = 16F
Figure 19: Water-to-Air Refrigerant Circuit with Desuperheater
To suction line
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Discharge
Heating
Mode
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C
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Discharge
Cooling
Mode
F
F
Discharge Line
psi
(saturation)
F
Suction Line
psi
(saturation)
F
Suction temp
F
Load
Coax
A
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C
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TXV
Filter Drier
Reversing
Valve
Source
Coax
Source (loop) IN
Source (loop) OUT
F
psi
F
psi
Load IN
F
psi
Load OUT
F
psi
Return Air
F
Supply Air
F
GPM
GPM
Desuperheater
August, 2010
Section 4: Desuperheater Operation
The desuperheater option includes a water-
to-refrigerant coaxial heat exchanger
installed between the compressor
discharge line and reversing valve,
which is connected to the condenser
(air coil in heating, coax in cooling) as
shown in fgure 19. Unlike the source
coax in all Roth geothermal heat pumps,
the desuperheater coax is a double-
wall, vented water-to-refrigeration heat
exchanger. Figure 20 illustrates a cut-away
of the desuperheater coax.
The operation of the desuperheater
takes advantage of the superheat at
the discharge line. For example, in fgure
16, the discharge pressure is 300 psi. The
saturation temperature at 300 psi is 96F.
The discharge line at these conditions
would typically be around 160F. Therefore,
the superheat (actual temperature
saturation temperature) is 64F. As
domestic hot water fows through the
desuperheater heat exchanger, some of
the superheat at the discharge line is used
to heat domestic water, which lowers the
superheat at the discharge line, thus the
term desuperheater.
Water fow rate through the desuperheater
coax must be very low to avoid turning
the desuperheater into a condensor, and
robbing too much heat from the main
condenser. Typically, about 0.4 GPM per
ton is used for desuperheater fow rate. The
desuperheater pump operates anytime the
compressor is operating (unless the one of
the temperature limits is open).
In cooling, the desuperheater takes some
of the heat that would have been rejected
to the ground loop via the condenser
(coax), and uses it to make domestic
hot water. Therefore, the desuperheater
produces nearly free hot water (other
than the fractional horsepower circulating
pump) in the cooling mode.
In heating, the desuperheater takes some
of the heat that would have been used
to heat the space via the condenser (air
coil), and uses it to make domestic hot
water. Even though the desuperheater
is robbing some of the heat from the
space, it is a very small amount, and the
system is heating water at a very high
C.O.P. (3.0 to 4.0, depending upon loop
temperature), compared to an electric
water heater at a C.O.P. of 1.0.
Some geothermal heat pumps turn off the
desuperheater pump when back up heat
is energized. However, studies show that on
an annual basis, the system is more energy
effcient when the desuperheater is utilized
any time the compressor is running. When
the hot water tank is already heated, a
thermal switch turns off the desuperheater
pump. The pump may also be turned off if
the compressor discharge line is too cool.
Figure 20: Desuperheater coax cut-away
Steel Outer Wall
Rifled Copper Tube
Smooth Wall
Inner Tube
Refrigerant
Air Gap
Water
August, 2010
Roth
Troubleshooting Form
Please make copies of this form.
Diagram: Water-to-Air and Water-to-Water Units
Customer/Job Name:____________________________________________ Date:________________________________
Model #:__________________________________________ Serial #:____________________________________________
Antifreeze Type:____________________________________
HE or HR = GPM x TD x Fluid Factor
(Use 500 for water; 485 for antifreeze)
SH = Suction Temp. - Suction Sat.
SC = Disch. Sat. - Liq. Line Temp.
To suction line
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Discharge
Heating
Mode
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Discharge
Cooling
Mode
F
F
Discharge Line
psi
(saturation)
F
Suction Line
psi
(saturation)
F
Suction temp
F
Load
Coax
A
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C
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TXV
Filter Drier
Reversing
Valve
Source
Coax
troubleshooting)
Source (loop) IN
Source (loop) OUT
F
psi
F
psi
Load IN
F
psi
Load OUT
F
psi
Return Air
F
Supply Air
F
GPM
GPM
Note: DO NOT connect
refrigerant gauges
until Heat of Extraction
or Rejection has been
checked.
Note: Disconnect desuperheater before proceeding
P.O. Box 245
Syracuse, NY 13211
888-266-7684 US
800-969-7684 CAN
866-462-2914 FAX
www.roth-america.com
info@roth-usa.com
* AHRI certifcation is shown as the Roth brand under the Enertech Manufacturing certifcation reference number
**Roth Industries geothermal heat pumps are shown as a multiple listing of Enertech Manufacturings ETL certifcation
*** Roth geothermal heat pumps are listed as a brand under Enertech Manufacturings Energy Star ratings
*
**
***

Heat Pumps Refrigeration Troubleshooting Manual

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