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

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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

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

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

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

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

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

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

71 22

42 94 47

81 63 54 45

81 32 72

92 45 97 28

32 14 05 25

11 02 42 62

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

MUMIXAM

LANRETXE ROESUF TIUCRIC

REKAERB

EZIS

01 8 4

21 8 8

01 8

8 4

01 8 8 6

01 8

6 4 4

01 8 8 6

DLEIF

REWOP

ERIW

EZIS

01 01

21 01 01

41 21 01

01 01

01 01 01 01

41 21 01 01

01 8 8

MUMINIM TIUCRIC

DNUORG

YTICAPMA

TKC

MUMIXAM

ROESUF

TIUCRIC

TKC

LANRETXE

REKAERB

TKC

DLEIF

REWOP

TKC

DNUORG

EZISERIW

TKC

EZISERIW

TKC

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

TABLE 2A

ELECTRICAL SPECIFICATIONS

(Continued)

TIUCRICELGNISTIUCRICLAUD

.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

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

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

MUMIXAM

LANRETXE ROESUF TIUCRIC

REKAERB

ERIW

EZIS

8 6 4 4

01 8 6 6

01 8

6 3 3

8 8 6 6

01 8

4 3 3

8 6 6

01 8 8

DLEIF

REWOP

ERIW

EZIS

01 8 8

01 8 8 8

01 8 6 6

01 8 8

MUMINIM

DNUORG

TIUCRIC

YTICAPMA

TKC

MUMIXAM

ROESUF

TIUCRIC

REKAERB

TKC

LANRETXE

TKC

DLEIF

REWOP

EZISERIW

TKC

DNUORG

EZISERIW

TKC

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 2100-420H 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

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.

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

FRESH AIR INTAKE

CONDENSATE DRAIN

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.

FIGURE 9

OPTIONAL SIDE DRAIN (SIDE VIEW)

INSTALLATION

QTEC UNIT

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, both standard and heated versions, are available to facilitate easy installation, and also removability of heat pump for service. The standard version provides a connection that allows the evaporator condensate to drain independently bypassing the lower drain pan. Note that on models equipped with a refrigerant subcooler in the lower drain pan may experience a slight decrease in cooling performance and efficiency.

Manual 2100-420H Page 12 of 34

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

UNIT

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.

FIGURE 12

UNIT MOUNTING

SIDE TRIM (2 PCS.)

(LIGHT COLOR)

MOUNTING BRACKET

#8 SCREW PROVIDED

CABINET

SIDE PANEL

ENLARGED VIEW OF MOUNTING BRACKET SHOWING SLEEVE TO

CABINET ATTACHMENT

MOUNTING BRACKET

WALL SLEEVE

HEAD SCREW

PROVIDED

#10 HEX

BOTTOM TRIM PIECE

BOTTOM TRIM EXTENSION

Manual 2100-420H Page 13 of 34

INSTALLATION INSTRUCTIONS

MOUNTING THE UNIT

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

When installing a QTEC unit near an interior wall on the right side, a minimum of 18 inches is required as additional space is required to connect the side drain. If the rear condensate drain kit QCDS48 is used the minimum can be reduced to 8 inches.

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

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

Following are the steps for mounting the QTEC, for reference see Figure 12 (page 13).

1. Attach mounting brackets to the wall sleeve with screws provided.

2. Position the unit in front of the sleeve with the condenser section toward the sleeve.

3. Remove the locking screws from the wheels. Refer to Figure 13.

4. Roll the unit into the sleeve. Make sure to check both sides of the unit as it is being rolled to keep it centered in the sleeve. Also check the

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

5. Make sure the gasket on the rear of the unit is touching the sleeve across the top and down both sides. This is a rain water seal.

6. Secure the mounting brackets to the unit with screws provided, #10 hex head sheet metal screws.

7. Bottom trim extensions are provided for use when wall is less than 14 inches but greater than 10.5 inches. Secure to wall with screws (not provided).

8. Attach the bottom trim piece to the unit with the screws provided (dark colored).

9. Position side trim pieces to wall and attach with field supplied screws. There are two long pieces 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. The may be cut to suit your ceiling height or overlap the unit side trim. There is sufficient length to trip up to a 10'2" ceiling.

NOTE: If the exterior wall thickness is between 5

inches to 10.5 inches, a side trim extension

piece kit, model QSTX42, is available.

Manual 2100-420H Page 14 of 34

REMOVING LOCKING SCREWS FROM WHEELS

REMOVE SCREWS FROM

WHEELS BEFORE

ROLLING INTO PLACE

FIGURE 13

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.

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

FIGURE 14

COMPONENT LOCATION

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.

See Start Up section for information on three phase scroll compressor start-ups.

The field wiring connections are located behind the top and hinged panel in the circuit breaker panel. See Figure 14.

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

PATEGNAR

V042612–352 V802781–022

NOTE: The voltage should be measured at the filed

power connection point in the unit and while the unit is operating at full load (maximum amperage operating condition).

ELECTRIC HEATERS

UNIT MOUNTED THERMOSTAT LOCATION

DEHUMIDIFICATION CONTROL (OPTIONAL)

SIDE FIELD WIRE

ENTRANCE

REMOTE THERMOSTAT TERMINAL BLOCK

NDOOR

BLOWER

BREAKER PANEL

CIRCUIT

& CONTROLS

LOWER CONTROL PANEL

The standard Climate Control Option X is a remote thermostat connection terminal block. See Figure 16 for wiring diagram. Compatible thermostats are listed in Table 4.

The Climate Control Option A is an electronic, nonprogrammable manual or auto changeover thermostat. The subbase of the thermostat is factory wired to the front panel of the unit. See Figure 17 for wiring diagram. Compatible for use with Bard CS2000A1 Controller and Energy Recovery Ventilator.

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. See Figure 18 for wiring diagram. Compatible for use with Energy Recovery Ventilator or Economizer.

NOTE: On option X or A the CS2000A1 (or other field

provided means to control ventilation) must be used if any of the motorized ventilation options are installed.

Manual 2100-420H Page 15 of 34

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 compressor input.

“B” terminal or pin 8 of P2 is the reversing valve input.

The reversing valve must be energized for heating mode.

“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 compressor lockout

output

pressure trip by the electronic heat pump control. This is a 24 VAC output.

. This terminal is activated on a high or low

NOTE: For total and proper control using DDC, a total

of 6 controlled outputs are required (5 if no ventilation system is installed). For proper system operation under Emergency Heat conditions. Where the compressor needs to be deactivated, the B-W2-E outputs need to be energized. Removing the Y (compressor) signal alone turns the compressor off, but does not activate the additional circuitry embedded in the heat pump for proper and complete operation.

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“W2” terminal or pin 9 of P2 is second stage heat (if equipped). If the unit is equipped with an optional hot water coil plenum box or electric heat these will be energized by this terminal.

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

“E” terminal or pin 3 of P2 is the emergency heat input. This terminal energizes the emergency heat relay.

GENERAL

This unit is equipped with a variable speed ECM motor. The motor is designed to maintain rated airflow up to the maximum static allowed. It is important that the

blower motor plugs are not plugged in or unplugged while the power is on. Failure to remove power prior to unplugging or plugging in the motor could result in motor failure.

CAUTION

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

Manual 2100-420H Page 16 of 34

TABLE 4

WALL THERMOSTATS

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060-3048

)544-0211(

850-3048

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Manual 2100-420H Page 17 of 34

FIGURE 16

REMOTE THERMOSTAT WIRING DIAGRAM

“X” THERMOSTAT OPTION

NOTE: On option X or A the CS2000A1 (or other field

provided means to control ventilation) must be used if any of the motorized ventilation options are installed.

Manual 2100-420H Page 18 of 34

VENTILATOR OR DAMPER

FIGURE 17

UNIT MOUNTED THERMOSTAT WIRING DIAGRAM

“A” THERMOSTAT OPTION

NOTE: On option X or A the CS2000A1 (or other field

provided means to control ventilation) must be used if any of the motorized ventilation options are installed.

Manual 2100-420H Page 19 of 34

FIGURE 18

UNIT MOUNTED THERMOSTAT WIRING DIAGRAM

“D” THERMOSTAT OPTION

Manual 2100-420H Page 20 of 34

START UP

DESCRIPTION OF STANDARD EQUIPMENT

Solid State Electronic Heat Pump Control

Provides efficient 30-minute defrost cycle. A thermistor sensor and speed up terminal for service along with a 10- minute defrost override are standard on the electronic heat pump control.

High / Low Pressure Switch

Provides refrigerant circuit high pressure and loss of charge protection. Includes lockout circuit that is resettable from room thermostat.

Five Minute Compressor Time Delay

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

Service Lights

One service light indicates when service is required.

• Check System – detects high or low pressure switch operation for compressor protection.

OPTIONAL CFM (QH362, QH422, QH482 AND QH602 ONLY)

These units are shipped from the factory set to operate at the optional CFM level shown in Table 9. 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 return air service panel

3. Open inner control panel cover

4. Locate low voltage terminal strip. There is a pink jumper wire with both ends attached to terminal marked “G2”. Move one end of this jumper to terminal “Y”.

5. Reverse steps to reassemble.

IMPORTANT INSTALLER NOTE

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

PHASE MONITOR

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

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

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

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

THREE PHASE SCROLL COMPRESSOR START UP INFORMATION

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

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

verification of proper rotation must be made.

Verification of proper rotation direction is made by observing that suction pressure drops and discharge pressure rises when the compressor is energized. Reverse rotation also results in an elevated sound level over that with correct rotation, as well as, substantially reduced current draw compared to tabulated values.

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

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

Manual 2100-420H Page 21 of 34

SERVICE HINTS

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

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

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

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

g. Remove screws that attach the duct work to

the unit flanges.

This unit is equipped with four rollers mounted to the base. For ease of pulling unit out from the wall, you may want to remove the bottom service door which requires removal of the return air panel, and grip the front flange of the base pan then pull straight out.

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

a. Check to make sure that the drains are not

obstructed in any way.

b. Remove any debris in the condenser section of

the unit.

c. Inspect and clean mist eliminator as described

below.

d. Inspect and wash outdoor coil as necessary.

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

6. Some service requires the need to remove the unit from the wall including replacement of the indoor coil and/or the outdoor coil. Also, servicing the outdoor fan motor or fan blade will require removing the unit from the wall if the unit is installed at a height that is not easily accessible from the outside of the building.

In order to remove the unit from the wall the following procedure must be used:

a. Turn off power to the unit at the remote

location. Some units may have more than one power supply.

b. Disconnect field wiring at unit terminal block

and remove from unit.

c. Disconnect condensate drain.

d. Remove the lower skirting around the unit.

e. Remove wall mounting brackets from wall on

each side of the unit.

f. If unit is attached to duct work, remove upper

cabinet extension by removing the top center screw only from the cabinet side panel.

MIST ELIMINATOR SERVICE

A mist eliminator is supplied with the wall sleeve. The mist eliminator is constructed of an 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.

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 by using a vacuum cleaner. The outdoor grille must be removed. Use the vacuum to remove dirt and debris from the surface of the mist eliminator. If additional cleaning is required, the mist eliminator will have to be removed from the sleeve.

The ventilation package will have to be removed to gain access to the mist eliminator. If the blank off plate option is used, it is not necessary to service the mist eliminator. The steps necessary to remove each of the vent options are listed on the following pages.

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.

Manual 2100-420H Page 22 of 34

VENT OPTIONS

BAROMETRIC FRESH AIR DAMPER (Standard)

Before starting, make sure the power has been turned off. The return air grille panel must be removed. The fresh air damper assembly can be seen on the back of the unit. See Figure 19.

QTEC R ENERGY RECOVERY VENTILATOR (Option)

Before starting, make sure that the power has been turned off. The return air grille panel must be removed. The energy recovery ventilator (QERV) can be seen after the panel has been removed. To gain access to the mist eliminator, the QERV must be removed. See Figure 20.

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 starting, make sure the power has been turned off. The return air grille panel must be removed. 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.

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 in 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.

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 2100-420H Page 23 of 34

FIGURE 19

FRESH AIR DAMPER REMOVAL

MOUNTING SCREW

Manual 2100-420H Page 24 of 34

FIGURE 20

QERV REMOVAL

MOUNTING SCREWS

POWER

CONNECTORS

LOWER

BLOWER

ASSEMBLY

POWER

CONNECTOR

FRONT FILL

Manual 2100-420H Page 25 of 34

SEQUENCE OF OPERATION

Cooling – Circuit R-Y makes the thermostat pull in the compressor contactor starting the compressor and outdoor motor. The G (indoor motor) circuit is automatically completed on any call for cooling operation, or can be energized by manual fan switch on subbase for constant air circulation.

control has a bypass to eliminate nuisance lockout on cold start up.

The bypass timer should be set to 200 seconds and this is to assure there is no nuisance tripping of the lowpressure control during startup in heating mode under cold weather conditions. See Figure 22.

Heating – A 24V solenoid coil on the reversing valve controls heating cycle operation. Two thermostat options, one allowing “Auto” change over from cycle to cycle and the other constantly energizing solenoid coil during heating season and thus eliminating pressure equalization noise except during defrost, are to be used on “Auto” option, a circuit is completed for R-W1 and R-Y on each heating “on” cycle, energizing reversing valve solenoid and pulling in compressor contactor starting compressor and outdoor motor. R-G also makes starting indoor blower motor. Heat pump heating cycle now in operation.

The second option has no “Auto” change over position, but instead energizes the reversing valve solenoid constantly whenever the system switch on subbase is placed in “Heat” position, the “B” terminal being constantly energized from R. A thermostat demand for heat completes R-Y circuit, pulling in compressor contactor starting compressor and outdoor motor. R-G also make starting indoor blower motor.

High / Low Pressure control provides protection for the compressor. In the event system pressures go above 450 PSI or below 3.5 PSI in either cooling or heating mode, the compressor will be stopped. This will activate the red light located in the control panel. The lockout circuit will hold compressor off line. When the system problem is corrected, the unit operation can be restored by turning of the main power supply off and then back on, or reset the room thermostat. The low pressure

OPTIONAL CLIMATE CONTROLS SEQUENCE OF OPERATION

The Climate Control Option A is an electronic, nonprogrammable manual or auto changeover thermostat. The thermostat may be manually set to heat or cool mode. The thermostat will maintain the temperature set on the thermostat in the mode in which it is set.

The Climate Control Option D is an electronic, programmable thermostat. The thermostat can be set in the heat, cool or automatic mode. When the thermostat is set in the heat mode, it can heat only to maintain the temperature set on the thermostat. When the thermostat is set in the cool mode, it can cool only to maintain the temperature set on the thermostat. When the thermostat is set in the automatic mode, the thermostat can change automatically to the heat or cool modes to maintain the temperature set on the thermostat.

PRESSURE SERVICE PORTS

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

Manual 2100-420H Page 26 of 34

FIGURE 21

HEAT PUMP CONTROL BOARD (HPC)

DEFROST CYCLE

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

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

After 30 minutes at 30°F or below, the heat pump control will place the system in the defrost mode.

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

If some abnormal or temporary condition such as a high wind causes the heat pump to have a prolonged defrost cycle, the heat pump control will restore the system to heating operation automatically after 10 minutes.

There are three settings on the heat pump control – 30, 60 and 90-minute. Models are shipped wired on the 30minute setting for greatest operating economy. If special circumstances require a change to another time, remove wire connected to terminal 30 and reconnect to desired terminal. Refer to Figure 21. The manufacturer’s recommendation is for 30-minute defrost cycles.

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

FIGURE 22

LOW PRESSURE CONTROL BYPASS TIMER

Use a small screwdriver or other metallic object, or another 1/4 inch QC, to short between the SPEEDUP terminals to accelerate the HPC timer and initiate defrost. Be careful not to touch any other terminals with the instrument used to short the SPEEDUP terminals. It may take up to 10 seconds with the SPEEDUP terminals shorted for the speedup to be completed and the defrost cycle to start.

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

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

There is an initial defrost jumper (sen jmp) on the control that can be used at any outdoor ambient during the heating cycle to simulate a 0° coil temperature. This can be used to check defrost operation of the unit without waiting for the outdoor ambient to fall into the defrost region.

By placing a jumper across the SEN JMP terminals (a 1/4 inch QC terminal works best) the defrost sensor mounted on the outdoor coil is shunted out and will activate the timing circuit. This permits the defrost cycle to be checked out in warmer weather conditions without the outdoor temperature having to fall into the defrost region.

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

There is also a 5-minute compressor time delay function built into the HPC. This is to protect the compressor from short cycling conditions. In some instances, it is helpful to the service technician to override or speed up this timing period, and shorting out the SPEEDUP terminals for a few seconds can do this.

Manual 2100-420H Page 27 of 34

TROUBLESHOOTING

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TABLE 5

TROUBLESHOOTING

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Manual 2100-420H Page 28 of 34

SOLID STATE HEAT PUMP CONTROL TROUBLESHOOTING PROCEDURE

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

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

3. Turn thermostat blower to “auto” position. Indoor blower should stop. NOTE: Many models have a

1-minute blower time delay on “off” command; wait for this to time-out.

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

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

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

FR FR FR FR

0.52-

0.42-

0.32-

0.22-

0.12-

0.02-

0.91-

0.81-

0.71-

0.61-

0.51-

0.41-

0.31-

0.21-

0.11-

0.01-

0.9-

0.8-

0.7-

0.6-

0.5-

0.4-

0.3-

0.2-

0.1-

0.0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

0.01

0.11

0.21

178691 990091 585381 813771 982171 784561 409951 925451 553941 473441 675931 659431 605031 912621 980221 801811 272411 575011 010701 475301 062001 46079

18939 80019 93188

17358 99628

12108 23677 03257 01927 07607 70586 81466 99346 94426 56506 54785

0.31

0.41

0.51

0.61

0.71

0.81

0.91

0.02

0.12

0.22

0.32

0.42

0.52

0.62

0.72

0.82

0.92

0.03

0.13

0.23

0.33

0.43

0.53

0.63

0.73

0.83

0.93

0.04

0.14

0.24

0.34

0.44

0.54

0.64

0.74

0.84

0.94

0.05

CHECKING TEMPERATURE SENSOR

TABLE 6

58965 48255 04635

15025 41505 82094 09574 00264 55844 45534 59224 77014 89893 75783 25673 38563 84553 54543 47533 43623 32713 04803 68992 75192 55382 77572 32862 29062 38352 69642 03042 48332 85722 05122

16512 98902 53402 69891

1. Disconnect temperature sensor from board and from outdoor coil.

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

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

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

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

0.35

0.25

0.35

0.45

0.55

0.65

0.75

0.85

0.95

0.06

0.16

0.26

0.36

0.46

0.56

0.66

0.76

0.86

0.96

0.07

0.17

0.27

0.37

0.47

0.57

0.67

0.77

0.87

0.97

0.08

0.18

0.28

0.38

0.48

0.58

0.68

0.78

0.88

47391 76881 57381 98971 43471 48961 74561 22161 01751 01351

12941 44541 77141 02831 47431 73131 01821 29421 38121 38811

19511 70311

13011 26701

10501 74201 00001 0679 6259 9929 7709 2688 3568 9448 0528 7508 9687 6867

0.98

0.09

0.19

0.29

0.39

0.49

0.59

0.69

0.79

0.89

0.99

0.001

0.101

0.201

0.301

0.401

0.501

0.601

0.701

0.801

0.901

0.011

0.111

0.211

0.311

0.411

0.511

0.611

0.711

0.811

0.911

0.021

0.121

0.221

0.321

0.421

7057 4337 5617 0007 0486 3866

1356 3836 9326 8906

1695 7285 7965 0755 6445 6235 8025 4905 2894 3784 7674 3664 2654 4644 7634 4724 2814 3904 6004

1293 8383 7573 8763

1063 6253 2543

Manual 2100-420H Page 29 of 34

TROUBLESHOOTING GE ECM

™

MOTORS

CAUTION:

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

Symptom Cause/Procedure

Motor rocks slightly • This is normal start-up for ECM when starting

Motor won’t start • Check blower turns by hand

• No movement

• Motor rocks, • Check for loose or compliant motor mount but won’t start

Motor oscillates up • It is normal for motor to oscillate with no load & down while being on shaft tested off of blower

Motor starts, but runs erratically

• Varies up and down • Check line voltage for variation or “sag”

or intermittent • Check low voltage connections

• “Hunts” or “puffs” at • Does removing panel or filter reduce

high CFM (speed) “puffing”?

• Stays at low CFM • Check low voltage (Thermostat) wires and

despite system call connections for cool or heat CFM • Verify fan is not in delay mode; wait until

• Stays at high CFM • “R” missing/not connected at motor

• Blower won’t shut off •

• Check power at motor

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

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

• Check for unseated pins in connectors on motor harness

• Test with a temporary jumper between R - G

• Check motor for tight shaft

• Perform motor/control replacement check

• Perform Moisture Check

• Make sure blower wheel is tight on shaft

• Perform motor/control replacement check

(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

- Reduce restriction

- Reduce max airflow

delay complete

• “R” missing/not connected at motor

• Perform motor/control replacement check

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

• Perform motor/control replacement check

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

Symptom Cause/Procedure

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

• “Hunts” or “puffs” at • Does removing panel or filter reduce high CFM (speed)

Evidence of Moisture

• Motor failure or • Replace motor and malfunction has occurred and moisture is present

• Evidence of moisture • Perform Moisture Check

present inside air mover

• High static creating high blower speed?

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

- Check for cabinet/duct deformation

“puffing”?

- Reduce restriction

- Reduce max. airflow

Perform Moisture Check

Do Don’t

• Check out motor, controls, • Automatically assume the motor is bad.

wiring and connections thoroughly before replacing motor

• Orient connectors down so • Locate connectors above 7 and 4 o’clock

water can’t get in positions

- Install “drip loops”

• Use authorized motor and • Replace one motor or control model # with

model #’s for replacement another (unless an authorized replacement)

• Keep static pressure to a • Use high pressure drop filters some have

minimum: H20 drop!

- Recommend high • Use restricted returns

efficiency, low static filters

- Recommend keeping filters

clean.

- Design ductwork for min.

static, max. comfort

- Look for and recommend

ductwork improvement, where necessary

• Size the equipment wisely • Oversize system, then compensate with low

airflow

• Check orientation before • Plug in power connector backwards

inserting motor connectors • Force plugs

½"

Moisture Check

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

manufacturer)

• Arrange harness with “drip loop” under motor

• Is condensate drain plugged?

• Check for low airflow (too much latent capacity)

• Check for undercharged condition

• Check and plug leaks in return ducts, cabinet

Comfort Check

• Check proper airflow settings

• Low static pressure for lowest noise

• Set low continuous-fan CFM

• Use humidistat and 2-speed cooling units

• Use zoning controls designed for ECM that regulate CFM

• Thermostat in bad location?

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

• Air noise • High static creating high blower speed?

motor noise; interview customer, if necessary

- Is airflow set properly?

- Does removing filter cause blower to slow down? Check filter

- Use low-pressure drop filter

- Check/correct duct restrictions

Manual 2100-420H Page 30 of 34

TROUBLESHOOTING GE ECM

™

MOTORS CONT’D.

Replacing ECM Control Module

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

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

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

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

3. It is usually not necessary to remove the motor from the blower assembly. However, it is recommended that the whole blower assembly, with the motor, be removed from the furnace/air handler. (Follow the manufacturer’s procedures). Unplug the two cable connectors to the motor. There are latches on each connector. DO NOT PULL ON THE WIRES. The plugs remove easily when properly released.

4. Locate the two standard housing (at the back end of the control opposite the shaft end). Refer to Figure 23. Remove these two bolts from the motor and control assembly while holding the motor in a way that will prevent the motor or control from falling when the bolts are removed. If an ECM2.0 control is being replaced (recognized by an aluminum casting rather that a deep-drawn black steel can housing the electronics), remove only the hex-head bolts. DO NOT REMOVE THE TORX-HEAD

SCREWS.

5. The control module is now free of mechanical attachment to the motor endshield but is still connected by a plug and three wires inside the control. Carefully rotate the control to gain access to the plug at the control end of the wires. With thumb and forefinger, reach the latch holding the plug to the control and release it by squeezing the latch tab and the opposite side of the connector plug and gently pulling the plug out of the connector socket in the control. DO NOT PULL

ON THE WIRES. GRIP THE PLUG ONLY.

6. The control module is now completely detached from the motor. Verify with a standard ohmmeter that the resistance from each motor lead (in the motor plug just removed) to the motor shell is >100K ohms. Refer to Figure 24. (Measure to unpainted motor end plate.) If any motor lead fails this test, do not proceed to install the control module. THE MOTOR IS DEFECTIVE AND MUST BE REPLACED. Installing the new control module will cause it to fail also.

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

USING THE WRONG CONTROL WILL RESULT IN IMPROPER OR NO BLOWER OPERATION. Orient the control

module so that the 3-wire motor plug can be inserted into the socket in the control. Carefully insert the plug and press it into the socket until it latches. A SLIGHT CLICK WILL BE HEARD WHEN PROPERLY INSERTED. one of the three following paragraphs, 8a, 8b or 8c.

8a. IF REPLACING AN ECM 2.0 CONTROL (control in cast

aluminum can with air vents on the back of the can) WITH AN ECM

2.3 CONTROL (control containing black potting for water protection in black deep-drawn steel case with no vents in the bottom of the can), locate the two through-bolts and plastic tab that are packed with the replacement control. Insert the plastic tab into the slot at the perimeter of the open end of the can so that the pin is located on the inside of the perimeter of the can. Rotate the can so that the tab inserts into the tab locater hole in the endshield of the motor. Using the two throughbolts provided with the replacement control, reattach the can to the motor.

THE TWO THROUGH-BOLTS PROVIDED WITH THE REPLACEMENT ECM 2.3 CONTROL ARE SHORTER THAN THE BOLTS ORIGINALLY REMOVED FROM THE ECM 2.0 CONTROL AND MUST BE USED IF SECURE ATTACHMENT OF THE CONTROL TO THE MOTOR IS TO BE ACHIEVED.

DO NOT OVERTIGHTEN THE BOLTS.

¼" hex head bolts at the rear of the control

Finish installing the replacement control per

8b. IF REPLACING AN ECM 2.3 CONTROL WITH AN ECM

2.3 CONTROL, the plastic tab and shorter through-bolts are not needed. The control can be oriented in two positions 180° apart. MAKE SURE

THE ORIENTATION YOU SELECT FOR REPLACING THE CONTROL ASSURES THE CONTROL'S CABLE CONNECTORS WILL BE LOCATED DOWNWARD IN THE APPLICATION SO THAT WATER CANNOT RUN DOWN THE CABLES AND INTO THE CONTROL. Simply orient the new control to the motor's

endshield, insert bolts, and tighten. DO NOT OVERTIGHTEN THE BOLTS.

8c. IF REPLACING AN ECM 2.0 CONTROL WITH AN ECM 2.0

CONTROL (It is recommended that ECM 2.3 controls be used for all

replacements), the new control must be attached to the motor using through bolts identical to those removed with the original control. DO

NOT OVERTIGHTEN THE BOLTS.

9. Reinstall the blower/motor assembly into the HVAC equipment.

Follow the manufacturer's suggested procedures.

10. Plug the 16-pin control plug into the motor. The plug is keyed.

Make sure the connector is properly seated and latched.

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

FAILURE OF THE CONTROL MODULE.

12.

Final installation check. Make sure the motor is installed as follows: a. Unit is as far INTO the blower housing as possible. b.Belly bands are not on the control module or covering vent holes. c. Motor connectors should be oriented between the 4 o’clock and 8

o’clock positions when the blower is positioned in its final location and orientation.

d.Add a drip loop to the cables so that water cannot enter the motor

by draining down the cables. Refer to Figure 25.

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

Back of Control

Figure 24

Figure 4

Winding Test

Figure 25

Figure 5

Drip Loop

Connector Orientation

Between 4 and 8 o'clock

Drip Loop

Motor OK when R > 100k ohm

Only remove Hex Head Bolts

ECM 2.0

Note: Use the shorter bolts and alignment pin supplied when replacing an ECM 2.0 control.

Control Disassembly

Push until Latch Seats Over Ramp

ECM

2.3/2.5

Hex-head Screws

Figure 23

Figure 3

From Motor

Circuit Board

Motor

Motor Connector (3-pin)

Control Connector

(16-pin) Power Connector (5-pin)

Motor Connector (3-pin)

Manual 2100-420H Page 31 of 34

FAN BLADE SETTING DIMENSIONS

REFRIGERANT CHARGE

Any service work requiring removal or adjustment in the fan and/or motor area will require that the dimensions in Table 7 be checked and blade adjusted in or out of the motor shaft accordingly.

FIGURE 26

FAN BLADE SETTING

TABLE 7

FAN BLADE DIMENSIONS

ANOISNEMID

LEDOM

342HQ 203HQ 263HQ 224HQ 284HQ 206HQ

)SEHCNI(

057.

The correct system R-22 charge is shown on the unit rating plate. Optimum unit cooling performance will occur with a refrigerant charge resulting in a Super Heat as shown in Table 8. If correct charge is in doubt, recover the refrigerant and recharge per the charge on the unit rating plate.

TABLE 8

SUPER HEAT AT COMPRESSOR

ledoM

342HQ00881-6161-41 203HQ000181-6171-51 263HQ002181-6161-41 224HQ002112-9181-61 284HQ004152-3242-22 206HQ05519-751-31

detaR

MFC

DO°59

erutarepmeT

DO°28

erutarepmeT

TABLE 9

INDOOR BLOWER PERFORMANCE

ledoM

342HQ

203HQ51.8.000010001019 263HQ51.8.00021000100015711 224HQ51.8.00021000100015711 284HQ51.8.00041001100115711 206HQ02.5.00551052105210041

NOTE: These units are equipped with a variable speed (ECM) indoor motor that automatically adjust itself to

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

2 Rated CFM for ducted applications – required for maximum performance rating. To obtain full CFM on models QH362, QH422,

3 Optional CFM – the unit is shipped from the factory set to operate at the optional CFM level shown. This provides lower

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

5 Model QH243 – when operating on 2nd stage heating the indoor air will increase to 1000 CFM.

maintain approximately the same rate of indoor airflow in both heating and cooling, dry and wet coil conditions and at both 230/208 or 460 volts.

QH482 and QH602 connect the pink jumper wire (provided) to terminal #G2 and #Y on the low voltage terminal block located in the circuit breaker box.

operating sound levels for non-ducted, free discharge applications. This reduces system capacity performance by approximately 2% at the same energy efficiency.

PSEdetaR

01.5.0008008007

PSE.xaM

lanoitpO

MFCdetaR

MFC

suounitnoC

MFC

@MFC

xaM

PSE.

Manual 2100-420H Page 32 of 34

TABLE 10

COOLING PRESSURE

(ALL TEMPERATURES IN DEGREES F)

NRUTER

RIA

LEDOM

342HQ

203HQ

263HQ

224HQ

284HQ

206HQ

Low side pressure ± 2 psig High side pressure ± 5 psig

Tables are based upon rated CFM (airflow) across the evaporator coil. If there is any doubt as to correct operating charge being in the system, the charge should be removed, system evacuated and recharged to serial plate instructions.

.PMETERUSSERP

BD57

BW26

BD08

BW76

BD58

BW27

BD57

BW26

BD08

BW76

BD58

BW27

BD57

BW26

BD08

BW76

BD58

BW27

BD57

BW26

BD08

BW76

BD58

BW27

BD57

BW26

BD08

BW76

BD58

BW27

BD57

BW26

BD08

BW76

BD58

BW27

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1 LIOCROODTUOGNIRETNEERUTAREPMETRIA

5708580959001501011511

37 591

87 302

57 622

08 822

68 832

47 212

97 912

58 322

642 57

57 822

732 96

442 47

052 77

952

37 991

87 402

121

312 57

202 08

332

68 042

47 512

97 022

58 822

842 67

152

162

122

342 28

262

732 67

442 28

252 07

062 57

762 87

672

47 412

97 912

58 822

67 242

842 78

752 57

332 08

932 68

742

27 462

77 072

38 972

27 252

67 062

28 962

772 67

482 97

492

67 922

08 432

68 442

77 852

28 462

88 372

752 78

762 37

87 882

48 892

27 072

77 672

38 582

27 492

77 203

08 313

77 442

28 052

88 952

87 372

38 082

98 092

152

962

28 672

88 682

182

992 97

703 58

813 37

782 87

492

48 403

37 313

233

97 952

48 462

98 472

97 913

48 692

09 603

87 782

38 492

98 503

57 813

08 723

68 033

47 503

97 213

58 323

47 233

123 18

28 353

08 472

58 082

092 08

303 58

113 19

323 97

503 48

213 09

423 67

933

943 78

163

57 323

133

68 243

57 253

143

163

38 473

982 78

692 39

503

913 68

723 29

933 08

323 58

133 19

343 77

263 28

173

88 483

57 343

153

68 363

67 273

283 48

593

38 403

88 213

49 023

28 533

78 343

39 653

18 143

68 053

29 363

97 583

38 593

09 904

67 363

273 78

583 77

393 28

304 58

714

 75°F outdoor temperature condenser fan motor is running on low speed.

Manual 2100-420H Page 33 of 34

TABLE 11

HEATING PRESSURE

(ALL TEMPERATURES IN DEGREES F)

NRUTER

RIA

LEDOM

342HQ

203HQ

263HQ

224HQ

284HQ

206HQ

Refer to notes following Table 10

.PMETERUSSERP

05 0151025203530454055506

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741

551

461

271

181

981

891

602

512

422

751

361

961

571

081

781

391

991

502

112

741

351

951

461

171

671

281

881

491

002

161

861

471

081

781

391

991

602

212

812

451

061

761

371

081

681

291

991

602

312

261

661

071

571

181

781

391

002

802

612

LIOCROODTUOGNIRETNEERUTAREPMETRIA

232

042

942

712

222

822

602

112

712

522

132

732

912

522

232

522

432

442

Manual 2100-420H Page 34 of 34

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

Specifications and Main Features

Frequently Asked Questions

User Manual