Bard Q42A1, Q24A1, Q30A1, Q36A1, Q60A1 User Manual

...

Q-TEC SERIES

PACKAGED INSTALLATION INSTRUCTIONS

AIR CONDITIONER

Models: Q24A1 Q30A1 Q36A1 Q42A1 Q48A1 Q60A1

Bard Manufacturing Company, Inc. Bryan, Ohio 43506

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

Manual: 2100-522B Supersedes: 2100-522A File: Vol II Tab 14 Date: 12-15-11

Manual 2100-522B Page 1 of 38

CONTENTS

Getting Other Information and Publications

For more information, contact these publishers: .......... 3

EC General Information

Q-T

Q-TEC Model Nomenclature ......................................... 4

Shipping Damage ......................................................... 8

Unit Removal From Skid .............................................. 8

Handling Unit After Removal From Skid ....................... 9

General ......................................................................... 9

Minimum Installation Height ......................................... 9

Duct Work .................................................................. 11

Filters .......................................................................... 11

Fresh Air Intake .......................................................... 12

Service Light ............................................................... 12

Condensate Drain ...................................................... 12

Optional Rear Drain Kit .............................................. 12

Separate Evaporator Drain Connection ..................... 12

Installation Instructions

Mounting the Unit ....................................................... 19

Wiring — Main Power ................................................. 20

Wiring — Low Voltage Wiring..................................... 20

Low Voltage Connections ........................................... 21

General ....................................................................... 21

Figures

Figure 1 Unit Dimensions .......................................... 7

Figure 2 Air Seal Under Unit ...................................... 8

Figure 3 Removal of Unit From Skid ......................... 8

Figure 4 Unit on Appliance Cart for Moving ............... 9

Figure 5 Installation With Free Blow Plenum .......... 10

Figure 6 Ducted Application ..................................... 10

Figure 7 Supply Duct Connections .......................... 11

Figure 8 Filter Location ............................................ 11

Figure 9 Optional Side Drain ................................... 13

Figure 10 Standard Rear Drain .................................. 13

Figure 11 Rear Drain (Top View) ............................... 13

Figure 12A Figure 12B Figure 12C Figure 12D Figure 13A Figure 13B Figure 14 Removing Locking Screws from Wheels ... 19

Figure 15 Component Location ................................. 20

Figure 16 Thermostat Plug Terminals ........................ 22

Figure 17 Thermostat Wiring Diagram "X" Option .... 23

Figure 18 Thermostat Wiring Diagram "A" Option .... 24

Figure 19 Thermostat Wiring Diagram "D" Option ... 25 Figure 20 Thermostat Wiring Diagram "H" Option ... 26

Figure 21 Fresh Air Damper Removal ....................... 32

Figure 22 QERV Removal ......................................... 33

Figure 23 CO

Figure 24 Control Disassembly ................................. 36

Figure 25 Winding Test .............................................. 36

Figure 26 Drip Loop ................................................... 36

Figure 27 Fan Blade Setting ...................................... 37

Optional Rear Drain Kit ............................. 14

Optional Rear Drain Kit ............................. 15

Optional Rear Drain Kit ............................. 16

Optional Rear Drain Kit ............................. 17

Unit Mounting ............................................ 18

Controller ........................................... 34

Start Up

R-410A Refrgerant ......................................................... 27

Topping Off System Charge ........................................... 27

Safety Practices ............................................................. 27

Description of Standard Equipment ............................... 28

Optional CFM (Q36A1, Q42A1, Q48A1 & Q60A1 Only) 28

Important Installer Note.................................................. 28

Phase Monitor ................................................................ 28

Three Phase Scroll Compressor Start Up

Information ....................................................... 28 & 29

Compressor Control Module .......................................... 29

Adjustments ................................................................... 29

Service Hints ......................................................... 29 & 30

Mist Eliminator Service .................................................. 30

Vent Options ......................................................... 30 & 31

Sequence of Operation .................................................. 34

Optional Climate Controls Sequence

of Operation .............................................................. 34

Pressure Service Ports .................................................. 34

Troubleshooting

Troubleshooting GE ECM™ Blower Motors............. 35-36

Fan Blade Setting Dimensions ...................................... 37

Refrigerant Charge ........................................................ 37

Pressure Chart ............................................................... 38

Tables

Table 1 Factory Built-In Electric Heat Table .............. 5

Table 2 Electrical Specifications ................................ 6

Table 3 Operating Voltage Range ........................... 20

Table 4 Wall Thermostats ........................................ 22

Table 5 Fan Blade Dimensions ............................... 37

Table 6 Indoor Blower Performance ........................ 37

Table 7 Cooling Pressure ........................................ 38

Manual 2100-522B Page 2 of 38

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 2100-522B Page 3 of 38

Q-T

Series General Information

Q-TEC MODEL NOMENCLATURE

Q 42 A 1 A 10 X X V X X X

MODEL NUMBER

Q-Tec™

CAPACITY

24 - 2 Ton 30 - 2½ Ton 36 - 3 Ton 42 - 3½ Ton 48 - 4 Ton 60 - 5 Ton

VENTILATION OPTIONS

X - Barometric Fresh Air Damper (Standard) B - Blank-off Plate E - Economizer (Not available on dehumidification versions) P - Commercial Ventilator - Motorized w/Exhaust Power Return V - Commercial Ventilator - Motorized w/Exhaust Spring Return R - Energy Recovery Ventilator w/Independent Intake & Exhaust Control

NOTE: 1 Insert “D” for dehumidification with hot gas reheat. Reference 7960-584 for complete details. 2 If “X” control option is selected, then thermostat and humidistat, if applicable, or DDC control system must be field supplied.

AIR

CONDITIONER

REVISION |

SPECIALTY PRODUCTS 1 |

(Non-Standard)

VOLTS & PHASE |

A - 230/208/60/1 B - 230/208/60/3 C - 460/60/3

0Z - 0KW 05 - 5KW 06 - 6KW 09 - 9KW 10 -10KW 12 -12KW 15 -15KW

FILTER OPTIONS

X - 1 inch Fiberglass (Standard) F - 2 inch Fiberglass P - 2 inch Pleated

COLOR

V - Platinum w/Slate Front (Vinyl) X - Beige paint 4 - Gray paint

STANDARD UNITS DEHUMIDIFICATION UNITS X - None 2 X - None 2 A - Electronic/Non Prog E - Electronic/Prog/Humidistat D - Electronic/Prog G - Electronic Non-Prog/Humidistat H - Electronic/Prog/CO

CLIMATE CONTROL2

COIL OPTIONS

X -Standard 1 -Phenolic coated

evaporator*

2 -Phenolic coated

condenser

3 -Phenolic coated

evaporator and condenser coil*

*and reheat if applicable

I - Electronic Prog/Humidistat/CO

INTERNAL CONTROLS

X - Standard

• High Pressure Switch

• Low Pressure Switch

• Compressor Control Module w/Time Delay

J - Alarm Relay +

LAC + Above

Manual 2100-522B Page 4 of 38

C-1A63Q

C-1A24Q

C-1A84QA-1A06QB-1A06QC-1A06Q

B-1A63Q

B-1A24Q

B-1A84Q

A-1A63Q

A-1A24Q

A-1A84Q

TABLE 1

FACTORY BUILT-IN ELECTRIC HEAT TABLE

A-1A42Q

A-1A03QB-1A42QB-1A03QC-1A42QC-1A03Q

1-V0421-V8021-V0421-V8021-V0421-V8023-V0843-V0841-V0421-V8021-V0421-V8023-V0841-V0421-V8021-V0421-V8023-V084

sledoM

0.5083,61092,21 083,61092,21

WKHUTBHUTBHUTBHUTBHUTBHUTBHUTBHUTBHUTBHUTBHUTBHUTBHUTBHUTBHUTBHUTBHUTBHUTB

0.9007,03000,32007,03000,32007,03007,03007,03000,32007,03007,03000,32007,03

0.6005,02063,51005,02063,51005,02005,02005,02063,51005,02

0.21000,14007,03000,14

0.01076,23075,42 076,23075,42076,23075,42

0.51 051,94068,63051,94068,63051,94051,94068,63051,94068,63051,94

Manual 2100-522B Page 5 of 38

TABLE 2

ELECTRICAL SPECIFICATIONS

tiucriCelgniS tiucriClauD

detaR

ledoM

Z0A-1A42Q 50A 01A Z0B-1A42Q 60B 90B Z0C-1A42Q 60C 90C Z0A-1A03Q 50A 01A Z0B-1A03Q 60B 90B 21B Z0C-1A03Q 60C 90C 21C Z0A-1A63Q 50A 01A 51A Z0B-1A63Q 60B 90B 51B Z0C-1A63Q 60C 90C 51C Z0A-1A24Q 50A 01A 51A Z0B-1A24Q 60B 90B 51B Z0C-1A24Q 60C 90C 51C Z0A-1A84Q 50A 01A 51A Z0B-1A84Q 60B 90B 51B Z0C-1A84Q 60C 90C 51C Z0A-1A06Q 01A 51A Z0B-1A06Q 90B

51B Z0C-1A06Q 90C 51C

stloV

esahPdna

1-802/032

3-802/032

3-064

1-802/032

3-802/032

3-064

1-802/032

3-802/032

3-064

1-802/032

3-802/032

3-064

1-802/032

3-802/032

3-064

1-802/032

3-802/032

3-064

3 muminiM

dleiF.oN rewoP stiucriC

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

2ro1 1 1 1 1 1 1 1 1 1 1 1

2ro1 1 1 1 1 1 1 1 1 1 1

2ro1 1

1 1

1 1 1

1 mumixaM

tiucriC

yticapmA

22 03 55 71 52 33 01 21 71 52 23 75 81 52 43 34 11 41 81 32 92 43 85 48 12 62 53 35 21 41 81 72 53 53 85 38 62 62 53 35 31 41 81 72 73 73 85 38 82 82 53 35 41 41 81 72 54 95 48

13 63 55

61 91 82

2 dleiF esuFlanretxE .rkrB.tkCro

03 03 06 02 52 53 51 51 02 53 53 06 52 52 53 54 51 51 02 52 54 54 06 09 03 03 53 06 51 51 02 03 05 05 06 09 53 53 53 06 51 51 02 03 05 05 06 09 04 04 04 06 02 02 02 03 06 06 09

54 54 06

02 02 03

2 dnuorG

rewoP

eziSeriW

01 01

21 01

41 41

21 8 8 6

01 8 6

01 8 8 6 4

01 8 6

01 8 8 6 4 8 8 8 6

01 8 6 4 8 8 6

8 8

3 muminiM

tiucriC

eriW

01 01 01 21 01 01 41 41 21 01 01 01 01 01 01 01 41 41 21 01 01 01

01 01 01 01 41 41 21 01 01 01

01 01 01 01 41 41 21 01 01 01 01

01 01 01 01 21 21 21 01 01 01

01 01 01

21 21 01

yticapmA

A.tkC B.tkC A.tkC B.tkC A.tkC B.tkC A.tkC B.tkC

1 mumixaM

esuFlanretxE

2 dleiF

rekaerB.tkCro

rewoP

eziSeriW

1 Maximum size of the time delay fuse or HACR type circuit breaker for protection of field wiring conductors. 2 Based on 75°C copper wire. All wiring must conform to the National Electrical Code and all local codes. 3 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.

2 dnuorG

eziSeriW

Manual 2100-522B Page 6 of 38

FIGURE 1

UNIT DIMENSIONS

Manual 2100-522B Page 7 of 38

SHIPPING DAMAGE

Upon receipt of equipment, the carton should be checked for external signs of shipping damage. The skid must remain attached to the unit 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 and remove from the skid. Check unit wheels to ensure that wheels are locked before removing from skid. Extreme caution must be taken to prevent injury to personnel and damage to the unit.

It is recommended that the unit not be removed from the skid with a forklift since the air seal under the unit could be damaged. See Figure 2.

The shipping brackets on each side of the unit must be removed and discarded. See Figure 3-A. The return air grille panel can be removed to provide a place to hold

FIGURE 2

AIR SEAL UNDER QT

Air Seal

the unit. The unit can be slid forward on the skid until the front wheels hang over the edge of the skid. See Figure 3-B. The unit can be tipped forward and slid down the edge of the skid until the front wheels touch the ground. See Figure 3-C. The wheels will not roll. They are shipped from the factory locked so they will not roll. The back of the skid will have to be held down to keep it from tipping up. The skid can be slid out from under the unit. The unit can then be set upright.

UNIT

FIGURE 3

REMOVAL OF UNIT FROM SKID

Hold Skid Down

A Shipping Brackets B Front Wheels Over Edge

Manual 2100-522B Page 8 of 38

C Front Wheels On Floor

HANDLING UNIT AFTER REMOVAL FROM SKID

WARNING

Exercise extreme caution when pushing the unit on the rollers. Handle and push from the lower 1/3 of the unit. Insure that debris is not on the floor where the unit is to be moved on the rollers. Failure to do so could result in the unit tipping over and causing bodily injury and/ or damage to the unit.

The unit will have to be turned sideways and removed from the skid to fit through a 36" doorway. If the door height allows, the unit can be slid sideways through the door.

If the unit can not be slid through the door, then the unit will have to be put on a cart and tipped down to roll through the door. It is recommended that an appliance cart by used with a strap to hold the unit on the cart. The wheels of the unit must be locked. If the wheels were allowed to roll, the unit could roll off the cart. The unit should always be carted from the left side. This is the side where the compressor is located. See Figure 4.

The blade of the appliance cart should be slid under the wheels of the unit. The strap of the appliance cart should be placed around the unit and strapped tightly. Help will be required to tip the unit back onto the cart. The unit can be leaned far enough back to be rolled through the door. Be careful when setting the unit back up to keep from damaging the unit.

GENERAL

The equipment covered in this manual is to be installed by trained, experienced service and installation technicians. A QWS-Series wall sleeve supplied as a separate accessory must be ordered and installed with Q-Tec unit.

The unit is designed for use with or without duct work. For use without duct work, Plenum Box QPB42 is recommended.

These instructions explain the recommended method to install the air cooled self-contained unit and the electrical wiring connections to the unit.

These instructions and any instructions packaged with any separate equipment required to make up the entire 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.

APPLIANCE CART

COMPRESSOR

FIGURE 4

UNIT ON APPLIANCE CART

Q-TEC UNIT (Right Side)

STRAP

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 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.

MINIMUM INSTALLATION HEIGHT

The minimum installation height of the unit with a Free Blow Plenum is 8 ft. 6 in. This provides enough clearance for the plenum to be removed. See Figure 5.

The minimum installation height for ducted applications is 8 ft. 4½ in. This provides enough clearance to install the duct work. See Figure 6.

Manual 2100-522B Page 9 of 38

FIGURE 5

INSTALLATION WITH FREE BLOW PLENUM

FIGURE 6

DUCTED APPLICATION

Manual 2100-522B Page 10 of 38

DUCT WORK

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 Q-TEC series unit has provision to attach a supply air duct to the top of the unit. Duct connection size is 12 inches x 20 inches. The duct work is field supplied and must be attached in a manner to allow for ease of removal when it becomes necessary to slide the unit out from the wall for service. See Figure 7 for suggested attachment method.

The Q-T return (non-ducted) and either free blow with the use of QPB Plenum Box or a duct supply air system.

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

For hot water coil option a QPBHWxx-F for free blow or QPBHWxx-D for ducted airflow is used.

series units are designed for use with free

When used with a ducted supply, a QCX Cabinet Extension can be used to conceal the duct work above the unit to the ceiling. This extends 20" above the unit for a total height above the floor of 10'-7/8". 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 7. 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 1-inch throw away filters [(1) 16x16 and (1) 16x20] are supplied with each unit. The filters slide into filter brackets. Refer to Figure 8.

The filters are serviced from the inside of the building by opening the hinged door. This door is attached by a screw and one locking latch.

The internal filter brackets are adjustable to accommodate 2-inch filters. The tabs for the 1-inch filters must be bent down to allow the 2-inch filters to slide in place.

FIGURE 7

SUPPLY DUCT CONNECTIONS

SUPPLY DUCT TO BE FIELD SUPPLIED

ATTACHMENT SCREWS TO BE FIELD SUPPLIED

ROOM SIDE OF

EC UNIT

Q-T

DUCT FLANGE PROVIDED WITH UNIT

NOTE: Unit cabinet, supply air duct and free blow

plenum are approved for “0” clearance to combustible material.

FILTERS

RETURN AIR GRILLE

FIGURE 8

FILTER LOCATION

Manual 2100-522B Page 11 of 38

FRESH AIR INTAKE

This unit is equipped with a fresh air damper assembly. The damper blade is locked in the closed position when the unit is shipped from the factory. To allow the damper to operate remove the two plastic locking pins, one on each end of the blade. This will allow for maximum fresh airflow. The damper blade will now open when the indoor blower is operating. If less than maximum fresh airflow is required, reinsert the plastic pins to limit damper blade opening to desired level. Two extra pins are provided (taped to the inside of the assembly) which may be used to hold the blade in some position other than minimum or maximum position. This fresh air assembly is located in the rear of the unit and to gain access to make these adjustments remove the air filter service door.

All capacity, efficiency and cost of operation information as required for Department of Energy “Energyguide” Fact Sheets are based upon the fresh air blank-off plate in place and is recommended for maximum energy efficiency.

The blank-off plate is available upon request from the factory and is installed in place of the fresh air damper shipped with each unit.

For details on energy recovery ventilation see separate section.

SERVICE LIGHT

The unit is equipped with a service light, which signals the user that service is required. The light is located in the upper control panel and is visible only when the hinged service/filter access door is open.

The Service Unit light indicates that the unit has been shut off by a high or low pressure device. This indicates that the unit needs to be serviced.

CONDENSATE DRAIN

There are two drain connections on the unit. The rear drain is the primary drain, and is located on the right lower rear panel of the unit. The optional side drain is located on the bottom right side of the unit. The side drain is shipped with a plug installed.

The side drain requires a water trap for proper drainage. See Figure 9. The drain can be routed through the floor or through the wall. If the drain is to be routed through

an unconditioned space, it must be protected from freezing. The drain line must be able to be removed

from the unit if it is necessary to remove the unit from the wall. When the side drain is used, the plug must be removed and installed in the rear drain outlet.

The rear drain can be used with wall thickness of up to 10 inches where a water trap can be installed between the unit and the interior wall. See Figure 10. The trap cannot extend beyond the edge of the unit or it will interfere with the wall mounting bracket. The drain can be routed through the floor or through the wall. If the drain is routed through the wall, the drain line must be positioned such that it will not interfere with the sleeve flange or the grille. See Figure 11. If the drain is to be

routed through an unconditioned space, it must be protected from freezing.

OPTIONAL REAR DRAIN KITS

Optional Rear Drain Kit, Bard Model QCDS48A, is also available for these products. The optional rear drain kit offers multiple benefits that include the following:

• Allows unit to be rolled away from the sleeve without having to disconnect any hard plumbing connections.

• Allows indoor coil condensate to be easily connected to Rear Drain Box while bypassing the outdoor coil drain pan. This aids in minimizing the potential for biological growth to occur by minimizing the standing water and exposing it to warm temperatures.

See Figures 12A, 12B, 12C and 12D.

The drain box permanently mounts onto the wall sleeve and is then either piped directly outdoors, or can be piped vertically. The Q-Tec unit is then equipped with fittings on the rear of the unit that slide into the drain box as it is wheeled towards the wall sleeve.

NOTE: On models equipped with a refrigerant subcooler in the lower drain pan may experience a 23% decrease in cooling performance and efficiency when the indoor condensate is routed around the outdoor coil drain pan/subcooler assembly. Unit rated performance and efficiency are with the indoor condensate routed to the outdoor coil pan.

There is also a heated version of the rear drain box available (Model #QCDS48H) for installation in northern climates where freezing may occur.

SEPARATE EVAPORATOR DRAIN CONNECTION (OPTIONAL)

A knockout is provided in the back right corner of the units for use when draining the evaporator drain pan separately from the condenser. This knockout is 5 inches above the back condenser drain opening. To utilize a separate evaporator drain connection remove the knockout and route the existing evaporator drain hose out this knockout and then to an appropriate drain line.

Manual 2100-522B Page 12 of 38

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