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I-TECSERIES

PACKAGED HEAT PUMP

INSTALLATION

 

Models:

 

INSTRUCTIONS

I30H1

I36H1

I42H1

 

I48H1

I60H1

 

 

I30H1D

I36H1D

I42H1D

 

I48H1D

I60H1D

 

 

 

 

 

MIS-2957A

Bard Manufacturing Company, Inc.

Manual:

2100-549G

Bryan, Ohio 43506

Supersedes:

2100-549F

Since 1914 . . . Moving ahead, just as planned.

File:

Vol. II Tab 14

Date:

11-05-13

 

 

 

 

 

 

 

 

Manual

2100-549G

 

 

Page

1 of 59

CONTENTS

Getting Other Information and Publications

 

For more information, contact these publishers: ..........

3

General & ANSI Z535.5 Definitions .............................

4

I-TECGeneral Information

 

 

I-TECModel Nomenclature ..........................................

 

5

Shipping Damage, Unit Removal From Skid ...............

8

Handling Unit After Removal From Skid .......................

8

Required Steps after Final Placement ..........................

9

Minimum Installation Height .........................................

 

9

Securing Unit to Structure & Seismic Considerations ..

9

Duct Work, Supply Duct Connections & Filters..........

17

Condensate Drain ......................................................

 

18

With No Vent Option and With CRV & ERV ...............

18

Installation Instructions

 

 

Mounting the Unit & Wiring — Main Wiring ................

21

Wiring—LowVolt. Wiring & Low Volt.Connections ....

22

Start Ups

 

 

 

R-410ARefrigerant Required .....................................

 

30

Topping Off System Charge .......................................

 

30

Safety Practices .........................................................

 

30

Description of Standard Equipment............................

31

Important Installer Note ..............................................

 

31

Phase Monitor ............................................................

 

31

Three Phase Scroll Compressor ................................

 

31

Figures

 

 

 

 

Figure 1

Unit Dimensions ..........................................

 

7

Figure 2A & 2B Unit on Lift & Unit Side ........................

8

Wall Mounting Bracket Location ....................................

 

9

Bracket Wall Sect. View & Wood Framed Install ........

10

Figure 3

Center of Gravity .......................................

 

11

Figure 4

Req. Clearances & Rec. Access ...............

12

Figure 5

Compressor Shipping Bolts .......................

13

Figure 6

Removal of Air Duct ...................................

 

13

Figure 7A

Ducted Application .....................................

 

14

Figure 7B

3" Riser Application ...................................

 

15

Figure 7C

6" Riser Application ...................................

 

16

Figure 8

Supply Duct Connections ..........................

17

Figure 9

Filter Location ............................................

 

17

Figure 10

Drain Locations .........................................

 

18

Figures 11A & 11B Unit Mounting .......................

19 & 20

Figure 12

Component Location .................................

 

21

Figure 13

Basic Heat Pump w/No Vent Pkg. .............

23

Figure 14

HP w/CRV, without CO2 Control .................

24

Figure 15

HP with CRV & CO2 Control ......................

25

Figure 16

HP with ERV, w/o CO2

Control ...................

26

Figure 17

HP with ERV & CO2 Control ......................

27

Figure 18

HP w/ERV & CO2 Control (Fully Mod.) ......

28

Figure 19

HP w/Comb. CRV & DB Econ. ("N" Vent) ....

29

Figure 20

Defrost Cycle .............................................

 

33

Figure 21

CRV Motor Speed/CFM Configuration ......

35

Figure 22

CRV Speed Change Terminal Access .......

36

Figure 23

Economizer Control Circuit ........................

38

Figure 24

Motor Speed / CFM Configuration .............

39

Fig. 25A

ERV Manual Mode "M" Terminal ...............

43

Fig. 25B

ERV Mod. Mode "P" Terminal ....................

43

Figure 26

Ventilation Airflow Diagram ........................

44

Figure 27

ERV Control Access ..................................

 

45

Figure 28

Control Board Config./Setting ....................

46

Manual

2100-549G

 

 

Page

2 of 59

 

 

Service Hints ..............................................................

 

31

Sequence of Operation ..............................................

 

32

Pressure Service Ports ...............................................

 

32

Lowering Outdoor Fan Speed for Sound ....................

 

32

Defrost Cycle ..............................................................

 

33

I-TECCommercial Room Ventilator System

 

 

Gen. Description, Control Wiring & Rec. Seq. ...........

 

34

Setting the Ventilation CFM Levels ............................

 

34

I-TECComb. CRV & Economizer Vent System

 

 

Description & Control Wiring ......................................

 

37

Setting the Ventilation CFM Levels ............................

 

37

Economizer Seq. of Operation ...................................

 

38

Heating & Vent Mode .................................................

 

39

I-TECEnergy Recovery Ventilator System

 

 

General Description & Control Wiring ........................

 

40

Recommended Control Sequences ...........................

 

41

Changing Ventilation CFM Rates in Manual Mode ....

41

Changing to Fully Modulating Mode ...........................

 

41

Configuring Control for ERV Mod. Control ............

47-48

Maintenance (Gen., Frequency, Clean & Perform.) .....

49-50

Troubleshooting

 

 

Solid State HP Control Troubleshooting Procedure ...

51

Checking Temperature Sensor ...................................

 

52

Troubleshooting ECM™ 142R Motor ................

43 & 54

Replacing the Motor ..................................................

 

54

Troubleshooting Indoor ECM™ Motor ..................

55-56

Fan Blade Setting Dimensions ...................................

 

57

Refrigerant Charge .....................................................

 

57

Figures (continued)

 

 

Figure 29 Hub Assembly w/Ball Bearings ..................

 

50

Figure 30

Control Disassembly .................................

 

56

Figure 31

Winding Test ..............................................

 

56

Figure 32

Drip Loop ...................................................

 

56

Figure 33 Control Connector Motor Half ....................

 

57

Tables

 

 

 

Table 1 Factory Built-InElectric Heat Table ..............

 

5

Table 1A Indoor Blower Performance ..........................

 

5

Table 2

Elec. Specifications .......................................

 

6

Center of Gravity Reference Table ..............................

 

11

Table 3 Operating Voltage Range ...........................

 

22

Table 4

Wall Thermostats ........................................

 

22

Low Voltage Connections for DDC Control .................

 

22

Performance & App. Data:

 

 

 

Summer Cooling & Winter Heating ............

 

42

Table 5

Troubleshooting ..........................................

 

51

Table 6 Temp. vs Resistance of Temp. Sensor

.......

52

Table 7 Troubleshooting ECM™ 142R ....................

 

54

Table 8

Cooling Mode ..............................................

 

54

Table 9 Heat Pump Mode ........................................

 

54

Troubleshooting ECM™ Blower Motors ......................

 

57

Power Connector ........................................................

 

57

Table 10A Pressures: Full Load Cooling .....................

 

58

Table 10B Pressures: Full Load Heating .....................

 

58

Table 11A Pressures: Part Load Cooling .....................

 

59

Table 11B Pressures: Part Load Heating ....................

 

59

GETTING OTHER INFORMATION AND PUBLICATIONS

These publications can help you install the air conditioner or heat pump. You can usually find these at your local library or purchase them directly from the publisher. Be sure to consult current edition of each standard.

National Electrical Code .....................

ANSI/NFPA 70

Standard for the Installation .............

ANSI/NFPA 90A

of Air Conditioning and Ventilating Systems

Standard for Warm Air ......................

ANSI/NFPA 90B

Heating and Air Conditioning Systems

Load Calculation for .......................

ACCA Manual J or

Winter and Summer

Manual N

Air Conditioning

 

Low Pressure, Low Velocity ........

ACCA Manual D or

Duct System Design

Manual Q

Winter and Summer Air Conditioning

FOR MORE INFORMATION, CONTACT THESE PUBLISHERS:

ACCA Air Conditioning Contractors of America

1712 New Hampshire Avenue

Washington, DC 20009

Telephone: (202) 483-9370

Fax: (202) 234-4721

ANSI

American National Standards Institute

 

11 West Street, 13th Floor

 

New York, NY 10036

 

Telephone: (212) 642-4900

 

Fax: (212) 302-1286

ASHRAE American Society of Heating, Refrigeration,

and Air Conditioning Engineers, Inc.

1791 Tullie Circle, N.E.

Atlanta, GA 30329-2305

Telephone: (404) 636-8400

Fax: (404) 321-5478

NFPA

National Fire Protection Association

 

Batterymarch Park

 

P.O. Box 9101

 

Quincy, MA 02269-9901

 

Telephone: (800) 344-3555

 

Fax: (617) 984-7057

Manual

2100-549G

Page

3 of 59

GENERAL

The equipment covered in this manual is to be installed by trained, experienced service and installation technicians.

The I-TECmust be installed with the Bard manufactured IWS wall sleeve and ILG louver grille accessories. These are sold as separate accessories. Any substitutions will void the manufacturer’s warranty.

The unit is designed for use with or without ductwork. For use without ductwork, Plenum Box IPBDF8-color(8" height) orIPBDF12-color(12" height) is recommended.

These instructions explain the recommended method to install the air cooled self-containedunit and the electrical connections to it.

These instructions and any instructions packaged with any separate equipment required to make up the entire heating and air conditioning system should be carefully read before beginning the installation. Note particularly “Start Procedure” and any tags and/or labels attached to the equipment.

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.

While these instructions are intended as a general recommended guide, they do not supersede any national and/or local codes in any way. Authorities having jurisdiction should be consulted before the installation is made. See Page 3 for information on codes and standards.

Size of unit for a proposed installation should be based on heat loss or heat gain calculation made according to methods of Air Conditioning Contractors of America (ACCA). The air duct should be installed in accordance with the Standards of the National Fire Protection Systems of Other Than Residence Type, NFPA No. 90A, and Residence Type Warm Air Heating and Air Conditioning Systems, NFPA No. 90B. Where local regulations are at a variance with instructions, installer should adhere to local codes.

Manual

2100-549G

Page

4 of 59

I-TECSeries General Information

I-TECMODEL NOMENCLATURE

I 36 H

1 D A 0Z

R

P

4

X X

2

 

 

 

 

 

 

MODEL

SYSTEM TYPE:

SERIES

HEAT PUMP

NOMINAL

 

REVISION

CAPACITY

 

 

 

30

= 30,000 BTUH

SPECIAL UNITS

36

=

36,000

 

(–)= Standard

42

= 42,000

 

D = Dehum.

48

=

48,000

 

 

60

=

60,000

 

 

VOLTS & PHASE |

A= 230/208, 60-1

B= 230/208, 60-3

C= 460-60-3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CONTROLS

 

 

 

 

 

 

COLOR OPTIONS

 

 

 

 

ELECTRIC HEAT

 

 

X - Beige paint

 

 

 

 

X = 24V Terminal Block Only w/o

0Z = No heat w/breaker

 

 

 

 

 

1

- White paint

 

 

 

 

CompleteStat

04

= 4KW

1-Phase

 

 

 

 

4

- Gray paint

 

 

 

 

1 = CompleteStat THO (Temp,

05

= 5KW

1-Phase

 

 

 

 

 

 

 

 

 

 

 

 

 

Humidity & Occupancy)

06

= 6KW

3-Phase

 

 

 

 

 

 

 

 

 

2 = CompleteStat THO w/CO2

09

= 9KW

3-Phase

FILTER OPTIONS

 

 

 

 

3 = CompleteStat THO w/Ethernet

10

= 10KW 1-Phase

P = 2" Pleated MERV 8

 

 

 

 

4 = CompleteStat THO w/CO2 &

15

= 15KW 1 & 3-Phase

M = 2" Pleated MERV 11

 

 

 

Ethernet

18

= 18KW 3-Phase

N = 2" Pleated MERV 13

 

 

 

 

 

 

 

 

Note: CompleteStat must be field

20

= 20KW 1-Phase

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

installed & wired. All units have

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

24V terminal block.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

VENTILATION OPTIONS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

COIL TREATMENT

 

B = Blank-OffPlate

 

 

 

 

 

 

M = Multi-SpeedCRV

 

 

 

 

 

X - Std. Hydrophilic Fin Evap. &

 

N = Comb. CRV & DB Economizer

 

 

 

 

Uncoated Alum. Cond. Coil

 

R = ERV

 

 

 

 

 

 

 

1 - Phenolic Coated ID Coil

 

 

 

 

 

RESERVED

2 - Phenolic Coated OD Coil

 

 

 

 

 

3 - Phenolic Coated ID & OD Coil

 

 

 

 

 

 

 

 

 

 

TABLE 1

FACTORY BUILT-INELECTRIC HEAT TABLE

Models

I30H1-A

I30H1-B

I30H1-C

I36H1-A

I36H1-B

I36H1-C

I48H1-A

I48H1-B

I48H1-C

I60H1-A

I42H1-A

I42H1-B

I42H1-C

I60H1-B

I60H1-C

 

 

 

 

 

 

 

 

 

 

KW

240V-1

208V-1

240V-3

208V-3

460V-3

240V-1

208V-1

240V-3

208V-3

460V-3

240V-1

208V-1

240V-3

208V-3

460V-3

240V-1

208V-1

BTUH

BTUH

BTUH

BTUH

BTUH

BTUH

BTUH

BTUH

BTUH

BTUH

BTUH

BTUH

BTUH

BTUH

BTUH

BTUH

BTUH

 

4.0

 

 

 

 

 

 

 

 

 

 

13,652

10,239

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5.0

17,065

12,799

 

 

 

17,065

12,799

 

 

 

17,065

12,799

 

 

 

17,065

12,799

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

6.0

 

 

20,478

15,359

20,478

 

 

20,478

15,359

20,478

 

 

20,478

15,359

20,478

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

9.0

 

 

30,717

23,038

30,717

 

 

30,717

23,038

30,717

 

 

30,717

23,038

30,717

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

10.0

34,130

25,598

 

 

 

34,130

25,598

 

 

 

34,130

25,598

 

 

 

34,130

25,598

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

15.0

 

 

 

 

 

51,195

38,396

51,195

38,396

51,195

51,195

38,396

51,195

38,396

51,195

51,195

38,396

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

18.0

 

 

 

 

 

 

 

 

 

 

 

 

61,434

46,076

61,434

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

20.0

 

 

 

 

 

 

 

 

 

 

68,260

51,195

 

 

 

68,260

51,195

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TABLE 1A

INDOOR BLOWER PERFORMANCE 1

 

 

 

2

 

 

3

4

 

 

 

Continuous

Rated 2nd

Rated 1st

5 - 9 KW

13.5 - 18

Model

Rated ESP

Max. ESP

CFM

Stage CFM

Stage CFM

CFM

KW CFM

I30H1

.15

0.50

500

900

650

700

1400

 

 

 

 

 

 

 

 

I36H1

.15

0.50

600

1150

850

700

1400

 

 

 

 

 

 

 

 

I42H1

.20

0.50

650

1300

950

700

1400

 

 

 

 

 

 

 

 

I48H1

.20

0.50

725

1500

1050

700

1400

 

 

 

 

 

 

 

 

I60H1

.20

0.50

850

1700

1200

700

1400

 

 

 

 

 

 

 

 

1 Motor will deliver consistent CFM through voltage supply range with no deterioration.2 Continuous fan CFM is the total air being circulated during continuous fan mode.

3 Will operate at rated Full Load Airflow when operating with Heat Pump.

4Will occur automatically with a call for "W3" or "Emergency Heat" signal from the thermostat (Heat Pump Operation is terminated at this condition).

Manual

2100-549G

Page

5 of 59

TABLE 2

ELECTRICAL SPECIFICATIONS

 

 

 

 

Single Circuit

 

 

 

 

Dual Circuit

 

 

 

 

Rated

No. Field

Minimum

Maximum

Field

 

Minimum

Maximum

Field

Ground

Model

Volts, Hertz

Power

Ground

Circuit

External Fuse

Power

Circuit

External Fuse

Power

Wire

and Phase

Circuits

Wire

Ampacity

or Ckt. Breaker

Wire Size

 

Ampacity

or Ckt. Brkr.

Wire Size

 

 

 

 

 

 

Ckt. A

Ckt. B

Ckt. A

Ckt. B

Ckt. A

Ckt. B

Ckt. A

Ckt. B

 

 

 

 

 

 

 

I30H1-A0Z

 

1

22

35

8

10

 

 

 

 

 

 

 

 

A05

230/208-1

1

48

50

8

10

 

 

 

 

 

 

 

 

A10

 

1 or 2

74

80

4

8

48

30

50

30

8

10

10

10

I30H1-B0Z

 

1

17

25

10

10

 

 

 

 

 

 

 

 

B06

230/208-3

1

35

35

8

10

 

 

 

 

 

 

 

 

B09

 

1

44

45

8

10

 

 

 

 

 

 

 

 

I30H1-C0Z

 

1

9

10

14

14

 

 

 

 

 

 

 

 

C06

460-3

1

18

20

12

12

 

 

 

 

 

 

 

 

C09

 

1

22

25

10

10

 

 

 

 

 

 

 

 

I36H1-A0Z

 

1

26

40

8

10

 

 

 

 

 

 

 

 

A05

230/208-1

1

52

60

6

10

 

 

 

 

 

 

 

 

A10

1 or 2

78

80

4

8

26

52

40

60

8

6

10

10

 

1 A15

 

1 or 2

84

90

4

8

26

52

40

60

8

6

10

10

I36H1-B0Z

 

1

22

30

10

10

 

 

 

 

 

 

 

 

B06

230/208-3

1

40

45

8

10

 

 

 

 

 

 

 

 

B09

1

49

50

8

10

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1 B15

 

1

51

60

6

10

 

 

 

 

 

 

 

 

I36H1-C0Z

 

1

11

15

14

14

 

 

 

 

 

 

 

 

C06

460-3

1

20

20

12

12

 

 

 

 

 

 

 

 

C09

1

24

25

10

10

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1 C15

 

1

28

30

10

10

 

 

 

 

 

 

 

 

I42H1-A0Z

 

1

30

45

8

10

 

 

 

 

 

 

 

 

A05

230/208-1

1

56

60

6

10

 

 

 

 

 

 

 

 

A10

1 or 2

82

90

4

8

56

26

60

30

6

10

10

10

 

1 A15

 

1 or 2

82

90

4

8

56

52

60

60

6

6

10

10

I42H1-B0Z

 

1

25

35

8

10

 

 

 

 

 

 

 

 

B06

230/208-3

1

43

50

8

10

 

 

 

 

 

 

 

 

B09

1

52

60

6

10

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1 B15

 

1

52

60

6

10

 

 

 

 

 

 

 

 

I42H1-C0Z

 

1

12

15

14

14

 

 

 

 

 

 

 

 

C06

460-3

1

21

25

10

10

 

 

 

 

 

 

 

 

C09

1

26

30

10

10

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1 C15

 

1

28

30

10

10

 

 

 

 

 

 

 

 

I48H1-A0Z

 

1

34

50

8

10

 

 

 

 

 

 

 

 

A04

 

1

54

60

6

10

 

 

 

 

 

 

 

 

A05

230/208-1

1 or 2

59

70

6

8

35

26

45

30

8

10

10

10

A10

1 or 2

85

90

3

8

35

52

45

60

8

6

10

10

 

1 A15

 

1 or 2

85

90

3

8

35

52

45

60

8

6

10

10

1 A20

 

1 or 2

110

110

2

6

59

52

60

60

6

6

10

10

I48H1-B0Z

 

1

26

35

8

10

 

 

 

 

 

 

 

 

B06

 

1

44

50

8

10

 

 

 

 

 

 

 

 

B09

230/208-3

1

53

60

6

10

 

 

 

 

 

 

 

 

1 B15

 

1

53

60

6

10

 

 

 

 

 

 

 

 

1 B18

 

1

53

60

6

10

 

 

 

 

 

 

 

 

I48H1-C0Z

 

1

15

20

12

12

 

 

 

 

 

 

 

 

C06

 

1

25

30

10

10

 

 

 

 

 

 

 

 

C09

460-3

1

29

30

10

10

 

 

 

 

 

 

 

 

1 C15

 

1

29

30

10

10

 

 

 

 

 

 

 

 

1 C18

 

1

29

30

10

10

 

 

 

 

 

 

 

 

I60H1-A0Z

 

1

44

60

8

10

 

 

 

 

 

 

 

 

A05

 

1 or 2

70

80

4

8

44

26

60

30

8

10

10

10

A10

230/208-1

1 or 2

96

100

3

8

44

52

60

60

8

6

10

10

1 A15

 

1 or 2

96

100

3

8

44

52

60

60

8

6

10

10

1 A20

 

1 or 2

112

120

2

6

60

52

60

60

6

6

10

10

I60H1-B0Z

 

1

31

45

8

10

 

 

 

 

 

 

 

 

B06

 

1

49

60

8

10

 

 

 

 

 

 

 

 

B09

230/208-3

1

58

60

6

10

 

 

 

 

 

 

 

 

1 B15

 

1

58

60

6

10

 

 

 

 

 

 

 

 

1 B18

 

1 or 2

63

70

6

8

31

54

45

60

8

6

10

10

I60H1-C0Z

 

1

15

20

12

12

 

 

 

 

 

 

 

 

C06

 

1

25

30

10

10

 

 

 

 

 

 

 

 

C09

460-3

1

29

30

10

10

 

 

 

 

 

 

 

 

1 C15

 

1

29

30

10

10

 

 

 

 

 

 

 

 

1 C18

 

1

29

30

10

10

 

 

 

 

 

 

 

 

These “Minimum Circuit Ampacity” values are to be used for sizing the field power conductors. Refer to the National Electric Code (latest revision), article 310 for power conductor sizing.

Caution: When more than one field power conductor circuit is run through one conduit, the conductors must be derated. Pay special attention to note 8 of table 310 regarding Ampacity Adjustment Factors when more than three conductors are in a raceway.

Maximum size of the time delay fuse or HACR type circuit breaker for protection of field wiring conductors. Based on 75°C copper wire. All wiring must conform to the National Electrical Code and all local codes. Maximum KW that can operate with heat pump on is 10KW for 1-Phaseand 9KW for3-Phase.

1 Represents Electric Heat Only. Electrical Control Circuit will lockout Heat Pump Operation.

Manual

2100-549G

Page

6 of 59

Page

Manual

59 of 7

549G-2100

 

 

 

 

 

 

FIGURE 1

 

 

 

 

 

 

UNIT DIMENSIONS

Top View

 

 

 

47 85 " Total Width

 

1

 

 

 

46 81 " With Sides Removed

 

 

 

1

 

 

20" x 24" Supply Frame

3 4

"

11

4

"

20"

Unit Specification Sheet

 

 

 

 

 

 

28 41 "

 

 

 

 

 

26 43 "

 

24"

 

 

 

 

3

 

 

 

 

 

31 8 "

 

 

 

 

 

 

 

 

 

 

 

 

Total Depth

2 41 "

Low Voltage

 

Entrance

Front View

(2) 2"x24"x30" Return Air Filters

Control Panel

(2) Washable

Vent Intake

Air Filters

(2) 12" x 20" Vent Exhaust Air Filters

2"

 

 

High Voltage

11

7

"

Entrance

 

 

8

 

 

 

Electric Heat

 

 

 

 

Wire Channel

 

 

 

 

(4) Lift-Off

 

 

 

 

Hinges

 

 

 

 

Locking

 

 

 

 

Door Latch

94"

 

 

 

 

 

 

 

 

Total

 

 

 

Electrical

Height

 

 

 

Disconnect

 

71 34 "58" Upper

Section

 

 

 

 

Locking

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Door Latch

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

22

 

1

"

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4

 

 

 

 

 

 

 

 

 

 

 

15

 

5

"

Lower

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

 

8

Section

 

 

 

 

 

13 4

"

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Right Side View

30" With Doors and

Sides Removed

Front Forklift Holes

Side Forklift Holes

(Remove Front Trim)

(Remove Sides)

(2) Return

Supply

Back View

Openings

 

Air

 

Outer

 

 

Sleeve

 

 

Return

 

Return

Air

 

Air

 

 

Outer

 

 

Sleeve

Inner

 

 

Sleeve

 

Inner

 

 

Sleeve

 

 

 

71 21 "

 

 

 

 

 

 

 

 

(2) Side

 

 

 

 

 

 

 

Handles

 

 

 

 

 

 

 

(2) Unit

 

 

 

 

 

 

 

Drains

 

 

 

 

 

 

 

 

 

 

(2) Opt.

24

1

"

 

 

 

 

Unit Drain

2

 

 

 

 

Entrances

 

 

 

 

8"

 

 

 

 

3

3

"

3

81

"

3 81 "

 

4

 

 

 

 

MIS-2917A

SHIPPING DAMAGE

Upon receipt of equipment, the unit should be checked for external signs of shipping damage. The skid must remain attached until the unit is ready for installation. If damage is found, the receiving party must contact the last carrier immediately, preferably in writing, requesting inspection by the carrier’s agent.

UNIT REMOVAL FROM SKID

WARNING

This unit is heavy and requires more than one person to handle during installation and removal from the skid. Extreme caution must be taken to prevent injury to personnel and damage to the unit. Use appropriate safety equipment, including gloves when handling. Failure to do so may result in serious injury.

A forklift or a lift rated for the load (Figure 2A) is required to lift the unit off from the skid. This unit is top heavy and should never be tipped while moving it.

The I-TECis designed to be lifted off the skid from the front or rear of the unit without having to remove any doors or side panels. See Figure 1 for fork openings. The shipping brackets on front and rear of the unit must be removed and discarded. The unit can now be lifted straight up and the skid can be slid out from underneath.

Tip unit from left side only.

Failure to do so may result in injury due to unit top-heavinessor compressor damage!

FIGURE 2A — UNIT ON LIFT

HANDLING UNIT AFTER REMOVAL FROM SKID

If a wide and tall enough opening exists, the I-TECcan be moved as a complete assembled unit. If not, it is designed to break down into two sections to allow it to pass through a 36 inch wide door.

1.Depress & release both top & bottom door latches and open doors.

2.Remove the doors by lifting straight up and off from the hinge pins.

3.Remove cabinet sides by first removing the four (4) sheet metal screws from the front (leading edge) of the side panel. The panel will not fall off. Swing the panel away from the chassis 20 to 30 degrees & then pull forward from the two (2) tabs supporting the rear edge.

4.On each side of the unit is a tie plate that secures the top and bottom sections with four (4) cap bolts. Using a ½ inch wrench or socket, remove these screws from both plates and set aside.

5.If the unit is equipped with a CRV or ERV, you must unplug the wire harness on the left-handside of the control box.

6.A forklift or a lift rated for the load is required to lift the top section off from the bottom base. Do not attempt to do this manually. Failure to do so could result in the unit tipping over & causing bodily injury and/or damage to the unit.

7.The top section can be forked from either the RH or LH side. See Figure 1 for fork openings.

8.Carefully lift the top section straight up avoiding tipping.

9.Move the top section through the doorway and place on flat surface free of debris.

10.The bottom base can now be moved through the doorway the same way.

11.Reassemble the unit by reversing this procedure.

FIGURE 2B UNIT SIDE

É

ERV/CRV

HARNESS CONNECTION

 

(4) CAP BOLTS

FORK OPENING

É

(Visible after

 

removing tie plate)

É

 

É

TIE PLATE

(Covers entire width; shortened for illustration purposes to show Fork Openings)

Manual

2100-549G

Page

8 of 59

REQUIRED STEPS AFTER FINAL PLACEMENT SECURING UNIT TO STRUCTURE

The compressor is secured to the base with two (2) bolts for shipping. Although the unit will perform as designed with the shipping bolts in place, there may be a noticeable additional noise and vibration noted. To obtain the lowest noise and vibration levels, remove the shipping bolts after the unit is in its final operating location. To gain access to the compressor, the compressor access panel must be removed (Figure 9). Once this panel is removed, the CRV/ERV air duct must be removed. See Figure 6.

The air duct is removed by pulling it straight toward you; there are no screws securing it in place. Both the top and bottom slide toward you at the same time (pull hard). Once removed, the compressor is visible as well as the tags on the shipping bolts (Figure 5).

After the compressor shipping bolts have been removed, the CRV/ERV air duct can be slid back in place and the compressor access panel attached.

MINIMUM INSTALLATION HEIGHT

The minimum installation height to the bottom of the roof or fixed ceiling for ducted applications is 9 ft. 7 in. This provides enough clearance to install the duct work. See Figure 7A.

The IWS Series wall sleeve has a built-invertical adjustment to fit window sill heights from31-34inches. If additional height is required, two riser platform accessories are available. The IRP3 increases the unit height by 3 inches (Figure 7B) and the IRP6 by 6 inches (Figure 7C).

Several construction options are available for unit installation of the IZ Series. Serviceability and filter access must be considered before installing. See Figure 5D for required clearances and recommended service access dimensions.

Shipped with the I-TECunit is a wall mounting bracket (screwed to shipping skid on backside of unit). This bracket can be utilized to secure the top portion of the unit to the wall using the appropriate field supplied hardware based upon the material you are fastening to.

(There are several offset holes, sized to accept up to a 1/4" diameter fastener that will easily allow you to hit studs on a framed wall.) See BRACKET SECTION VIEW for locating this top wall bracket which will need to be applied after the unit is located in the final position.

Additional/optional mounting holes for up to a 3/8" diameter fastener are also available in the backside of the unit. These can be accessed by:

removing the air filters for the uppermost set

removing the compressor section service door for the lower set

Refer to WOOD FRAMED INSTALLATIONfor additional framing required to secure unit to wall.

The additional/optional mounting holes will require a long extension to drive the fasteners.

SEISMIC CONSIDERATIONS

The I-TECproduct features several locations for product securement but all site conditions are different. Consult with a licensed Seismic Engineer to advise of particular needs when attaching theI-TECunit to the structure.

WALL MOUNTING BRACKET LOCATION

 

2"

1 11/16"

43 3/8"

 

Ø1/4" BRACKET

3/4"

1 1/2"

7/8"

94" FROM BOTTOM OF BRACKET TO FLOOR WITHOUT RISER KIT

MIS-3029

Manual

2100-549G

Page

9 of 59

BRACKET WALL SECTION VIEW

 

Optional

 

 

 

 

 

 

 

 

Duct

 

 

 

 

 

 

 

 

 

Optional Top

 

3

 

 

 

3"

 

Outside

Bracket

 

 

 

 

Ceiling

 

43 8

"

 

 

 

Wall

 

 

 

 

 

 

(4) optional Unit

 

 

 

 

 

 

Optional

 

Mounting holes

 

 

 

 

 

 

Telescoping

 

7

 

 

7

 

 

Trim or

20

"

20

"

6"

Wall Sleeve**

8

8

Supply Duct

 

 

 

 

 

 

 

 

Sleeve Mounting

 

 

 

 

 

 

Box

 

 

 

 

 

 

 

 

Hole Locations

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Centered on

 

 

Centered

 

 

 

Opening

 

 

 

 

 

 

 

 

 

 

 

Outside

 

 

 

 

20"

 

 

 

 

 

 

 

 

42-3/4"Min.

 

 

 

 

 

Wall

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

43-1/4"Max.

 

 

 

 

 

94 81 "

 

 

48" Min.

 

49

3

"

 

 

 

 

48-1/2"Max.

 

8

21

 

Grille

 

 

 

 

20"

 

 

56

"

 

Centered

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(4) optional Unit

 

 

 

 

 

 

 

 

 

 

Mounting holes

 

 

 

 

 

 

 

 

 

Unit

 

 

 

 

 

 

 

 

 

 

 

8"

20

7

8"

4

1611 "

 

 

31" Min.*

8 "

 

 

 

 

 

 

1 1615 "

 

 

 

 

 

 

 

 

 

34" Max.

 

 

 

 

 

 

29

17

"

 

*

20"

 

20"

 

 

 

32

 

31" Min.

 

 

 

 

 

 

 

Floor

34" Max.

 

43 87 "

 

 

 

 

 

 

 

 

 

 

Room Floor Level

 

 

 

 

 

 

 

 

 

 

 

 

 

C

C

 

L

L

18 3/4

7 3/8

17.5"

 

 

Right Side View

 

35"

Front (Wall Only) View

 

*Higher Sill Heights Acheivable With Base Kit.

**Separate telescoping sleeves available for different wall thicknesses.

FLOOR MOUNTING HOLE & CENTERLINES

MIS-2918C

WOOD FRAMED INSTALLATION (for Wall Attachment)

41.75

Inner wall

(4) Upper fastener holes

6.00

Unit

(4) lower fastener holes

56.50

8.00

29.56*

20.88

36.88 8.00

Floor * Height dimension shown without riser kit. If unit uses riser kit add appropriate dimension to height.

MIS-3072

Manual

2100-549G

Page

10 of 59

FIGURE 3

CENTER OF GRAVITY

CENTER OF GRAVITY

"Z"

"X"

"Y"

MIS-3269

 

FRONT OF UNIT

LEFT SIDE

FLOOR TO CENTER

FLOOR TO CENTER

UNIT TESTED

DOOR TO CENTER

TO CENTER

CRV & ERV

NO VENT

 

"X" Dimension

"Y" Dimension

"Z" Dimension

"Z" Dimension

 

 

 

 

 

I30H1-A,-B

14"

24"

43½"

47"

 

 

 

 

 

I30H1-C

14"

24¼"

43½"

47"

 

 

 

 

 

I36H1-A,-B

14"

24"

43½"

47"

 

 

 

 

 

I36H1-C

14"

24¼"

43½"

47"

 

 

 

 

 

I42H1-A,-B

14"

24"

43½"

47"

 

 

 

 

 

I42H1-C

14"

24¼"

43½"

47"

 

 

 

 

 

I48H1-A,-B

14"

24"

43½"

47"

 

 

 

 

 

I48H1-C

14"

24¼"

43½"

47"

 

 

 

 

 

I60H1-A,-B

14"

24"

43½"

47"

 

 

 

 

 

I60H1-C

14"

24¼"

43½"

47"

 

 

 

 

 

Manual

2100-549G

Page

11 of 59

FIGURE 4

REQUIRED CLEARANCES & RECOMMENDED ACCESS

WING WALL CONSTRUCTION TOP VIEW

12" MIN.

 

12" MIN.

 

CLOSET CONSTRUCTION TOP VIEW

 

 

 

 

31 3/8"

 

12" MIN.

 

12" MIN.

 

12" MIN.

12" MIN.

RECOMMENDED SERVICE

 

 

 

 

 

ACCESS DIMENSIONS

 

 

12" MIN.

12" MIN.

48" MIN.

 

FOR LEFT

FOR RIGHT

 

 

SIDE

SIDE

 

 

ACCESS

ACCESS

LEFT CORNER CONSTRUCTION TOP VIEW

 

 

 

FILTERS

 

24" MIN.

24" MIN.

0" REQUIRED

 

48"

12" RECOMENDED

 

MIN. FOR

 

 

FILTER ACCESS

RIGHT CORNER CONSTRUCTION TOP VIEW

 

 

0" REQUIRED

12" RECOMENDED

MIS-3273

Manual

2100-549G

Page

12 of 59

FIGURE 5

COMPRESSOR SHIPPING BOLTS

COMPRESSOR SHIPPING BOLT

É

COMPRESSOR

SHIPPING BOLT

É

FIGURE 6

REMOVAL OF AIR DUCT

CRV / ERV

AIR DUCT

Manual

2100-549G

Page

13 of 59

Page

Manual

of 14

2100

59

549G-

 

 

 

FIELD SUPPLIED DUCT

BOTTOM OF ROOF

TURNING VANES

OR FIXED CEILING

RECOMMENDED

 

SUSPENDED

20"

CEILING

MINIMUM

7'-93/4" UNIT HEIGHT

12" MINIMUM

4" MINIMUM FROM TOP OF UNIT TO DUCT BOTTOM

9'-7"MINIMUM

CLEARANCE RECOMMENDED TO BOTTOM OF ROOF OR FIXED CEILING

9'-2"MINIMUM REQUIRED INSTALLATION HEIGHT

FLOOR

MIS-2958B

– APPLICATION DUCTED

7A FIGURE

UNIT BASIC

 

Page

Manual

59 of 15

549G-2100

BOTTOM OF ROOF

OR FIXED CEILING

SUSPENDED

 

 

20"

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CEILING

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MINIMUM

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

7'-93/4" UNIT HEIGHT

3" RISER

FIELD SUPPLIED DUCT

TURNING VANES

RECOMMENDED

12" MINIMUM

4" MINIMUM FROM TOP OF UNIT TO DUCT BOTTOM

9'-10"MINIMUM

9'-5"

CLEARANCE

MINIMUM

RECOMMENDED TO

REQUIRED

BOTTOM OF ROOF

INSTALLATION

OR FIXED CEILING

HEIGHT

FLOOR

MIS-2989B

7B FIGURE APPLICATION RISER 3"

Page

Manual

of 16

2100

59

549G-

 

 

BOTTOM OF ROOF

 

FIELD SUPPLIED DUCT

 

OR FIXED CEILING

 

TURNING VANES

 

RECOMMENDED

 

 

SUSPENDED

20"

CEILING

MINIMUM

7'-93/4" UNIT HEIGHT

12" MINIMUM

4" MINIMUM FROM TOP OF UNIT TO DUCT BOTTOM

10'-1"MINIMUM CLEARANCE RECOMMENDED TO BOTTOM OF ROOF OR FIXED CEILING

9'-8"MINIMUM REQUIRED INSTALLATION HEIGHT

FLOOR

6" RISER

MIS-2988B

7C FIGURE APPLICATION RISER 6"

DUCT WORK

Any heat pump is more critical of proper operating charge and an adequate duct system than a straight air conditioning unit. All duct work must be properly sized for the design airflow requirement of the equipment. Air Conditioning Contractors of America (ACCA) is an excellent guide to proper sizing. All duct work or portions thereof not in the conditioned space should be properly insulated in order to both conserve energy and prevent condensation or moisture damage. When duct runs through unheated spaces, it should be insulated with a minimum of one inch of insulation. Use insulation with a vapor barrier on the outside of the insulation. Flexible joints should be used to connect the duct work to the equipment in order to keep the noise transmission to a minimum.

The I-TECseries heat pump has provision to attach a supply air duct to the top of the unit. Duct connection size is 20 inches x 24 inches. The flanges are shipped flat and must be bent upward using sheet metal flanging pliers. The duct work is field supplied. See Figure 8 for suggested attachment method.

Make sure to seal the slots in the bend-upflange at the time of securing your ductwork to the flange. This can be accomplished with either foil tape or caulk. Failing to do so may cause air leakage/whistling of air.

FIGURE 8

SUPPLY DUCT CONNECTIONS

20"

SUPPLY DUCT AND

24"

FASTENERS TO BE

 

FIELD SUPPLIED

BEND THE PROVIDED

SUPPLY FRAME FLANGES

UP FOR DUCT INSTALLATION

a floor mounted install (9'-9"with IRP3 riser &10'-0"with IRP6 riser). The ICX10 extends 28" above the unit for a total height of10'-2"for a floor mounted install(10'-5"with IRP3 riser &10'-8"with IRP6 riser).

The unit is equipped with a variable speed indoor blower motor which increases in speed with an increase in duct static pressure. The unit will therefore deliver proper rated airflow up to the maximum ESP shown in Table 1A. However, for quiet operation of the air system, the duct static should be kept as low as practical, within the guidelines of good duct design.

FILTERS

Two 2-inchthrow away filters (24 x 30) and two 1- inch throw away filters (12 x 20) are supplied with each unit. The2-inchfilters slide into brackets on both sides for the return air openings. The1-inchfilters are in the cabinet doors for the vent (room air) exhaust. If a CRV or ERV vent option is used, there are two (2) additional ½" (8 x 17) washable filters included with that option. See Figure 9 for specific locations. The filters are serviced from the inside of the building by opening the cabinet doors, and do not require any tools to access.

FIGURE 9

FILTER LOCATION

 

24" X 30" X 2"

 

 

FILTERS

 

É

INDOOR

É

 

BLOWER

 

 

ACCESS

 

MIS-2959

NOTE: Unit cabinet, supply air duct and duct free plenum are approved for “0” clearance to combustible material.

The I-TECseries heat pumps are designed for use with free return(non-ducted)and either duct free with the use of IPBDF Series Plenum Box (8" or 12") or a duct supply air system.

The IPBDF Plenum Box mounts on top of the unit and has both vertically and horizontally adjustable louvers on the front discharge grille.

When used with a ducted supply, an ICX9 or ICX10 Cabinet Extension may be used to conceal the ductwork above the unit to the ceiling. The ICX9 extends 20" above the unit for a total height of 9'-6"for

É

 

COMPRESSOR

 

ACCESS

 

ACCESS TO

 

WASHABLE

 

FILTERS

É

É

VENT

OPTION

ACCESS

12" X 20" X 1"

FILTERS

É

Manual

2100-549G

Page

17 of 59

CONDENSATE DRAIN

There are two condensate drain connections from the condenser drain pan (compressor area). These are visible from the rear of the unit. Factory installed tubing connects the two drains at a tee connection and then a single drain hose with a barbed hose connector carries the condensate to the draining option of your choice. Enough tubing is provided to reach all drain options and can be cut down in length.

The unit is shipped from the factory with the drain line on the left-handside as you look at the rear of the unit. The tubing can be removed from the drain connections and flipped for aright-handdrain. See Figure 10.

The drain can be routed directly through the floor or through the wall. There are also two optional drain locations in the lower rear back panel. See Figure 8.

The I-TECdesign does not require a trap in the condensate disposal tubing. Check your local codes to see if a “P” trap is required.

For a stand pipe floor drain or through the wall, there is adequate hose length to reach anything located behind the unit. The lower rear portion of the cabinet is recessed approximately 4 inches allowing room for a “P” trap to be installed with the cabinet flush with the wall. Keep in mind, the drain line must be able to be removed from the unit if necessary to remove the unit from the wall.

Access plates are located on the rear of the unit for servicing the drain trap. See Figure 10. If the drain line is to be routed through an unconditioned space, it must be protected from freezing.

The condensate drain line can also be routed back into the unit through either the right-handorleft-handoptional drain locations on the rear of the unit. The hole is covered by insulation on the inside of the unit and will have to be cut away. Located inside the unit, about 12 inches in from the front on both the left and right side are drain holes in the bottom of the base. These holes are covered with insulation and are not visible. They are located very close to the side panels and can be found by pressing down on the insulation. Cut insulation away to expose the hole. A drain trap can now be installed inside of the cabinet, and the drain hose routed directly through the floor.

Once the I-TECis installed, the rear drains exiting the condenser section can be easily serviced with removal of thepre-paintedmetal sides(lift-offdoors, remove four [4] screws to remove side).

If side access is not available, the drain lines and trap can be serviced by removing either one of the drain access panels on the rear of the unit (in the ventialtion package area.) See Figure 10.

WITH NO VENT OPTION

To access the drain access panels in the rear of this section, simply remove the front door/cover from the box, and the plates are located in the rear of the box.

WITH COMMERCIAL ROOM VENTILATOR

1.Open hinged front doors.

2.Disconnect unit power to eliminate shock hazard.

3.Remove front cover/door of CRV vent package. (Can leave filter access panels in place.)

4.Unplug wires coming in on left side from upper unit section.

5.Unplug two wire harness from front (intake) blower.

6.Remove two (2) screws securing front (intake) blower and slide blower out of unit.

7.Remove four (4) screws that retian the partition behind/beneath intake blower removed in Step #6.

8.Rear drain access panels are now visible on both right-handandleft-handsides in rear of box.

WITH ENERGY RECOVERY VENTILATOR

To access the rear drain access panels of this section:

1.Open hinged front doors.

2.Disconnect unit power to eliminate shock hazard.

3.Remove front cover/door of ERV vent package. (Can leave filter access panels in place.)

4.Unplug wires coming in on left side from upper unit section.

5.Unplug heat recovery cassette on the side you wish to access, and slide cassette out the front of the unit.

6.Remove two (2) screws securing partition on outboard side of cassette and remove.

7.Rear drain access panels are now visible on both right-handandleft-handsides in rear of box.

FIGURE 10 — DRAIN LOCATIONS

(2) Unit Drains

Drain Access

Locations

8"

3 83 "

3 83 "

(2)

Optional

Unit Drain

Entrances

(2)OPTIONAL

 

DRAIN HOLES

WALL

 

7 3/16"

16 1/2"

 

 

18 3/4"

OPTIONAL FLOOR

 

MOUNTING HOLES

 

35"

 

40 43 "

MIS-2960B

Manual

2100-549G

Page

18 of 59

FIGURE 11A

UNIT MOUNTING

Use (12) Field Supplied Concrete or Wood Screws to Secure Outer Sleeve to Structure.

IMPORTANT!

Apply liberal amount of caulk to back of flange before installing.

Use (6) 3/4" Long

REF. Self Tapping Screws

A to Attach Inner Sleeve

to Outer Sleeve

IMPORTANT!

Apply Caulk bead to entire perimeter seam between inner and outer sleeve.

Use (12) 3/4" Long

REF. Self Tapping Screws

Bto Attach Inner Sleeve to Unit Back

Use (6) 3/4" Long

REF. Screws to Attach

C Exhaust Sleeve to

Unit Fan Shroud

REF.

(16) 5/16" - 3/4" SELF TAPPING A AND B

(6) 5/16" - 3/4" NON-TAPPING

REF.

C

 

(4) 5/16" - 1/2" NON-TAPPING

REF.

D

 

IMPORTANT!

Use care when inserting screws to not damage gasketing material. Doing so may compromise water seal between unit and sleeve.

Pull Inner Frame

Out Until Flush

With Grille Mounting

Angle

Use (4) 1-1/2"Long Screws to Attach Louver Grille to Outer Sleeve.

Use (4) 1/2" Long

Screws to Attach

REF. frame to Exhaust

D Sleeve

MIS-3014

Manual

2100-549G

Page

19 of 59

OUTSIDE WALL (INSULATED)

AREA BETWEEN WALL AND SLEEVE (INSULATED)

OUTDOOR GRILLE

SLEEVE

FILL INSULATION

DRAIN AREA INSULATED WITH 6" BATT MATERIAL

FIGURE 11B

UNIT MOUNTING

INSIDE WALL (SIZE VARIES)

I-TECUNIT

INTERIOR FLOOR

MIS-2928B

Manual

2100-549G

Page

20 of 59

INSTALLATION INSTRUCTIONS

MOUNTING THE UNIT

The wall sleeve is attached to the I-TECunit from the outside of the building. See Figures 11A & 11B. Refer to wall sleeve Manual2100-562supplied with sleeve.

Following are the steps for attaching the I-TECto the wall sleeve.

1.Lift the unit into place making sure that it is aligned side to side.

2.Push the unit back until the rear panel touches the sleeve gasket.

3.This unit must be level from side to side and from front to back. If adjustments are necessary, shim up under the base rails with sheets of metal or any substance not affected by moisture.

4.Attach the sleeve to the unit using the ten (10) ¾" long self-tappingscrews supplied with the sleeve.

5.The exhaust sleeve has three (3) ¾" long screw slots in each side flange. Line these up with the screw engagement holes in the fan panel. Attach using six

(6)¾" long pointed sheet metal screws supplied with the sleeve. Extend the sleeve out until it is flush with the louver grill attachment angles.

6.Lock the sleeve in place using two (2) ½" long pointed sheet metal screws on each side by shooting through the slot into a pre-punchedhole.

7.A bottom trim piece is shipped loose for installation beneath the doors. Attach the trim piece to the unit with screws provided.

8.The compressor is secured to the base with two

(2)bolts for shipping. Both bolts are identified with a tag. Remove shipping bolts (Figure 5).

WIRING – MAIN POWER

Refer to the unit rating plate and/or Table 2 for wire sizing information and maximum fuse or “HACR Type” circuit breaker size. Each unit is marked with a “Minimum Circuit Ampacity”. This means that the field wiring used must be sized to carry that amount of current. Depending on the installed KW of electric heat, there may be two field power circuits required. If this is the case, the unit serial plate will so indicate. All models are suitable only for connection with copper wire. Each unit and/or wiring diagram will be marked “Use Copper Conductors Only suitable for at least 75°C”. THESE INSTRUCTIONS MUST BE ADHERED TO. Refer to the National Electrical Code (NEC) for complete current carrying capacity data on the various insulation grades of wiring material. All wiring must conform to NEC and all local codes.

The electrical data lists fuse and wire sizes (75°C copper) for all models, including the most commonly used heater sizes. Also shown are the number of field power circuits required for the various models with heaters.

The unit rating plate lists a “Maximum Time Delay Relay Fuse” or “HACR Type” circuit breaker that is to be used with the equipment. The correct size must be used for proper circuit protection, and also to assure that there will be no nuisance tripping due to the momentary high starting current of the compressor motor.

See “START UP” section for information on three phase scroll compressorstart-ups.

The field wiring conduit connections are located on the top right-handcorner of the unit with a wire raceway to feed the wires down to the circuit breaker(s). See Figure 12.

 

 

 

 

 

 

 

FIGURE 12

 

 

 

 

COMPONENT LOCATION

ELECTRIC HEAT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WIRE RACEWAY

 

 

 

 

 

 

 

 

 

 

 

 

 

INDOOR BLOWER

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

EVAPORATOR COIL

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

LOW VOLTAGE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CONTROL PANEL

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

REFRIGERANT PORT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CONDENSER COIL

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

OUTDOOR FAN

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

COMPRESSOR

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

VENT OPTION

Manual

2100-549G

Page

21 of 59

WIRING – LOW VOLTAGE WIRING

230/208V, 1 PHASE AND 3 PHASE EQUIPMENT DUAL PRIMARY VOLTAGE TRANSFORMERS.

All Equipment leaves the factory wired on 240V tap. For 208V operation, reconnect from 240V to 208V tap. The acceptable operating voltage range for the 240 and 208V taps are as noted in Table 3.

TABLE 3 — OPERATING VOLTAGE RANGE

TAP

RANGE

 

 

240V

253 – 216

 

 

208V

220 – 187

 

 

NOTE: The voltage should be measured at the field power connection point in the unit and while the unit is operating at full load (maximum amperage operating condition).

The standard unit includes a remote thermostat connection terminal strip. See Figures 13 through 19 for connection diagrams. Compatible thermostats are listed in Table 4.

TABLE 4 — WALL THERMOSTATS

Thermostat

Predominant Features

 

 

 

3 stage Cool; 3 stage Heat

8403-060

Programmable/Non-ProgrammableElectronic

(1120-445)

HP or Conventional

 

Auto or Manual changeover

 

 

8403-067

Carbon Dioxide Sensor with LCD for

(CDT-2W40-LCD-RLY)

Sensor Readings

 

 

 

3 Stage Heat, 3 Stage Cool, Prog/NonProg, HP or Conv,

CS9B-THO

Auto or Manual Changeover, Humidity Sensor w/

dehumidification, Motion Sensor w/ Intelligent Learning

 

 

Control, BACnet-compatible

 

 

 

3 Stage Heat, 3 Stage Cool, Prog/NonProg, HP or Conv,

CS9B-THOC

Auto or Manual Changeover, Humidity Sensor w/

dehumidification, CO2 Sensor, Motion Sensor w/

 

 

Intelligent Learning Control, BACnet-compatible

 

 

 

3 Stage Heat, 3 Stage Cool, Prog/NonProg, HP or Conv,

CS9BE-THO

Auto or Manual Changeover, Humidity Sensor w/

dehumidification, Motion Sensor, Intelligent Learning

 

 

Control, BACnet-compatible,Ethernet-compatible

 

 

 

3 Stage Heat, 3 Stage Cool, Prog/NonProg, HP or Conv,

 

Auto or Manual Changeover, Humidity Sensor w/

CS9BE-THOC

dehumidification, CO2 Sensor, Motion Sensor w/

 

Intelligent Learning Control, BACnet-compatible,

 

Ethernet-compatible

 

 

LOW VOLTAGE CONNECTIONS

These units use a grounded 24 volt AC low voltage circuit. “G” terminal is thefan input.

“Y1” terminal is the compressor part load input. “Y2”terminal is the compressor full load input.

“B/W1” terminal is the reversing valve input.

The reversing valve must be energized for heating mode.

“R” terminal is 24 VAC hot.

“C” terminal is 24 VAC grounded.

“L” terminal is compressor lockoutoutput. This terminal is activated on a high or low pressure trip and condensate overflow trip by the electronic heat pump control. This is a 24 VAC output.

“W2” terminal is first stage electric heat(if equipped). First stage electric heat can be operated simultaneously with the heat pump operating.

“A” terminal is theventilation input. This terminal energizes any factory installed ventilation option.

“W3” terminal is second stage electric heat. When “W3” terminal is energized, it locks out compressor operation to limit discharge air temperature and required branch circuit ampacity.

“D” terminal is thedehumidification mode (on models so equipped).

NOTE: For total and proper control using DDC, a minimum of 9 controlled outputs are needed when above 10KW Electric Heat is employed with ventilation, a total of 8 controlled outputs with below 10KW Electric Heat with Ventilation, 7 controlled outputs below 10KW Electric Heat with no ventilation, 7 controlled outputs with no Electric Heat, but with ventilation, and 6 controlled outputs with no electric heat and no ventilation. If Dehumidification Model & Vent, 10 controlled outputs are needed when above 10KW Electric Heat is employed with ventilation.

LOW VOLTAGE CONNECTIONS FOR DDC CONTROL

Fan Only

Cooling Part Load

Cooling Full Load

HP Heating Part Load

HP Heating Full Load

HP Heating Full Load + Electric Heat

(up to 10KW)

Heating with Bank #1 Electric Heat Only

Emergency Heat (Heat pump operation is negated for this condition)

Ventilation

Dehumidification *

* Models with Dehumidification Only

Energize G

Energize G, Y1

Energize G, Y1, Y2

Energize G, Y1, B/W1

Energize G, Y1, Y2, B/W1

Energize G, Y1, Y2, B/W1, W2

Energize G, W2

Energize G, W2, W3

Energize A

Energize G, D

GENERAL

This unit is equipped with a variable speed ECM motor. The motor is designed to maintain rated airflow up to the maximum static allowed. It is important that the blower motor plugs are not plugged in or unplugged while the power is on. Failure to remove power prior to unplugging or plugging in the motor could result in motor failure.

CAUTION

Do not plug in or unplug blower motor connectors while the power is on. Failure to do so may result in motor failure.

Manual

2100-549G

Page

22 of 59

FIGURE 13

BASIC HEAT PUMP WITH NO VENTILATION PACKAGE

SC

SC

SC

 

 

 

 

 

 

Completestat

 

 

 

 

 

 

 

 

Model #CS9B-THOor

 

 

 

 

 

 

 

 

Model #CS9BE-THO

 

 

 

 

 

 

 

 

24V

COM

G

Y1

Y2

O/B W2 W1/E

L

A

D

 

 

 

 

 

 

 

2

3

Thermostat

R

C

G

Y1

Y2 O/B W2 W1/E

L

A

YO/D

Bard #8403-060

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2

3

Low

 

 

 

 

 

 

 

 

 

 

 

R

RT

C

G

Y1

Y2 B/W1 W2 W3

L

A

D

6

3

4

Voltage

Term. Strip

1

1Factory installed jumper. Remove jumper and connect to N.C fire alarm

2Not needed below 15KW

3 Additional wire required for dehumidification models

MIS-3016

Manual

2100-549G

Page

23 of 59

FIGURE 14

HEAT PUMP WITH CRV, WITHOUT CO2 CONTROL

SC SC SC

Completestat

Model #CS9B-THOor

Model #CS9BE-THO

24V COM G

Y1

Y2 O/B W2 W1/E

L

A

D

2

3

Thermostat

R

C

G

Y1

Y2 O/B W2 W1/E

L

A

YO/D

Bard #8403-060

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2

3

Low

R

RT

C

G

Y1

Y2

B/W1 W2

W3

L

A

D

6

3

4

Voltage

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Term. Strip

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

 

 

 

 

5

 

 

 

 

 

 

 

 

 

 

 

 

4

 

 

 

 

 

 

 

 

 

RED/WHITE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BLACK/WHITE

 

 

 

 

 

 

 

 

 

 

 

 

 

ORANGE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BROWN/WHITE

 

 

 

 

 

 

 

 

 

 

 

 

 

CRV Wiring Harness

1Factory installed jumper. Remove jumper and connect to N.C fire alarm circuit if emergency shutdown required.

4 Connect to "G" terminal when thermostat has "Occupancy Signal".

2Not needed below 15KW.

3Additional wire required for dehumidification models.

5Install a jumper between "G" and "A" only when thermostat without "Occupance Signal" is used.

MIS-3017

Manual

2100-549G

Page

24 of 59

FIGURE 15

HEAT PUMP WITH CRV AND CO2 CONTROL

SC SC SC

Completestat

Model #CS9B-THOor

Model #CS9BE-THO

24V COM G

Y1

Y2 O/B W2 W1/E

L

A

D

 

 

 

 

 

 

 

2

 

3

 

 

 

 

 

 

 

 

 

NOTE: Bard8403-060

 

 

 

 

 

 

 

 

 

thermostat must be

Thermostat

R

C

G

Y1

Y2 O/B W2 W1/E

L

A

YO/D

in programmed

operation mode and

Bard #8403-060

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

in programmed fan

 

 

 

 

 

 

 

 

 

mode for ventilation

 

 

 

 

 

 

 

 

 

to function.

 

 

 

 

 

 

 

2

 

3

Low

R

RT

C

Voltage

 

 

 

Term. Strip

 

 

 

 

 

1

 

RED/WHITE

 

 

 

BLACK/WHITE

 

 

ORANGE

 

 

 

BROWN/WHITE

 

 

G

Y1

Y2 B/W1 W2 W3

L

A

D

6

3

4

5 2

4

1

5

CRV Wiring Harness

1Factory installed jumper. Remove jumper and connect to N.C fire alarm circuit if emergency shutdown required.

2Not needed below 15KW.

3Additional wire required for dehumidification models.

6

6

 

6 CO2 Control

Bard #8403-067

4Connect to "G" terminal when thermostat has "Occupancy Signal".

5Install a jumper between "G" and "A" only when thermostat without "Occupance Signal" is used.

6If CS9B-THOCorCS9BE-THOCis used, connect "Brown/White" directly to "A" and do not use seperate CO2 controller.

MIS-3018

Manual

2100-549G

Page

25 of 59

FIGURE 16

HEAT PUMP WITH ERV, WITHOUT CO2 CONTROL

SC SC SC

Completestat

Model #CS9B-THOor

Model #CS9BE-THO

24V COM G

Y1

Y2 O/B W2 W1/E

L

A

D

 

 

 

 

 

 

 

2

 

3

 

 

 

 

 

 

 

 

 

NOTE: Bard8403-060

 

 

 

 

 

 

 

 

 

thermostat must be

Thermostat

 

 

 

 

 

 

 

 

in programmed

R

C

G

Y1

Y2 O/B W2 W1/E

L

A

YO/D

operation mode and

Bard #8403-060

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

in programmed fan

 

 

 

 

 

 

 

 

 

mode for ventilation

 

 

 

 

 

 

 

 

 

to function.

 

 

 

 

 

 

 

2

 

3

Low

R

RT

C

G

Y1

Y2

 

W2

W3

L

A

D

6

3

4

Voltage

B/W1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Term. Strip

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

 

 

 

 

 

5

 

 

 

 

 

 

 

 

 

 

 

 

4

 

 

 

 

 

 

 

 

 

 

RED/WHITE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BLACK/WHITE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ORANGE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BROWN/WHITE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PINK

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PURPLE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ERV Wiring Harness

1Factory installed jumper. Remove jumper and connect to N.C fire alarm circuit if emergency shutdown required.

4 Connect to "G" terminal when thermostat has "Occupancy Signal".

2Not needed below 15KW.

3Additional wire required for dehumidification models.

5Install a jumper between "G" and "A" only when thermostat without "Occupance Signal" is used.

MIS-3019

Manual

2100-549G

Page

26 of 59

FIGURE 17

HEAT PUMP WITH ERV AND CO2 CONTROL (ON/OFF CYCLING)

SC SC SC

Completestat

Model #CS9B-THOor

Model #CS9BE-THO

24V COM G

Y1

Y2 O/B W2 W1/E

L

A

D

 

 

 

 

 

 

 

2

 

3

 

 

 

 

 

 

 

 

 

NOTE: Bard8403-060

 

 

 

 

 

 

 

 

 

thermostat must be

Thermostat

 

 

 

 

 

 

 

 

in programmed

R

C

G

Y1

Y2 O/B W2 W1/E

L

A

YO/D

operation mode and

Bard #8403-060

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

in programmed fan

 

 

 

 

 

 

 

 

 

mode for ventilation

 

 

 

 

 

 

 

 

 

to function.

 

 

 

 

 

 

 

2

 

3

Low

R

RT

C

G

Y1

Y2

 

W2

W3

L

A

D

6

3

4

Voltage

B/W1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Term. Strip

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

 

 

 

 

 

5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

RED/WHITE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BLACK/WHITE

 

 

 

 

 

 

 

 

6

 

 

 

 

5

ORANGE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BROWN/WHITE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PINK

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PURPLE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

6

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ERV Wiring Harness

6 CO2 Control

Bard #8403-067

1

Factory installed jumper. Remove jumper and connect

4 Connect to "G" terminal when thermostat has "Occupancy Signal".

to N.C fire alarm circuit if emergency shutdown required.

 

 

 

 

2

Not needed below 15KW.

5

 

 

3 Additional wire required for dehumidification models.

6

Install a jumper between "G" and "A" only when thermostat without "Occupance Signal" is used.

If CS9B-THOCorCS9BE-THOCis used, connect "Brown/White" directly to "A" and do not use seperate CO2 controller.

MIS-3020

Manual

2100-549G

Page

27 of 59

FIGURE 18

HEAT PUMP WITH ERV AND CO2 CONTROL (FULLY MODULATING)

SC SC SC

Completestat

Model #CS9B-THOor

Model #CS9BE-THO

24V COM G

Y1

Y2 O/B W2 W1/E

L

A

D

 

 

 

 

 

 

 

2

 

3

 

 

 

 

 

 

 

 

 

NOTE: Bard8403-060

 

 

 

 

 

 

 

 

 

thermostat must be

Thermostat

R

C

G

Y1

Y2 O/B W2 W1/E

L

A

 

in programmed

YO/D

operation mode and

Bard #8403-060

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

in programmed fan

 

 

 

 

 

 

 

 

 

mode for ventilation

 

 

 

 

 

 

 

 

 

to function.

 

 

 

 

 

 

 

2

 

3

Low

R

RT

C

G

Y1

Y2

 

W2

W3

L

A

D

6

3

4

Voltage

B/W1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Term. Strip

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

 

 

 

 

 

5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

RED/WHITE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BLACK/WHITE

 

 

 

 

 

 

 

 

 

 

 

 

 

3

ORANGE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BROWN/WHITE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PINK

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PURPLE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CO2 Control

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ERV Wiring Harness

 

 

 

 

 

 

 

 

 

 

 

 

Bard #8403-067

1Factory installed jumper. Remove jumper and connect to N.C fire alarm circuit if emergency shutdown required.

2

Not needed below 15KW.

4

 

 

3 Additional wire required for dehumidification models.

5

Connect to "G" terminal when thermostat has "Occupancy Signal".

Install a jumper between "G" and "A" only when thermostat

without "Occupance Signal" is used.

MIS-3021A

Manual

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FIGURE 19

HEAT PUMP WITH COMBINATION CRV AND DB ECONOMIZER (“N” VENT CODE)

Only Recommend Bard CS9B-THOCorCS9BE-THOCas Require 3 Heating/Cooling Stages

SC SC SC

Completestat

Model #CS9B-THOCor

Model #CS9BE-THOC

 

 

24V

COM

G

Y0

Y1

Y2

O/B

W2

W1/E

L

A

D

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3

 

 

 

 

 

 

 

 

 

 

 

 

2

 

 

 

 

Low

R

RT

C

G

6

7

8

 

W2

W3

L

A

D

Y1

Y2

Voltage

B/W1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Term. Strip

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4

 

 

 

 

 

 

 

 

 

 

 

 

1

 

 

 

 

 

 

 

 

 

 

 

 

 

RED/WHITE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BLACK/WHITE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ORANGE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

GRAY

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

YELLOW

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PURPLE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BROWN/WHITE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PURPLE/WHITE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

YELLOW/BLACK

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BLUE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CRV/ECON Wiring Harness

1Factory installed jumper. Remove jumper and connect to N.C fire alarm circuit if emergency shutdown required.

2Not needed below 15KW.

3Additional wire required for dehumidification models.

4 Connect orange wire to "G" terminal

MIS-3270

Manual

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29 of 59

START UP

THESE UNITS REQUIRE R-410AREFRIGERANT AND POLYOL ESTER OIL.

GENERAL:

1.Use separate service equipment to avoid cross contamination of oil and refrigerants.

2.Use recovery equipment rated for R-410Arefrigerant.

3.Use manifold gauges rated for R-410A(800 psi/250 psi low).

4.R-410Ais a binary blend ofHFC-32andHFC-125.

5.R-410Ais nearly azeotropic - similar toR-22andR-12.Although nearly azeotropic, charge with liquid refrigerant.

6.R-410Aoperates at40-70%higher pressure thanR-22,and systems designed forR-22cannot withstand this higher pressure.

7.R-410Ahas an ozone depletion potential of zero, but must be reclaimed due to its global warming potential.

8.R-410Acompressors use Polyol Ester oil.

9.Polyol Ester oil is hygroscopic; it will rapidly absorb moisture and strongly hold this moisture in the oil.

10.A liquid line dryer must be used - even a deep vacuum will not separate moisture from the oil.

11.Limit atmospheric exposure to 15 minutes.

12.If compressor removal is necessary, always plug compressor immediately after removal. Purge with small amount of nitrogen when inserting plugs.

TOPPING OFF SYSTEM CHARGE

If a leak has occurred in the system, Bard Manufacturing recommends reclaiming, evacuating (see criteria above), and charging to the nameplate charge. However, if done correctly, topping off the system charge can be done without problems.

With R-410A,there are no significant changes in the refrigerant composition during multiple leaks and recharges.R-410Arefrigerant is close to being an azeotropic blend (it behaves like a pure compound or single component refrigerant). The remaining refrigerant charge, in the system, may be used after leaks have occurred and then“top-off”the charge by utilizing the charging charts on the inner control panel cover as a guideline.

REMEMBER: When addingR-410Arefrigerant, it must come out of the charging cylinder/tank as a liquid to avoid any fractionation, and to insure optimal system performance. Refer to instructions for the cylinder that is being utilized for proper method of liquid extraction.

WARNING

Failure to conform to these practices could lead to injury or death.

SAFETY PRACTICES:

1.Never mix R-410Awith other refrigerants.

2.Use gloves and safety glasses. Polyol Ester oils can be irritating to the skin, and liquid refrigerant will freeze the skin.

3.Never use air and R-410Ato leak check; the mixture may become flammable.

4.Do not inhale R-410A– the vapor attacks the nervous system, creating dizziness, loss of coordination and slurred speech. Cardiac irregularities, unconsciousness and ultimate death can result from breathing this concentration.

5.Do not burn R-410A.This decomposition produces hazardous vapors. Evacuate the area if exposed.

6.Use only cylinders rated DOT4BA/4BW 400.

7.Never fill cylinders over 80% of total capacity.

8.Store cylinders in a cool area, out of direct sunlight.

9.Never heat cylinders above 125°F.

10.Never trap liquid R-410Ain manifold sets, gauge lines or cylinders.R-410Aexpands significantly at warmer temperatures. Once a cylinder or line is full of liquid, any further rise in temperature will cause it to burst.

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START UP

DESCRIPTION OF STANDARD

EQUIPMENT

Solid State Electronic Heat Pump Control

Provides efficient 30, 60 or90-minutedefrost cycle.A thermistor sensor and speed up terminal for service along with a8-minutedefrost override are standard on the electronic heat pump control. By default, the I-TEC are factory shipped on the 90-minute defrost cycle.

High / Low Pressure Switch

Provides refrigerant circuit high pressure and loss of charge protection. Includes lockout circuit built into heat pump control that is resettable from room thermostat.

Five Minute Compressor Time Delay

Provides short cycle protection for the compressor which extends compressor life. Built into the electronic heat pump control as standard.

Dual Sensor Condensate Overflow

Senses and provides system shut down if draining issue causes water level to rise in either drain pan.

Low Ambient Control

The low ambient control permits cooling operation down to 0°F outdoor ambient.

IMPORTANT INSTALLER NOTE

For improved start-upperformance, wash the indoor coil with a dishwasher detergent.

PHASE MONITOR

All units with three phase scroll compressors are equipped with a 3 phase line monitor to prevent compressor damage due to phase reversal.

The phase monitor in this unit is equipped with two LEDs. If the Y signal is present at the phase monitor and phases are correct the green LED will light and the compressor contactor is allowed to energize.

If phases are reversed, the red fault LED will be lit and compressor operation is inhibited.

If a fault condition occurs, reverse two of the supply leads to the unit. Do not reverse any of the unit factory wires as damage may occur.

THREE PHASE SCROLL COMPRESSOR START UP INFORMATION

Scroll compressors, like several other types of compressors, will only compress in one rotational direction. Direction of rotation is not an issue with single phase compressors since they will always start and run in the proper direction.

However, three phase compressors will rotate in either direction depending upon phasing of the power. Since there is a 50-50chance of connecting power in such a way as to cause rotation in the reverse direction,verification of proper rotation must be made.

Verification of proper rotation direction is made by observing that suction pressure drops and discharge pressure rises when the compressor is energized.

Reverse rotation also results in an elevated sound level over that with correct rotation, as well as, substantially reduced current draw compared to tabulated values.

Verification of proper rotation must be made at the time the equipment is put into service. If improper rotation is corrected at this time there will be no negative impact on the durability of the compressor. However, reverse operation for even one hour may have a negative impact on the bearing due to oil pump out.

All three phase scroll compressors used in the I-TECseries are wired identically internally. As a result, once the correct phasing is determined for a specific system or installation, connecting properly phased power leads to the same Fusite terminal should maintain proper rotation direction. The direction of rotation of the motor may be changed by reversing any two line connections to the unit.

SERVICE HINTS

1.Caution user to maintain clean air filters at all times. Also, not to needlessly close off supply air registers. This may reduce airflow through the system, which shortens equipment service life as well as increasing operating costs and noise levels.

2.Switching to heating cycle at 75°F or higher outside temperature may cause a nuisance trip of the remote reset high pressure switch. Turn thermostat off, then on to reset the high pressure switch.

3.The heat pump wall thermostats perform multiple functions. Be sure that all function switches are correctly set for the desired operating mode before trying to diagnose any reported service problems.

4.Check all power fuses or circuit breakers to be sure they are the correct rating.

5.Periodic cleaning of the outdoor coils to permit full and unrestricted airflow circulation is essential.

6.Annual maintenance is required to make sure that all of the systems are functioning properly.

a.Check to make sure that the drains are not obstructed in any way.

b.Remove any debris in the condenser section of the unit.

c.Inspect and wash outdoor coils as necessary.

7.All motors are sealed and require no oiling.

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SEQUENCE OF OPERATION

COOLING PART LOAD – CircuitR-Y1makes at thermostat pulling in compressor contactor, starting the compressor and outdoor motor. The G (indoor motor) circuit is automatically completed on any call for cooling operation or can be energized by manual fan switch on subbase for constant air circulation.

COOLING FULL LOAD – CircuitR-Y1& Y2 makes at the thermostat energizing the 2nd stage solenoid in the compressor. The default position of the compressor staging solenoid isnon-energized.The compressor will run at low capacity until this solenoid is energized.

HEATING STAGE 1 – A 24V solenoid coil on reversing valve controls heating cycle operation. Two thermostat options, one allowing “Auto” changeover from cycle to cycle and the other constantly energizing solenoid coil during heating season and thus eliminating pressure equalization noise except during defrost, are to be used. On “Auto” option a circuit is completed fromR-BandR-Y1on each heating “on” cycle, energizing reversing valve solenoid and pulling in compressor contactor starting compressor and outdoor motor.R-Galso make starting indoor blower motor. Heat pump heating cycle now in operation. The second option has no “Auto” changeover position, but instead energizes the reversing valve solenoid constantly whenever the system switch on subbase is placed in “Heat” position, the “B” terminal being constantly energized from R. A thermostat demand for Stage 1 heat completesR-Y1circuit, pulling in compressor contactor starting compressor and outdoor motor.R-Galso make starting indoor blower motor.

HEATING STAGE 2 – CircuitR-Y1& Y2 makes at the thermostat energizing the 2nd stage solenoid in the compressor.

PRESSURE SERVICE PORTS

High and low pressure service ports are installed on all units so that the system operating pressures can be observed. Pressure tables can be found later in the manual covering all models. It is imperative to match the correct pressure table to the unit by model number. Upper and lower service doors must be attached to obtain proper reading.

LOWERING OUTDOOR FAN SPEED for SOUND

Supplied in the Literature Assembly is a Fan Control Resistor Assembly that can be installed to lower the fan speed for reduced sound performance. This Resistor Assembly is to be installed in series with the Outdoor Fan Control Thermistor to change the temperature curve that the fan logic control sees.

It is anticipated that you will see a 2-3%drop in system capacity and efficiency when this resistor is installed.

To install the Resistor Assembly:

1.Locate Fan Control Resistor Assembly in Literature Packet hanging on right inside door of unit.

2.Throw main power disconnect to the “OFF” position to eliminate risk of injury or death due to electrical shock.

3.Remove four (4) screws that retain the control panel cover to the unit.

4.Locate Fan Logic Control Board.

5.Locate one of the red leads of the Fan Control Thermistor where it attaches to the Fan Logic Control and remove it.

6.Install resistor in-linewith the thermistor lead removed in Step #5, and then connect back onto the Fan Logic Control Board.

Manual

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DEFROST CYCLE

The defrost cycle is controlled by temperature and time on the solid state heat pump control. See Figure 20.

When the outdoor temperature is in the lower 40°F temperature range or colder, the outdoor coil temperature is 32°F or below. This coil temperature is sensed by the coil temperature sensor mounted near the bottom of the outdoor coil. Once coil temperature reaches 30°F or below, the coil temperature sensor sends a signal to the control logic of the heat pump control and the defrost timer will start accumulating run time.

After 30, 60 or 90 minutes of heat pump operation at 30°F or below, the heat pump control will place the system in the defrost mode. Factory default setting is 90 minutes.

During the defrost mode, the refrigerant cycle switches back to the cooling cycle, the outdoor motor stops, electric heaters are energized, and hot gas passing through the outdoor coil melts any accumulated frost. When the temperature rises to approximately 57°F, the coil temperature sensor will send a signal to the heat pump control which will return the system to heating operations automatically.

If some abnormal or temporary condition such as a high wind causes the heat pump to have a prolonged defrost cycle, the heat pump control will restore the system to heating operation automatically after 8 minutes.

The heat pump defrost control board has an option of 30, 60 or 90-minutesetting. All models are shipped from the factory on the90-minutepin. If special circumstances require a change to another time, remove the wire from the90-minuteterminal and reconnect to the desired terminal.

The manufacturer’s recommendation is for 90-minutedefrost cycles.Refer to Figure 20.

There is a cycle speed up jumper on the control. This can be used for testing purposes to reduce the time between defrost cycle operation without waiting for time to elapse.

Use a small screwdriver or other metallic object, or another ¼ inch QC, to short between the SPEEDUP terminals to accelerate the HPC timer and initiate defrost.

Be careful not to touch any other terminals with the instrument used to short the SPEEDUP terminals. It may take up to 15 seconds with theSPEEDUP terminals shorted for the speedup to be completed and the defrost cycle to start.

As soon as the defrost cycle kicks in remove the shorting instrument from the SPEEDUP terminals.

Otherwise the timing will remain accelerated and run through the 1-minuteminimum defrost length sequence in a matter of seconds and will automatically terminate the defrost sequence.

There is an initiate defrost jumper (sen jump) on the control that can be used at any outdoor ambient during the heating cycle to simulate a 0° coil temperature.

This can be used to check defrost operation of the unit without waiting for the outdoor ambient to fall into the defrost region.

By placing a jumper across the SEN JMP terminals (a ¼ inch QC terminal works best) the defrost sensor mounted on the outdoor coil is shunted out & will

activate the timing circuit. This permits the defrost cycle to be checked out in warmer weather conditions without the outdoor temperature having to fall into the defrost region.

In order to terminate the defrost test the SEN JMP jumper must be removed. If left in place too long, the compressor could stop due to the high pressure control opening because of high pressure condition created by operating in the cooling mode with outdoor fan off. Pressure will rise fairly fast as there is likely no actual frost on the outdoor coil in this artificial test condition.

There is also a 5-minutecompressor time delay function built into the HPC. This is to protect the compressor from short cycling conditions. The board’s LED will have a fast blink rate when in the compressor time delay. In some instances, it is helpful to the service technician to override orspeedupthistimingperiod,andshortingouttheSPEEDUP terminals for a few seconds can do this.

FIGURE 20

DEFROST CYCLE

 

SW

SW

 

 

1

2

TIME (SEC)

 

 

 

 

 

OFF

OFF

30

 

 

 

 

LOW PRESSURE BYPASS TIMER SWITCH

ON

OFF

60

OFF

ON

120*

*(FACTORY SETTING 120 SECONDS)

ON

ON

180

 

 

 

 

 

OFF

ON

ACCUMULATED DEFROST TIME TIMER

(FACTORY SETTING 60 MIN.)

(FACTORY SETTING 90 MIN.)

MIS-2668A

Manual

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I-TEC COMMERCIAL ROOM VENTILATOR SYSTEM

GENERAL DESCRIPTION

The I-TECCommercial Room Ventilator (CRV) is designed to be used with all BardI-TECmodels. The only intent of this device is to provide the required ventilation by delivering fresh air to meet I.A.Q. (Indoor Air Quality) requirements. In the installed application, this system also includes exhaust provisions which are balanced with the intake air to maintain building pressurization requirements of ASHRAE 62.1 Standard.

Ventilation is accomplished with (2) blower/motor assemblies for maximum ventilation at low sound levels. The intake and exhaust blowers are programmed independently and are balanced to maintain a slight positive pressurization in accordance to ASHRAE 62.1 Standard.

The I-TECCRV is also provided with filters to reduce the required service needed and to further improve the I.A.Q. The exhaust air blowers are protected by disposable filters, and the intake air blowers are protected by washable filters. Both are accessible without the need for tools.

CONTROL WIRING

The I-TECCRV comes wired from the factory set to 375 CFM of ventilation. Care must be taken when deciding how to control the operation of the ventilator. When designing the control circuit for the ventilator, the following requirements must be met.

1.The indoor blower must be run whenever the I-TECCRV is run.

2.Select and configure the correct CFM ventilation level that the I-TECCRV needs to operate and configure the system to this level following later instructions within this section. Over ventilating serves no useful purpose and significantly affects the overall efficiency of the heat pump system. System operating costs would also increase.

3.Run the I-TECCRV only during periods when the conditioned space is occupied. Running the ventilation during unoccupied periods wastes energy, decreases the expected life of the CRV, and can result in large moisture buildup in the structure. Running the CRV when the structure is unoccupied allows moisture to build up in the structure because there is little or no cooling load. Thus, the air conditioner is not running enough to remove the excess moisture being brought in. Use a control system that in some way can control the system based upon occupancy.

Operating the I-TEC CRV during unoccupied periods can result in a build up of excess moisture in the structure.

RECOMMENDED CONTROL SEQUENCES

Several possible scenarios are listed below:

1.Use a programmable electronic thermostat with auxiliary terminal to control the CRV based on daily programmed occupance periods. Bard markets and recommends Bard Part #8403-060programmable electronic thermostat.

2.Use Bard CompleteStat™ that incorporates temperature, humidity and occupancy control with learning capability into a single device. No programming required.

3.Use a DDC control system to control the CRV based upon a room occupancy schedule to control the CRV.

4.Tie the operation of the CRV into the light switch. The lights in a room are usually on only when occupied.

5.Use a manual timer that the occupants turn to energize the CRV for a specific number of hours.

6.Use a programmable mechanical timer to energize the CRV and indoor blower during occupied periods of the day.

NOTE: The ventilation package comes with a blower interlock function, but is disabled when it is shipped from the factory in case you do not utilize a thermostat with an occupancy output, or a occupancy sensor and must tie "A" terminal to "G" terminal to drive the ventilation package. If you do have a thermostat or control that does drive occupancy output, you will need to remove the tape from the orange wire located in the low voltage terminal box, and connect it to the "G" terminal to activate this function. (See Figures13-19.)

SETTING THE VENTILATION CFM LEVELS

The I-TECCRV has fourpre-setlevels of ventilation CFM available. These are 300, 375, 450 and 525 CFM of ventilation air. TheI-TECCRV is shipped from the factory set on the 375 CFM ventilation level. To change between these four different levels of provided ventilation CFM, first refer to Figure 21 to look up the corresponding CFM needed for the intake and exhaust blowers to meet the design criteria and determine which “speed/wire color” is needed. Then, perform the following steps.

!

WARNING

 

HAZARD OF ELECTRICAL SHOCK.

 

ELECTRICAL SHOCK CAN RESULT

 

IN SERIOUS INJURY OR DEATH.

-2

DISCONNECT THE REMOTE

-754

ELECTRIC POWER SUPPLY OR

7961

SUPPLIES BEFORE SERVICING.

1.Open front swinging doors of main unit (by popping front door latches).

2.Throw main power disconnect to the “OFF” position to eliminate risk of injury or death due to electrical shock.

3.Remove six (6) screws holding front CRV door in place (See Figure 22).

4.Locate “Brown Wire with White Trace” that has a black terminal on the end where it connects to the terminal strip (See Figure 21).

5.Move “Brown Wire with White Trace” to the corresponding CFM level needed in accordance with Figure 21.

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FIGURE 21

CRV MOTOR SPEED/CFM CONFIGURATION

VENT OPTION INTAKE/EXHAUST SPEEDS

WIRE COLOR

SPEED

NOM. CFM

 

 

 

BLACK

HI

525

 

 

 

BLUE

MED-HI

450

 

 

 

ORANGE

MED-LO

375

 

 

 

RED

LO

300

 

 

 

TO CHANGE SPEEDS, MOVE BROWN WIRE WITH WHITE TRACE.

7961-755-2

BROWN/WHITE

Move brown/white wire to corresponding motor speed for required ventilation CFM. Factory setting is Medium Lo (375 CFM).

HI

SPEEDS

MED. HI

MED. LO

MOTOR

LO

7961-7554

BLACK

BLUE

ORANGE

RED

MIS-3022A

Manual

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FIGURE 22

CRV SPEED CHANGE TERMINAL ACCESS

CRV INTAKE BLOWER

NOTE: CRV EXHAUST

BLOWER IS BEHIND

INTAKE BLOWER

REMOVE (5) SCREWS FROM

CRV DOOR TO ACCESS CRV

COMPONENTS

MIS-3023

BLOWER SPEED

CONTROL LOCATION

BLOWER

SPEED

CONTROL

BLOWER REMOVED

FOR CLARITY

Manual

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I-TEC COMBINATION CRV & ECONOMIZER VENTILATION SYSTEM

DESCRIPTION

The I-TECcombination Commercial Room Ventilator (CRV) and Dry Bulb Economizer is designed to be used with all BardI-TECmodels. This ventilation package and its control provides two (2) roles:

It will provide the required ventilation by delivering fresh air to meet I.A.Q. (Indoor Air Quality) requirements through CRV portion of the device.

It will provide up to 525 CFM of free outdoor cooling CFM when the outdoor ambient temperature is below the outdoor thermostat setpoint.

Operating the I-TEC CRV during unoccupied periods can result in a build up of excess moisture in the structure.

SETTING THE VENTILATION CFM LEVELS

The I-TECCRV has four (4)pre-setlevels of ventilation CFM available. These are 300, 375, 450 and 525 CFM of ventilation air. This ventilation package is shipped from the factory set on the 375 CFM ventilation level while the Economizer portion is set on the 525 CFM ventilation level. To change between these four different levels of provided ventilation CFM, refer to Figure 24 to look up the corresponding CFM needed for the intake and exhaust blowers to meet the design criteria and determine which “speed/wire color” is needed.

Perform the following steps:

1.Open front swinging doors of main unit (by popping front door latches).

Ventilation is accomplished with (2) blower/motor assemblies for maximum ventilation at low sound levels. The intake and exhaust blowers are programmed independently and are balanced to maintain a slight positive pressurization in accordance to ASHRAE 62.1 Standard.

The Ventilation Package is also provided with filters to reduce the required service needed and to further improve the I.A.Q. The exhaust air blowers are protected by disposable filters, and the intake air blowers are protected by washable filters. Both are accessible without the need for tools.

CONTROL WIRING

Refer to Low Voltage Connection (Figure 19).

Reference Figure 23 for Control Sequence of Operation.

Open disconnect to shut all power OFF before doing this! Failure to do so could result in injury or death due to electrical shock.

2.Throw main power disconnect to the “OFF” position to eliminate risk of injury or death due to electrical shock.

3.Remove six (6) screws holding front CRV door in place (see Figure 22).

4.For CRV blower speed, locate “Brown Wire with White Trace” that has as black terminal on the end where it connects to the terminal strip (see Figure 24).

5.Move the “Brown Wire with White Trace” to the corresponding CFM level needed in accordance with Figure 24.

6.For Economizer Blower Speed, locate “Pink Wire” that has a black terminal on the end where it connects to the terminal strip (see Figure 24).

7.Move the “Pink” to the corresponding CFM level needed in accordance with Figure 24.

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I-TEC ECON. SEQUENCE OF OPERATION

If outdoor temperature is below outdoor thermostat setpoint

On call from CompleteStat for first stage cooling:

“YO” thermostat signal powers vent blower motors at Economizer Speed/Airflow (black – 525 CFM) through NC contacts of Relay “R1” (“Dehum Relay”).

On call from CompleteStat for first and second stage cooling:

“YO” thermostat signal powers vent blower motors at Economizer Speed/Airflow (black – 525 CFM) through NC contacts of Relay “R1” (“Dehum Relay”).

“Y1” thermostat signal powers “Y1” terminal on unit low voltage terminal strip through NC contacts of relay “R2” (“High Ambient Relay”).

On call from CompleteStat for first, second and third stage cooling:

“YO” thermostat signal powers vent blower motors at Economizer Speed/Airflow (black – 525 CFM) through NC contacts of Relay “R1” (“Dehum Relay”).

“Y1” thermostat signal powers “Y1” terminal on unit low voltage terminal strip through NC contacts of relay “R2” (“High Ambient Relay”).

“Y2” thermostat signal powers “Y2” terminal on unit low voltage terminal strip through NC contacts of relay “R2” (“High Ambient Relay”).

FIGURE 23 ECONOMIZER CONTROL CIRCUIT

 

UNIT LOW

 

 

 

VOLTAGE

 

 

THERMOSTAT

TERMINAL

 

 

SIGNALS

STRIP

 

 

 

 

 

R2

Y2

8

6

3

 

Y2

 

 

 

 

 

R3

 

 

COM

NO

 

 

 

R2

 

R

8

5

 

 

 

R4

 

 

COM

NO

 

G

 

 

 

Y1

 

R2

 

 

 

 

 

7

1

Y1

7

 

R2

 

 

 

 

 

7

4

D

D

 

 

 

 

 

R1

YO

6

NC

COM

 

C

 

 

A

A

 

 

R1 = DEHUM RELAY

R2 = HIGH AMBIENT RELAY

R3 = FULL LOAD RELAY

R4 = BLOWER INTERLOCK RELAY

FIELD WIRE

FACTORY WIRE

If outdoor temperature is above outdoor thermostat setpoint

On call from CompleteStat for first stage cooling:

“YO” thermostat signal powers relay coil “R2”. “R2” relay then closes NO contact between “R” and “Y1” at low voltage terminal strip engaging stage 1 mechanical cooling. NC contacts of relay “R2” that connects thermostat “Y1” to “Y1” on low voltage terminal strip is opened to eliminate feedback.

On call from CompleteStat for first and second stage cooling:

“YO” thermostat signal powers relay coil “R2”. “R2” relay then closes NO contact between “R” and “Y1” at low voltage terminal strip engaging stage 1 mechanical cooling. NC contacts of relay “R2” that connects thermostat “Y1” to “Y1” on low voltage terminal strip is opened to eliminate feedback.

“Y1” thermostat signal powers relay coil “R3” through now closed relay contacts “R2” closing contacts between “R” and “Y2” at low voltage terminal strip.

“Y2” thermostat signal will do nothing, as NC contacts of relay “R2” are now opened to eliminate any feedback to thermostat.

Dehumidification Mode

On call from CompleteStat for dehumidification:

“D” thermostat signal powers relay coil “R1” (Dehum. Relay). “R1” relay, then opens NC contact between “YO” and outdoor thermostat.

This will then negate any ECONOMIZER SPEED SIGNAL from energizing the ventilation package.

“Y1” & “Y2” thermostat signals will pass through NC contacts of Relay “R2” (“High Ambient Relay”) as relay coil “R2” will be rendered inoperable by “R1” contacts opening. Normal cooling calls can then still apply to override Dehum. call.

R3

R1

R2

ECON VENT SPEED

R4

CRV VENT SPEED

MIS-3272

Manual

2100-549G

Page

38 of 59

HEATING MODE OPERATION

CompleteStat should never energize “YO” terminals in conjunction with “B”, so relay “R2” will never energize, and neither will Economizer Ventilation Speed.

“Y1” and “Y2” signals will pass through NC contacts of relay “R2” contacts, and all heating operations will be normal.

VENTILATION MODE

The call for ventilation will never be disrupted with this control circuit. Anytime “A” signal from CompleteStat is present, the “VENTILATION SPEED” of the vent package will be energized. “A” Signal from thermostat will also energize relay “R4” (“Blower Interlock Relay”) completing a circuit from “R” to “G” through the “NO” contacts to ensure blower operations on the ventilation call.

FIGURE 24

MOTOR SPEED/CFM CONFIGURATION

VENT OPTION INTAKE/EXHAUST SPEEDS

WIRE COLOR

SPEED

NOM. CFM

 

 

 

BLACK

HI

525

 

 

 

BLUE

MED-HI

450

 

 

 

ORANGE

MED-LO

375

 

 

 

RED

LO

300

 

 

 

TO CHANGE SPEEDS, MOVE BROWN WIRE WITH WHITE TRACE.

7961-755-2

Move pink wire to corresponding motor

speed for required economizer operation CFM. Factory setting is High (525 CFM).

PINK

BROWN/WHITE

Move brown/white wire to corresponding motor speed for required ventilation CFM. Factory setting is Medium Lo (375 CFM).

HI

SPEEDS

MED. HI

MED. LO

MOTOR

LO

7961-7554

BLACK

BLUE

ORANGE

RED

MIS-3271

Manual

2100-549G

Page

39 of 59

I-TEC ENERGY RECOVERY VENTILATOR SYSTEM

GENERAL DESCRIPTION

The I-TECEnergy Recovery Ventilator (ERV) was designed to provide energy efficient, cost effective ventilation to meet I.A.Q (Indoor Air Quality) requirements while still maintaining good indoor comfort and humidity control for a variety of applications such as schools, classrooms, lounges, conference rooms and others. It provides a constant supply of fresh air for control of airborne pollutants including CO2, smoke, radon, formaldehyde, excess moisture, virus and bacteria.

The ERV incorporates patented rotary heat exchanger technology to remove both heat and moisture. The package consists of unique rotary Energy Recovery Cassettes that can be easily removed for cleaning or maintenance. It has two 15-inchdiameter heat transfer wheels for efficient heat transfer. The heat transfer wheels use a permanently bonded dry dessicant coating for total heat recovery.

The I-TECERV is also provided with filters to reduce the required service needed and to extend the life of the heat recovery wheels. The exhaust air blower is protected by disposable filters, and the intake air blower is protected by washable filters. Both are accessible without the need for tools.

Ventilation is accomplished with (2) blower/motor assemblies for maximum ventilation at low sound levels. The intake and exhaust blowers can be independently adjusted to maintain desired building pressurization conditions. The rotating wheels provide the heat transfer effectively during both summer and winter conditions. Provides required ventilation to meet the requirements of ASHRAE 62.1 Standard.

NOTE: During operation below 5°F outdoor temperature, freezing of moisture in the heat transfer wheel can occur. Consult the factory if this possibility exists.

The I-TECERV can be controlled in different ways. It can be turned ON/OFF with an occupancy control, thermostat, or CO2 control. It can also be configured forfully-modulatingvariable speed with a CO2 control to only bring in the minimal amount of ventilation required (helping to minimize sound levels and ventilation load on the structure).

CONTROL WIRING

The I-TECERV comes wired from the factory ready to operate in manual mode (ON/OFF cycling) and set to 375 CFM of ventilation. Care must be taken when deciding how to control the operation of the ventilator. When designing the control circuit for the ventilator, the following requirements must be met.

1.The indoor blower must be run whenever the I-TECERV is run.

2.Select and configure the correct CFM ventilation level that the I-TECERV needs to operate and configure the system to this level following later instructions within this section. Over ventilating serves no useful purpose and significantly affects the overall efficiency of the heat pump system. System operating costs would also increase.

3.Run the I-TECERV only during periods when the conditioned space is occupied. Running the ERV during unoccupied periods wastes energy, decreases the expected life of the ERV, and can result in large moisture buildup in the structure. The ERV removes60-70%of the moisture in the incoming air, not 100% of it. Running the ERV when the structure is unoccupied allows moisture to build up in the structure because there is little or no cooling load. Thus, the air conditioner is not running enough to remove the excess moisture being brought in. Use a control system that in some way can control the system based upon occupancy.

Operating the I-TEC ERV during unoccupied periods can result in a build up of excess moisture in the structure.

Manual

2100-549G

Page

40 of 59

RECOMMENDED CONTROL SEQUENCES

Several possible scenarios are listed below:

1.Use a programmable electronic thermostat with auxiliary terminal to control the ERV based on daily programmed occupance periods. Bard markets and recommends Bard Part #8403-060programmable electronic thermostat.

2.Use a motion sensor in conjuntion with a mechanical thermostat to determine occupancy in the structure. Bard markets the CS2000A for this use.

3.Use a DDC control system to control the ERV based upon a room occupancy schedule to control the ERV.

4.Tie the operation of the ERV into the light switch. The lights in a room are usually on only when occupied.

5.Use a manual timer that the occupants turn to energize the ERV for a specific number of hours.

6.Use a programmable mechanical timer to energize the ERV and indoor blower during occupied periods of the day.

NOTE: The ventilation package comes with a blower interlock function, but is disabled when it is shipped from the factory in case you do not utilize a thermostat with an occupancy output, or a occupancy sensor and must tie "A" terminal to "G" terminal to drive the ventilation package. If you do have a thermostat or control that does drive occupancy output, you will need to remove the tape from the orange wire located in the low voltage terminal box, and connect it to the "G" terminal to activate this function. (See Figures 13-19.)

CHANGING VENTILATION CFM RATES IN MANUAL MODE

!

WARNING

 

HAZARD OF ELECTRICAL SHOCK.

 

ELECTRICAL SHOCK CAN RESULT

 

IN SERIOUS INJURY OR DEATH.

-2

DISCONNECT THE REMOTE

-754

ELECTRIC POWER SUPPLY OR

7961

SUPPLIES BEFORE SERVICING.

 

To adjust the airflow ventilation rate, first refer to Figure 25A to look up the “FLOW INDEX” needed for the intake and exhaust blowers for the CFM you require. Then, perform the following steps:

1.Open front swinging doors of main unit (by popping front door latches).

2.Throw main power disconnect to the “OFF” position to eliminate risk of injury or death due to electrical shock.

3.Remove five (5) screws holding front ERV door in place (See Figure 27).

4.Remove ERV Control Panel Cover by removing four (4) screws (See Figure 27).

5.Locate two 0-10VdcMotor Control Boards in control panel (See Figure 28).

6.On intake Motor Control Board, observing “GREEN STATUS LIGHT”, turn manual adjust potentiometer “CCW” to increase “FLOW INDEX” or CW to reduce “FLOW INDEX” to

match desired setting.

NOTE: After long pause, the green status light will blink long-blinksfor the “TEN COUNT” of the “FLOW RATE INDEX”, then immediately followed by fast blinks which indicate the second digit. For example, a Flow Index of 23 would be two long blinks, followed by 3 fast blinks of the “GREEN STATUS LIGHT”.

7.On exhaust Motor Control Board, observing “GREEN STATUS LIGHT”, turn manual adjust potentiometer “CCW” to increase “FLOW INDEX” or CW to reduce “FLOW INDEX” to

match desired setting.

NOTE: Same “GREEN STATUS LIGHT” blink as Step #6.

CHANGING TO FULLY MODULATING MODE

If you want to operate the ERV in fully variable mode (Fig. 25B) (only run at required speed to maintain set-pointCO2 levels), you will need to configure the ERV to the following:

1.Open front swinging doors of main unit (by popping front door latches).

2.Throw main power disconnect to the “OFF” position to eliminate risk of injury or death due to electrical shock.

3.Remove ERV Control Panel Cover by removing four (4) screws (See Figure 27).

4.Locate two 0-10VdcMotor Control Boards in control panel (See Figure 28).

5.Pull jumper pins from “M” terminals, and move to “P” terminals (See Figure 28).

6.Connect “+” 0-10Vdcoutput from CO2 control to Terminal #3 (along with pink wire), and connect“-”to Terminal #4 (along with purple wire) of unit low voltage terminal strip.

7.Follow the directions supplied with the CO2 control to configure the control appropriately.

Manual

2100-549G

Page

41 of 59

PERFORMANCE AND APPLICATION DATA

SUMMER COOLING PERFORMANCE (INDOOR DESIGN CONDITIONS 75°DB/62°WB)

Ambient

 

VENTILATION RATE 450 CFM

 

 

VENTILATION RATE 375 CFM

 

 

VENTILATION RATE 300 CFM

 

O.D.

 

 

65% EFFICIENCY

 

 

 

66% EFFICIENCY

 

 

 

 

67% EFFICIENCY

 

 

DB/

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WB

F

VLT

VLS

VLL

HRT

 

HRS

HRL

VLT

VLS

VLL

HRT

 

HRS

HRL

VLT

VLS

VLL

HRT

 

HRS

HRL

 

75

21465

14580

6884

13952

 

9477

4475

17887

12150

5737

11805

 

8018

3786

14310

9720

4590

9587

 

6512

3075

105

70

14580

14580

0

9477

 

9477

0

12150

12150

0

8018

 

8018

0

9720

9720

0

6512

 

6512

0

 

65

14580

14580

0

9477

 

9477

0

12150

12150

0

8018

 

8018

0

9720

9720

0

6512

 

6512

0

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

80

31590

12150

19440

20533

 

7897

12635

26325

10125

16200

17374

 

6682

10692

21060

8100

12960

14110

 

5427

8683

 

75

21465

12150

9314

13952

 

7897

6054

17887

10125

7762

11805

 

6682

5123

14310

8100

6210

9587

 

5427

4160

100

70

12352

12150

202

8029

 

7897

131

10293

10125

168

6793

 

6682

111

8235

8100

135

5517

 

5427

90

 

65

12150

12150

0

7897

 

7897

0

10125

10125

0

6682

 

6682

0

8100

8100

0

5427

 

5427

0

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

60

12150

12150

0

7897

 

7897

0

10125

10125

0

6682

 

6682

0

8100

8100

0

5427

 

5427

0

 

80

31590

9720

21870

20533

 

6318

14215

26325

8100

18225

17374

 

5345

12028

21060

6480

14580

14110

 

4341

9768

 

75

21465

9720

11744

13952

 

6318

7634

17887

8100

9787

11805

 

5345

6459

14310

6480

7830

9587

 

4341

5246

95

70

12352

9720

2632

8029

 

6318

1711

10293

8100

2193

6793

 

5345

1447

8235

6480

1755

5517

 

4341

1175

 

65

9720

9720

0

6318

 

6318

0

8100

8100

0

5345

 

5345

0

6480

6480

0

4341

 

4341

0

 

60

9720

9720

0

6318

 

6318

0

8100

8100

0

5345

 

5345

0

6480

6480

0

4341

 

4341

0

 

80

31590

7290

24300

20533

 

4738

15794

26325

6075

20250

17374

 

4009

13365

21060

4860

16200

14110

 

3256

10854

 

75

21465

7290

14175

13952

 

4738

9213

17887

6075

11812

11805

 

4009

7796

14310

4860

9450

9587

 

3256

6331

90

70

12352

7290

5062

8029

 

4738

3290

10293

6075

4218

6793

 

4009

2784

8235

4860

3375

5517

 

3256

2261

 

65

7290

7290

0

4738

 

4738

0

6075

6075

0

4009

 

4009

0

4860

4860

0

3256

 

3256

0

 

60

7290

7290

0

4738

 

4738

0

6075

6075

0

4009

 

4009

0

4860

4860

0

3256

 

3256

0

 

80

31590

4860

26730

20533

 

3159

17374

26325

4050

22275

17374

 

2672

14701

21060

3240

17820

14110

 

2170

11939

 

75

21465

4860

16605

13952

 

3159

10793

17887

4050

13837

11805

 

2672

9132

14310

3240

11070

9587

 

2170

7416

85

70

12352

4860

7492

8029

 

3159

4870

10293

4050

6243

6793

 

2672

4120

8235

3240

4995

5517

 

2170

3346

 

65

4860

4860

0

3159

 

3159

0

4050

4050

0

2672

 

2672

0

3240

3240

0

2170

 

2170

0

 

60

4860

4860

0

3159

 

3159

0

4050

4050

0

2672

 

2672

0

3240

3240

0

2170

 

2170

0

 

75

21465

2430

19035

13952

 

1579

12372

17887

2025

15862

11805

 

1336

10469

14310

1620

12690

9587

 

1085

8502

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

80

70

12352

2430

9922

8029

 

1579

6449

10293

2025

8268

6793

 

1336

5457

8235

1620

6615

5517

 

1085

4432

65

4252

2430

1822

2764

 

1579

1184

3543

2025

1518

2338

 

1336

1002

2835

1620

1215

1899

 

1085

814

 

 

 

 

 

60

2430

2430

0

1579

 

1579

0

2025

2025

0

1336

 

1336

0

1620

1620

0

1085

 

1085

0

 

70

12352

0

12352

8029

 

0

8029

10293

0

10293

6793

 

0

6793

8235

0

8235

5517

 

0

5517

75

65

4252

0

4252

2764

 

0

2764

3543

0

3543

2338

 

0

2338

2835

0

2835

1899

 

0

1899

 

60

0

0

0

0

 

0

0

0

0

0

0

 

0

0

0

0

0

0

 

0

0

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WINTER HEATING PERFORMANCE (INDOOR DESIGN CONDITIONS 70°F DB)

Ambient

 

 

VENTILATION RATE

 

 

450 CFM

375 CFM

300 CFM

O.D.

80% EFFICIENCY

81% EFFICIENCY

82% EFFICIENCY

 

DB/°F

WVL

WHR

WVL

WHR

WVL

WHR

65

2430

1944

2025

1640

1620

1328

60

4860

3888

4050

3280

3240

2656

55

7290

5832

6075

4920

4860

3985

50

9720

7776

8100

6561

6480

5313

45

12150

9720

10125

8201

8100

6642

40

14580

11664

12150

9841

9720

7970

35

17010

13608

14175

11481

11340

9298

30

19440

15552

16200

13122

12960

10627

25

21870

17496

18225

14762

14580

11955

20

24300

19440

20250

16402

16200

13284

15

26730

21384

22275

18042

17820

14612

LEGEND:

VLT

=

Ventilation Load – Total

VLS

=

Ventilation Load – Sensible

VLL

=

Ventilation Load – Latent

HRT

=

Heat Recovery – Total

HRS

=

Heat Recovery – Sensible

HRL

=

Heat Recovery – Latent

WVL

=

Winter Ventilation Load

WHR =

Winter Heat Recovery

Note: All performance data is based on operating intake and exhaust blower on the same speed.

Manual

2100-549G

Page

42 of 59

FIGURE 25A

ERV “MANUAL MODE” JUMPER PIN ON “M” TERMINAL

 

 

To adjust the airflow ventilation rate (NO CO2

 

FLOW INDEX (Light

CONTROL/NON-MODULATING) , determine the "FLOW

ERV CFM

Blink Code)

INDEX" needed for the intake and exhaust blowers for

 

 

450

100

the CFM you require.

 

 

 

 

425

89

1.> Locate two 0-10VdcMotor Control Boards in control panel

400

83

 

375

76

2.> On intake Motor Control Board, observing "GREEN STATUS

350

59

LIGHT", turn manual adjust potentiometer (with a small phillips-head

screwdriver) "CCW" to increase "FLOW INDEX" or CW to reduce

325

50

"FLOW INDEX" to match desired setting. (NOTE: After long pause,

the green status light will blink long-blinksfor the "TEN COUNT" of

 

 

300

40

the "FLOW RATE INDEX", which then is immediately followed by

275

32

fast blinks which indicate the second digit. For example, a Flow

Index of 23 would be two long blinks, followed by 3 fast blinks of

 

 

the "GREEN STATUS LIGHT".)

250

25

 

225

12

3.> On exhaust Motor Control Board, observing "GREEN STATUS

200

9

LIGHT", turn manual adjust potentiometer (with a small phillips-head

screwdriver) "CCW" to increase "FLOW INDEX" or CW to reduce

 

 

175

4

"FLOW INDEX" to match desired setting. (Same GREEN STATUS

150

1

LIGHT blink (refer to Step #5))

 

 

 

 

FIGURE 25B

ERV “MODULATING MODE” JUMPER PIN ON “P” TERMINAL

 

Vdc Signal

 

CFM

from CO2

 

 

Control

 

450

10

 

 

 

 

425

8.87

 

400

8.31

 

375

7.61

After determining the air volume

rates needed for the intended

350

6.73

application (Maximum &

325

5.91

Minimum), the table

immediately to the left will allow

300

5.15

for you to program your CO2

275

4.58

control output voltages in

 

250

4.06

correlation to the CO2 levels you

wish to control when Bard Part #

225

2.91

8403-067CO2 Control is applied.

200

2.57

 

175

2.24

 

150

1.74

 

 

 

 

125

0.96

 

100

0.77

 

 

 

 

Manual

2100-549G

Page

43 of 59

FIGURE 26

VENTILATION AIRFLOW DIAGRAM

SUPPLY

BLOWER

Return Air

VENT

INTAKE

BLOWER

Indoor Air

Supply Air

Outdoor Air

VENT

EXHAUST

BLOWER

MIS-3024

Manual

2100-549G

Page

44 of 59

FIGURE 27 ERV ACCESS

ERV INTAKE

BLOWER

NOTE: ERV

EXHAUST

BLOWER IS

BEHIND INTAKE

BLOWER

ERV CASSETTE

ASSEMBLIES

REMOVE (5) SCREWS FROM ERV DOOR TO ACCESS ERV COMPONENTS

MIS-3025

ERV CONTROL PANEL LOCATION

Manual

2100-549G

Page

45 of 59

FIGURE 28

CONTROL BOARD CONFIGURATION/SETTING

ECM Motor Control Cable

To Automation

 

 

 

 

 

 

 

 

 

Control Signal

 

 

 

 

 

 

 

 

 

 

 

 

Controller

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Signal Common

0-2,000RPM

 

 

 

 

 

 

 

 

 

 

 

RPM Out

= 0-10Vdc

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Aux

 

 

Common

 

 

 

 

 

 

 

Signal Common,

Power

 

 

 

 

 

 

 

 

 

 

 

 

 

24Vac/dc

Aux Common &

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Neutral/Common are

 

 

 

 

 

 

 

 

 

 

 

 

internally connected

 

 

 

 

 

 

 

 

 

 

 

24Vac/dc

Class II Power Source

 

 

 

 

 

 

Neutral/Common

 

 

 

 

 

 

Earth neutral/Common

 

 

 

 

 

 

 

 

 

 

at transformer

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

for electrical safety.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Move jumper pin to “P” position to allow variable ventilation control using 4-20MACO2 controller

Board mode pins factory shipped on “M” pin for On/Off control scheme using “A” signal on low voltage control board.

“Red” status light (on when unit has power)

“Green” signal light continuously indicates the flow index the blower is producing. After a pause, the lamp will flash out long digits which will indicate the “TENS” count, which is immediately followed by short flashes between 1 and 99. For example, a flow index of 23 would yield two long flashes and three short flashes.

CONFIGURING BARD PART #8403-067CO2 CONTROL for ERV MODULATING CONTROL

BARD PART #8403-067

Manual adjust screw. Use when operating in manual mode (“M” jumper installed) along with the “GREEN SIGNAL LIGHT” to adjust to the required CFM of ventilation. CW rotation reduces the “FLOW INDEX”, CCW rotation increases the “FLOW INDEX”.

Carbon Dioxide and Temperature Transmitters accurately monitorthe CO2concentration and temperature in schools, office buildings, and otherindoor environments to help achieve LEED® certification.

SPECIFICATIONS

Range: CO2: 0 to 2000 or 0 to 5000 ppm (depending on model) Temperature: 32 to 122°F (0 to 50°C).

Accuracy: ±40 ppm + 3% of reading.

Temperature Dependence: ±8 ppm / °C at 1100 ppm.Non-Linearity: 16 ppm.

Pressure Dependence: 0.13% of reading per mm of Hg.Response Time: 2 minutes for 99% step change.

Ambient Operating Temperature: 32 to 122°F (0 to 50°C). Ambient Operating Humidity:10 to 95% RH (noncondensing).

Power Requirements: 16 to 35 VDC / 19 to 28 VAC.Power Consumption: Average: 2 watts; Peak: 3.75 watts.Sensor: Single beam,dual-wavelength NDIR.

Output:

Current: 4 to 20 mA (max 500 Ω);

Voltage: 0 to 5 VDC or 0 to 10 VDC (min 500 Ω); Relay: SPST NO 2A @ 30 VDC;

RTD or thermistor per r-tcurves (depending on model)Weight: 5.6 oz (158.8 g)

WARNING Disconnect power supply before installation to prevent electricalshock and equipment damage.

Make sure all connections are in accordance with the job wiring diagram and in accordance with national and local electrical codes. Use copper conductors only.

CAUTION Use electrostatic discharge precautions (e.g., use of wrist straps) during installation and wiring to prevent equipment damage.

CAUTION Avoid locations where severe shock or vibration, excessive moisture or corrosive fumes are present.

CAUTION Do not exceed ratings of this device, permanent damage not covered by warranty may result.

NOTICE

Upon powering the transmitter, the firmware version will flash on

the display. A warm up period of 30 minutes is required for the

 

 

transmitter to adjust to the current CO2 concentration.

NOTICE Self calibration feature of the transmitter requires exposure to normal outdoor equivalent carbon dioxide level once every thirty days.

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CONFIGURING BARD PART #8403-067CO2 CONTROL for ERV MODULATING CONTROL (Continued)

MOUNTING

1.Push tab on bottom of cover and lift cover from back plate.

2.Select the mounting location, away from diffusers, lights or any external influences.

3.Mount transmitter on a vertical surface to a standard electrical box using the two #6 M2C type screws provided.

4.Pull wires through sub base hole and make necessary connections.

5.Reattach cover to base plate.

WIRING

Use maximum 18 AWG wire for wiring to terminals. Refer to Figures 13-19for wiring information.

SELECTION OF VOLTAGE OUTPUTS

Prior to wiring, verify the voltage selector jumpers on jumpers PJ1 and PJ2 are set to voltage (See Figure below).

CURRENT/VOLTAGE OUTPUT

SELECTION JUMPER (PJ1 & PJ2)

VOLTAGE

OUTPUT

CV

Next, move jumper PJ5 to the 0-10Vrange (See Figure below).

OUTPUT RANGE SELECTION JUMPER PJ5

0 to 10 V

0 to 20 mA

EDITING MENU PARAMETERS

Before any adjustment can be made to the transmitter, the Menu Lockout Jumper (PJ4) must be set to the “On” position (See Figure below).

MENU LOCKOUT JUMPER

ENABLED DISABLED

MENU MENU

PJ4

PJ4

ON OFF

ON OFF

Finish installing/wiring the control. Then, refer to Figure 20 and the building ventilation specifications to decide what the maximum ventilation rate desired is and what the minimum/maximum voltage signal is required for those levels.

Next, enter the control programming stage listed below once the system is powered-upto configure the control.

ACCESSING MENU PARAMETERS

Step 1: To enter the menu structure, pressU andV simultaneously for 5 seconds (display

will show RON parameter).

Step 2: Press

U or

V to cycle between

menu items.

 

Step 3: Press

to edit the value for the

displayed menu item (SET will appear on

display).

 

Step 4: Press

U or

V to adjust the value of

the menu item.

 

Step 5: Press

to save the changes (SET will

disappear).

Step 6: Repeat Steps 2 through 5 for each of the parameters.

Step 7: To exit the menu at any time, press and holdU andV simultaneously for 5

seconds or wait 10 seconds without pushing any buttons.

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MENU DESCRIPTIONS

RON Relay on set point

Sets the CO2 concentration which the optional relay is energized.

Low limit: 0 PPM Factory setting: 1000 PPM

High limit: 2000/5000 PPM (depending on model)

ROF Relay off set point

Sets the CO2 concentration which the optional relay isde-energized.Setting value lower than RON provides direct action for detecting high concentrations of CO2. Setting value higher than RON provides indirect action for detecting low concentrations of CO2.U orV on the LCD display will be lit to indicate when the relay is energized.

Low limit: 0 PPM Factory setting: 950 PPM

High limit: 2000/5000 PPM (depending on model)

DSP Display configuration

Determines the LCD display configuration during normal operation. The LCD display can indicate the CO2 concentration and the temperature, the CO2 concentration only or the temperature only. The factory default is to display both the temperature and the CO2 concentration.

CT CO2 concentration and temperature C CO2 concentration only

T Temperature only

UNI Units selection

Temperature and barometric pressure measurements can be displayed in US engineering units or SI engineering units. The factory default is to display US engineering units.

US units

F for temperature and in Hg for

 

barometeric pressure

SI units

C for temperature and hPa for

 

barometric pressure

COL CO2 low output range

Sets the CO2 concentration for the lowest output (4 mA or 0 VDC).

Low limit: 0 PPM Factory setting: 0 PPM

High limit: 2000/5000 PPM (depending on model)

COH CO2 high output range

Sets the CO2 concentration for the highest output (20 mA, 5 VDC or 10 VDC). When COH is set above COL, the transmitter is direct acting and the output will increase with an increase in CO2 level. When COH is below COL, the transmitter is reverse acting and the output will increase with a decrease in CO2 level.

Low limit: 0 PPM

Factory setting: 2000/5000 PPM (depending on model) High limit: 2000/5000 PPM (depending on model)

TOL Temperature low output range

Sets the temperature for the lowest output (4 mA or 0 VDC).

Low limit: 32.0°F / 0.0°C Factory setting: 32.0°F / 0.0°C High limit: 122.0°F / 50.0°C

TOH Temperature high output range

Sets the temperature for the highest output (20 mA, 5 VDC or 10 VDC). When TOH is set above TOL, the transmitter is direct acting and the output will increase with an increase in temperature. When TOH is below TOL, the transmitter is reverse acting and the output will increase with a decrease intemperature.

Low limit: 32.0°F / 0.0°C Factory setting: 122.0°F / 50.0°C High limit: 122.0°F / 50.0°C

BAR Barometric pressure

Sets the typical barometric pressure for the location where the transmitter is mounted. The factory setting is for standard pressure at sea level. Adjusting the barometric pressure gives a more accurate measurement, especially at higher elevations.

Low limit: 20.0 in Hg / 600 hPa Factory setting: 29.9 in Hg / 1013 hPa High limit: 32.0 in Hg / 1100 hPa

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ENERGY RECOVERY VENTILATOR MAINTENANCE

GENERAL INFORMATION

The ability to clean exposed surfaces within air moving systems is an important design consideration for the maintenance of system performance and air quality. The need for periodic cleaning will be a function of operating schedule, climate, and contaminants in the indoor air being exhausted and in the outdoor air being supplied to the building. All components exposed to the airstream, including energy recovery wheels, may require cleaning in most applications.

Rotary counterflow heat exchanges (heat wheels) with laminar airflow are “self-cleaning”with respect to dry particles. Smaller particles pass through; larger particles land on the surface and are blown clear as the flow direction is reversed. For this reason, the primary need for cleaning is to remove films ofoil-basedaerosols that have condensed on energy transfer surfaces. Buildup of material over time may eventually reduce airflow. Most importantly, in the case of desiccant coated (enthalpy) wheels, such films can close off micron sized pores at the surface of the desiccant material, reducing the efficiency with which the desiccant can absorb and desorb moisture.

FREQUENCY

In a reasonably clean indoor environment such as a school, office building, or home, experience shows that reductions of airflow or loss of sensible (temperature) effectiveness may not occur for ten or more years. However, experience also shows that measurable changes in latent energy (water vapor) transfer can occur in shorter periods of time in commercial, institutional and residential applications experiencing moderate occupant smoking or with cooking facilities. In applications experiencing unusually high levels of occupant smoking, such as smoking lounges, nightclubs, bars and restaurants, washing of energy transfer surfaces, as frequently as every six months, may be necessary to maintain latent transfer efficiency. Similar washing cycles may also be appropriate for industrial applications involving the ventilation of high levels of smoke or oil-basedaerosols such as those found in welding or machining operations, for example. In these applications, latent efficiency losses of as much as 40% or more may develop over a period of one to three years.

CLEANABILITY AND PERFORMANCE

In order to maintain energy recovery ventilation systems, energy transfer surfaces must be accessible for washing to remove oils, grease, tars and dirt that can impede performance or generate odors. Washing of the desiccant surfaces is required to remove contaminate buildups that can reduce adsorption of water molecules. The continued ability of an enthalpy wheel to transfer latent energy depends upon the permanence of the bond between the desiccant and the energy transfer surfaces.

Bard wheels feature silica gel desiccant permanently bonded to the heat exchange surface without adhesives; the desiccant will not be lost in the washing process. Proper cleaning of the Bard energy recovery wheel will restore latent effectiveness to near original performance.

MAINTENANCE PROCEDURES

NOTE: Local conditions can vary and affect the required time between routine maintenance procedures, therefore all sites (or specific units at a site) may not have the same schedule to maintain acceptable performance. The following timetables are recommended and can be altered based on local experience.

QUARTERLY MAINTENANCE

1.Inspect mist eliminator/prefilter and clean if necessary. This filter is located in the fresh air intake hood on the front of the unit. This is an aluminum mesh filter and can be cleaned with water and any detergent not harmful to aluminum.

2.Inspect wall mount unit filter and clean or replace as necessary. This filter is located either in the unit, in a return air filter grille assembly, or both. If in the unit it can be accessed by removing the lower service door on the front of the unit. If in a return air filter grille, by hinging the grille open to gain access.

3.Inspect energy recovery ventilator for proper wheel rotation and dirt buildup. This can be done in conjunction with Item 2 above. Energize the energy recovery ventilator after inspecting the filter and observe for proper rotation and/or dirt buildup.

4.Recommended energy recovery wheel cleaning procedures follow Steps 5 through 8.

5.Disconnect all power to unit. Remove the lower service door of the wall mount unit to gain access to the energy recovery ventilator.

6.Remove the front access panel on the ventilator. Unplug amp connectors to cassette motors. Slide energy recovery cassette out of ventilator.

7.Use a shop vacuum with brush attachment to clean both sides of the energy recovery wheels.

8.Reverse shop vacuum to use as a blower and blow out any residual dry debris from the wheel.

NOTE: Discoloration and staining of the wheel does not affect its performance. Only excessive buildup of foreign material needs to be removed.

9.If any belt chirping or squealing noise is present, apply a small amount of LPS-1or equivalent dry film lubricant to the belt.

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ANNUAL MAINTENANCE

1.Inspect and conduct the same procedures as outlined under Quarterly Maintenance.

2.To maintain peak latent (moisture) removal capacity, it is recommended that the energy recovery wheels be sprayed with a diluted nonacid based evaporator coil cleaner or alkaline detergent solution such as 409.

NOTE: Do not use acid based cleaners, aromatic solvents, temperatures in excess of 170° F or steam. Damage to the wheel may result.

Do not disassemble and immerse the entire heat wheel in a soaking solution, as bearing and other damage may result.

3.Rinse wheel thoroughly after application of the cleaning solution, and allow to drain before reinstalling.

4.No re-lubricationis required to heat wheel bearings of the drive motor, or to the intake and exhaust blower motors.

5.If any belt chirping or squealing noise is present, apply a small amount of LPS-1or equivalent dry film lubricant to the belt.

FIGURE 29

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TROUBLESHOOTING

SOLID STATE HEAT PUMP CONTROL TROUBLESHOOTING PROCEDURE

1.NOTE: A thorough understanding of the defrost cycle sequence is essential. Review that section earlier in this manual prior to troubleshooting the control.Turn on AC power supply to unit.

2.Turn thermostat blower switch to “fan on” – the indoor blower should start. (If it doesn’t, troubleshoot indoor unit and correct problem.)

3.Turn thermostat blower to “auto” position. Indoor blower should stop.

4.Set system switch to “heat” or “cool”. Adjust thermostat to call for heat or cool. The indoor blower, compressor and outdoor fan should start.

NOTE: If there was no power to 24 volt transformer, the compressor and outdoor fan motor will not start for 5 minutes. This is because of the compressor short cycle protection.

CODES

FUNCTION

Slow Blink

Normal Operation

Fast Blink

Compressor Time Delay

1 Blink

Low Pressure Switch Failure

2 Blink

High Pressure Switch Failure

 

or Condensate Overflow

 

Switch Activated

3 Blink

Defrost Mode Active

4 Blink

High Pressure Soft Lockout

TABLE 5

TROUBLESHOOTING

 

Symptom

 

Description, Check & Possible Causes

What & How to Check / Repair

 

 

 

 

 

Compressor will

1. Check for LED illumination.

Yes = go to Step #2; No = go to Step #3

not start (heating

Is there an LED illuminated on the board (flashing)?

 

 

or cooling)

 

 

 

 

2. Check for error codes.

Yes = go to Step #4; No = go to Step #8

 

 

 

 

Is the LED flashing a Code?

 

 

 

 

 

 

 

 

 

 

 

3. Check for power at board.

Yes = go to Step #13; No = go to Step #9

 

 

Is there 24 volts AC between R and C?

 

 

 

 

 

 

 

 

 

 

 

4. Check codes.

Code "1", go to Step #6; Code "2", go to Steps #7A & #7B; Fast Blink, go to Step #5

 

 

What code is blinking?

 

 

 

 

 

 

 

 

 

 

 

5. Compressor delay active.

Check for proper operation; if still needed, go back to Step #1.

 

 

Wait for 5 minute delay or jump board's "speed up pins".

 

 

 

 

 

 

 

6. Low pressure fault.

Check wiring circuit and unit pressures.

 

 

 

 

 

 

 

 

7A.

High pressure fault.

Check wiring circuit and unit pressures.

 

 

 

 

 

 

 

 

7B.

Condensate overflow fault.

Check upper indoor coil drains; check lower outdoor coil drains; check main drain line.

 

 

 

 

 

 

 

8. Check for Compressor input signal.

Yes = go to Step #10; No = go to Step #11

 

 

Is there 24 volts AC between Y and C?

 

 

 

 

 

 

 

 

 

 

 

9. No power to board.

The unit either does not have unit voltage, the transformer is bad or the unit wiring is incorrect.

 

 

 

 

 

 

 

10. Check for Compressor output signal.

Yes = go to Step #12; No = go to Step #13

 

 

Is there 24 volts AC between CC & C?

 

 

 

 

 

 

 

 

 

 

 

11. No "Y" compressor input signal.

Check thermostat wiring, incorrect phase of unit (see section on Phase Monitor), and finally

 

 

 

 

unit wiring.

 

 

 

 

 

 

 

12. No "CC" compressor output signal.

Check compressor contactor for proper operation and finally check compressor.

 

 

 

 

 

 

 

 

13.

Faulty board.

Replace defrost board.

 

 

 

 

 

Fan outdoor motor

Heat pump control defective

Check across fan relay on heat pump control. (Com-NC)

does not run

 

 

Replace heat pump control.

(cooling or heating

 

 

 

Motor defective

Check for open or shorted motor winding. Replace motor.

except during

 

 

 

 

Motor capacitor defective

Check capacitor rating. Check for open or shorted capacitor. Replace capacitor.

defrost)

 

 

 

 

 

Reversing valve

Heat pump control defective

Check for 24V between RV-CandB-C.

does not energize

 

 

1. Check control circuit wiring.

(heating only)

 

 

2. Replace heat pump control

 

 

 

 

 

 

 

Reversing valve solenoid coil defective

Check for open or shorted coil.

 

 

 

 

Replace solenoid coil.

 

 

 

 

 

Unit will not go

Temperature sensor or heat pump control defective

Disconnect temperature sensor from board and jumper across "SPEEDUP" terminals and "SEN

into defrost

 

 

JMP" terminals. This should cause the unit to go through a defrost cycle within one minute.

(heating only)

 

 

1. If unit goes through defrost cycle, replace temperature sensor.

 

 

 

 

2. If unit does not go through defrost cycle, replace heat pump control.

 

 

 

 

 

Unit will not come

Temperature sensor or heat pump control defective.

Jumper across "SPEEDUP" terminal.

out of defrost

 

 

This should cause the unit to come out of defrost within one minute.

(heating only)

 

 

1. If unit comes out of defrost cycle, replace temperature sensor.

 

 

 

 

2. If unit does not come out of defrost cycle, replace heat pump control.

 

 

 

 

 

 

 

 

 

 

 

 

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CHECKING TEMPERATURE SENSOR

1.Disconnect temperature sensor from board and from right-handoutdoor coil.

2.Use an ohmmeter and measure the resistance of the sensor. Also use ohmmeter to check for short or open.

3.Check resistance reading to chart of resistance use sensor ambient temperature. (Tolerance of part is ± 10%.)

4.If sensor resistance reads very low, then sensor is shorted and will not allow proper operation of the heat pump control.

5.If sensor is out of tolerance, shorted, open, or reads very low ohms then it should be replaced.

TABLE 6

TEMPERATURE (F) VS RESISTANCE (R) OF TEMPERATURE SENSOR

F

R

F

R

F

R

F

R

F

R

 

 

 

 

 

 

 

 

 

 

-25.0

196871

5.0

72910

35.0

29986

65.0

13474

95.0

6531

-24.0

190099

6.0

70670

36.0

29157

66.0

13137

96.0

6383

-23.0

183585

7.0

68507

37.0

28355

67.0

12810

97.0

6239

-22.0

177318

8.0

66418

38.0

27577

68.0

12492

98.0

6098

-21.0

171289

9.0

64399

39.0

26823

69.0

12183

99.0

5961

-20.0

165487

10.0

62449

40.0

26082

70.0

11883

100.0

2827

-19.0

159904

11.0

60565

41.0

25383

71.0

11591

101.0

4697

-18.0

154529

12.0

58745

42.0

24696

72.0

11307

102.0

5570

-17.0

149355

13.0

56985

43.0

24030

73.0

11031

103.0

5446

-16.0

144374

14.0

55284

44.0

23384

74.0

10762

104.0

5326

-15.0

139576

15.0

53640

45.0

22758

75.0

10501

105.0

5208

-14.0

134956

16.0

52051

46.0

22150

76.0

10247

106.0

5094

-13.0

130506

17.0

50514

47.0

21561

77.0

10000

107.0

4982

-12.0

126219

18.0

49028

48.0

20989

78.0

9760

108.0

4873

-11.0

122089

19.0

14590

49.0

20435

79.0

8526

109.0

4767

-10.0

118108

20.0

46200

50.0

19896

80.0

9299

110.0

7663

-9.0

114272

21.0

44855

51.0

19374

81.0

9077

111.0

4562

-8.0

110575

22.0

43554

52.0

18867

82.0

8862

112.0

4464

-7.0

107010

23.0

42295

53.0

18375

83.0

8653

113.0

4367

-6.0

103574

24.0

41077

54.0

17989

84.0

8449

114.0

7274

-5.0

100260

25.0

39898

55.0

17434

85.0

8250

115.0

4182

-4.0

97064

26.0

38757

56.0

16984

86.0

8057

116.0

4093

-3.0

93981

27.0

37652

57.0

16547

87.0

7869

117.0

4006

-2.0

91008

28.0

36583

58.0

16122

88.0

7686

118.0

3921

-1.0

88139

29.0

35548

59.0

15710

89.0

7507

119.0

3838

0.0

85371

30.0

34545

60.0

15310

90.0

7334

120.0

3757

1.0

82699

31.0

33574

61.0

14921

91.0

7165

121.0

3678

2.0

80121

32.0

32634

62.0

14544

92.0

7000

122.0

3601

3.0

77632

33.0

31723

63.0

14177

93.0

6840

123.0

3526

4.0

75230

34.0

30840

64.0

13820

94.0

6683

124.0

3452

 

 

 

 

 

 

 

 

 

 

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TROUBLESHOOTING ECM™ 142R OUTDOOR FAN MOTOR

! WARNING

EXPOSED MOVING PARTS.

DISCONNECT ALL ELECTRICAL

POWER BEFORE SERVICING.

FAILURE TO DO SO CAN RESULT

IN SEVERE INJURY OR AMPUTATION.

!

WARNING

 

HAZARD OF ELECTRICAL SHOCK.

 

ELECTRICAL SHOCK CAN RESULT

 

IN SERIOUS INJURY OR DEATH.

-1

DISCONNECT THE REMOTE

-755

ELECTRIC POWER SUPPLY OR

7961

SUPPLIES BEFORE SERVICING.

 

1.In normal operation, this motor may rock back and forth on start up. Do not replace if this is the only symptom identified.

2.If the system is operating properly, but the motor appears to run slower than it should, the motor is good. High efficiency systems with optimized fan blades are engineered to run slow to decrease noise. The Bard I-TECSeries models also adjust fan speed based upon varied outdoor ambient conditions to optimize sound and unit efficiency.

3.If the system is noisy, freezing up, running a high head pressure, tripping the high pressure switch or compressor overload, check the following:

a.Ensure cleanliness of condenser coil(s) and fan blade/shroud.

b.Confirm the fan blade is not bent or deformed, isn't rubbing on the shroud, and that it is tight on the motor shaft. Also ensure the motor is secure in its mounting system, and the mounting system is secure to the unit.

Do not operate motor without fan blade attached. Such operations will cause the motor to oscillate up and down.

You must obtain the correct replacement motor from the manufacturer that is a direct replacement for the failed motor.

USING THE WRONG MOTOR VOIDS ALL WARRANTIES AND MAY PRODUCE UNEXPECTED RESULTS.

c.The Bard I-TECis equipped with a low ambient control pressure switch. This pressure switch completes the 24VAC Common feed to the outdoor fan motor control in cooling mode. If this switch is defective, or if the outdoor air temperature is too cold to raise the head pressure to the 325# switch closingset-point,or the system charge is too low, this could be the cause of the issue. (In heat pump {heating} mode, the low ambient fan cycling control is bypassed.)

d.If motor is not running, go to next section.

4.If the motor does not appear to be running at the proper speed or does not shut off, refer to the next section for voltage checks to determine if the motor is getting the proper input signals.

If the motor IS NOT receiving any communication, troubleshoot the communication issue using the diagnostic table for the Fan Logic Control.

a.This motor uses a 7 wire harness to control the motor.

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TROUBLESHOOTING ECM™ 142R OUTDOOR FAN MOTOR

Line power is connected as follows: “Red Wire” connects to “L1” “Black Wire” connects to “L2”

“Green/Yellow Wire” connects to “Ground”

Control power is connected as follows: “Blue Wire” connects to Fan Relay of the Defrost Logic Control, and subsequently connects to 24VAC Common through the Fan Logic Control Board. “Yellow Wire” connects to “Y” on the Fan Logic Control Board. “White Wire” connects to “W” on the Fan Logic Control Board. “Orange Wire” connects to “O” on the Fan Logic Control Board.

NOTE: A combination of the "Yellow", "White" and "Orange" wires being energized (with 24V "R" signal) determines five (5) different speeds the fan motor will operate at. The Fan Logic Control Board uses an outdoor thermistor sensor to determine the speed the fan should operate. It also utilizes the "B" reversing valve input for heat pump mode to determine speed should operate.

TABLE 7

TROUBLESHOOTING ECM™ 142R OUTDOOR FAN MOTOR

Check Line Power to Motor

Check between Red and Black Wires for Line Power

 

Verify Ground by checking Green Wire to L1 and L2 Line Power

 

 

 

 

Check "BR" terminal of Fan Logic Control Board

 

 

Check for 24VAC common

Check "Blue" Fan Lead on "Fan Relay Terminal" of "Defrost Logic Control"

 

** Is not energized in cooling mode until Low Ambient Fan Cycling Control is closed

signal to motor (against

Transformer "R" Signal)

by 325 PSIG refrigerant pressure.

 

** Circuit is completed automatically when "B" is energized on the Fan Logic Control

 

Board

 

 

Check 24VAC "hot" outputs (to "Blue" on Fan Logic Control) to motor. See the following tables based upon outdoor temperature and model of operation.

TABLE 8

TABLE 9

COOLING MODE

HEAT PUMP MODE

O.D. Temp Sensor

24VAC Signals Between

 

 

Below 55°F

Orange to Blue

 

 

Between 56° - 69°F

White to Blue

 

 

Between 70° - 85°F

Yellow to Blue

 

 

Between 86° - 112°F

Orange and White to Blue

 

 

Above 112°F

White and Yellow to Blue

 

 

O.D. Temp Sensor

24VAC Signals Between

 

 

Above 56°F

Orange to Blue

 

 

Between 55° - 30°F

White to Blue

 

 

Between 29° - 14°F

Yellow to Blue

 

 

Below 13°F

Orange and White to Blue

 

 

If the output signals are not matching the specified temperature range, then go to Table #6 and verify the thermistor output curve. If the motor is receiving proper communications and proper high voltage power, and is still not running, proceed with Motor Replacement. (When checking the resistance/temperature curve, don’t forget about the optional 2.2k ohm fan control resistor assembly.)

REPLACING THE MOTOR

This motor is replaced in one piece. The control cannot be replaced separately from the motor. Even if the control is remotely located, the replacement part will be a new control with harness and new motor.

You must have the correct replacement motor from the manufacturer that is a direct replacement for the failed motor.

USING THE WRONG MOTOR VOIDS ALL PRODUCT WARRANTIES AND MAY PRODUCE UNEXPECTED RESULTS.

Always mount the replacement motor and control according to the manufacturers specifications using all required hardware to reduce vibration. Make sure all wires are free of the fan blade and not pinched in mountings or cabinet through points.

Manual

2100-549G

Page

54 of 59

TROUBLESHOOTING INDOOR ECM™ BLOWER MOTORS

CAUTION:

Disconnect power from unit before removing or replacing connectors, or servicing motor. To avoid electric shock from the motor’s capacitors, disconnect power and wait at least 5 minutes before opening motor.

Symptom Cause/Procedure

Motor rocks slightly when starting

Motor won’t start

• No movement

This is normal start-upfor ECM

Check blower turns by hand

Check power at motor

Check low voltage (24 Vac R to C) at motor

Check low voltage connections (G, Y, W, R, C) at motor

Check for unseated pins in connectors on motor harness

Test with a temporary jumper between R - G

Check motor for tight shaft

Perform motor/control replacement check

Perform Moisture Check

Motor rocks, but won’t start

Motor oscillates up

load & down while being tested off of blower

Motor starts, but runs erratically

Varies up and down or intermittent

Check for loose or compliant motor mount

Make sure blower wheel is tight on shaft

Perform motor/control replacement check

It is normal for motor to oscillate with no on shaft

Check line voltage for variation or “sag”

Check low voltage connections

(G, Y, W, R, C) at motor, unseated pins in motor harness connectors

Check “Bk” for erratic CFM command (in variable-speedapplications)

Check out system controls, Thermostat

Perform Moisture Check

• “Hunts” or “puffs” at

• Does removing panel or filter reduce

high CFM (speed)

“puffing”?

 

- Reduce restriction

 

- Reduce max airflow

Stays at low CFM despite system call for cool or heat CFM

Stays at high CFM

Blower won’t shut off

Check low voltage (Thermostat) wires and connections

Verify fan is not in delay mode; wait until delay complete

“R” missing/not connected at motor

Perform motor/control replacement check

“R” missing/not connected at motor

Is fan in delay mode? - wait until delay time complete

Perform motor/control replacement check

Current leakage from controls into G, Y or W? Check for Triac switched thermostat or solidstate relay

Excessive noise

• Determine if it’s air noise, cabinet, duct or

 

motor noise; interview customer, if necessary

• Air noise

• High static creating high blower speed?

 

- Is airflow set properly?

 

- Does removing filter cause blower to slow

 

down? Check filter

 

- Use low-pressuredrop filter

 

- Check/correct duct restrictions

Symptom Cause/Procedure

Noisy blower or cabinet Check for loose blower housing, panels, etc.

High static creating high blower speed?

-Check for air whistling through seams in ducts, cabinets or panels

-Check for cabinet/duct deformation

“Hunts” or “puffs” at high CFM (speed)

Evidence of Moisture

Motor failure or

malfunction has occurred and moisture is present

Evidence of moisture present inside air mover

Does removing panel or filter reduce “puffing”?

-Reduce restriction

-Reduce max. airflow

Replace motor and Perform Moisture Check

Perform Moisture Check

Do

Check out motor, controls, wiring and connections thoroughly before replacing motor

Orient connectors down so water can’t get in

-Install “drip loops”

Use authorized motor and model #’s for replacement

Keep static pressure to a minimum:

-Recommend high efficiency, low static filters

-Recommend keeping filters clean.

-Design ductwork for min. static, max. comfort

-Look for and recommend ductwork improvement, where necessary

Size the equipment wisely

Check orientation before inserting motor connectors

Don’t

Automatically assume the motor is bad.

Locate connectors above 7 and 4 o’clock positions

Replace one motor or control model # with another (unless an authorized replacement)

Use high pressure drop filters some have ½" H20 drop!

Use restricted returns

Oversize system, then compensate with low airflow

Plug in power connector backwards

Force plugs

Moisture Check

Connectors are oriented “down” (or as recommended by equipment manufacturer)

Arrange harness with “drip loop” under motor

Is condensate drain plugged?

Check for low airflow (too much latent capacity)

Check for undercharged condition

Check and plug leaks in return ducts, cabinet

Comfort Check

Check proper airflow settings

Low static pressure for lowest noise

Set low continuous-fanCFM

Use humidistat and 2-speedcooling units

Use zoning controls designed for ECM that regulate CFM

Thermostat in bad location?

Manual

2100-549G

Page

55 of 59

TROUBLESHOOTING INDOOR ECM™ BLOWER MOTORS (Cont’d.)

Replacing ECM Control Module

To replace the control module for the GE variable-speedindoor blower motor you need to take the following steps:

1. You MUST have the correct replacement module. The controls are factory programmed for specific operating modes. Even though they look alike, different modules may have completely different functionality.

USING THE WRONG CONTROL MODULE VOIDS ALL PRODUCT WARRANTIES AND MAY PRODUCE UNEXPECTED RESULTS.

2.Begin by removing AC power from the unit being serviced. DO NOT WORK ON THE MOTOR WITH AC POWER APPLIED. To avoid electric shock from the motor’s capacitors, disconnect power and wait at least 5 minutes before opening motor.

3.It is not necessary to remove the motor from the blower assembly, nor the blower assembly from the unit. Unplug the two cable connectors to the motor control assembly. There are latches on each connector. DO NOT PULL ON THE WIRES. The plugs remove easily when properly released.

4.Locate the screws that retain to the motor control bracket to the sheet metal of the unit and remove them. Remove two (2) nuts that retain the control to the bracket and then remove two (2) nuts that retain sheet metal motor control end plate. Refer to Figure 30.

5.Disconnect the three (3) wires interior of the motor control by using your thumb and forefinger squeezing the latch tab and the opposite side of the connector plug, gently pulling the connector. DO NOT PULL ON THE WIRES, GRIP THE PLUG ONLY. Refer to Figure 30.

6.The control module is now completely detached from the motor. Verify with a standard ohmmeter that the resistance from each motor lead (in the motor plug just removed) to the motor shell is >100K ohms. Refer to Figure 31. (Measure to unpainted motor end plate.) If any motor lead fails this test, do not proceed to install the control module.THE MOTOR IS DEFECTIVE AND MUST BE REPLACED. Installing the new control module will cause it to fail also.

7.Verify that the replacement control is correct for your application. Refer to the manufacturer's authorized replacement list.

USING THE WRONG CONTROL WILL RESULT IN IMPROPER OR NO BLOWER OPERATION. Orient the control module so that the 3-wire motor plug can be inserted into the socket in the control. Carefully insert the plug and press it into the socket until it latches. A SLIGHT CLICK WILL BE HEARD WHEN

PROPERLY INSERTED.

8.Reverse the steps #5, 4, 3 to reconnect the motor control to the motor wires, securing the motor control cover plate, mounting the control to the bracket, and mounting the motor control bracket back into the unit. MAKE SURE THE ORIENTATION YOU SELECT

FOR REPLACING THE CONTROL ASSURES THE CONTROL'S CABLE CONNECTORS WILL BE LOCATED DOWNWARD IN THE APPLICATION SO THAT WATER CANNOT RUN DOWN THE CABLES AND INTO THE CONTROL. DO NOT OVERTIGHTEN THE BOLTS.

9.Plug the 16-pincontrol plug into the motor. The plug is keyed. Make sure the connector is properly seated and latched.

10.Plug the 5-pinpower connector into the motor. Even though the plug is keyed,OBSERVE THE PROPER ORIENTATION. DO NOT FORCE THE CONNECTOR. It plugs in very easily when properly oriented.REVERSING THIS PLUG WILL CAUSE

IMMEDIATE FAILURE OF THE CONTROL MODULE.

11.Final installation check. Make sure the motor is installed as follows:

a.Motor connectors should be oriented between the 4 o’clock and 8 o’clock positions when the control is positioned in its final location and orientation.

b.Add a drip loop to the cables so that water cannot enter the motor by draining down the cables. Refer to Figure 32.

The installation is now complete. Reapply the AC power to the HVAC equipment and verify that the new motor control module is working properly. Follow the manufacturer's procedures for disposition of the old control module.

 

 

 

Figure 30

 

Figure 31

 

 

 

Figure 3

 

Figure 4

 

 

Control Disassembly

 

Winding Test

 

 

 

 

Motor Connector

 

Only remove

 

From Motor

(3-pin)

 

 

Hex Head Bolts

Push until

 

 

 

 

Latch Seats

 

 

 

 

Over Ramp

 

 

 

 

 

Circuit

 

 

 

 

 

Board

 

 

 

ECM 2.0

 

Motor

 

 

 

 

 

 

 

 

 

 

 

 

Motor OK when

 

Note:

 

 

 

R > 100k ohm

 

Use the shorter

 

 

 

 

 

bolts and

 

 

 

 

 

alignment pin

 

 

 

Figure 32

 

supplied when

 

 

 

Figure 5

 

replacing an

 

 

 

Drip Loop

 

ECM 2.0

 

Motor Connector

 

 

 

control.

 

(3-pin)

Back of

Connector Orientation

 

ECM

 

Control

Between 4 and 8 o'clock

 

EON

Control Connector

 

 

 

2.3/2.5

 

 

 

5.0

 

(16-pin)

 

 

 

 

 

 

 

 

 

 

Power Connector

 

 

 

 

 

(5-pin)

 

 

 

 

 

Hex-headScrews

 

Drip Loop

Manual

2100-549G

 

 

 

 

Page

56 of 59

 

 

 

 

TROUBLESHOOTING ECM™ BLOWER MOTORS (Cont’d.)

 

 

Continuous

 

 

 

Dehum.

 

 

Heat Pump

Heat Pump

 

MODE of

OFF

Blower

Part Load

Full Load

 

Part Load

Full Load

Full Load with

Full Load with

Emergency

 

Mode

OPERATION

(Ventilation

Cooling

Cooling

 

Heat Pump

Heat Pump

1st Bank of

1st & 2nd Bank of

Heat Mode

 

 

Mode)

 

 

(when equipped)

 

 

Electric Heat

Electric Heat

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Thermostat

 

 

"G",

"G",

 

 

"G", "B",

"G", "B",

"G", "Y1",

"G", "Y1", "Y2",

"G",

24 VAC

"G"

 

"D"

"Y1", "Y2"

"Y1", "Y2"

 

"Y1"

"Y1, "Y2"

"Y2", "B", "W1"

"B", "W2", "W3"

"W2", "W3"

Input Signals

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Pin #1

24 VAC "C" (Common) Signal, Always Energized

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Pin #2

 

 

 

 

 

 

 

 

X

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Pin #3

24 VAC "C" (Common) Signal, Always Energized

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Pin #4

Not Used

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Pin #5

Not Used

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Pin #6

 

 

X

X

 

X

X

X

X

X

 

 

 

 

 

 

 

 

 

 

 

 

 

Pin #7

Not Used

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Pin #8

Not Used

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Pin #9

 

 

 

 

 

 

X

X

X

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Pin #10

Not Used

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Pin #11

Not Used

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Pin #12

24 VAC Hot "R" Signal, Always Energized

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Pin #13

 

 

 

 

 

 

 

 

 

X

X

 

 

 

 

 

 

 

 

 

 

 

 

Pin #14

 

 

 

X

 

X

X

 

X

X

 

 

 

 

 

 

 

 

 

 

 

 

 

Pin #15

 

X

X

X

 

X

X

X

X

X

X

 

 

 

 

 

 

 

 

 

 

 

 

Pin #16

Not Used

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FIGURE 33

CONTROL CONNECTOR MOTOR HALF

9 10 11 12 13 14 15 16

1

2

3

4

5

6

7

8

POWER CONNECTOR *

PWB HEADER

AMP 1-350945-0

 

 

PIN

Description

 

 

1

Jumper Pin 1 to Pin 2 for

 

2120VAC Line Input Only **

3Chassis Ground

4AC Line

5AC Line

*Suggested mating connector Housing — AMP 350809-1Contact — AMP350537-1

**WARNING — Applying 240VAC line input with PIN 1 to PIN 2 jumper in place will permanently damage unit!

MIS-2839

POWER CONNECTOR

1 2 3 4 5

MOTOR HALF

 

FAN BLADE SETTING DIMENSIONS

The position of the fan blade should be flush with the leaving face of the orifice plate. Check to make sure the blades do not extend beyond the rear casing of the unit. Spin the blade by hand to make sure it does not hit the ring.

REFRIGERANT CHARGE

This unit was charged at the factory with the quantity of refrigerant listed on the serial plate. AHRI capacity and efficiency ratings were determined by testing with this refrigerant charge quantity. The following pressure tables show nominal pressures and temperatures for the units. Since many installation specific situations can affect the pressure readings, this information should only be used by certified technicians as a guide for evaluating proper system performance. They shall not be used to adjust charge. If charge is in doubt, reclaim, evacuate and recharge the unit to the serial plate charge.

Manual

2100-549G

Page

57 of 59

TABLE 10A

FULL LOAD COOLING PRESSURE/TEMPERATURE

 

RETURN

 

 

 

 

AIR TEMPERATURE ENTERING OUTDOOR COIL °F

 

 

 

 

AIR

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

55

60

65

70

75

80

85

90

95

100

105

110

115

120

125

MODEL

TEMP.

PRESSURE

 

75 DB

Low Side

117

118

120

121

123

124

126

128

129

130

132

133

135

136

137

 

62 WB

High Side

202

224

246

267

289

310

332

354

375

399

423

448

472

496

520

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

I30H1

80 DB

Low Side

130

131

133

134

136

139

140

141

142

144

145

147

148

150

151

67 WB

High Side

201

225

248

271

294

315

345

362

386

411

436

461

486

510

535

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

85 DB

Low Side

145

146

148

149

151

152

154

156

157

159

160

162

164

165

167

 

72 WB

High Side

210

233

256

278

301

323

346

369

391

416

442

467

492

517

542

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

75 DB

Low Side

126

127

129

130

131

132

134

135

136

137

138

139

141

142

143

 

62 WB

High Side

209

231

252

274

295

317

338

360

381

405

429

452

476

500

524

I36H1

80 DB

Low Side

139

140

142

143

144

146

147

148

149

150

152

153

154

155

157

67 WB

High Side

208

231

254

277

300

327

358

370

392

417

441

466

490

515

539

 

 

85 DB

Low Side

154

155

157

158

159

160

162

163

164

165

167

168

170

171

172

 

72 WB

High Side

217

240

262

285

307

330

352

375

397

422

447

471

496

521

540

 

75 DB

Low Side

122

123

125

127

128

130

131

133

134

135

136

137

138

139

140

 

62 WB

High Side

218

238

258

279

299

319

339

360

380

404

428

452

476

500

524

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

I42H1

80 DB

Low Side

134

136

138

139

141

142

144

146

147

148

149

150

151

152

153

67 WB

High Side

217

239

260

282

304

326

355

369

391

416

440

465

490

514

539

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

85 DB

Low Side

139

140

142

143

144

145

147

148

149

150

151

152

153

154

155

 

72 WB

High Side

226

247

269

290

311

332

353

375

396

421

446

471

496

521

546

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

75 DB

Low Side

125

126

127

128

129

129

130

131

132

134

135

136

138

139

140

 

62 WB

High Side

203

225

248

271

293

316

339

361

384

411

437

464

491

517

544

I48H1

80 DB

Low Side

136

138

139

140

141

143

144

145

147

148

150

151

153

154

156

67 WB

High Side

208

231

254

276

299

321

351

367

390

417

444

471

498

526

553

 

 

85 DB

Low Side

148

149

151

153

154

156

158

159

161

162

164

166

167

169

171

 

72 WB

High Side

215

238

261

284

307

331

354

377

400

428

456

484

512

539

567

 

75 DB

Low Side

123

124

124

125

126

127

128

129

129

131

132

133

134

135

136

 

62 WB

High Side

218

241

265

289

312

336

360

383

407

434

462

489

516

544

571

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

I60H1

80 DB

Low Side

134

135

137

138

139

140

141

142

143

145

146

147

148

150

151

67 WB

High Side

224

248

271

295

319

341

373

389

413

441

469

497

524

552

580

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

85 DB

Low Side

146

147

148

150

151

153

154

156

157

159

160

161

163

164

166

 

72 WB

High Side

231

255

279

303

327

352

376

400

424

453

481

510

538

567

595

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TABLE 10B

FULL LOAD HEATING PRESSURE/TEMPERATURE

 

RETURN

 

 

 

 

AIR TEMPERATURE ENTERING OUTDOOR COIL °F

 

 

 

 

AIR

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

0

5

10

15

20

25

30

35

40

45

50

55

60

65

70

MODEL

TEMP.

PRESSURE

I30H1

70° DB

Low Side

33

40

48

55

63

70

78

85

91

98

107

116

125

134

143

High Side

247

257

267

277

287

296

306

316

317

319

345

371

398

424

451

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

I36H1

70° DB

Low Side

30

38

45

52

59

67

74

81

89

97

105

112

120

127

135

High Side

244

252

259

267

275

283

290

298

305

311

320

328

337

345

354

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

I42H1

70° DB

Low Side

34

40

47

54

60

67

74

81

88

95

102

109

116

123

130

High Side

255

263

271

278

286

294

301

309

314

319

325

331

337

343

349

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

I48H1

70° DB

Low Side

33

40

47

54

60

67

74

81

89

97

106

114

122

130

138

High Side

268

276

285

293

301

309

318

326

334

342

349

356

363

370

377

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

I60H1

70° DB

Low Side

38

42

46

50

54

58

63

67

80

94

102

110

118

127

135

High Side

290

294

297

300

303

306

310

313

335

357

366

375

384

393

402

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Manual

2100-549G

Page

58 of 59

TABLE 11A

PART LOAD COOLING PRESSURE/TEMPERATURE

 

RETURN

 

 

 

 

AIR TEMPERATURE ENTERING OUTDOOR COIL °F

 

 

 

 

AIR

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

55

60

65

70

75

80

85

90

95

100

105

110

115

120

125

MODEL

TEMP.

PRESSURE

 

75 DB

Low Side

127

128

129

129

130

131

132

133

134

135

137

138

140

141

143

 

62 WB

High Side

184

206

227

249

270

292

313

334

356

380

403

427

451

475

498

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

I30H1

80 DB

Low Side

141

141

142

143

143

144

144

145

146

147

149

151

152

154

156

67 WB

High Side

187

209

231

252

274

293

322

338

361

385

409

433

457

481

505

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

85 DB

Low Side

154

154

155

156

156

157

157

158

159

161

162

164

166

168

170

 

72 WB

High Side

194

216

237

259

280

302

323

344

366

390

415

439

464

488

512

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

75 DB

Low Side

131

133

134

136

137

139

140

142

143

144

145

146

148

149

150

 

62 WB

High Side

188

209

230

250

271

292

313

333

354

378

403

427

452

476

500

I36H1

80 DB

Low Side

145

146

148

149

150

152

153

154

155

156

158

159

160

161

163

67 WB

High Side

191

212

233

254

275

295

323

338

359

384

409

433

458

483

508

 

 

85 DB

Low Side

158

159

161

162

163

164

166

167

168

169

171

172

173

175

176

 

72 WB

High Side

198

219

240

260

281

302

323

343

364

389

414

439

464

489

515

 

75 DB

Low Side

126

128

130

132

134

136

138

139

141

142

143

144

145

146

147

 

62 WB

High Side

192

212

233

253

274

294

315

335

356

379

402

426

449

472

496

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

I42H1

80 DB

Low Side

140

141

143

145

146

148

150

151

153

154

155

156

157

158

159

67 WB

High Side

195

216

236

257

278

299

326

340

361

384

408

432

455

479

503

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

85 DB

Low Side

144

145

147

148

150

151

152

154

155

156

157

158

159

160

161

 

72 WB

High Side

202

223

243

264

284

304

325

345

366

390

414

438

462

486

510

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

75 DB

Low Side

129

130

131

132

133

133

134

135

136

137

139

140

142

143

144

 

62 WB

High Side

183

205

226

248

269

291

313

334

356

381

407

432

458

484

509

I48H1

80 DB

Low Side

140

141

142

144

145

146

148

149

151

152

154

155

157

158

160

67 WB

High Side

187

209

230

252

274

295

324

339

361

387

413

439

465

491

517

 

 

85 DB

Low Side

154

155

157

158

160

161

162

164

165

167

168

170

172

173

175

 

72 WB

High Side

189

212

234

257

280

303

325

348

371

397

424

451

477

504

530

 

75 DB

Low Side

127

127

128

128

129

130

130

131

131

133

134

135

136

137

139

 

62 WB

High Side

196

218

240

261

283

305

326

348

370

396

422

448

474

500

526

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

I60H1

80 DB

Low Side

137

138

139

140

142

142

143

144

146

147

148

150

151

152

154

67 WB

High Side

200

222

244

266

288

310

339

353

375

402

428

454

481

507

534

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

85 DB

Low Side

152

153

153

154

155

156

157

158

159

161

162

164

165

167

168

 

72 WB

High Side

203

226

249

271

294

317

340

363

385

412

440

467

494

521

548

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TABLE 11B

PART LOAD HEATING PRESSURE/TEMPERATURE

 

RETURN

 

 

 

 

AIR TEMPERATURE ENTERING OUTDOOR COIL °F

 

 

 

 

AIR

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

0

5

10

15

20

25

30

35

40

45

50

55

60

65

70

MODEL

TEMP.

PRESSURE

I30H1

70° DB

Low Side

40

47

54

61

68

75

83

90

97

104

115

125

135

146

156

High Side

239

249

258

268

278

288

297

307

311

315

328

341

353

366

378

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

I36H1

70° DB

Low Side

36

44

51

58

65

73

80

87

96

104

114

123

133

142

152

High Side

233

241

248

255

262

270

277

284

292

299

307

315

322

330

338

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

I42H1

70° DB

Low Side

37

45

52

60

67

75

82

90

96

103

110

118

126

134

142

High Side

242

250

258

265

273

281

288

296

303

309

316

323

331

338

345

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

I48H1

70° DB

Low Side

35

43

51

59

67

75

83

92

98

105

115

124

134

143

153

High Side

265

271

277

282

288

293

299

305

318

331

340

348

357

365

374

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

I60H1

70° DB

Low Side

38

45

52

60

67

74

82

89

96

104

113

122

131

140

149

High Side

263

272

281

291

300

309

318

327

336

345

356

366

377

387

398

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Manual

2100-549G

Page

59 of 59