Bard Q36H1, Q30H1, Q48H1, Q60H1, Q42H1 User Manual

...

INSTALLATION INSTRUCTIONS

Q-TEC SERIES PACKAGED HEAT PUMP

Models: Q24H1 Q30H1 Q36H1 Q42H1 Q48H1 Q60H1

Bard Manufacturing Company, Inc. Bryan, Ohio 43506

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

Manual: 2100-519C Supersedes: 2100-519B File: Vol. II Tab 14 Date: 02-17-12

Manual 2100-519C Page 1 of 42

CONTENTS

Getting Other Information and Publications

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

Q-TEC General Information

EC Model Nomenclature ......................................... 4

Q-T

Shipping Damage ......................................................... 7

Unit Removal From Skid .............................................. 7

Handling Unit After Removal From Skid ....................... 8

General ......................................................................... 8

Minimum Installation Height ......................................... 8

Duct Work .................................................................. 10

Filters .......................................................................... 10

Fresh Air Intake .......................................................... 11

Service Light ............................................................... 11

Condensate Drain ...................................................... 11

Optional Rear Drain Kits............................................. 11

Installation Instructions

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

Wiring — Main Power ................................................. 19

Wiring — Low Voltage Wiring ..................................... 19

Low Voltage Connections ........................................... 20

Figures

Figure 1 Unit Dimensions .......................................... 6

Figure 2 Air Seal on Bottom of Unit ........................... 7

Figure 3 Removal of Unit From Skid ......................... 7

Figure 4 Unit on Appliance Cart for Moving ............... 8

Figure 5 Installation With Free Blow Plenum ............ 9

Figure 6 Ducted Application ....................................... 9

Figure 7 Supply Duct Connections .......................... 10

Figure 8 Filter Location ............................................ 10

Figure 9 Optional Side Drain ................................... 12

Figure 10 Standard Rear Drain .................................. 12

Figure 11 Rear Drain (Top View) ............................... 12

Figure 12A Figure 12B Figure 12C Figure 12D

Figure 13A Unit Mounting - Method 1 .......................... 17

Figure 13B Unit Mounting - Method 2 .......................... 17

Figure 14 Removing Locking Screws from Wheels ... 18

Figure 15 Component Location ................................. 19

Figure 16 Thermostat Plug Terminals ........................ 21

Figure 17A T-Stat Wiring Diagram "X" Option .............. 22

Figure 17B T-Stat Wiring Diagram "X" Option w/Demand 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 ....................... 31

Figure 22 QERV Removal ......................................... 32

Figure 23 CO

Figure 24 Defrost Control Board ................................ 35

Figure 25 Control Disassembly ................................. 39

Figure 26 Winding Test .............................................. 39

Figure 27 Drip Loop ................................................... 39

Figure 28 Fan Blade Setting ...................................... 40

Optional Rear Drain Kit ............................. 13

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

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

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

Controller ........................................... 33

Start Up

R-410A Refrigerant Required ........................................ 27

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

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

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

Optional CFM (Q36, Q42, Q48 & Q60 Only) ................. 28

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

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

Three Phase Scroll Compressor Start Up

Information ................................................................ 28

Service Hints .................................................................. 29

Mist Eliminator Service .................................................. 29

Vent Options .................................................................. 30

Sequence of Operation .................................................. 33

Optional Climate Controls Sequence

of Operation .............................................................. 33

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

Defrost Cycle ................................................................. 34

Troubleshooting

Solid State Heat Pump Control Troubleshooting

Procedure ...................................................................... 36

Checking Temperature Sensor ...................................... 37

Troubleshooting GE ECM™ Blower Motors............. 38-39

Fan Blade Setting Dimensions ...................................... 40

Refrigerant Charge ........................................................ 40

Pressure Charts ...................................................... 41 - 42

Tables

Table 1 Factory Built-In Electric Heat Table .............. 4

Table 2 Electrical Specifications ................................ 5

Table 3 Operating Voltage Range ........................... 19

Table 4 Wall Thermostats ........................................ 21

Table 5 Troubleshooting .......................................... 36

Table 6 Temperature vs Resistance of

Temperature Sensor ................................... 37

Table 7 Fan Blade Dimensions ............................... 40

Table 8 Indoor Blower Performance ........................ 40

Table 9 Cooling Pressure ........................................ 41

Table 10 Heating Pressure ........................................ 42

Manual 2100-519C Page 2 of 42

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 2100-519C Page 3 of 42

Q-T

Series General Information

Q-TEC MODEL NOMENCLATURE

Q 36 H 1–A 10 X X V X X X

MODEL NUMBER

Q - Q-TEC

CAPACITY |

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

sledoM

HEAT PUMP

REVISION

SPECIAL UNITS |

L - Low Ampacity Circuit

VOLTS & PHASE |

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

FILTER OPTIONS

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

VENTILATION OPTIONS

X - Barometric Fresh Air Damper (Standard) B - Blank-off Plate V - Commercial Ventilator - Motorized w/Exhaust

Spring Return

P - Commercial Ventilator - Motorized w/Exhaust

Power Return

R - Energy Recovery Ventilator w/Exhaust

X - 1-Inch Fiberglass

(Standard) F - 2-Inch Fiberglass P - 2-Inch Pleated

COLOR OPTIONS

V - Platinum w/Slate

Front (Vinyl) X - Beige paint 4 - Gray paint

CLIMATE CONTROL OPTIONS

X - None A - Electronic/Non Prog/Man C/O D - Electronic/Prog/Man/Auto H - Electronic/Prog/Man/Auto with CO

COIL OPTIONS

X - Standard

NTERNAL CONTROLS

X - Standard

• High Pressure Switch

• Low Pressure Switch

• Compressor Time Delay E - Low Ambient Control Q - Outdoor Thermostat R - Low Ambient Control &

Outdoor Thermostat

TABLE 1

FACTORY BUILT-IN ELECTRIC HEAT TABLE

A-1H63Q

A-1H42Q A-1H03QB-1H42QB-1H03QC-1H42QC-1H03Q

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

A-1H24Q A-1H84Q A-1H06Q

B-1H63Q B-1H24Q B-1H84Q B-1H06Q

C-1H63Q C-1H24Q C-1H84Q C-1H06Q

WKHUTBHUTBHUTBHUTBHUTBHUTBHUTBHUTBHUTBHUTBHUTBHUTBHUTB

0.5083,61092,21 083,61092,21

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

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

0.01076,23075,42 076,23075,42

0.21000,14007,03000,14

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

Manual 2100-519C Page 4 of 42

TABLE 2

ELECTRICAL SPECIFICATIONS

tiucriCelgniS tiucriClauD

ledoM

Z0A-1H42Q 50A 01A Z0B-1H42Q 60B 90B Z0C-1H42Q 60C 90C Z0A-1H03Q 50A 01A Z0B-1H03Q 60B 90B 21B Z0C-1H03Q 60C 90C 21C Z0A-1H63Q 50A 01A

4 51A

Z0B-1H63Q 60B 90B

5 51B

Z0C-1H63Q 60C 90C

5 51C

Z0A-1H24Q 50A 01A

4 51A

Z0B-1H24Q 60B 90B

5 51B

Z0C-1H24Q 60C 90C

5 51C

Z0A-1H84Q 50A 01A

4 51A

Z0B-1H84Q 60B 90B

5 51B

Z0C-1H84Q 60C 90C

5 51C

Z0A-1H06Q 1 54 06 8 01 - - - - - - - 50A 01A

5 51A

Z0B-1H06Q 1 13 54 8 01 - - - - - - - 90B

5 51B

Z0C-1H06Q 1 71 52 01 01 - - - - - - - 90C

5 51C

detaR

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 1

3-064 1

3 muminiM

dleiF.oN rewoP stiucriC

1 1

2ro1 1 1 1 1 1 1 1 1

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

2ro1

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

2ro1

2ro1 1 1 1 1 1 1 1 1 1

2ro1

2ro1 1 1 1 1 1 1 1 1

2ro1

1 mumixaM

tiucriC

yticapmA

22 74 27 71 53 44 01 91 32 52 05 57 81 73 54 55 21 12 52 03 13 65 18 38 52 34 25 35 21 12 62 72 43 95 48 48 52 34 25 35 31 22 62 72 83 36 88 88 92 74 65 65 51 42 82 82

07 59 59

85 85

13 13

03 05 08 02 53 54 51 02 52 53 05 08 52 04 54 06 51 52 52 03 54 06 09 09 03 05 06 06 51 52 03 03 05 06 09 09 53 05 06 06 51 52 03 03 05 07 09 09 04 05 06 06 02 52 03 03

06 06

53 53

2 dleiF

esuFlanretxE

.rkrB.tkCro

001 001

2 dnuorG

rewoP

eziSeriW

01 8 4

21 8 8

01 8 8 4

01 8 8 6

01 8 6 4 4

01 8 6 6

01 8 6 4 4 8 8 6 6

01 8 6 3 3 8 8 6 6

01 4

3 3

6 6

8 8

8 8 8

3 muminiM

tiucriC

eriW

01 01

21 01 01 41 21 01 01 01

01 01 01 01 41 01 01 01 01 01

01 01 01 01 41 01 01 01 01

01 01 01 01 21 01 01 01

01 01

yticapmA

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

43 43

83 83 83

54 54 54

1 mumixaM

esuFlanretxE

05 05

52 05 05

05 05

2 dleiF

rekaerB.tkCro

rewoP

eziSeriW

8 8

8 8 8

2 dnuorG

eziSeriW

8 8

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.

4 Maximum KW that can operate with heat pump on is 10KW. Other 5KW energizes during emergency heat only. 5 Maximum KW that can operate with heat pump on is 9KW. Other 6KW energizes during emergency heat only.

Manual 2100-519C Page 5 of 42

FIGURE 1

Q24H1

UNIT DIMENSIONS

Q30H1

Q36H1

Q48H1

Q42H1

Q60H1

Manual 2100-519C Page 6 of 42

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.

FIGURE 2

AIR SEAL UNDER QT

Air Seal

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 the unit. The unit can be slid forward on the skid until

REMOVAL OF UNIT FROM SKID

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.

FIGURE 3

Hold Skid Down

A Shipping Brackets B Front Wheels Over Edge C Front Wheels On Floor

Manual 2100-519C Page 7 of 42

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 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.

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 cannot 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 be 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.

FIGURE 4

UNIT ON APPLIANCE CART

Q-TEC UNIT (Right Side)

STRAP

APPLIANCE CART

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.

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.

COMPRESSOR

Manual 2100-519C Page 8 of 42

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.

FIGURE 5

INSTALLATION WITH FREE BLOW PLENUM

FIGURE 6

DUCTED APPLICATION

Manual 2100-519C Page 9 of 42

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 Q-TEC series heat pump 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.

FIGURE 7

SUPPLY DUCT CONNECTIONS

SUPPLY DUCT TO BE FIELD SUPPLIED

ATTACHMENT

SCREWS TO

BE FIELD

SUPPLIED

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

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 air flow up to the maximum ESP shown in Table 9. 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 T-25 torx 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 8

FILTER LOCATION

ROOM SIDE

EC UNIT

OF 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.

The Q-T

series heat pumps are designed for use with free 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.

Manual 2100-519C Page 10 of 42

FILTERS

RETURN AIR GRILLE

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 Page 30.

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. See Page 33 for details.

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 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.

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.

Manual 2100-519C Page 11 of 42

FIGURE 9

OPTIONAL SIDE DRAIN (SIDE VIEW)

INSTALLATION

Q-TEC UNIT

FIGURE 10

STANDARD REAR DRAIN

SLEEVE

WATER TRAP

FIGURE 11

REAR DRAIN (TOP VIEW)

DRAIN LINE

WALL (MAXIMUM 10" FOR REAR DRAIN)

COUPLINGS NOT SHOWN BUT RECOMMENDED FOR EASE OF REMOVABILITY FOR SERVICE.

WALL BRACKET

Manual 2100-519C Page 12 of 42

UNIT

WALL SLEEVE

MIS-2469

FIGURE 12A

OVERFLOW TUBE

CAULK AROUND TUBE

DRAIN BOX

Manual 2100-519C Page 13 of 42

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