Bard QH243, QH602, QH482, QH422, QH302 User Manual

INSTALLATION INSTRUCTIONS

QTEC SERIES PACKAGED HEAT PUMP

Models: QH243 QH302 QH362 QH422 QH482 QH602

Bard Manufacturing Company, Inc. Bryan, Ohio 43506

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

Manual: 2100-420H Supersedes: 2100-420G File: Vol II Tab 14 Date: 06-28-07

Manual 2100-420H Page 1 of 34

CONTENTS

Getting Other Information and Publications

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

EC General Information

QT

QTEC 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

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

Service Light ............................................................... 13

Installation Instructions

Mounting the Unit ....................................................... 14

Wiring — Main Power ................................................. 15

Wiring — Low Voltage Wiring ..................................... 15

Low Voltage Connections ........................................... 16

Start Up

Description of Standard Equipment ............................... 21

Optional CFM (QH362, QH422, QH482 & QH602 Only) ..... 21

Important Installer Note.................................................. 21

Phase Monitor ................................................................ 21

Three Phase Scroll Compressor Start Up

Information ................................................................ 21

Service Hints .................................................................. 22

Mist Eliminator Service .................................................. 22

Vent Options .................................................................. 23

Sequence of Operation .................................................. 26

Optional Climate Controls Sequence

of Operation .............................................................. 26

Pressure Service Ports .................................................. 26

Defrost Cycle ................................................................. 27

Troubleshooting

Solid State Heat Pump Control Troubleshooting

Procedure ...................................................................... 29

Checking Temperature Sensor ...................................... 29

Troubleshooting GE ECM™ Blower Motors............. 30-31

Fan Blade Setting Dimensions ...................................... 32

Refrigerant Charge ........................................................ 32

Pressure Charts ...................................................... 33 - 34

Figures

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

Figure 2 Air Seal on Bottom of 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 ................................... 12

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

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

Figure 12 Unit Mounting ............................................ 13

Figure 13 Removing Locking Screws from Wheels ... 14

Figure 14 Component Location ................................. 15

Figure 15 Thermostat Plug Terminals ........................ 17

Figure 16 Thermostat Wiring Diagram "X" Option .... 18

Figure 17 Thermostat Wiring Diagram "A" Option .... 19

Figure 18 Thermostat Wiring Diagram "D" Option ... 20

Figure 19 Fresh Air Damper Removal ....................... 24

Figure 20 QERV Removal ......................................... 25

Figure 21 Heat Pump Control Board ......................... 26

Figure 22 Low Pressure Control Bypass Timer ......... 27

Figure 23 Control Disassembly ................................. 31

Figure 24 Winding Test .............................................. 31

Figure 25 Drip Loop ................................................... 31

Figure 26 Fan Blade Setting ...................................... 32

Tables

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

T

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

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

Table 3 Operating Voltage Range ........................... 15

Table 4 Wall Thermostats ........................................ 17

Table 5 Troubleshooting .......................................... 28

Table 6 Temperature vs Resistance of

Temperature Sensor ................................... 29

Table 7 Fan Blade Dimensions ............................... 32

Table 8 Super Heat at Compressor ......................... 32

Table 9 Indoor Blower Performance ........................ 32

Table 10 Cooling Pressure ........................................ 33

Table 11 Heating Pressure ........................................ 34

Manual 2100-420H Page 2 of 34

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 2100-420H Page 3 of 34

QT

EC

Series General Information

QTEC MODEL NOMENCLATURE

QH 36 2 – A 10 X X X X X X

MODEL NUMBER |

QH - QTEC Model

CAPACITY |

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

sledoM

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

FILTER OPTIONS

X - 1-Inch Fiberglass

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

REVISION |

SPECIAL UNITS |

L - Low Ampacity Circuit

VOLTS & PHASE |

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

KW

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

TABLE 1

FACTORY BUILT-IN ELECTRIC HEAT TABLE

A-342HQ A-203HQB-342HQB-203HQC-342HQC-203HQ

COLOR OPTIONS

V - Platinum w/Slate

Front (Vinyl)

4 - Gray paint

COIL OPTIONS

X - Standard

I

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

CLIMATE CONTROL OPTIONS

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

A-263HQ A-224HQ A-284HQ A-206HQ

B-263HQ B-224HQ B-284HQ B-206HQ

C-263HQ C-224HQ C-284HQ C-206HQ

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 2100-420H Page 4 of 34

TABLE 2

ELECTRICAL SPECIFICATIONS

TIUCRICELGNISTIUCRICLAUD

4

5

3

DETAR

SLEDOM

Z0A-342HQ 50A01A-

Z0B-342HQ 60B90B-

Z0C-342HQ 60C90C-

Z0A-203HQ 50A01A-

Z0B-203HQ 60B90B21B-

Z0C-203HQ 60C90C21C-

Z0A-263HQ 50A01A-

-

51A Z0B-263HQ

60B90B-

-

51B Z0C-263HQ

60C90C-

-

51C

&STLOV SESAHP

1-802/032

3-802/032

3-064

1-802/032

3-802/032

3-064

3-802/032

3-064

.ON

DLEIF

REWOP

STIUCRIC

1 1

2RO1

1 1 1

1 1

2RO1

1 1 1 1

1 1

2RO1 2RO1

1 1 1 1

MUMINIM TIUCRIC

22 74 27

71 53 44

8

71 22

42 94 47

81 63 54 45

9

81 32 72

92 45 97 28

32 14 05 25

11 02 42 62

1

YTICAPMA

03 05 08

02 53 54

51 02 52

53 05 08

52 04 54 06

51 02 52 03

54 06 09 09

03 54 05 06

51 02 03 03

2

MUMIXAM

LANRETXE ROESUF TIUCRIC

REKAERB

EZIS

01 8 4

21 8 8

41

21

01 8

8 4

01 8 8 6

41

21

01

01 8

6 4 4

01 8 8 6

41

21

01

2

DLEIF

REWOP

ERIW

EZIS

01 01

8

21 01 01

41 21 01

01 01

8

01 01 01 01

41 21 01 01

01

01 8 8

01

41

21

01

3

MUMINIM TIUCRIC

DNUORG

YTICAPMA

TKC

A

B

--

22

05

--

42

05

--

92

05

23

05

--

1

MUMIXAM

ROESUF

TIUCRIC

TKC

A

B

--

03

05

--

03

05

--

04

05

04

05

--

2

LANRETXE

REKAERB

TKC

DLEIF

REWOP

TKC

A

B

--

01

8

--

01

8

--

8

--

2

DNUORG

EZISERIW

TKC

EZISERIW

TKC

A

B

--

01

--

01

--

01

--

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

ELECTRICAL SPECIFICATIONS CONTINUED ON PAGE 6 TABLE 2A

Manual 2100-420H Page 5 of 34

4

5

4

5

4

5

TABLE 2A

ELECTRICAL SPECIFICATIONS

(Continued)

TIUCRICELGNISTIUCRICLAUD

3

.ON

DETAR

LEDOM

Z0A-224HQ 50A01A-

-

51A Z0B-224HQ

60B90B-

-

51B Z0C-224HQ

60C90C-

-

51C Z0A-284HQ

50A01A-

-

51A Z0B-284HQ

60B90B-

-

51B Z0C-284HQ

60C90C-

-

51C Z0A-206HQ

50A01A51A-

Z0B-206HQ 90B51B-

Z0C-206HQ 90C51C-

&STLOV

ESAHP

1-802/032

3-802/032

3-064

1-802/032

3-802/032

3-064

1-802/032

3-802/032

3-064

DLEIF

REWOP

STIUCRIC

1 1

2RO1 2RO1

1 1 1 1

1 1

2RO1 2RO1

1 1 1 1

1

2ro1 2ro1 2ro1

1 1 1

MUMINIM TIUCRIC

33 85 38 38

42 34 25 25

21 12 62 62

63 16 68 68

62 44 35 35

41 32 72 72

64 17 69 69

13 85 85

71 03 03

1

YTICAPMA

05 06 09 09

03 05 06 06

51 52 03 03

05 07 09 09

04 05 06 06

51 52 03 03

06 08

011 011

54 07 07

52 53 53

2

MUMIXAM

LANRETXE ROESUF TIUCRIC

REKAERB

ERIW

EZIS

8 6 4 4

01 8 6 6

41

01

01 8

6 3 3

8 8 6 6

41

01

01 8

4 3 3

8 6 6

01 8 8

2

DLEIF

REWOP

ERIW

EZIS

01

01 8 8

01

41

01

01 8 8 8

01

41

01

01 8 6 6

01 8 8

01

3

MUMINIM

DNUORG

TIUCRIC

YTICAPMA

TKC

A

B

--

33

05

33

05

--

63

52

63

05

63

05

--

64

52

64

05

64

05

--

1

MUMIXAM

ROESUF

TIUCRIC

REKAERB

TKC

A

B

--

04

05

04

05

--

05

52

05

--

06

52

06

05

06

05

--

2

LANRETXE

TKC

DLEIF

REWOP

EZISERIW

TKC

A

B

--

8

--

8

01

8

--

8

01

8

--

2

DNUORG

EZISERIW

TKC

A

TKC

B

--

01

--

01

--

01

--

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

Manual 2100-420H Page 6 of 34

FIGURE 1

UNIT DIMENSIONS

Manual 2100-420H Page 7 of 34

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

EC

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 2100-420H Page 8 of 34

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 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.

FIGURE 4

UNIT ON APPLIANCE CART

QTEC UNIT

(Right Side)

STRAP

APPLIANCE CART

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.

MINIMUM INSTALLATION HEIGHT

COMPRESSOR

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 2100-420H Page 9 of 34

FIGURE 5

INSTALLATION WITH FREE BLOW PLENUM

FIGURE 6

DUCTED APPLICATION

Manual 2100-420H Page 10 of 34

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 QT 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.

EC

series heat pump has provision to attach a

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 1/4 turn fasteners 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 QT

DUCT FLANGE PROVIDED WITH UNIT

NOTE: Unit cabinet, supply air duct and free blow

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

The QTEC 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.

FILTERS

RETURN AIR GRILLE

Manual 2100-420H Page 11 of 34