Bard QC501 User Manual

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QC SERIES INSTALLATION CHILLED WATER UNIT

INSTRUCTIONS

Model: QC501

MIS-1554

Bard Manufacturing Company	Manual No.:	2100-416C
Bryan, Ohio 43506	Supersedes:	2100416B
Since 1914...Moving ahead, just as planned.	File:	Vol II Tab 14
Since 1914...Moving ahead, just as planned.	Date:	12-22-03
	Date:	12-22-03

CONTENTS

Getting Other Information and Publications
For more information, contact these publishers: .....	1
QC General Information
QC Model Nomenclature .........................................	2
Shipping Damage ....................................................	5
Unit Removal From Skid ..........................................	5
Handling Unit After Removal From Skid ..................	5
Removal of Wall Bracket from Shipping Location ...	6
General ....................................................................	6
Minimum Installation Height ....................................	6
Duct Work ................................................................	9
Filters .......................................................................	9
Condensate Drain ..................................................	10
Mist Eleminator Service ..........................................	11

Figures
Figure 1	Unit Dimensions .....................................	4
Figure 2	Removal of Unit From Skid ....................	5
Figure 3	Proper Handling of Unit After Removal
	from Skid ................................................	6
Figure 4	Installation of Unit w/Wall Sleeve ..........	7
Figure 5	Installation With Free Blow Plenum .......	8
Figure 6	Ducted Application .................................	8
Figure 7	Supply Duct Connections ......................	9
Figure 8	Filter Location ........................................	9
Figure 9A	Side Drain (Side View) .........................	10
Figure 9B	Optional Rear Drain .............................	10
Figure 9C	Rear Drain (Top View) ..........................	10
Figure 10	Fresh Air Damper Removal .................	12
Figure 11	Removal of QTEC ERV .........................	13
Figure 12	Remove Locking Screws from Wheels 14
Figure 13	Unit Mounting Without Wall Sleeve .....	15
Figure 14	Component Location ............................	16
Figure 15	Low Voltage Wire Harness Plug ..........	18
Figure 16	Remote Thermostat Wiring "X" Option	19
Figure 17	Remote Thermostat Wiring "D" Option	20
Figure 18	Internal 2-Way Valve Piping .................	24
Figure 19	Internal 3-Way Valve Piping .................	25

Installation Instructions
Mounting the Unit ..................................................	14
Wiring – Main Power .............................................	17
Wiring – Low Voltage Wiring .................................	17
General Information ...............................................	17
Fluid Connections ..................................................	17
Low Voltage Connections ......................................	18
Start Up
Optional CFM ........................................................	21
Important Installer Note .........................................	21
Service Hints .........................................................	21
Sequence of Operation ..........................................	21
Troubleshooting ECM Blower Motors .............	22-23

Tables
Table 1	Factory Built-In Electric Heat ...................	2
Table 2	Electrical Specifications ...........................	2
Table 2A	Cooling Performance Chart ......................	3
Table 3	Operating Voltage Range .......................	17
Table 4	Wall Thermostats and Subbase
	Combinations .........................................	17
Table 5	Indoor Blower Performance ...................	21

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 Residential ......	ACCA Manual J
Winter and Summer
Air Conditioning
Duct Design for Residential .............	ACCA Manual D
Winter and Summer Air Conditioning
and Equipment Selection
Closed-Loop/Ground Source Heat Pump ........		IGSHPA
Systems Installation Guide
Grouting Procedures for Ground-Source ........		IGSHPA
Heat Pump Systems

Soil and Rock Classification for the Design ... IGSHPA of Ground-Coupled Heat Pump Systems

Ground Source Installation Standards .............

IGSHPA

Closed-Loop Geothermal Systems – Slinky ... IGSHPA

Installation Guide

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 Refrigerating,

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

IGSHPA International Ground Source

Heat Pump Association

490 Cordell South

Stillwater, OK 74078-8018

Manual 2100-416

Page 1

Climate Control

X - None

D - Electronic/prog/man/auto

QC SERIES WATER SOURCE GENERAL INFORMATION

QC MODEL NOMENCLATURE

QC 50 1 – A

Model Number

QC - QTec™ Model

Revision

Capacity

50 - 4 ton

Volts & Phase

A - 230/208-60-1

K - 115-60-1

NOTE 1: Electric heat available for -A models only

Filter Options

Valve Options

X - 1 Inch Fiberglass

0Z - 0KW

(Standard)

4 -

2-way valve

05 - 5 KW

F - 2 Inch Fiberglass

5 -

3-way valve

10 - 10KW

P - 2 Inch pleated

15 - 15KW

Internal Controls

(Note 1)

X - None

Color

V - Platinum w/Slate

Front (vinyl)

4 - Gray Paint

Ventilation Option

B - Blank Off Plate (no ventilation)

X - Barometric Fresh Air Damper (no exhaust) V - Commercial Ventilator (w/Exhaust)

P - Commercial Ventilator (w/Exhaust)

Motorized, Power Return

R - Energy Recovery Ventilator (w/Exhaust) - 230/208-60-1 versions only

TABLE 1

FACTORY BUILT-IN ELECTRIC HEAT TABLE

Models		QC501-A

	240V-1		208V-1

KW	BTUH		BTUH
5.0	16,380		12,290

10.0	32,670		24,570
15.0	49,150		36,860

TABLE 2

ELECTRICAL SPECIFICATIONS

Single Circuit

Dual Circuit

Maximum

External

No.

Maximum

Minimum

Fuse or

Field

External

Field

Circuit

Power

Ground

Rated

Field

Minimum

Fuse or

Power

Ground

Ampacity

Breaker

Wire Size

Volts &

Power

Circuit

Wire

CKT

Phases

Circuits

Ampacity

Breaker

Size

Models

QC501-A0Z

–

-A05

230/208-1

–

-A10

–

-A15

1 or 2

QC501-K0Z

115-1

–

QMaximum size of the time delay fuse or HACR type circuit breaker for protection of field wiring conductors.

RBased on 75° C copper wire. All wiring must conform to the National Electrical Code and all local codes.

SThese “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.

Manual 2100-416

Page 2

TABLE 2A

COOLING PERFORMANCE CHART

			BTUH Capacity (1000)			BTUH Capacity (1000)				Water Coil
										Water Coil
				Stage 1			Stage 1 and 2			Pressure Drop

GPM	EWT	CFM	Total	Sensible	Latent	Total		Sensible	Latent	PSIG	Ft. Hd.
6			15.1	10.5	4.6	38.5		25.3	13.2	1.9	4.4
8	42	1000	16.4	11.1	5.3	41.5		26.8	14.7	3.3	7.5

10			17.4	11.7	5.7	43.2		27.4	15.8	4.9	11.3

6			13.9	10.0	3.9	35.8		24.2	11.6	1.9	4.4
8	44	1000	15.1	10.6	4.5	38.4		25.4	13.0	3.3	7.5

10			16.0	11.1	4.9	40.0		26.0	14.0	4.9	11.3
6			12.8	9.6	3.2	33.0		23.0	10.0	1.9	4.4

8	46	1000	13.9	10.1	3.8	35.3		24.0	11.3	3.3	7.5

10			14.7	10.6	4.1	36.9		24.6	12.3	4.9	11.3
6			11.6	9.1	2.5	30.3		21.9	8.4	1.9	4.4

8	48	1000	12.6	9.6	3.0	32.2		22.6	9.6	3.3	7.5

10			46.6	10.0	3.3	33.7		23.2	10.5	4.9	11.3
6			15.9	11.5	4.4	42.1		29.0	13.1	1.9	4.4

8	42	1200	17.4	12.2	5.2	46.0		30.6	15.4	3.3	7.5
10			18.8	12.8	6.0	49.3		31.9	17.4	4.9	11.3

6			14.8	11.1	3.7	39.3		27.7	11.6	1.9	4.4

8	44	1200	16.2	11.7	4.5	42.7		29.2	13.5	3.3	7.5
10			17.4	12.3	5.1	45.6		30.4	15.2	4.9	11.3

6			13.6	10.7	2.9	36.4		26.5	9.9	1.9	4.4

8	46	1200	14.9	11.3	3.6	39.5		27.9	11.6	3.3	7.5

10			16.1	11.7	1.1	42.0		29.0	13.0	4.9	11.3

6			12.5	10.3	2.2	33.6		25.2	8.4	1.9	4.4
8	48	1200	13.7	10.8	2.9	36.2		26.5	9.7	3.3	7.5

10			14.7	11.2	3.5	38.3		27.5	10.8	4.9	11.3

Manual 2100-416

Page 3

416-2100 Manual

4 Page

FIGURE 1

UNIT DIMENSIONS

FIGURE 2

REMOVAL OF UNIT FROM SKID

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 fork lift.

The shipping brackets on each side of the unit must be removed and discarded. See Figure 2-A on Page 5. 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 the front wheels hang over the edge of the skid. See Figure 2-B. The unit can be tipped forward and slid down the edge of the skid until the front wheels touch the ground. See Figure 2-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.

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 blade of the appliance cart should be slid under the wheels of the unit. See Figure 3. 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.

HOLD SKID DOWN

MIS-1603

A SHIPPING BRACKETS

B FRONT WHEELS OVER EDGE

C FRONT WHEELS ON FLOOR

Manual 2100-416

Page 5

FIGURE 3

PROPER HANDLING OF UNIT

AFTER REMOVAL FROM SKID

QTEC UNIT

(RIGHT SIDE)

STRAP

APPLIANCE

CART

REMOVAL OF WALL BRACKET FROM SHIPPING LOCATION

The wall brackets are attached to the back of the unit. Remove and retain the wall brackets for use when attaching the unit to the wall. In those installations where a wall sleeve is required these two wall brackets are to be discarded. A different style bracket is supplied with the sleeve assembly.

GENERAL

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

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

These instructions explain the recommended method to install the water source 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 1 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. 4-1/2 in. This provides enough clearance to install the duct work. See Figure 6.

Manual 2100-416

Page 6

FIGURE 4

INSTALLATION OF UNIT THRU WALL WITH WALL SLEEVE

MIS-1564

Manual 2100-416

Page 7

FIGURE 5

INSTALLATION WITH FREE BLOW PLENUM

CEILING

MIS-1558

FLOOR

FIGURE 6

DUCTED APPLICATION

20 IN.

SUSPENDED

FIXED CEILING

DUCT

	MINIMUM	CEILING
	MINIMUM	DUCT FLANGE
		DUCT FLANGE

FLOOR	MIS-1559

Manual 2100-416

Page 8

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 air flow 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 QTEC 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.

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

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”. See Optional Accessories, Page 18 for the correct Cabinet Extension model number. 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 5. 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 are supplied with each unit. The filters fit into a fixed rack.

The filters are serviced from the inside of the building . To gain access to the filters release the latch on the circuit breaker door and one 1/4 turn fastener near the bottom of the door. This door is hinged on the left so it will swing open.

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

FILTERS

ROOM SIDE

OF QC UNIT

	MIS-978	DUCT FLANGE
	MIS-978	PROVIDED WITH UNIT
		PROVIDED WITH UNIT

The QTEC series units 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. RETURN AIR GRILLE

The QPB Plenum Box mounts on top of the unit and has both vertically and horizontally adjustable louvers on the front discharge grille. See Optional Accessories, Page 18, for the correct Plenum Box model number.

FIGURE 8

FILTER LOCATION

Manual 2100-416

Page 9

CONDENSATE DRAIN

The condensate drain hose is routed down from the evaporator drain pan on the right side of the unit into the compressor compartment. There are three locations that the drain can exit the cabinet. For a stand pipe type of drain, the drain hose can exit the rear of the cabinet. There is adequate hose length to reach the floor on the right hand side of the unit.

If the drain is to be hard plumbed, there is a 3/4 inch pipe connection located on the right hand cabinet side near the rear and one on the cabinet rear panel. In these installations the drain tube is to be slipped over the pipe connection inside of the cabinet.

FIGURE 9A

SIDE DRAIN (SIDE VIEW)

QTEC UNIT

MIS-976

See Figures 9A, 9B and 9C.

NOTE: Whichever type of drain connection is used a “P” trap must be formed.

The side drain requires a water trap for proper drainage. See Figure 8A. 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.

FIGURE 9C

REAR DRAIN (TOP VIEW)

DRAIN LINE

WALL (MAXIMUM 10”

FOR REAR

DRAIN)

SLEEVE

COUPLINGS NOT

SHOWN BUT

RECOMMENDED

FOR EASE OF

REMOVABILITY

FOR SERVICE

WATER
TRAP	WALL
	BRACKET

FIGURE 9B

OPTIONAL REAR DRAIN

UNIT

MIS-977

MIS-974

Manual 2100-416

Page 10

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 8B. 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 9C on Page 10. If the drain is to be routed through an unconditioned space, it must be protected from freezing.

MIST ELIMINATOR SERVICE (Optional – only used with one of the vent options)

A mist eliminator is supplied with the wall sleeve. The mist eliminator is constructed of aluminum frame and mesh. The mist eliminator is located in the top section of the wall sleeve and can be removed from the inside of the building without removing the unit from the wall. This requires that the ventilation package must be removed.

The steps necessary to remove each of the vent options are listed following.

It is recommended that the mist eliminator be inspected annually and serviced as required. The mist eliminator can be inspected from the outside of the building by looking through the outdoor grille. The mist eliminator can be serviced from the outside. The outdoor grille must be removed to do so.

The mist eliminator can be cleaned by washing with soap and water. The excess water should be shaken off the mist eliminator before it is reinstalled.

BAROMETRIC FRESH AIR DAMPER (Optional)

Before start to remove make sure the power has been turned off. The hinged return air grille panel must be opened. The fresh air damper assembly can be seen on the back of the unit. Refer to Figure 10.

1.The fresh air damper is attached to the back of the unit with one screw on either side of the assembly. Both of the screws must be removed.

2.Once the mounting screws are removed, tilt the assembly down and lift it out.

The mist eliminator can be seen through the opening. The mist eliminator must be raised up and the bottom can be pulled toward the front of the unit.

COMMERCIAL ROOM VENTILATOR OPTION

Before stating the removal make sure the power has been turned off. The hinged return air grille must be opened. The commercial room ventilator (CRV) can be seen after the panel has been removed. The CRV must be removed to gain access to the mist eliminator.

1.The two mounting screws in the front of the CRV must be removed.

2.The power connectors for the CRV (located on the right side of the unit) must be disconnected. Squeeze the tabs on the sides of the connector and pull straight out. Unplug both of the connectors.

3.Slide the CRV straight out of the unit.

The mist eliminator can be seen through the opening in the back of the unit. The mist eliminator must be raised up and the bottom can be pulled toward the front of the unit and removed.

Manual 2100-416

Page 11

FIGURE 10

FRESH AIR DAMPER REMOVAL

MOUNTING SCREW

MIS-1627

Manual 2100-416

Page 12

QTEC ENERGY RECOVERY VENTILATOR OPTION

Before starting the removal make sure that the power has been turned off. The hinged return air grille panel must be opened. The energy recovery ventilator (QERV) can be seen after the panel is opened. To gain access to the mist eliminator, the QERV must be removed. Refer to Figure 11

1.The front fill plate of the QERV must be removed. There is one screw on either side of the plate. Remove these screws and remove the plate.

2.On either side of the QERV there are mounting screws that hold the QERV in place. Remove both of these screws.

3.Underneath the heat recovery cassette there is a power connector for the lower blower assembly. To disconnect this plug, the tabs on both sides of the plug must be squeezed to release the plug. While squeezing the tabs, pull the plug out of the socket.

4.The QERV is plugged into the unit on the right side of the unit. Both of these plugs must be disconnected to remove the QERV. Squeeze the tabs on the sides of the connector and pull straight out.

5.Slide the QERV assembly straight out of the unit being careful not to let the cassette slide out of the QERV.

The mist eliminator can be seen through the opening in the back of the unit. The mist eliminator must be raised up and the bottom can be pulled toward the front of the unit and removed.

FIGURE 11

REMOVAL OF THE QTEC ENERGY RECOVERY VENTILATOR

POWER

CONNECTORS

MOUNTING

SCREWS

LOWER BLOWER

ASSEMBLY POWER

CONNECTOR

FRONT FILL

MIS-1605

Manual 2100-416

Page 13

INSTALLATION INSTRUCTIONS

MOUNTING THE UNIT

When installing a QC unit near an interior wall on the left side, a minimum of 8 inches is required; 12 inches is preferred.

When installing a QC unit near an interior wall on the right side, a minimum of 12 inches is required as additional space is required to connect the drain.

This clearance is required to allow for the attachment of the unit to the wall mounting brackets and the side trim pieces to the wall.

This unit is to be secured to the wall with the wall mounting brackets provided. The unit itself, the supply duct, and the free blow plenum are suitable for “0” clearance to combustible material.

NOTE: When a wall sleeve is to be used discard the brackets shipped with the heat pump and attache the unit to the sleeve with bracket supplied with the wall sleeve.

Following are the steps for mounting the QC units for reference see Figure 13.

1.Attach wall mounting bracket to the structure wall with field supplied lag bolts. The fluid piping connections are to be within the confines of this bracket. See Figure 1 for cabinet openings and location of fluid coil connection points.

2.Position the unit in front of the wall mounting bracket.

3.Remove the locking screws from the wheels. Refer to Figure 11.

4.Roll the unit up to the wall mounting bracket. The unit must be level from side to side. If any adjustments are necessary, shim up under the rollers with sheets of steel or any substance that is not affected by moisture.

5.Secure the unit to the wall bracket with provided #10 hex head sheet metal screws. There are prepunched holes in the cabinet sides, and the bracket has slotted holes to allow for some misalignment.

6.Position the bottom trim piece to the unit and attach with provided screws (dark colored).

7.Position side trim pieces to the wall and attach with field supplied screws. There are two long and two short pieces supplied. The long pieces are to enclose the gap behind the unit. The short pieces are to fill the gap behind the cabinet extension or the free blow plenum box. They may be cut to suit the ceiling height or overlap the unit side trim. There is sufficient length to trim up to a 10’2” ceiling.

FIGURE 12

REMOVING LOCKING SCREWS FROM WHEELS

MIS-1523

REMOVE SCREWS FROM WHEELS BEFORE ROLLING INTO PLACE

Manual 2100-416

Page 14

FIGURE 13

UNIT MOUNTING WITHOUT VENTILATION WALL SLEEVE (REFER TO MOUNTING INSTRUCTIONS ON PAGE 13)

SIDE TRIM

(2 PIECES)

SIDE TRIM (2

PIECES)

WALL MOUNTING

BRACKET

MIS-1557

BOTTOM TRIM PIECE	BOTTOM TRIM
	EXTENSION

Manual 2100-416

Page 15

FIGURE 14

COMPONENT LOCATION

SIDE FIELD

WIRE ENTRANCE

REMOTE THERMOSTAT

TERMINAL BLOCK

INDOOR BLOWER

CONTROL BOX/ CIRCUIT

BREAKER PANEL

MIS-1736

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”. 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.

Manual 2100-416

Page 16

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.

The disconnect access door on this unit may be locked to prevent unauthorized access to the disconnect.

The field wiring connections are located behind the top panel in the circuit breaker panel. The return air panel must be removed first. This panel is equipped with a door switch which shuts the unit down when it is removed. The filter rack must be removed next.

The Climate Control Option D is an electronic, programmable thermostat. The subbase of the thermostat is factory wired to the front panel of the unit. Compatible for use with Energy Recovery Ventilator or Economizer.

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.

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 Climate Control Option X is a remote thermostat connection terminal block. See Figure 17 for wiring diagram. Compatible thermostats are listed in Table 4.

CAUTION

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

FLUID CONNECTIONS

See Figure 1 for location of fluid connection. Connection size is 1” FPT.

If the free blow plenum box is to be used, there are knock outs in the top of the box that can be removed to allow passage of the fluid piping.

All plumbing to and from the unit is to be installed in accordance with local plumbing codes. The use of plastic pipe where permissible is recommended to prevent electrolytic corrosion of the fluid pipes.

It is strongly recommended that the fluid piping to the unit be insulated to prevent water droplets from condensing on the pipe surface.

TABLE 4

WALL THERMOSTATS AND SUBBASE COMBINATIONS

Thermostat	Subbase	Predominant Features
8403-049	N/A	Manual / Auto / Heat / Cool
(IF93-380)	N/A	Programmable Electronic
(IF93-380)		Programmable Electronic

Manual 2100-416

Page 17

LOW VOLTAGE CONNECTIONS

These units use a grounded 24 volt AC low voltage circuit.

The “R” terminal is the hot terminal and the “C” terminal is grounded.

“G” terminal or pins 6 and 1 of P2 are the fan inputs. Both must be energized for proper fan operation. This is done automatically in the factory installed climate control options. If the climate control option is abandoned and connections are made directly to P2 both pins 6 and 1 of P2 must be energized for proper operation.

“Y” terminal or pin 7 of P2 is the first stage cooling input.

“B” terminal or pin 8 of P2 is the first stage heating input.

“R” terminal or pin 10 of P2 is 24 VAC hot.

“C” terminal or pin 11 of P2 is 24 VAC grounded.

“L” terminal or pin 12 of P2 is the second stage cooling input.

“W2” terminal or pin 9 of P2 is second stage heating output.

“O1” terminal of pin 5 of P2 is the ventilation input. This terminal energizes any factory installed ventilation option.

LOW VOLTAGE CONNECTIONS FOR

DDC CONTROL

Fan Only	Energize G
1st Cooling Mode	Energize Y, G
2nd Cooling Mode	Energize Y, L, G
1st Stage Heating	Energize G, B
2nd Stage Heating	Energize G, B, W2
Ventilation	Energize G, O1

FIGURE 15

BLOWER MOTOR LOW VOLTAGE

WIRE HARNESS PLUG

VIEWED FROM PIN END	VIEWED FROM PIN END

MIS-1285

Manual 2100-416

Page 18

FIGURE 16

REMOTE THERMOSTAT WIRING DIAGRAM

“X” OPTION

IF93-380

MIS-1734

Manual 2100-416

Page 19

FIGURE 17

REMOTE THERMOSTAT WIRING DIAGRAM

“D” THERMOSTAT OPTION

IF93-380

4102-028

Manual 2100-416

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START UP

OPTIONAL CFM

These units are shipped from the factory set to operate at the optional CFM level shown in Table 4. This provides lower operating sound levels for non-ducted, free discharge applications. This CFM level will reduce the system capacity performance by approximately 2% at the same energy efficiency.

Rated CFM is required for ducted applications for maximum performance rating. To obtain full CFM on these models, connect jumper wire as follows:

1.Disconnect all power to the unit. Failure to do so may result in damage to the motor.

2.Open hinged return air grille panel

3.Open control panel cover.

4.Add pink jumper wire (provided) to terminal 5 and 6 on the terminal board.

5.Reverse steps to reassemble.

IMPORTANT INSTALLER NOTE

For improved start up performance, wash the indoor coil with dishwashing detergent.

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 air flow through the system which shortens equipment service life as well as increasing operating costs and noise levels.

2.The wall thermostat 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.

SEQUENCE OF OPERATION

FIRST STAGE COOLING – Circuit R-Y makes the thermostat open the first stage cooling water valve.

SECOND STAGE COOLING – Circuit R-Y2 make the thermostat open the second stage cooling water valve. 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.

Caution: Second stage cooling must always be energized in conjunction with first stage. If the second state were energized alone, the condensate from the upper part of the coil could be blow off or re-evaporated as it passes down over the dry portion of the coil.

HEATING – A thermostat demand for heating makes R-W1 circuit as well as R-G circuit. This starts the indoor blower as well as turns on the electric heater.

SECOND STAGE HEATING (15 KW only) – Circuit R-W2 energizes the second contactor and brings on the last 5 KW of heat.

TABLE 5

INDOOR BLOWER PERFORMANCE

	RATED	1	2	3	4	CFM @ MAX.
	RATED			OPTIONAL	CONTINUOUS	CFM @ MAX.
MODEL	ESP	MAX. ESP	RATED CFM	CFM	CFM	ESP
QC501	0.0	0.8	1200	1000	1000	1175

NOTE: These units are equipped with a variable speed (ECM) indoor motor that automatically adjusts itself to maintain approximately the same rate of indoor air flow in both heating and cooling, dry and wet coil conditions, and at both 230/208 or 460 volts.

j Maximum ESP (inches WC) shown is with 1” thick disposable filter (reduced by .2 for 2” filter).

k Rated CFM for ducted applications – required for maximum performance rating. To obtain full CFM locate low voltage terminal strip in the circuit breaker box.There is a pink jumper wire with both ends attached to terminal marked “G2”. Move one end of the jumper to terminal“Y”.

l Optional CFM – the unit is shipped from the factory set to operate at the optional CFM level shown. This provides lower operating sound levels for non-ducted, free discharge applications. This reduces system capacity performance by approximately 2% at the same energy efficiency.

m Continuous fan CFM is the total air being circulated during continuous fan mode.

Manual 2100-416

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TROUBLESHOOTING ECM BLOWER MOTORS

CAUTION

Disconnect power from unit before removing or replacing connectors, or servicing motor. Wait at least 5 minutes after disconnection power before opening motor.

SYMPTOM

Motor rocks slightly when starting.

Motor won't start

% No movement

%Motor rocks, but wo'nt start

Motor oscillates up and down while being tested off of blower

%Noisy blower of cabinet

%"Hunts" or "puffs" at high CFM (speed)

Evidence of Moisture

CAUSE / PROCEDURE

%This is normal start-up for ICM

%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

%Run Mositure Check

%Check for loose or compliant motor mount

%Make sure blower wheel is tight on shaft

%It is normal for motor to oscillate with no load on shaft.

%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

%Does removing panel or filter reduce "puffing"?

–Reduce restiction

–Reduce maximum airflow

% Motor failure of malfunction has occured and		%	Replace motor and perform Moisture Check
%	moisture is present	%	Perform Moisture Check
%	Evidence of moisture present inside air mover	%	Perform Moisture Check
DO		DON'T
%	Check out motor, controls, wiring and connections	%	Automatically assume the motor is bad
	thoroughly before replacing motor
%	Orient connectors down so water ca'nt get in;	% Locate connectors above 7 and 4 o'closk postions
	install "drip loops"
%	Use authorized motor and control model numbers	%	Replace one motor of control model number with another
	for replacement		(unless an authorized replacement)
%	Keep static pressure to a minimum:	%	Use high pressure drop filters. Some have 1/2" H O drop!
			2
	– Recommend high efficiency, low static filters	%	Use restricted returns

–Recommend keeping filters clean

–Design duct work for minimum static, maximum comfort

–Look for and recommend duct work improvement,where necessary, in replacement.

Manual 2100-416

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SYMPTOM		CAUSE / PROCEDURE
Motor starts but runs erratically
%	Varies up and down or intermittent	%	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 speed
			applications
		%	Check out system controls - thermostat?
		%	Perform Moisture Check
%	"Hunts" or puffs" at high CFM (speed)	%	Does removing panel or filter reduce "puffing"?
			–	Reduce restriction
			–	Reduce maximum airflow

%Stays at low CFM despite sysstem call for cool or % Check low voltage (thermostat) wires and connections heat CFM

%Verify fan is not in dalay mode - wait until delay is complete

%"R" missing / not connected at motor Perform motor / control replacement check

% Stays at high CFM	%	"R" missing / not connected at motor
	% Is fan in dalay mode? - wait until delay time complete
% Blower won't shut off	% Current leakage from controls into G, Y or W?
		–	Check for Triac switched thermostat or solid state
			relay
SYMPTON	CAUSE / PROCEDURE
Excessive noise	%	Determine if it is air noise, cabinet, duct or motor noise .
		Interview customer if necessry.
% Air Noise	%	High static creating high blower speed?
		–	Is airflow set properly?
		–	Does removing filter cause blower to slow down?
			Check / replace filter
		–	Use low pressure drop filter
		–	Check / correct duct restirctions

%Size the equpment wisely

%Check orientation before inserting motor connectors

DON'T

%Oversize system then compensate with low airflow

%Plug in power connector backwards

%Force plugs

MOISTURE CHECK PROCEDURE		COMFORT CHECK PROCEDURE
%	Connectors are oriented "down"	%	Check proper airflow settings
%	Arrange harnesses with "drip loop" under motor	%	Low static pressure for lowest noise
%	Condenste drain plugged?	%	Set low continuous fan CFM
% Check for low airflow (too much latent capacity)		%	Use humidistat and 2-speed cooling units
%	Check for undercharged condition	%	Use zoning controls designed for ICM that regulate CFM
%	Check and plug leaks in reutrn ducts and cabinet	%	Thermostat in bad location?