2100-633

2100-633
INSTALLATION INSTRUCTIONS
& REPLACEMENT PARTS LIST
GEO TRIO
COUNTERFLOW
HEATER ACCESSORY
Models:
GTCFHK1-A10
GTCFHK1-A20
10 KW Counterflow Heater Accessory
20 KW Counterflow Heater Accessory
This accessory heater is only to be applied along with
Bard Model GTA____UD1-A Coil + GTB1-A Blower
Section + GTC__S2-AD_X Compressor Section as an
add-on counterflow heater.
BMC, Inc.
Bryan, Ohio 43506
Manual:2100-633A
Supersedes:2100-633
Date:10-13-15
Page
1 of 12
CONTENTS
General Information
General.............................................................. 6
Shipping Damage................................................ 6
Application......................................................... 6
Location............................................................. 6
Installation
Locking Cabinet Sections Together........................ 7
Supply Duct Requirements................................... 8
Power and Control Wiring..................................... 9
ANSI Z535.5 Definitions:
DANGER: Indicate[s] a hazardous situation which, if
not avoided, will result in death or serious injury. The
signal word “DANGER” is to be limited to the most
extreme situations. DANGER [signs] should not be used
for property damage hazards unless personal injury risk
appropriate to these levels is also involved.
WARNING: Indicate[s] a hazardous situation which,
if not avoided, could result in death or serious injury.
WARNING [signs] should not be used for property
damage hazards unless personal injury risk appropriate
to this level is also involved.
CAUTION: Indicate[s] a hazardous situation which, if
not avoided, could result in minor or moderate injury.
CAUTION [signs] without a safety alert symbol may be
used to alert against unsafe practices that can result in
property damage only.
NOTICE: [this header is] preferred to address practices
not related to personal injury. The safety alert symbol
shall not be used with this signal word. As an
alternative to “NOTICE” the word “CAUTION” without
the safety alert symbol may be used to indicate a
message not related to personal injury.
Replacement Parts........................................... 12
Figures
Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Assembled System with
Counterflow Heater.................................. 4
Assembled Dimensions............................ 5
Supply Duct Floor Penetration.................. 7
Supply Duct Turn Requirements............... 8
Field Wire Entry and Routing.................... 9
GTCFHK1-A10 Wiring Diagram............... 10
GTCFHK1-A20 Wiring Diagram............... 11
CAUTION
!
All geothermal equipment is designed for
indoor installation only. Do not install or store
unit in a corrosive environment or in a location
where temperature and humidity are subject
to extremes. Equipment is not certified for
outdoor applications. Such installation will
void all warranties.
WARNING
!
Use care and wear appropriate protective
clothing, safety glasses and protective gloves
when servicing unit and handling parts.
Failure to follow this warning may result in
personal injury.
!
DANGER
Before drilling or driving any screws into
cabinet, check to be sure screw will not hit any
internal parts, refrigerant lines, water lines or
electrical wires/components.
Manual 2100-633A
Page
2 of 12
DESCRIPTION OF EQUIPMENT
NOMENCLATURE
The GTCFHK1-A** Counterflow Electric Heater
Assembly is only to be applied along with Bard Model
GTA____UD1-A Coil + GTB1-A Blower + GTC__S2AD_X Compressor Section models as an add-on
counterflow heater. It is a self-contained package that
includes the entire electric heat workings, along with
the circuit breaker(s), installation instructions and
wiring diagrams.
GTCFHK
1- A
10
Geo Trio
Counterflow
Heater Kit
Revision
Electrical
A = 240/208V - 1PH
Nominal KW
10 = 10 KW
20 = 20 KW
EQUIPMENT THIS HEATER PACKAGE IS TO BE INSTALLED IN COMBINATION WITH:
INDOOR COIL
+
BLOWER SECTION
+
COMPRESSOR SECTION
GTA3600UD1-A
GTB1-A GTC36S2-AD*X
GTA4860UD1-A GTC48S2-AD*X
GTC60S2-AD*X
*C = Copper Coaxial Coil
N = Cupro Nickel Coaxial Coil
!
WARNING
Fire hazard.
Install this heater only in combination with the
equipment listed above.
Installing this heater in any combination other
than what is listed above could result in fire
causing damage, injury or death.
SINGLE HIGH VOLTAGE CIRCUIT APPLICATIONS
Heater
Package
Model
Heater
Package
Volts/Hertz/
Phase
Heater Amps
@
240/208
Heater KW
@
240/208
Heater Btuh
@
240/208
Minimum
Circuit
Ampacity
240/208 Volts
Maxiumum
Circuit
Breaker
Field
Wire
Size
Ground
Wire
Size
GTCFHK1-A10
240/208-60-1
40/34.6
9.6/7.2
32,765/24,575
50/45
50/50
#6
#10
GTCFHK1-A20
240/208-60-1
80/69.2
19.2/14.4
65,530/49,150
100/100
100/100
#2
#6
DUAL HIGH VOLTAGE CIRCUIT APPLICATIONS (two separate supplied power circuits)
Heater
Package
Model
Heater
Package
Volts/Hertz/
Phase
Heater Amps
@
240/208
Heater KW
@
240/208
Heater Btuh
@
240/208
Minimum
Circuit
Ampacity
240/208 Volts
Maxiumum
Circuit
Breaker
Field
Wire
Size
Ground
Wire
Size
GTCFHK1-A20
240/208-60-1
40/34.6
9.6/7.2
32,765/24,575
50/45
50/50
#6
#10
Manual2100-633A
Page
3 of 12
FIGURE 1
Assembled System with Counterflow Heat
RETURN AIR DUCT
GTA_UD1-A COIL SECTION
GTC_S2-AD*X COMPRESSOR SECTION
THIS IS THE ONLY
ASSEMBLED
CONFIGURATION THAT
IS APPROVED
GTB1-A BLOWER SECTION
GTCFHK1-A
COUNTERFLOW
GTCFHK-1-A COUNTER
FLOW HEATER
HEATER ACCESSORY
ACCESSORY
SUB FLOOR
SUB FLOOR
SUPPLY FLANGE BELOW
SUBFLOOR
Manual 2100-633A
Page
4 of 12
MIS-3690
Manual2100-633A
Page
5 of 12
14"
21"
23"
79 5/8"
21 5/8"
3/4"
30"
LEFT SIDE
31 1/4"
41 7/8"
51 1/16"
69"
65 1/4"
37 7/16"
"A"
73 11/16"
75 5/8"
REFRIGERANT
CONNECTIONS
22"
FRONT
MODEL
GTC36S2
GTC48S2
GTC60S2
44 9/16"
47 5/16"
32 13/16"
39 13/16"
42 15/16"
51 7/8"
WATER IN
DESUPERHEATER
INLET
DESUPERHEATER
OUTLET
WATER OUT
OVERFLOW DRAIN OUTLET
30"
RIGHT SIDE
LOW VOLTAGE
HIGH
VOLTAGE
LOW
VOLTAGE
LOW VOLTAGE
TOP
27 15/16"
TOP DUCT OUTLET FLANGE
MAIN DRAIN OUTLET
DIM. A
53 7/16"
54 15/16"
55 15/16"
SECURE SECTIONS TOGETHER
USING BOLT PART #1012-015
AND WASHER PART #1012-109
FIGURE 2
Assembled Dimensions
MIS-3687
71 7/8"
19 13/16"
GENERAL INFORMATION
GENERAL
APPLICATION
Each unit is shipped internally wired, requiring line
power and 24V thermostat inputs.
Capacity of the unit for a proposed installation should
be based on heat loss calculations made in accordance
with methods of Air Conditioning Contractors of
America. The piping and electrical systems should
be installed in accordance all local, state and federal
requirements.
These instructions and any instructions packaged with
any separate equipment required to make up the entire
heat pump system should be carefully read before
beginning the installation. Note particularly any tags
and/or labels attached to the equipment.
While these instructions are intended as a general
recommended guide, they do not in any way supercede
any national and/or local codes. Authorities having
jurisdiction should be consulted before the installation
is made.
SHIPPING DAMAGE
Upon receipt of equipment, the carton should be
checked for external signs of shipping damage. If
damage is found, the receiving party must contact
the last carrier immediately, preferably in writing,
requesting inspection by the carrier’s agent.
LOCATION
The complete assembled unit may be installed in
a closet or utilility room provided adequate service
access is ensured, and equipment won’t freeze.
These units are not approved for outdoor installation
and therefore must be installed inside structure being
conditioned. Do not locate in areas subject to freezing
in the winter or sweating in the summer.
Prior to setting the assembled unit, consider ease of
piping and electrical connections for the unit. For
units which will be used with a desuperheater, consider
the proximity of the unit to the water heater or storage
tank. Place the unit on a solid base to minimize
undesirable noise and vibration.
Note that the GTCFHK1-A** models have a spacer to
force a 1” clearance to the combustible subfloor, but
is compensated in the detailed application drawings
included with this installation instruction (see Figure
3).
Manual 2100-633A
Page
6 of 12
INSTALLATION
LOCKING CABINET SECTIONS
TOGETHER
section below (will lock into the back). Next, insert
the 1/4" bolt and washer (included with the literature
assembly) in the front center of each section to secure
the sections together. See Figure 2 for bolt detail.
When stacking unit sections together, initially stack
the sections aligning the sides of the units. Then slide
the top section backwards (away from the front) until
the section drops down flush with the section below
it. Then pull the upper section forward to engage the
FIGURE 3
Supply Duct Floor Penetration
MIN. INCLUSIVE CLEARANCE
CUT OUT TO COMBUSTIBLES
17 1/2"
MIN. CUT
19 11/16"
MIN. CUT
29 3/32"
9 13/32"
SUB FLOOR
2 1/4"
19 3/4"
TOP VIEW
1/4" MIN CLEARANCE
TO SUPPLY FLANGE
TYPICAL ALL (4) SIDES
SUB FLOOR
BOTTOM VIEW
SUB FLOOR
MIS-3691
Manual2100-633A
Page
7 of 12
SUPPLY DUCT REQUIREMENTS
Note that the supply air duct MUST make a 90˚ turn
within the first 3' of vertical run (see Figure 4).
FIGURE 4
Supply Duct Turn Requirements
RETURN AIR DUCT
GTA_UD1-A COIL SECTION
GTC_S2-AD*X COMPRESSOR SECTION
GTB1-A BLOWER SECTION
GTCFHK-1-A COUNTER FLOW HEATER
ACCESSORY
SUB FLOOR
SUB FLOOR
SUPPLY FLANGE BELOW
SUBFLOOR
3'
90°
SUPPLY DUCT
NOTE: DUCT MUST MAKE A 90° TURN (IN ANY DIRECTION)
WITHIN THE FIRST 3' OF VERTICAL RUN.
MIS-3788
Manual 2100-633A
Page
8 of 12
POWER AND CONTROL WIRING
Low Voltage Control Wires
High Voltage LIne Supply
A junction point for low voltage connections is supplied
with this accessory. A short piece of thermostat wire
will need to be supplied and conjoined with low voltage
wires using supplied blue wire nuts.
This accessory item requires a separate line power
circuit from the main unit. The minimum circuit
ampacity and maximum overcurrent protection ratings
are listed on the heater serial plate.
A high voltage line supply entrance is available on
both sides of the heater box (a triple knockout). Route
the properly sized conduit and wire sizes through
whichever side best fits the application, and route
wiring internal of the box behind the contactors and
land on the circuit breakers on the left hand side of the
compartment.
Removal of Jumper Bar on Model GTCFHK1-A20 for
Dual Circuit Application
Back out phillips head screw from circuit breaker
entrance cover. Back out slotted circuit breaker screws
to release jumper bar. Individual circuit wires will
then directly land on entrance side of circuit breakers.
Two ground lugs are also provided when two separate
circuits are utilized.
A low voltage entrance is available on both sides of the
heater box (a finger grommet). Route the field-supplied
thermostat wire through whichever side best fits the
application. Route the thermostat wire to the front side
of the control platform and connect to supplied wires
with supplied blue wire nuts (see Figure 5).
Model GTCFHK1-A10 requires a 2-conductor
thermostat wire that will run between the GTH1 heater
accessory and the GTB1-A blower section for low
voltage connections. Land the low voltage wires in the
GTB1-A blower section on the blower control board
screw terminals in the designated location/signal (see
Figure 6 on page 10).
Model GTCFHK1-A20 requires a 4-conductor
thermostat wire that will run between the GTH1 heater
accessory and the GTB1-A blower section for low
voltage connections. Land the low voltage wires in the
GTB1-A blower section on the blower control board
screw terminals in the designated location/signal (see
Figure 7 on page 11).
FIGURE 5
Field Wire Entry and Routing
Route
field
wiring
through
ROUTE
FIELD
WIRING
THRU access
ACCESSpanel
PANELand then
behind
control
panel.
Connect
per AND
wiring
diagram
AND THEN
BEHIND
CONTROL
PANEL
CONNECT
toTO
proper
wireTERMINAL
with blue
wire
nuts.DIAGRAM
PROPER
PER
WIRING
MIS-3692
Manual2100-633A
Page
9 of 12
26
13
12
18
19
HEATER 7
CONTACTOR 1
14
14
50 A
GROUND LUG 6
29
3
4
LIMIT
SWITCH
1
C
15
29
2
LIMIT
SWITCH
10 KW 240V 28
ELEC. HEAT STRIP
BLACK/WHITE
L1
W1
L2
BROWN
T1
RED
RED
15
SINGLE CIRCUIT
BREAKER SIZE
BLACK
208/240-60-1
LINE POWER
RED
Circuit Breaker
BLACK
CLASS 2 WIRING
GTB1-A
TAP SELECT
CONTROL
C
W1
CIRCUIT
BREAKER #1
L1
GTB1-A
TAP SELECT
CONTROL
FIGURE 6
GTCFHK1-A10 Wiring Diagram
BLACK
RED
RED
Manual 2100-633A
Page
10 of 12
T2
L1
Low Voltage
High Voltage
LIMIT
SWITCH
T1
HEAT
CONTACTOR #1
99
4
2
HEAT
STRIP
L2
HEATER
CONTACTOR #1
T2
Factory
Field
Optional
Wire Identification numbers
for Bard use only.
3
1
HEAT
HEAT
STRIP CONTACTOR #1
208/240-60-1 LINE POWER
L2
DANGER
4117-104 A
!
WARNING
*ELECTRICAL SHOCK HAZARD
*DISCONNECT POWER BEFORE
SERVICING.
!
USE COPPER CONDUCTORS
ONLY SUITABLE FOR AT LEAST
75° C.
CIRCUIT
BREAKER #1
GND
11
10
L2
L1
Ckt B
5
2
CIRCUIT BREAKER
3
4
Terminal Block
L2
L1
Ckt A
RED
19
13
12
18
18
18
HEATER 7
CONTACTOR 1
22
HEATER 7
CONTACTOR 2
T1
L2
L1
BLUE
LIMIT
SWITCH
8
6
29
LIMIT
SWITCH 29
Y1
W2
7
5
W1
17
16
16
17
10 KW 240V 28
ELEC. HEAT STRIP
LIMIT
SWITCH
29
3
BROWN
20
21
15
15
4
1
C
YELLOW
BLUE
14
2
BLACK/WHITE
COM
RED
RED
BLUE
EMERGENCY 8
HEAT RELAY
T2
NC NO
14
LIMIT
SWITCH
29
10 KW 240V 28
ELEC. HEAT STRIP
23
23
23
GTB1-A
TAP SELECT
CONTROL
23
GTB1-A
TAP SELECT
CONTROL
C
W1
Y
W2
CIRCUIT
BREAKER #2
CIRCUIT
BREAKER #1
CLASS 2 WIRING
DUAL CIRCUIT
BREAKER SIZE
CKT. A
CKT. B
50 A
50 A
L1
FIGURE 7
GTCFHK1-A20 Wiring Diagram
BROWN
BROWN
100 A
L1
BROWN
BLUE
BLACK
SINGLE CIRCUIT
BREAKER SIZE
BLACK
6
GROUND LUG
L2
BLACK/WHITE
BLACK
RED
RED
RED
208/240-60-1
LINE POWER
BLUE/BLACK
T1
RED
T2
Manual2100-633A
Page
11 of 12
LIMIT
SWITCH
T1
L1
Low Voltage
High Voltage
EMERGENCY
HEAT RELAY
LIMIT
SWITCH
T1
HEAT
CONTACTOR #2
L1
HEAT
CONTACTOR #1
99
HEAT
STRIP
HEAT
STRIP
8
6
T2
L2
L2
Factory
Field
WARNING
DANGER
4117-105 A
*ELECTRICAL SHOCK HAZARD
*DISCONNECT POWER BEFORE
SERVICING.
!
USE COPPER CONDUCTORS
ONLY SUITABLE FOR AT LEAST
75° C.
!
CIRCUIT
BREAKER #2
HEATER
CONTACTOR #1
Optional
L2
CIRCUIT
BREAKER #1
GND
HEATER
CONTACTOR #2
T2
HEAT
CONTACTOR #2
4
2
HEAT
STRIP
Wire Identification numbers
for Bard use only.
7
5
3
1
HEAT
HEAT
STRIP CONTACTOR #1
208/240-60-1 LINE POWER
REPLACEMENT PARTS
1
20
3
19
4
5
6
7
18
2
9
10
Drawing
Part No.
No.
Manual 2100-633A
Page
12 of 12
11
14
SEXP-773
17
16
Description
GTCFHK1-A20
8
15
GTCFHK1-A10
12 13
1
S507-299-1
Top Assembly
1
1
2
2
8604-104
136-360
Heat Strip 9.6KW
Zero KW Blank Off Plate
1
1
2
0
3
S501-745-1
Left Side
1
1
4
8402-188
Limit Control 150-105 Line Break
2
4
5
515-262
Heater Box Front
1
1
6
533-244
Control Partition
1
1
7
553-574
Heater Access Cover
1
1
8
S153-565-1
Front Service Door
1
1
9
9
4117-104
4117-105
Wiring Diagram
Wiring Diagram
1
0
0
1
10
8615-047
Jumper Bar Base 4 Pole
0
1
11
8615-049
Jumper Bar Cover 4 Pole
0
1
12
8615-057
Circuit Breaker Mounting Foot
1
2
13
8615-040
Circuit Breaker, 50A, 2 Pole
1
2
14
8201-130
Relay, SPDT, Pilot Duty
0
1
15
527-446
Base
1
1
16
8401-025
Contactor 2 Pole 50 Amp Resistive
1
2
17
111-213
Duct Flange
2
2
18
S501-744-1
Right Side
1
1
19
509-287-1
Back
1
1
20
117-344
Heater Box Wrapper
1
1
SEXP-773
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