Bard QH422, QH482, QH602, QH243, QH362, QH302 User Manual

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QTEC SERIES

PACKAGED HEAT PUMP

INSTALLATION

INSTRUCTIONS Models: QH243 QH302

QH362 QH422

QH482 QH602

Bard Manufacturing Company, Inc.

Manual:

2100-420H

Bryan, Ohio 43506

Supersedes: 2100-420G

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

File:

Vol II Tab 14

Date:

06-28-07

 

 

 

 

 

 

 

© Copyright 2004

 

Manual 2100-420H

Page

1 of 34

CONTENTS

Getting Other Information and Publications

 

For more information, contact these publishers:

.......... 3

QTEC 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

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

Manual

2100-420H

 

 

Page

2 of 34

 

 

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

Tables

 

 

Table 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

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

QTEC Series General Information

QTEC MODEL NOMENCLATURE

 

 

 

QH 36 2 A 10

X

X

X

MODEL NUMBER |

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

KW

 

 

FILTER OPTIONS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

QH - QTEC Model

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

0Z - 0KW

 

 

X - 1-Inch Fiberglass

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

05 - 5KW

 

 

 

(Standard)

 

 

CAPACITY |

 

 

 

 

 

 

 

 

 

 

 

06 - 6KW

 

 

F

- 2-Inch Fiberglass

 

 

 

 

 

 

 

 

 

 

 

 

 

09 - 9KW

 

 

P - 2-Inch Pleated

 

 

24

- 2 Ton

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

10 - 10KW

 

 

 

 

 

 

 

 

 

30

- 2½ Ton

REVISION |

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

36

- 3 Ton

 

 

 

 

 

 

 

 

 

 

12 - 12KW

 

 

 

 

 

 

 

 

 

42

- 3½ Ton

SPECIAL UNITS |

 

 

 

 

15 - 15KW

 

 

 

 

COLOR OPTIONS

 

 

 

 

 

 

 

 

 

 

 

48

- 4 Ton

L - Low Ampacity Circuit

 

 

 

 

 

 

 

 

V - Platinum w/Slate

60

- 5 Ton

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Front (Vinyl)

 

 

 

VOLTS & PHASE |

 

 

 

 

 

 

 

 

 

4

- Gray paint

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

A - 230/208/60/1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

B - 230/208/60/3

 

VENTILATION OPTIONS

 

 

 

 

 

 

 

C - 460/60/3

 

 

 

 

 

 

 

 

 

X - Barometric Fresh Air Damper (Standard)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

B - Blank-off Plate

 

 

 

 

 

 

 

 

 

V- Commercial Ventilator - Motorized w/Exhaust Spring Return

P - Commercial Ventilator - Motorized w/Exhaust

Power Return

R - Energy Recovery Ventilator w/Exhaust

X X X

COIL OPTIONS

X - Standard

INTERNAL 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

TABLE 1

FACTORY BUILT-IN ELECTRIC HEAT TABLE

 

 

 

 

 

 

 

 

 

QH362-A

QH362-B

QH362-C

 

 

 

 

 

 

 

 

 

QH422-A

QH422-B

QH422-C

 

QH243-A

 

 

 

 

 

 

QH482-A

QH482-B

QH482-C

Models

QH302-A

QH243-B

QH302-B

QH243-C

QH302-C

QH602-A

QH602-B

QH602-C

 

240V-1

208V-1

240V-1

208V-1

240V-1

208V-1

480V-3

480V-3

240V-1

208V-1

240V-1

208V-1

480V-3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

KW

BTUH

BTUH

BTUH

BTUH

BTUH

BTUH

BTUH

BTUH

BTUH

BTUH

BTUH

BTUH

BTUH

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5.0

16,380

12,290

 

 

 

 

 

 

16,380

12,290

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

6.0

 

 

20,500

15,360

20,500

15,360

20,500

20,500

 

 

20,500

15,360

20,500

 

 

 

 

 

 

 

 

 

 

 

 

 

 

9.0

 

 

30,700

23,000

30,700

23,000

30,700

30,700

 

 

30,700

23,000

30,700

 

 

 

 

 

 

 

 

 

 

 

 

 

 

10.0

32,670

24,570

 

 

 

 

 

 

32,670

24,570

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

12.0

 

 

 

 

41,000

30,700

 

41,000

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

15.0

 

 

 

 

 

 

 

 

49,150

36,860

49,150

36,860

49,150

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Manual

2100-420H

Page

4 of 34

TABLE 2

ELECTRICALSPECIFICATIONS

SINGLE CIRCUIT

DUAL CIRCUIT

 

 

 

3

1

2

2

 

3

 

1

2

2

 

 

 

 

 

 

 

 

 

 

MAXIMUM

 

 

 

 

 

 

 

 

 

 

 

MINIMUM

EXTERNAL

FIELD

 

 

 

 

 

 

 

 

 

FUSE OR

 

 

 

 

 

 

MAXIMUM

FIELD

 

CIRCUIT

CIRCUIT

POWER

GROUND

 

 

NO.

 

EXTERNAL

 

AMPACITY

BREAKER

WIRE SIZE

WIRE SIZE

 

RATED

FIELD

MINIMUM

FUSE OR

POWER

GROUND

 

 

 

 

 

 

 

 

 

 

 

VOLTS &

POWER

CIRCUIT

CIRCUIT

WIRE

WIRE

CKT

 

CKT

CKT

 

CKT

CKT

CKT

CKT

CKT

MODELS

PHASES

CIRCUITS

AMPACITY

BREAKER

SIZE

SIZE

A

 

B

A

 

B

A

B

A

B

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

QH243-A0Z

 

1

22

30

10

10

--

 

--

--

 

--

--

--

--

--

-A05

230/208-1

1

47

50

8

10

--

 

--

--

 

--

--

--

--

--

-A10

 

1 OR 2

72

80

4

8

22

 

50

30

 

50

10

8

10

10

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

QH243-B0Z

 

1

17

20

12

12

--

 

--

--

 

--

--

--

--

--

-B06

230/208-3

1

35

35

8

10

--

 

--

--

 

--

--

--

--

--

-B09

 

1

44

45

8

10

--

 

--

--

 

--

--

--

--

--

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

QH243-C0Z

 

1

8

15

14

14

--

 

--

--

 

--

--

--

--

--

-C06

460-3

1

17

20

12

12

--

 

--

--

 

--

--

--

--

--

-C09

 

1

22

25

10

10

--

 

--

--

 

--

--

--

--

--

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

QH302-A0Z

 

1

24

35

8

10

--

 

--

--

 

--

--

--

--

--

-A05

230/208-1

1

49

50

8

10

--

 

--

--

 

--

--

--

--

--

-A10

 

1 OR 2

74

80

4

8

24

 

50

30

 

50

10

8

10

10

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

QH302-B0Z

 

1

18

25

10

10

--

 

--

--

 

--

--

--

--

--

-B06

230/208-3

1

36

40

8

10

--

 

--

--

 

--

--

--

--

--

-B09

1

45

45

8

10

--

 

--

--

 

--

--

--

--

--

-B12

 

1

54

60

6

10

--

 

--

--

 

--

--

--

--

--

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

QH302-C0Z

 

1

9

15

14

14

--

 

--

--

 

--

--

--

--

--

-C06

460-3

1

18

20

12

12

--

 

--

--

 

--

--

--

--

--

-C09

1

23

25

10

10

--

 

--

--

 

--

--

--

--

--

 

 

 

-C12

 

1

27

30

10

10

--

 

--

--

 

--

--

--

--

--

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

QH362-A0Z

 

1

29

45

8

10

--

 

--

--

 

--

--

--

--

--

-A05

230/208-3

1

54

60

6

10

--

 

--

--

 

--

--

--

--

--

-A10

1 OR 2

79

90

4

8

29

 

50

40

 

50

8

8

10

10

4 -A15

 

1 OR 2

82

90

4

8

32

 

50

40

 

50

8

8

10

10

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

QH362-B0Z

 

1

23

30

10

10

--

 

--

--

 

--

--

--

--

--

-B06

230/208-3

1

41

45

8

10

--

 

--

--

 

--

--

--

--

--

-B09

1

50

50

8

10

--

 

--

--

 

--

--

--

--

--

5 -B15

 

1

52

60

6

10

--

 

--

--

 

--

--

--

--

--

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

QH362-C0Z

 

1

11

15

14

14

--

 

--

--

 

--

--

--

--

--

-C06

460-3

1

20

20

12

12

--

 

--

--

 

--

--

--

--

--

-C09

1

24

30

10

10

--

 

--

--

 

--

--

--

--

--

 

 

 

5 -C15

 

1

26

30

10

10

--

 

--

--

 

--

--

--

--

--

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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

ELECTRICALSPECIFICATIONS

(Continued)

SINGLE CIRCUIT

DUAL CIRCUIT

 

 

 

3

1

2

2

3

 

1

 

2

 

2

 

 

 

 

 

 

 

 

 

MAXIMUM

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

EXTERNAL

 

 

 

 

 

 

 

 

 

 

MAXIMUM

 

 

MINIMUM

FUSE OR

FIELD

 

 

 

 

 

NO.

 

EXTERNAL

FIELD

 

CIRCUIT

CIRCUIT

POWER

GROUND

 

RATED

FIELD

MINIMUM

FUSE OR

POWER

GROUND

AMPACITY

BREAKER

WIRE SIZE

WIRE SIZE

 

POWER

CIRCUIT

CIRCUIT

WIRE

WIRE

 

 

 

 

 

 

 

 

 

 

 

 

VOLTS &

CKT

CKT

CKT

 

CKT

CKT

 

CKT

CKT

 

CKT

MODEL

CIRCUITS

AMPACITY

BREAKER

SIZE

SIZE

 

 

 

PHASE

 

 

 

 

 

A

B

A

 

B

A

 

B

A

 

B

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

QH422-A0Z

 

1

33

50

8

10

--

--

--

 

--

--

 

--

--

 

--

-A05

230/208-1

1

58

60

6

10

--

--

--

 

--

--

 

--

--

 

--

-A10

1 OR 2

83

90

4

8

33

50

40

 

50

8

 

8

10

 

10

4 -A15

 

1 OR 2

83

90

4

8

33

50

40

 

50

8

 

8

10

 

10

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

QH422-B0Z

 

1

24

30

10

10

--

--

--

 

--

--

 

--

--

 

--

-B06

230/208-3

1

43

50

8

10

--

--

--

 

--

--

 

--

--

 

--

-B09

1

52

60

6

10

--

--

--

 

--

--

 

--

--

 

--

5 -B15

 

1

52

60

6

10

--

--

--

 

--

--

 

--

--

 

--

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

QH422-C0Z

 

1

12

15

14

14

--

--

--

 

--

--

 

--

--

 

--

-C06

460-3

1

21

25

10

10

--

--

--

 

--

--

 

--

--

 

--

-C09

1

26

30

10

10

--

--

--

 

--

--

 

--

--

 

--

 

 

 

 

5 -C15

 

1

26

30

10

10

--

--

--

 

--

--

 

--

--

 

--

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

QH482-A0Z

 

1

36

50

8

10

--

--

--

 

--

--

 

--

--

 

--

-A05

230/208-1

1

61

70

6

8

36

25

50

 

25

8

 

10

10

 

10

-A10

 

1 OR 2

86

90

3

8

36

50

50

 

50

8

 

8

10

 

10

4 -A15

 

1 OR 2

86

90

3

8

36

50

50

 

50

8

 

8

10

 

10

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

QH482-B0Z

 

1

26

40

8

10

--

--

--

 

--

--

 

--

--

 

--

-B06

230/208-3

1

44

50

8

10

--

--

--

 

--

--

 

--

--

 

--

-B09

1

53

60

6

10

--

--

--

 

--

--

 

--

--

 

--

5 -B15

 

1

53

60

6

10

--

--

--

 

--

--

 

--

--

 

--

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

QH482-C0Z

 

1

14

15

14

14

--

--

--

 

--

--

 

--

--

 

--

-C06

460-3

1

23

25

10

10

--

--

--

 

--

--

 

--

--

 

--

-C09

1

27

30

10

10

--

--

--

 

--

--

 

--

--

 

--

 

 

 

 

5 -C15

 

1

27

30

10

10

--

--

--

 

--

--

 

--

--

 

--

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

QH602-A0Z

 

1

46

60

8

10

--

--

--

 

--

--

 

--

--

 

--

-A05

230/208-1

1 or 2

71

80

4

8

46

25

60

 

25

8

 

10

10

 

10

-A10

 

1 or 2

96

110

3

6

46

50

60

 

50

8

 

8

10

 

10

4 -A15

 

1 or 2

96

110

3

6

46

50

60

 

50

8

 

8

10

 

10

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

QH602-B0Z

 

1

31

45

8

10

--

--

--

 

--

--

 

--

--

 

--

-B09

230/208-3

1

58

70

6

8

--

--

--

 

--

--

 

--

--

 

--

5 -B15

 

1

58

70

6

8

--

--

--

 

--

--

 

--

--

 

--

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

QH602-C0Z

 

1

17

25

10

10

--

--

--

 

--

--

 

--

--

 

--

-C09

460-3

1

30

35

8

10

--

--

--

 

--

--

 

--

--

 

--

5 -C15

 

1

30

35

8

10

--

--

--

 

--

--

 

--

--

 

--

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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.

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FIGURE 1

UNIT DIMENSIONS

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2100-420H

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SHIPPING DAMAGE

Upon receipt of equipment, the carton should be checked for external signs of shipping damage. The skid must remain attached to the unit until the unit is ready for installation. If damage is found, the receiving party must contact the last carrier immediately, preferably in writing, requesting inspection by the carrier’s agent.

UNIT REMOVAL FROM SKID

WARNING

This unit is heavy and requires more than one person to handle and remove from the skid. Check unit wheels to ensure that wheels are locked before removing from skid. Extreme caution must be taken to prevent injury to personnel and damage to the unit.

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

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

FIGURE 2

AIR SEAL UNDER QTEC UNIT

Air Seal

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

REMOVAL OF UNIT FROM SKID

Hold

Skid

Down

A Shipping Brackets

B Front Wheels Over Edge

C Front Wheels On Floor

 

 

 

 

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2100-420H

 

 

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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 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

COMPRESSOR

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 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

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.

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2100-420H

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FIGURE 5

INSTALLATION WITH FREE BLOW PLENUM

FIGURE 6

DUCTEDAPPLICATION

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2100-420H

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

FIGURE 7

SUPPLY DUCT CONNECTIONS

SUPPLY DUCT

TO BE FIELD

SUPPLIED

ATTACHMENT

SCREWS TO

BE FIELD

SUPPLIED

ROOM SIDE

OF QTEC UNIT

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.

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

FILTERS

RETURN AIR

GRILLE

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2100-420H

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FRESH AIR INTAKE

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

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

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

For details on energy recovery ventilation see separate section.

FIGURE 9

OPTIONAL SIDE DRAIN (SIDE VIEW)

INSTALLATION

QTEC UNIT

CONDENSATE DRAIN

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

The side drain requires a water trap for proper drainage. See Figure 9. The drain can be routed through the floor or through the wall. If the drain is to be routed through an unconditioned space, it must be protected from freezing. The drain line must be able to be removed from the unit if it is necessary to remove the unit from the wall. When the side drain is used, the plug must be removed and installed in the rear drain outlet.

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

Optional rear drain kits, 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.

FIGURE 10

STANDARD REAR DRAIN

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2100-420H

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SLEEVE

WATER TRAP

FIGURE 11

REAR DRAIN (TOP VIEW)

DRAIN LINE

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.

WALL (MAXIMUM 10"

The Service Unit light indicates that the unit has

FOR REAR DRAIN)

 

been shut off by a high or low pressure device.

COUPLINGS NOT

This indicates that the unit needs to be serviced.

 

SHOWN BUT

 

RECOMMENDED

 

FOR EASE OF

 

REMOVABILITY

 

FOR SERVICE.

 

WALL

 

BRACKET

 

UNIT

ENLARGED VIEW OF MOUNTING FIGURE 12 BRACKET SHOWING SLEEVE TO

CABINET ATTACHMENT

UNIT MOUNTING

SIDE TRIM

MOUNTING BRACKET

(2 PCS.)

 

WALL

SLEEVE

SIDE TRIM

(2 PCS.)

#8 SCREW

PROVIDED (LIGHT COLOR)

MOUNTING

CABINET

BRACKET

SIDE PANEL

#10 HEX HEAD SCREW PROVIDED

BOTTOM

TRIM

PIECE BOTTOM TRIM

EXTENSION

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2100-420H

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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.

FIGURE 13

REMOVING LOCKING SCREWS FROM WHEELS

REMOVE SCREWS FROM

WHEELS BEFORE

ROLLING INTO PLACE

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2100-420H

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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

COMPONENTLOCATION

 

SIDE FIELD WIRE

 

ENTRANCE

ELECTRIC

 

HEATERS

 

 

REMOTE

 

THERMOSTAT

UNIT

TERMINAL

MOUNTED

BLOCK

THERMOSTAT

 

LOCATION

 

 

INDOOR

 

BLOWER

DEHUMIDIFICATION

 

CONTROL

 

(OPTIONAL)

 

 

CIRCUIT

 

BREAKER PANEL

 

& CONTROLS

 

LOWER

 

CONTROL

 

PANEL

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

TAP

RANGE

 

 

240V

253 – 216

 

 

208V

220 – 187

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).

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.

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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. This terminal is activated on a high or low pressure trip by the electronic heat pump control. This is a 24 VAC output.

“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.

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.

LOW VOLTAGE CONNECTIONS FOR

DDC CONTROL

Fan Only

Energize G

Cooling Mode

Energize Y, G

Heat Pump Heating

Energize Y, G, B

2nd Stage Heating

Energize G, W2

(if employed)

 

Ventilation

Energize G, O1

Emergency Heat

Energize B, W2, E

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.

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2100-420H

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TABLE 4

 

WALLTHERMOSTATS

 

 

Thermostat

Predominant Features

 

 

 

3 stage Cool; 3 stage Heat

8403-060

Programmable/Non-Programmable Electronic

(1120-445)

HP or Conventional

 

Auto or Manual changeover

 

 

8403-058

2 stage Cool; 2 stage Heat

Electronic Non-Programmable

(TH5220D1151)

Auto or Manual changeover

 

 

FIGURE 15

MIS-1285

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2100-420H

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FIGURE 16

REMOTE THERMOSTAT WIRING DIAGRAM

“X” THERMOSTAT OPTION

VENTILATOR OR DAMPER

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.

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2100-420H

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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.

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2100-420H

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FIGURE 18

UNIT MOUNTED THERMOSTAT WIRING DIAGRAM

“D” THERMOSTAT OPTION

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2100-420H

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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 10minute 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 QTEC 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.

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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.

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.

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.

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.

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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.

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.

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.

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 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.

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FIGURE 19

FRESH AIR DAMPER REMOVAL

MOUNTING

SCREW

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FIGURE 20

QERV REMOVAL

POWER

CONNECTORS

MOUNTING

SCREWS

LOWER

BLOWER

ASSEMBLY

POWER

CONNECTOR

FRONT FILL

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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.

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

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.

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.

FIGURE 21

HEAT PUMP CONTROL BOARD (HPC)

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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.

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TROUBLESHOOTING

 

 

TABLE 5

 

 

TROUBLESHOOTING

 

 

 

Symptom

Possible Causes

What & How to Check / Repair

 

 

 

Compressor will

Check for 24V from R to C

If 24V is not present at R, check wiring from board to transformer and check transformer input

not start (heating

on the heat pump control

and output voltage. If transformer has no 24V output, determine cause and replace

or cooling)

 

transformer.

 

 

 

 

Check for 24V from Y to C

If 24V is not present, check thermostat and thermostat wiring, outdoor thermostat (if equipped)

 

on low voltage terminal strip

phase monitor (if equipped, used on some 3-phase models). If 24V is present continue to

 

 

next step.

 

 

 

 

Check for 24V from C to

If 24V is present, check and/or replace compressor contactor. If 24V is not present, jump the

 

CC on heat pump control

speed up terminal for 10 seconds. If compressor does not start check for 24V from C to L1

 

 

on the heat pump control.

 

 

 

 

Compressor lock out

If 24V is not present at L1 of the heat pump control, check the high pressure switch and low

 

 

pressure bypass relay (if equipped) and all associated wiring and terminals. The safety circuit

 

 

is a closed circuit. If the high pressure switch or low pressure bypass relay are open, the

 

 

control will lock out the compressor. Replace defective component. Cycle power off and on to

 

 

reset lock out. Jump speed up terminals for 10 seconds to override 5-minute time delay.

 

 

 

 

Defective heat pump control

If 24V is present from C to Y, and C to L1 on the heat pump control, the time delay has been

 

 

overridden or expired and no 24V is present at CC, replace the heat pump control.

 

 

 

Fan outdoor motor

Heat pump control defective

Check across fan relay on heat pump control. (Com-NC)

does not run

 

Replace heat pump control.

(cooling or heating

 

 

Motor defective

Check for open or shorted motor winding. Replace motor.

except during

 

 

Motor capacitor defective

Check capacitor rating. Check for open or shorted capacitor. Replace capacitor.

defrost)

 

 

 

Reversing valve

Heat pump control defective

Check for 24V between RV-C and B-C.

does not energize

 

1. Check control circuit wiring.

(heating only)

 

2. Replace heat pump control

 

 

 

 

Reversing valve solenoid

Check for open or shorted coil.

 

coil defective

Replace solenoid coil.

 

 

 

Unit will not go

Temperature sensor or heat

Disconnect temperature sensor from board and jumper across "SPEEDUP" terminals and "SEN

into defrost

pump control defective

JMP" terminals. This should cause the unit to go through a defrost cycle within one minute.

(heating only)

 

1. If unit goes through defrost cycle, replace temperature sensor.

 

 

2. If unit does not go through defrost cycle, replace heat pump control.

 

 

 

Unit will not come

Temperature sensor or heat

Jumper across "SPEEDUP" terminal.

out of defrost

pump control defective.

This should cause the unit to come out of defrost within one minute.

(heating only)

 

1. If unit comes out of defrost cycle, replace temperature sensor.

 

 

2. If unit does not come out of defrost cycle, replace heat pump control.

 

 

 

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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.

CHECKING TEMPERATURE SENSOR

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.

TABLE 6

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

 

F

R

F

R

F

R

F

R

 

 

 

 

 

 

 

 

 

 

 

 

-25.0

196871

13.0

56985

53.0

19374

89.0

7507

 

 

-24.0

190099

14.0

55284

52.0

18867

90.0

7334

 

 

-23.0

183585

15.0

53640

53.0

18375

91.0

7165

 

 

-22.0

177318

16.0

52051

54.0

17989

92.0

7000

 

 

-21.0

171289

17.0

50514

55.0

17434

93.0

6840

 

 

-20.0

165487

18.0

49028

56.0

16984

94.0

6683

 

 

-19.0

159904

19.0

47590

57.0

16547

95.0

6531

 

 

-18.0

154529

20.0

46200

58.0

16122

96.0

6383

 

 

-17.0

149355

21.0

44855

59.0

15710

97.0

6239

 

 

-16.0

144374

22.0

43554

60.0

15310

98.0

6098

 

 

-15.0

139576

23.0

42295

61.0

14921

99.0

5961

 

 

-14.0

134956

24.0

41077

62.0

14544

100.0

5827

 

 

-13.0

130506

25.0

39898

63.0

14177

101.0

5697

 

 

-12.0

126219

26.0

38757

64.0

13820

102.0

5570

 

 

-11.0

122089

27.0

37652

65.0

13474

103.0

5446

 

 

-10.0

118108

28.0

36583

66.0

13137

104.0

5326

 

 

-9.0

114272

29.0

35548

67.0

12810

105.0

5208

 

 

-8.0

110575

30.0

34545

68.0

12492

106.0

5094

 

 

-7.0

107010

31.0

33574

69.0

12183

107.0

4982

 

 

-6.0

103574

32.0

32634

70.0

11883

108.0

4873

 

 

-5.0

100260

33.0

31723

71.0

11591

109.0

4767

 

 

-4.0

97064

34.0

30840

72.0

11307

110.0

4663

 

 

-3.0

93981

35.0

29986

73.0

11031

111.0

4562

 

 

-2.0

91008

36.0

29157

74.0

10762

112.0

4464

 

 

-1.0

88139

37.0

28355

75.0

10501

113.0

4367

 

 

0.0

85371

38.0

27577

76.0

10247

114.0

4274

 

 

1.0

82699

39.0

26823

77.0

10000

115.0

4182

 

 

2.0

80121

40.0

26092

78.0

9760

116.0

4093

 

 

3.0

77632

41.0

25383

79.0

9526

117.0

4006

 

 

4.0

75230

42.0

24696

80.0

9299

118.0

3921

 

 

5.0

72910

43.0

24030

81.0

9077

119.0

3838

 

 

6.0

70670

44.0

23384

82.0

8862

120.0

3757

 

 

7.0

68507

45.0

22758

83.0

8653

121.0

3678

 

 

8.0

66418

46.0

22150

84.0

8449

122.0

3601

 

 

9.0

64399

47.0

21561

85.0

8250

123.0

3526

 

 

10.0

62449

48.0

20989

86.0

8057

124.0

3452

 

 

11.0

60565

49.0

20435

87.0

7869

 

 

 

 

12.0

58745

50.0

19896

88.0

7686

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Manual

2100-420H

 

 

 

 

 

 

 

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29 of 34

TROUBLESHOOTING GE ECMMOTORS

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 when starting

Motor won’t start

• No movement

This is normal start-up for ECM

Check blower turns by hand

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

• Motor rocks,

• Check for loose or compliant motor mount

but won’t start

• Make sure blower wheel is tight on shaft

 

 

• Perform motor/control replacement check

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

 

(G, Y, W, R, C) at motor, unseated pins in

 

motor harness connectors

 

• Check “Bk” for erratic CFM command (in

 

variable-speed applications)

 

• Check out system controls, Thermostat

 

• Perform Moisture Check

• “Hunts” or “puffs” at

• Does removing panel or filter reduce

high CFM (speed)

“puffing”?

 

- Reduce restriction

 

- Reduce max airflow

• 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

 

delay complete

 

• “R” missing/not connected at motor

 

• Perform motor/control replacement check

• Stays at high CFM

• “R” missing/not connected at motor

 

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

 

complete

 

• Perform motor/control replacement check

• Blower won’t shut off

• Current leakage from controls into G, Y or W?

 

Check for Triac switched thermostat or solid-

 

state relay

Excessive noise

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

 

motor noise; interview customer, if necessary

• Air noise

• High static creating high blower speed?

 

- Is airflow set properly?

 

- Does removing filter cause blower to slow

 

down? Check filter

 

- Use low-pressure drop filter

 

- Check/correct duct restrictions

Symptom Cause/Procedure

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

High static creating high blower speed?

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

-Check for cabinet/duct deformation

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

high CFM (speed)

“puffing”?

 

- Reduce restriction

 

- Reduce max. airflow

Evidence of Moisture

 

• Motor failure or

• Replace motor and Perform Moisture Check

malfunction has occurred

 

and moisture is present

 

• Evidence of moisture

• Perform Moisture Check

present inside air mover

 

Do

Don’t

Check out motor, controls, wiring and connections thoroughly before replacing motor

Orient connectors down so water can’t get in

-Install “drip loops”

Use authorized motor and model #’s for replacement

Keep static pressure to a minimum:

-Recommend high 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

Check orientation before inserting motor connectors

Automatically assume the motor is bad.

Locate connectors above 7 and 4 o’clock positions

Replace one motor or control model # with another (unless an authorized replacement)

Use high pressure drop filters some have ½" H20 drop!

Use restricted returns

Oversize system, then compensate with low airflow

Plug in power connector backwards

Force plugs

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?

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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 ¼" hex head bolts at the rear of the control 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. Finish installing the replacement control per 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.

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.

 

 

Figure23

 

Figure 24

 

 

 

Figure 4

 

Control Disassembly

 

Winding Test

 

 

 

Motor Connector

Only remove

 

From Motor

(3-pin)

 

Hex Head Bolts

Push until

 

 

 

Latch Seats

 

 

 

Over Ramp

 

 

 

 

Circuit

 

 

 

 

Board

 

 

ECM 2.0

 

Motor

 

 

 

 

 

 

 

 

 

 

Motor OK when

Note:

 

 

 

R > 100k ohm

Use the shorter

 

 

 

 

bolts and

 

 

 

 

alignment pin

 

 

 

Figure25

supplied when

 

 

 

replacing an

 

 

 

Drip Loop

ECM 2.0

 

Motor Connector

 

 

control.

 

 

Connector Orientation

 

(3-pin)

Back of

ECM

Control

Between 4 and 8 o'clock

 

2.3/2.5

Control Connector

 

 

 

 

(16-pin)

 

 

 

 

Power Connector

 

 

 

 

(5-pin)

 

 

 

 

Hex-head Screws

 

Drip Loop

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

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

TABLE 7

FAN BLADE DIMENSIONS

 

DIMENSION A

MODEL

(INCHES)

 

 

QH243

.750

QH302

.750

QH362

.750

QH422

.750

QH482

.750

QH602

.750

Model

Rated

95° OD

82° OD

CFM

Temperature

Temperature

 

 

 

 

 

 

QH243

800

16

- 18

14 - 16

 

 

 

 

 

QH302

1000

16

- 18

15 - 17

 

 

 

 

 

QH362

1200

16

- 18

14 - 16

 

 

 

 

QH422

1200

19 - 21

16 - 18

 

 

 

 

 

QH482

1400

23

- 25

22 - 24

 

 

 

 

 

QH602

1550

7

- 9

13 - 15

 

 

 

 

 

TABLE 9

INDOOR BLOWER PERFORMANCE

 

 

 

1

2

3

4

 

 

 

 

 

 

Optional

Continuous

CFM @

Model

 

Rated ESP

Max. ESP

Rated CFM

CFM

CFM

Max. ESP

 

 

 

 

 

 

 

 

QH243

5

.10

0.5

800

 

800

700

 

 

 

 

 

 

 

 

QH302

 

.15

0.8

1000

 

1000

910

 

 

 

 

 

 

 

 

QH362

 

.15

0.8

1200

1000

1000

1175

 

 

 

 

 

 

 

 

QH422

 

.15

0.8

1200

1000

1000

1175

 

 

 

 

 

 

 

 

QH482

 

.15

0.8

1400

1100

1100

1175

 

 

 

 

 

 

 

 

QH602

 

.20

0.5

1550

1250

1250

1400

 

 

 

 

 

 

 

 

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

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, 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.

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

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.

Manual

2100-420H

Page

32 of 34

TABLE 10

COOLINGPRESSURE

(ALL TEMPERATURES IN DEGREES F)

 

RETURN

 

 

1 AIR TEMPERATURE ENTERING OUTDOOR COIL

 

 

AIR

 

 

 

 

 

 

 

 

 

 

 

 

75

80

85

90

95

100

105

110

115

MODEL

TEMP.

PRESSURE

 

 

 

 

 

 

 

 

 

 

 

 

 

75 DB

Low Side

73

73

74

76

77

79

80

81

83

 

62 WB

High Side

195

199

214

229

244

259

274

289

304

QH243

80 DB

Low Side

78

78

79

80

82

84

85

87

88

67 WB

High Side

203

204

219

234

250

264

280

296

312

 

 

85 DB

Low Side

84

84

85

86

88

89

91

93

94

 

72 WB

High Side

121

213

228

244

259

274

290

305

320

 

75 DB

Low Side

75

75

76

77

78

79

80

81

82

 

62 WB

High Side

226

202

242

258

273

319

303

319

335

QH302

80 DB

Low Side

80

80

81

82

83

84

85

86

87

67 WB

High Side

228

233

248

264

280

296

311

327

343

 

 

85 DB

Low Side

86

86

87

88

89

90

91

92

93

 

72 WB

High Side

238

240

257

273

290

306

323

339

356

 

75 DB

Low Side

74

74

75

76

77

78

79

80

81

 

62 WB

High Side

212

215

233

251

269

287

305

323

341

QH362

80 DB

Low Side

79

79

80

81

82

83

84

85

86

67 WB

High Side

219

220

239

257

276

294

312

331

350

 

 

85 DB

Low Side

85

85

86

87

88

89

90

91

92

 

72 WB

High Side

223

228

247

267

286

305

324

343

363

 

75 DB

Low Side

71

71

72

73

74

75

76

77

79

 

62 WB

High Side

246

248

264

281

299

318

339

362

385

QH422

80 DB

Low Side

75

76

77

78

79

80

81

82

83

67 WB

High Side

251

243

270

288

307

327

349

371

395

 

 

85 DB

Low Side

82

82

83

84

85

86

87

88

90

 

72 WB

High Side

261

262

279

298

318

330

361

384

409

 

75 DB

Low Side

69

71

72

72

73

74

75

75

76

 

62 WB

High Side

221

237

252

270

287

305

323

343

363

QH482

80 DB

Low Side

75

76

76

77

78

79

80

80

81

67 WB

High Side

228

244

260

276

294

312

331

351

372

 

 

85 DB

Low Side

81

82

82

83

84

85

86

86

87

 

72 WB

High Side

237

252

269

285

304

323

342

363

385

 

75 DB

Low Side

69

70

71

72

73

74

75

76

77

 

62 WB

High Side

244

260

277

294

313

332

352

372

393

QH602

80 DB

Low Side

74

75

76

77

78

79

80

81

82

67 WB

High Side

250

267

284

302

321

341

361

382

403

 

 

85 DB

Low Side

77

78

79

80

81

82

83

84

85

 

72 WB

High Side

259

276

294

313

332

353

374

395

417

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.

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)

 

RETURN

 

 

 

AIR TEMPERATURE ENTERING OUTDOOR COIL

 

 

 

AIR

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

0

5

10

15

20

25

30

35

40

45

50

55

60

MODEL

TEMP.

PRESSURE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

QH243

70

Low Side

7

12

17

23

28

33

39

44

50

55

60

65

71

High Side

147

155

164

172

181

189

198

206

215

224

232

240

249

 

 

QH302

70

Low Side

16

20

24

28

33

37

41

45

49

54

58

62

67

High Side

157

163

169

175

180

187

193

199

205

211

217

222

228

 

 

QH362

70

Low Side

13

17

21

25

30

34

38

42

46

51

55

59

63

High Side

147

153

159

164

171

176

182

188

194

200

206

211

217

 

 

QH422

70

Low Side

13

18

22

26

31

35

39

44

48

53

57

61

65

High Side

161

168

174

180

187

193

199

206

212

218

225

231

237

 

 

QH482

70

Low Side

11

15

20

24

29

33

38

42

47

52

56

60

65

High Side

154

160

167

173

180

186

192

199

206

213

219

225

232

 

 

QH602

70

Low Side

21

21

22

23

25

28

31

36

41

46

53

60

68

High Side

162

166

170

175

181

187

193

200

208

216

225

234

244

 

 

Refer to notes following Table 10

Manual

2100-420H

Page

34 of 34