Bard QW242D, QW481D, QW601D, QW302D, QW361D Installation Instructions Manual

...

Download

QW SERIES WATER SOURCE

INSTALLATION INSTRUCTIONS

PACKAGED HEAT PUMP

Models:

QW242D QW302D QW361D QW421D QW481D QW601D

Earth Loop Fluid

Temperatures 25 – 110

Ground Water Temperature 45 – 75

Bard Manufacturing Company, Inc. Bryan, Ohio 43506

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

Manual No.: 2100-418F Supersedes: 2100-418E File: Vol II Tab 14 Date: 06-28-07

Manual 2100-418F Page 1 of 49

CONTENTS

Getting Other Information and Publications

For more information, contact these publishers:...... 4

QW General Information

QW Model Nomenclature ........................................ 5

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

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

Handling Unit After Removal From Skid .................. 7

Removal of Wall Bracket from Shipping Location ... 8

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

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

Duct Work ............................................................... 11

Filters ...................................................................... 11

Condensate Drain ........................................... 11 - 13

Mist Eliminator Service .......................................... 13

Installation Instructions

Mounting the Unit .................................................. 16

Wiring – Main Power ............................................. 19

Wiring – Low Voltage Wiring ................................. 19

General .......................................................... 19 & 20

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

Start Up

Description of Standard Equipment ....................... 24

Compressor Control Module .................................. 24

Adjustments ........................................................... 24

Optional CFM ........................................................ 25

Important Installer Note ......................................... 25

Phase Monitor ....................................................... 25

Service Hints ......................................................... 25

Sequence of Operation .................................. 25 & 26

Optional Climate Controls Sequence of

Operation ....................................................... 26 & 27

Refrigerant Tube Schematic for Reheat Coil ......... 27

Pressure Service Ports .......................................... 27

Pressure Tables .............................................. 32 - 33

Optional Accessories ............................................. 34

Closed Loop (Earth Coupled Ground Loop Applications)

Circulation System Design .................................... 35

Copper Water Coil Application ............................... 35

Start Up Procedure for Closed Loop System ......... 36

Open Loop (Well System Applications)

Water Connections ................................................ 38

Copper Water Coil Limitations ....................... 38 & 39

Well Pump Sizing .................................................. 39

Start Up Procedure for Open Loop System ... 39 & 40

Water Corrosion .................................................... 40

Remedies of Water Problems................................ 40

Lake and Pond Installations .................................. 41

Cooling Tower / Boiler Application ......................... 43

Service

Service Hints ......................................................... 44

Unbrazing System Components ............................ 44

Troubleshooting GE ECM™ Blower Motors . 45 - 46

Quick Reference Troubleshooting Chart for

Water to Air Heat Pump .......................................... 47

Ground Source Heat Pump

Performance Report ........................................ 48 - 49

Manual 2100-418F Page 2 of 49

CONTENTS

Figures

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

Figure 2 Removal of Unit From Skid .................... 7

Figure 3 Proper Handling of Unit After Removal

from Skid ................................................ 8

Figure 4 Installation of Unit w/Wall Sleeve .......... 9

Figure 5 Installation With Free Blow Plenum ..... 10

Figure 6 Ducted Application ............................... 10

Figure 7 Supply Duct Connections ..................... 11

Figure 8 Condensate Drain ................................ 12

Figure 8A Side Drain (Side View)......................... 12

Figure 8B Optional Rear Drain ............................. 12

Figure 8C Rear Drain (Top View).......................... 13

Figure 9 Fresh Air Damper Removal.................. 14

Figure 10 Removal of QT Figure 11 Remove Locking Screws from Wheels 16

Figure 12 Unit Mounting Without Wall Sleeve ..... 17

Figure 13 Component Location ............................ 18

Figure 14 Low Voltage Wire Harness Plug .......... 20

Figure 15 Remote Thermostat Wiring "X" Option 21 Figure 16 Remote Thermostat Wiring "E" Option 22 Figure 17 Remote Thermostat Wiring "G" Option 23 Figure 18 Heat Pump Dehumidification Mode

Circuit Diagram .................................... 28

Figure 19 Heap Pump Cooling Mode Circuit

Diagram ............................................... 28

Figure 20 Fluid Connections w/Ventilation

Wall Sleeve .......................................... 30

Figure 21 Fluid Connections w/o Ventilation

Wall Sleeve .......................................... 31

Figure 22 Circulation System ............................... 35

Figure 23 Water Temperature and Pressure

Test Procedure .................................. 36

Figure 24 Performance Model WGPM-1C ........... 37

Figure 25 Performance Model WGPM-2C ........... 37

Figure 26 Piping Diagram .................................... 38

Figure 27 Cleaning Water Coil ............................. 41

Figure 28 Water Well System .............................. 42

Figure 29 Control Disassembly ............................ 46

Figure 30 Winding Test ........................................ 46

Figure 31 Drip Loop ............................................. 46

EC ERV ......................... 15

Tables

Table 1 Electrical Specifications ........................... 5

Table 2 Operating Voltage Range....................... 19

Table 3 Wall Thermostats ................................... 19

Table 4 Indoor Blower Performance ................... 27

Table 5 Dehumidification Relay Logic Board ...... 29

Table 6 Cooling Pressure Table .......................... 32

Table 7 Heating Pressure ................................... 33

Table 8 Optional Accessories ............................. 34

Table 9 Constant Flow Valves ............................. 38

Table 10 Water Flow and Pressure Drop .............. 43

Manual 2100-418F Page 3 of 49

GETTING OTHER INFORMATION AND PUBLICATIONS

These publications can help you install the air conditioner or heat pump. You can usually find these at your local library or purchase them directly from the publisher. Be sure to consult current edition of each standard.

National Electrical Code ...................... ANSI/NFPA 70

Standard for the Installation .............. ANSI/NFPA 90A

of Air Conditioning and Ventilating Systems

Standard for Warm Air ...................... ANSI/NFPA 90B

Heating and Air Conditioning Systems

Load Calculation for Residential ....... ACCA Manual J

Winter and Summer Air Conditioning

Duct Design for Residential ............. ACCA Manual D

Winter and Summer Air Conditioning and Equipment Selection

Closed-Loop/Ground Source Heat Pump ........ IGSHPA

Systems Installation Guide

Grouting Procedures for Ground-Source ......... IGSHPA

Heat Pump Systems

Soil and Rock Classification for the Design .... IGSHPA

of Ground-Coupled Heat Pump Systems

FOR MORE INFORMATION, CONTACT THESE PUBLISHERS:

ACCA Air Conditioning Contractors of America

1712 New Hampshire Avenue Washington, DC 20009 Telephone: (202) 483-9370 Fax: (202) 234-4721

ANSI American National Standards Institute

11 West Street, 13th Floor New York, NY 10036 Telephone: (212) 642-4900 Fax: (212) 302-1286

ASHRAE American Society of Heating Refrigerating,

and Air Conditioning Engineers, Inc.

1791 Tullie Circle, N.E. Atlanta, GA 30329-2305 Telephone: (404) 636-8400 Fax: (404) 321-5478

NFPA National Fire Protection Association

Batterymarch Park P.O. Box 9101 Quincy, MA 02269-9901 Telephone: (800) 344-3555 Fax: (617) 984-7057

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

Closed-Loop Geothermal Systems – Slinky .... IGSHPA

Installation Guide

Manual 2100-418F Page 4 of 49

IGSHPA International Ground Source

Heat Pump Association

490 Cordell South Stillwater, OK 74078-8018

QW SERIES WATER SOURCE GENERAL INFORMATION

QW MODEL NOMENCLATURE

QW 36 1 D A 0Z B X V X X X

MODEL NUMBER

QTEC Model Water Source Heat Pump

CAPACITY

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

VENTILATION OPTIONS

B - Blank-off Plate X - Barometric Fresh Air Damper (Standard) V-

Commercial Ventilator - Motorized Spring Return w/Exhaust P - Commercial Ventilator - Motorized Power Return w/Exhaust R - Energy Recovery Ventilator w/Exhaust

REVISION

DEHUMIDIFICATION

0Z - None

VOLTS & PHASE

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

FILTER OPTIONS

X - 1-Inch Fiberglass

F - 2-Inch Fiberglass P - 2-Inch Pleated

COLOR OPTIONS

V - Platinum w/Slate

4 - Gray (Painted)

(Standard)

TABLE 1

ELECTRICAL SPECIFICATIONS

Front (Vinyl)

CLIMATE CONTROL OPTIONS 1

X - None E - Electronic/Prog/Man/Auto/Humidistat F - Electronic Non-Prog/Man or Auto

C/O/Humidistat/6-hr. timer

G - Electronic Non-Prog/Man or Auto

C/O/Humidistat

TIUCRICELGNIS

INTERNAL CONTROLS

X - Standard

• High Pressure Switch

• Low Pressure Switch

• Compressor Time Delay

COIL OPTIONS

X - Standard Cupronickel

Water Coil

4 - Copper Water Coil

MUMIXAM

LANRETXE

DETAR

&STLOV

LEDOM

Z0AD242WQ Z0BD242WQ Z0CD242WQ

Z0AD203WQ Z0BD203WQ Z0CD203WQ

Z0AD163WQ Z0BD163WQ Z0CD163WQ

Z0AD124WQ Z0BD124WQ Z0CD124WQ

Z0AD184WQ Z0BD184WQ Z0CD184WQ

Z0AD106WQ Z0BD106WQ Z0CD106WQ

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

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.ON

REWOP

STIUCRIC

1 1 1

MUMINIM TIUCRIC

YTICAPMA

91 41 8

12 61 01

42 91 01

72 02

13 42 21

54 43

ROESUF

TIUCRIC

REKAERB

52 02 51

03 02 51

53 52 51

04 03 51

54 53 51

06 54 02

DLEIF

REWOP

EZISERIW

01 21 41

01 01 41

8 01 41

8 8 41

8 8 21

DNUORG

EZISERIW

01 21 41

01 01 41

01 01 21

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.

Manual 2100-418F Page 5 of 49

FIGURE 1

UNIT DIMENSIONS

Manual 2100-418F Page 6 of 49

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

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.

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.

The shipping brackets on each side of the unit must be removed and discarded. See Figure 2-A on Page 7. The return air grille panel can be removed to provide a place to hold the unit. The unit can be slid forward on the skid until the front wheels hang over the edge of the skid. See Figure 2-B. The unit can be tipped forward and slid down the edge of the skid until the front wheels touch the ground. See Figure 2-C. The wheels will not roll. They are shipped from the factory locked so they will not roll. The back of the skid will have to be held down to keep it from tipping up. The skid can be slid out from under the unit. The unit can then be set upright.

REMOVAL OF UNIT FROM SKID

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 3. 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.

FIGURE 2

A SHIPPING BRACKETS B FRONT WHEELS OVER EDGE C FRONT WHEELS ON FLOOR

HOLD SKID DOWN

Manual 2100-418F Page 7 of 49

APPLIANCE CART

COMPRESSOR

FIGURE 3

PROPER HANDLING OF UNIT

AFTER REMOVAL FROM SKID

UNIT

(RIGHT SIDE)

STRAP

REMOVAL OF WALL BRACKET FROM SHIPPING LOCATION (UNITS WITH BLANK OFF PLATE ONLY)

The wall brackets are attached to the back of the unit. Remove and retain the wall brackets for use when attaching the unit to the wall. In units equipped with a ventilator a wall sleeve is required and these two wall brackets are not included. A different style bracket is supplied with the sleeve assembly.

GENERAL

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

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

These instructions explain the recommended method to install the water source self-contained unit and the electrical wiring connections to the unit.

These instructions and any instructions packaged with any separate equipment required to make up the entire air conditioning system should be carefully read before beginning the installation. Note particularly “Start Procedure” and any tags and/or labels attached to the equipment.

While these instructions are intended as a general recommended guide, they do not supersede any national and/or local codes in any way. Authorities having jurisdiction should be consulted before the installation is made. See Page 4 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.

Manual 2100-418F Page 8 of 49

FIGURE 4

INSTALLATION OF UNIT THROUGH WALL WITH WALL SLEEVE

Manual 2100-418F Page 9 of 49

FIGURE 5

INSTALLATION WITH FREE BLOW PLENUM

CEILING

FIGURE 6

DUCTED APPLICATION

FLOOR

Manual 2100-418F Page 10 of 49

FLOOR

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.

NOTE: Unit cabinet, supply air duct and free blow

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

The QT

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 Plenum Box mounts on top of the unit and has both vertically and horizontally adjustable louvers on the front discharge grille.

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 properly rated airflow up to the Maximum ESP shown in Table 4. However, for quiet operation of the air system, the duct static should be kept as low as practical, within the guidelines of good duct design.

FILTERS

Two 1-inch throw away filters are supplied with each unit. The filters fit into a fixed rack.

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

ROOM SIDE OF QW UNIT

FIGURE 7

SUPPLY DUCT CONNECTIONS

SUPPLY DUCT TO BE FIELD SUPPLIED

ATTACHMENT SCREWS TO BE FIELD SUPPLIED

DUCT FLANGE PROVIDED WITH UNIT

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.

CONDENSATE DRAIN

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

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

See Figures 8A, 8B and 8C.

NOTE: Whichever type of drain connection is used a

“P” trap must be formed. See Figure 8.

Manual 2100-418F Page 11 of 49

FIGURE 8

CONDENSATE DRAIN

The side drain requires a water trap for proper drainage. See Figure 8A. The drain can be routed through the floor or through the wall.

space, it must be protected from freezing

unit if it is necessary to remove the unit from the wall.

SIDE DRAIN (SIDE VIEW)

QTEC UNIT

FIGURE 8A

If the drain is to be routed through an unconditioned

. The drain line must be able to be removed from the

FIGURE 8B

OPTIONAL REAR DRAIN

Manual 2100-418F Page 12 of 49

The rear drain can be used with wall thickness of up to 10 inches where a water trap can be installed between the unit and the interior wall. See Figure 8B. The trap cannot extend beyond the edge of the unit or it will interfere with the wall mounting bracket. The drain can be routed through the floor or through the wall. If the drain is routed through the wall, the drain line must be positioned such that it will not interfere with the sleeve flange or the grille. See Figure 8C. If the drain is to be

routed through an unconditioned space, it must be protected from freezing.

FIGURE 8C

REAR DRAIN (TOP VIEW)

DRAIN LINE

WALL (MAXIMUM 10" FOR REAR DRAIN)

SLEEVE

WATER TRAP

COUPLINGS NOT SHOWN BUT RECOMMENDED FOR EASE OF REMOVABILITY FOR SERVICE

WALL BRACKET

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

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

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

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

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

BAROMETRIC FRESH AIR DAMPER (Optional)

Before starting to remove make sure the power has been turned off. The hinged return air grille panel must be opened. The fresh air damper assembly can be seen on the back of the unit. Refer to Figure 9.

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.

UNIT

Manual 2100-418F Page 13 of 49

COMMERCIAL ROOM VENTILATOR OPTION

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

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

FRESH AIR DAMPER REMOVAL

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.

FIGURE 9

MOUNTING SCREW

Manual 2100-418F Page 14 of 49

QTEC ENERGY RECOVERY VENTILATOR OPTION

Before starting the removal make sure that the power has been turned off. The hinged return air grille panel must be opened. The energy recovery ventilator (QERV) can be seen after the panel is opened. To gain access to the mist eliminator, the QERV must be removed. Refer to Figure 10

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.

REMOVAL OF THE QTEC ENERGY RECOVERY VENTILATOR

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

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

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

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

FIGURE 10

MOUNTING SCREWS

POWER CONNECTORS

LOWER BLOWER ASSEMBLY POWER CONNECTOR

FRONT FILL

Manual 2100-418F Page 15 of 49

INSTALLATION INSTRUCTIONS

MOUNTING THE UNIT

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

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

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

This unit is to be secured to the wall when there is not a vent sleeve used with the wall mounting brackets provided. (NOTE: Wall mounting brackets are only shipped on units with no vent inside.) The unit itself, the supply duct, and the free blow plenum are suitable for “0” clearance to combustible material.

NOTE: When a wall sleeve is to be used attach the

unit to the sleeve with bracket supplied with the wall sleeve.

Following are the steps for mounting the QW units for reference see Figure 12 on page 17.

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

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

FIGURE 11

REMOVING LOCKING SCREWS FROM

WHEELS

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

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

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

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

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

Manual 2100-418F Page 16 of 49

REMOVE SCREWS FROM WHEELS BEFORE ROLLING INTO PLACE

FIGURE 12

UNIT MOUNTING WITHOUT VENTILATION WALL SLEEVE

(REFER TO MOUNTING INSTRUCTIONS ON PAGE 16)

SIDE TRIM (2 PIECES)

BOTTOM TRIM PIECE

WALL MOUNTING BRACKET

BOTTOM TRIM EXTENSION

Manual 2100-418F Page 17 of 49

FIGURE 13

COMPONENT LOCATION

SIDE FIELD WIRE ENTRANCE

REMOTE THERMOSTAT TERMINAL BLOCK

INDOOR BLOWER

CONTROL BOX/ CIRCUIT BREAKER PANEL

ELECTRICAL CONNECTION PANEL

Manual 2100-418F Page 18 of 49

WIRING – MAIN POWER

Refer to the unit rating plate and/or Table 1 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

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 there will be no nuisance tripping due to the momentary high starting current of the compressor motor.

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

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

adhered to. Refer to the National Electrical

TABLE 2

OPERATING VOLTAGE RANGE

PATEGNAR

V042612-352 V802781-022

NOTE: The voltage should be measured at the field

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

The standard Climate Control Option X is a remote thermostat connection terminal block. See Figure 15 for wiring diagram. Compatible thermostats are listed in Table 3.

The Climate Control Option E is an electronic programmable thermostat and a humidistat. The subbase of the thermostat and the humidistat are factory wired to the front panel of the unit. See Figure 16 for wiring diagram. Compatible for use with Energy Recovery Ventilator or Ventilator.

GENERAL

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

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

WIRING – LOW VOLTAGE WIRING

230/208V, 1 PHASE AND 3 PHASE EQUIPMENT DUAL PRIMARY VOLTAGE TRANSFORMERS

All equipment leaves the factory wired on 240V tap. For 208V operation, reconnect from 240V to 208V tap. The acceptable operating voltage range for the 240 and 208V taps are as noted in Table 2.

WALL THERMOSTATS

tatsomrehTserutaeFtnanimoderP

830-3048 )A006H(

060-3048

)544-0211(

850-3048

)1511D0225HT(

CAUTION

Do not plug in or unplug blower motor

connectors while the power is on.

Failure to do so may result in motor failure.

TABLE 3

tatsidimuH

taeHegats3;looCegats3

cinortcelEelbammargorP-noN/elbammargorP

lanoitnevnoCroPH

revoegnahclaunaMrootuA

taeHegats2;looCegats2

elbammargorP-noNcinortcelE

revoegnahclaunaMrootuA

Manual 2100-418F Page 19 of 49

The climate Control Option G is an electronic non- programmable thermostat and humidistat. The subbase of the thermostat is factory wired to the front panel of the unit. This option is compatible for use with the optional CS2000A1 Energy Control Monitor and a terminal block is provided for connection to the CS2000A1. See Figure 17 for wiring diagram. Compatible for use with Energy Recovery Ventilator or Ventilator.

NOTE: The CS2000A1 (or other field provided means

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

“W2” terminal or pin 0 of P4 is second stage heat (if

equipped). If the unit is equipped with an optional hot water coil plenum box the water valve will be connected to this terminal.

“O1” terminal or pin 5 of P4 is the ventilation input. This terminal energizes any factory installed ventilation option.

NOTE: For total and proper control using DDC, a

total of 6 controlled outputs are required (5 if no ventilation system is installed).

“5” terminal of pin 2 of P4 is the 24 dehumidification circuit.

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 pin 6 of P4 is the fan input.

“Y” terminal or pin 7 of P4 is the compressor input.

“B” terminal or pin 8 of P4 is the reversing valve input.

The reversing valve must be energized for heating mode.

“R” terminal or pin 10 of P4 is 24 VAC hot.

“C” terminal or pin 11of P4 is 24 VAC grounded.

“L” terminal or pin 12 of P4 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.

FIGURE 14

BLOWER MOTOR LOW VOLTAGE

WIRE HARNESS PLUG

“4” terminal or pin 4 of P4 is the dehumidification circuit. A contact must connect terminals 4 and 5.

“6” terminal or pin 1 of P4 is VAC grounded to the humidistat, if needed.

LOW VOLTAGE CONNECTION

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

Dehumidification Connect 4 and 5

Manual 2100-418F Page 20 of 49

MIS-1285

H200

HUMIDISTAT

3 5

6 4

FIGURE 15

REMOTE THERMOSTAT WIRING DIAGRAM

“X” OPTION

6 5

W1/E D/YO

A G

E 4

R R

T 0

1 2

3 4 5

O/B

AUX

O/B

BL BR

8 9

C L

11 12

8403-058

8403-060

TH5220D1151

FACTORY INSTALLED JUMPER

LVTB

4102-034 C

Manual 2100-418F Page 21 of 49

FIGURE 16

REMOTE THERMOSTAT WIRING DIAGRAM

“E” THERMOSTAT OPTION

8403-060

W1/E D/YO

O/B

1 2

4102-050

Manual 2100-418F Page 22 of 49

FIGURE 17

REMOTE THERMOSTAT WIRING DIAGRAM

“G” THERMOSTAT OPTION

TB1

8403-060

W1/E D/YO

G Y

O/B

01 Y Y1

TO TB2 TERM. "C"

0 Y

1 2 3

4 5

R C

4102-054

Manual 2100-418F Page 23 of 49

START UP

DESCRIPTION OF STANDARD EQUIPMENT

LOW PRESSURE SWITCH

NOTE: This unit is supplied with two low pressure

switches installed, a 15 PSIG and a 27 PSIG.

The 27 PSIG is wired into the system. This switch is suitable for ground water (pump and dump), and water loop (boiler/tower applications).

To avoid nuisance lockouts for ground loop application with antifreeze, the 27 PSIG switch should be disconnected and connect the 15 PSIG switch.

The leads for both switches are located in the lower electrical connection panel. The switch bodies are marked with pressure settings. The 27 PSIG switch has yellow leads. The 15 PSIG switch has blue leads.

HIGH PRESSURE SWITCH

This unit is equipped with a high pressure switch that will stop the compressor in the event of abnormal high pressure occurrences over 450 PSI.

The high and low pressure switches are included in a lockout circuit that is resettable from the room thermostat.

COMPRESSOR CONTROL MODULE

The compressor control module is optional on the models covered by this manual. The compressor control is an anti-short cycle/lockout timer with high and low pressure switch monitoring and alarm relay output.

ADJUSTABLE DELAY ON MAKE AND BREAK TIMER

On initial power up or any time power is interrupted to the unit, the delay on make period begins, which will be 2 minutes plus 10% of the delay on break setting. When the delay on make is complete and the high pressure switch (and low pressure switch, if employed) is closed, the compressor contactor is energized. Upon shutdown, the delay on break timer starts and prevents restart until the delay on break and delay on make periods have expired.

During routine operation of the unit with no power interruptions the compressor will operate on demand with no delay.

HIGH PRESSURE SWITCH AND LOCKOUT SEQUENCE

If the high pressure switch opens, the compressor contactor will de-energize immediately. The lockout timer will go into a soft lockout and stay in soft lockout until the high pressure switch closes and the delay on break time has expired. If the high pressure switch opens again in the same operating cycle, the unit will go into manual lockout condition and the alarm relay circuit will energize. Recycling the wall thermostat resets the manual lockout.

LOW PRESSURE SWITCH, BYPASS AND LOCKOUT SEQUENCE

If the low pressure switch opens for more than 120 seconds, the compressor contactor will de-energize and go into a soft lockout. Regardless the state of the low pressure switch, the contactor will reenergize after the delay on make time delay has expired. If the low pressure switch remains open, or opens again for longer than 120 seconds, the unit will go into manual lockout condition and the alarm relay circuit will energize. Recycling the wall thermostat resets the manual lockout.

ALARM RELAY OUTPUT

Alarm terminal is output connection for applications where alarm relay is employed. This terminal is powered whenever compressor is locked out due to HPC or LPC sequences as described.

Note: Both high and low pressure switch controls are

inherently automatic reset devices. The high pressure switch and low pressure switch cut out and cut in settings are fixed by specific air conditioner or heat pump unit model. The lockout feature, both soft and manual, are a function of the Compressor Control Module.

ADJUSTMENTS

ADJUSTABLE DELAY ON MAKE AND DELAY ON BREAK TIMER

The potentiometer is used to select delay on break time from 30 seconds to 5 minutes. Delay on Make (DOM) timing on power up and after power interruptions is equal to 2 minutes plus 10% of Delay on Break (DOB) setting. See Delay on Make Timing chart on page 25.

During routine operation of the unit with no power interruptions the compressor will operate on demand with no delay.

Manual 2100-418F Page 24 of 49

DELAY ON MAKE TIMING

setunim50.)sdnoces03(BOD= MODsdnoces321 setunim0.1)sdnoces06(BOD= MODsdnoces621 setunim0.2)sdnoceS021(BOD= MODsdnoces231 setunim0.3)sdnoces081(BOD= setunim0.4)sdnoces042(BOD= MODsdnoces441 setunim0.5)sdnoces003(BOD= MODsdnoces051

MODsdnoces831

OPTIONAL CFM

This option is not available for QW242 or QW302.

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

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

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

2. Open hinged return air grille panel.

3. Open control panel cover.

4. 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 dishwashing detergent.

PHASE MONITOR

All units with three phase scroll compressors are equipped with a three 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 contactor will energize. If phases are reversed, the red fault LED will be lit and compressor operation is inhibited.

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. 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.

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 reversing valve controls heating cycle operation. Two thermostat options, one allowing “Auto” changeover 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. Heat Pump Heating cycle now in operation.

The second option has no “Auto” changeover 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.

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.

Manual 2100-418F Page 25 of 49

Reheat Circuit – There is a small orifice inserted between the reheat coil return line and suction line that will prevent liquid from accumulating in the reheat coil when it is inactive. This drain does not affect the normal operation of the system.

If the unit is running in heat pump mode and the humidistat calls for dehumidification, the dehumidification mode takes precedence over the heat pump heating mode. The unit will not return to the heating mode until second stage heating is called for.

There is a check valve located in the reheat coil return line. It has a soft spring to hold the ball on the seat. This will make the method of checking the ball freedom with a magnet difficult. Refer to Figures 19 and 20 for the location of the check valve and orifice.

When the system is operating in the dehumidification mode the suction pressure will be reduced by 4 to 8 psig and the discharge pressure will be reduced by 19 to 22 psig.

Return Air Thermostat – In dehumidification mode, if the return air temperature is lower than 65°, the return air thermostat closes and deactivates dehumidification.

High / Low Pressure Control provides protection for the compressor. In the event system pressures go high or low pressure settings in either heating or cooling 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.

OPTIONAL CLIMATE CONTROLS SEQUENCE OF OPERATION

The Climate Control Option E is an electronic programmable thermostat and humidistat. This unit has a refrigerant reheat circuit that is controlled by a three way valve.

When the humidity is above the setpoint of the humidistat, the compressor circuit and the three way valve are energized and the evaporator airflow is reduced. The three way valve directs hot discharge gas into a separate desuperheating condenser circuit that reheats the conditioned air before it is delivered to the room. When the humidistat is satisfied, the system switches back to normal air conditioning mode. If the thermostat call for cooling during dehumidification mode, the call for cooling takes precedence over the dehumidification and the unit will cool until the thermostat is satisfied. Once the call for cooling is satisfied, the unit may continue to dehumidify.

If the thermostat calls for first stage heat when the unit is in dehumidification mode, the unit will continue to run in dehumidification mode until a second stage heat call is received.

The climate Control Option F has a non-programmable electronic thermostat, timer and humidistat. This unit has a refrigerant reheat circuit that is controlled by a three way valve.

Unit operation is controlled by the manually operated timer. Normal heating, cooling or ventilation is available only when the timer is on. Dehumidification can be set to be available only when the timer is on, or to be available continuously by switching a jumper on the relay logic board.

When the humidity is above the setpoint of the humidistat, the compressor circuit and the three way valve are energized and the evaporator airflow is reduced. The three way valve directs hot discharge gas into a separate desuperheating condenser circuit that reheats the conditioned air before it is delivered to the room. If the return air thermostat senses a temperature below 65° during dehumidification is cancelled. When the humidistat is satisfied the system switches back to normal air conditioning mode.

If the thermostat calls for cooling during dehumidification mode, the call for cooling takes precedence over the dehumidification and the unit will cool until the thermostat is satisfied. Once the call for cooling is satisfied, the unit may continue to dehumidify.

If the thermostat calls for first stage heat when the unit is in dehumidification mode, the unit will continue to run in dehumidification mode until a second stage heat call is received.

The Climate Control Option G has a non-programmable electronic thermostat, humidistat and is compatible for use with a CS2000A1 Energy Control Monitor. This unit has a refrigerant reheat circuit that is controlled by a three way valve.

Unit operation is controlled by the thermostat and humidistat and optional CS2000A1 Energy Monitor Controller can be easily integrated by simple connection to the low voltage terminal block provided. See Figure

17.

Manual 2100-418F Page 26 of 49

NOTE: The CS2000A1 (or other means for ventilation

control) must be used if any mechanical (motorized) ventilation options are installed.

Dehumidification can be set to be available only when CS2000A1 is active or to be available continuously by switching a jumper at the relay logic board.

When the humidity is above the setpoint of the humidistat, the compressor circuit and the three way valve are energized and the evaporator airflow is reduced. The three way valve directs hot discharge gas into a separate desuperheating condenser circuit that reheats the conditioned air before it is delivered to the room. If the return air thermostat senses a temperature below 65° during dehumidification, dehumidification is cancelled. When the humidistat is satisfied the system switches back to normal air conditioning mode.

If the thermostat calls for first stage heat when the unit is in dehumidification mode, the unit will continue to run in dehumidification mode until a second stage heat call is received.

REFRIGERANT TUBE SCHEMATIC FOR REHEAT COIL

Figure 18 shows the refrigerant gas flow through the reheat coil during the dehumidification mode.

When the unit is in standard cooling, Figure 19, or heating mode the reheat coil is inactive.

PRESSURE SERVICE PORTS

High and low pressure service ports are installed on all units so that the system operating pressures an 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.

TABLE 4

INDOOR BLOWER PERFORMANCE

DETAR

LEDOM

D242WQ0.05.0007A/N007007 D203WQ0.08.00001A/N0001019 D163WQ0.08.00021000100015711 D124WQ0.08.00021000100015711 D184WQ0.08.00041001100115711 D106WQ0.08.00551052105210041

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

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 QW361, QW421, QW481 and QW601 locate low voltage terminal strip in the circuit breaker box. There is a pink jumper wire with both ends attached to terminal marked “G2”. Move one end of the jumper to terminal “Y”.

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.

PSE

adjusts 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.

PSE.XAM

LANOITPO

MFCDETAR

MFC

SUOUNITNOC

MFC

.XAM

PSE

Manual 2100-418F Page 27 of 49

HEAT PUMP DEHUMIDIFICATION

MODE CIRCUIT DIAGRAM

FILTER/

DRIER

EXPANSION

VALVE

FIGURE 18

4 WAY

VALVE

DISTRIBUTOR

CHECK VALVE

INDOOR COIL

REHEAT COIL

ORIFICE

DRAIN ASS'Y

WATER

COIL

BULB

WATER

HEAT PUMP COOLING

MODE CIRCUIT DIAGRAM

FILTER/

DRIER

EXPANSION

VALVE

OPEN CIRCUIT

3 WAY

VALVE

4 WAY VALVE

FIGURE 19

DISTRIBUTOR

CHECK VALVE

COMPRESSOR

MIS-1788 A

INDOOR COIL

REHEAT COIL

ORIFICE

DRAIN ASS'Y

WATER

COIL

BULB

WATER

Manual 2100-418F Page 28 of 49

CLOSED CIRCUIT

3 WAY

VALVE

COMPRESSOR

MIS-1788A

XXXX

draoBotstupnI draoBmorFstuptuO

TABLE 5

DEHUMIDIFICATION RELAY LOGIC BOARD

GY B 2W1E1AD TARL1GKBOYVRWE2AVWTL

XX X XXX X

XX X XXX

XX XXX

edoMgnilooCdeipuccO

edoMgnilooCdeipucconU

XXX

gnitaeHegatSts1deipucconU

edoMgnilooCmuheD/w

XXX X XXXX X

XXX X X X X X

gnitaeHegatSts1deipuccO

gnitaeHegatSts1muheD/w

XXXX XXXXX

gnitaeHegatSdn2deipucconU

XXX X

X XXXXX X

XXXX

XXXX X XXXXX

gnitaeHegatSdn2deipuccO

gnitaeHegatSdn2muheD/w

noitacifidimuheDdeipucconU

XX XXX XX

noitacifidimuheDdeipuccO

noitacifidimuheDTAR/w

NOTES:

1 Cooling takes precedence over dehumidification. A cooling call cancels dehumidification.

2 Dehumidification takes precedence over first stage heating.

3 Second stage heating cancels dehumidification.

Manual 2100-418F Page 29 of 49

29"

34"

FLOOR

WALL OPENING 35" x 29 1/2"

FLUID ACCESS FROM EACH SIDE

SLEEVE

OPENING IN REAR OF UNIT 3" x 8"

FLUID ACCESS FROM FLOOR

BACK OF UNIT

MOUNTING BRACKETS (SHIPPED WITH WALL SLEEVE)

MIS-1602 1-18-01

REF.

23 1/2"

63 1/2"

8 1/2"

33"

SIDE TRIM PIECES (SHIPPED WITH UNIT) IF THE WALL THICKNESS IS LESS THAN 14" BUT GREATER THAN 8", A SIDE TRIM EXTENSION KIT

TO UNIT SPEC. SHEET FOR PROPER COLOR

SIDE TRIM PEICES (SHIPPED WITH UNIT)

FLUID ACCESS FROM CEILING

8" TO 14" EXTERIOR WALL

SLEEVE

TOP OF UNIT

FIGURE 20

FLUID CONNECTIONS ON UNIT WITH VENTILATION WALL SLEEVE

QSTX42 IS REQUIRED. REFE

Manual 2100-418F Page 30 of 49

FLUID CONNECTIONS ON UNIT WITHOUT VENTILATION WALL SLEEVE

WALL BRACKET

FIGURE 21

TOP VIEW

WALL BRACKET

WATER LINES

FLUID ACCESS FROM TOP

OPENING IN REAR OF UNIT 3" x 8"

WALL LOCATION

BACK OF UNIT

63 1/2"

WALL BRACKET (LEFT BRACKET REMOVED FOR CLARITY)

8 1/2"

23 1/2"

FLOOR

FLUID ACCESS FROM FLOOR

MIS-1601 11/10/00

Manual 2100-418F Page 31 of 49

TABLE 6

PRESSURE TABLE

COOLING

ledoM

D242WQ

D203WQ

D163WQ

D124WQ

D184WQ

106WQ

Fluid Temperature Entering Water Coil Degree F

riAnruteR

erutarepmeTerusserP5405550656075508580959001501011

ediSwoL

26/57

76/08

27/58

26/57

76/08

27/58

26/57

76/08

27/58

26/57

76/08

27/58

26/57

76/08

27/58

26/57

76/08

27/58

ediShgiH

721

631

541

551

761

871

191

602

022

632

ediSwoL

ediShgiH

031

931

941

951

171

381

691

112

622

242

ediSwoL

ediShgiH

531

441

451

561

771

981

302

812

432

052

ediSwoL

ediShgiH

221

431

641

851

271

481

891

212

522

042

ediSwoL

ediShgiH

521

731

051

261

671

981

302

712

132

642

ediSwoL

ediShgiH

921

241

551

861

281

691

012

522

932

552

ediSwoL

ediShgiH

911

921

041

151

461

671

091

402

912

432

ediSwoL

ediShgiH

221

231

441

551

861

181

591

902

522

042

ediSwoL

ediShgiH

621

731

941

061

471

781

202

612

332

842

ediSwoL

ediShgiH

521

531

441

451

661

871

191

502

912

532

ediSwoL

ediShgiH

821

831

841

851

071

381

691

012

522

142

ediSwoL

ediShgiH

231

341

351

461

671

981

302

712

332

942

ediSwoL

ediShgiH

331

141

051

161

371

581

991

512

132

942

ediSwoL

001

401

ediShgiH

631

541

451

561

771

091

402

022

732

552

ediSwoL

001

401

801

ediShgiH

141

051

951

171

381

791

112

822

542

462

ediSwoL

ediShgiH

811

031

141

451

761

081

491

802

222

732

ediSwoL

ediShgiH

121

331

541

851

171

581

991

312

822

342

ediSwoL

ediShgiH

521

831

051

461

771

191

602

022

632

252

352

072

952

772

862

782

452

962

162

672

072

682

152

762

752

472

662

482

252

962

852

672

762

682

101

501

762

882

801

211

472

592

211

611

482

503

252

762

852

472

762

482

982

803

692

613

603

723

482

992

192

703

103

813

582

203

292

013

203

123

882

603

592

413

503

523

901

311

903

233

711

121

713

043

121

521

823

253

482

992

192

703

103

813

The data in the above pressure chart is based on the following flow rates:

FLOW RATE FOR VARIOUS FLUIDS

edirolhC

Manual 2100-418F Page 32 of 49

D242WQD203WQD163WQD124WQD184WQD106WQ

retawhserfMPGderiuqeretarwolF

muidoS%51MPGderiuqeretarwolF

4SG%52MPGderiuqeretarwolF

345669

46788 11

6788 11

TABLE 7

PRESSURE TABLE

HEATING

ledoM

D242WQ86

D203WQ86

D163WQ86

D124WQ86

D184WQ86

D106WQ86

riAnruteR

erutarepmeTerusserP520353045405550656075708

ediSwoL

ediShgiH

571

ediSwoL

ediShgiH

471

ediSwoL

ediShgiH

171

ediSwoL

ediShgiH

471

ediSwoL

ediShgiH

671

ediSwoL

ediShgiH

412

Fluid Temperature Entering Water Coil Degree F

671

771

871

971

081

181

871

381

781

391

891

502

571

181

781

391

991

602

971

581

291

891

502

212

181

781

491

002

702

512

612

912

322

922

632

542

The data in the above pressure chart is based on the following flow rates:

281

481

581

681

881

112

812

522

332

142

312

122

822

732

542

912

622

432

142

942

222

032

832

742

652

452

562

872

192

603

FLOW RATE FOR VARIOUS FLUIDS

retawhserfMPGderiuqeretarwolF

muidoS%51MPGderiuqeretarwolF

edirolhC

4SG%52MPGderiuqeretarwolF

D242WQD203WQD163WQD124WQD184WQD106WQ

345669

46788 11

6788 11

Manual 2100-418F Page 33 of 49

All

Unit Co

TABLE 8

OPTIONAL ACCESSORIES

Unit Co

including 460V. Connections are 1 inch FPT. Fully insulated cabinet.

Unit Co

10’ finished ceiling heights)

Optional Accessories – Must Be Used For Each Installation W/Ventilation Options

Ventilation Wall Sleeves

QWVS42 Ventilation wall sleeve for walls up to 14 inches thick

Ventilation Outdoor Louver Grilles:

QLG-11 Clear Anodized Aluminum for vent option

QLG-21 Medium Bronze Anodized Aluminum for vent option

QLG-31 Dark Bronze Anodized Aluminum for vent option

Manual 2100-418F

Page 34 of 49

Optional Accessories – For Ground Loop Installations

WGPM-1C Single pump module for individual loop system. 22 feet of head @ 16 GPM. Installs inside QW unit. 230V 60 Hz – 1-Ph. Used with al

WGPM-2C Dual pump module for individual loop system. 44 feet of head @ 16 GPM. Installs inside QW unit. 230V 60 Hz – 1-Ph. Used with all

WGRK-1 460 Volt relay kit. Required when installing a pump module in a 460 Volt.

WGHK-1 Hose kit for pump module installations. Connections are 1 inch MPT. Includes all parts for connection to pump module and PT adapte

Optional Accessories – Additional Items As Determined By Job Specifications

NOTE: The following accessory items must be selected so that the finish (color) is matched to the QW model that they will be used with.

Side Trim Extension Kits:

Required when wall thickness is less than 14 inches and works for walls down to 8 inches thick. Used in place of standard trim kit supplied with

unit to cover the space between unit and wall.

QSTX42A-V Platinum vinyl QSTX42-A4 Gray paint All

Free-Blow Plenum Boxes:

QPB42-V Platinum vinyl QPB42-4 Gray paint Front supply, 4-way deflection grille All MQPBS42-V Platinum vinyl QPBS42-4 Gray paint Same as QPB42, plus 2-way defection grill on each side All

Top Fill Systems for Finishing Plenum Boxes to Ceilings:

QPBX42-9-V Platinum vinyl QPBX42-9-4 Gray paint Use with QPB42 or QPBS42 (adjusts to ceilings up to 9’ 6”) All MQPBX42-10-V Platinum vinyl QPBX42-10-4 Gray paint Use with QPB42 or QPBS42 (adjusts to ceilings up to 10’ 2”) All

Cabinet Extensions for Ducted Applications:

QCX10A-V Platinum vinyl QCX10A-4 Gray paint 20” height (adjusts for ceilings up to 9’ 4”; add QPBX42-9 for 9’ 4” to

Hot Water Coils with Plenum Boxes:

QPBHW42-F-V Platinum vinyl QPBHW42-F-4 Gray paint Free-blow plenum box All MQPBHW42-D-V Platinum vinyl QPBHW42-D-4 Gray paint Ducted plenum box All

NOTE: The same top fill system and cabinet extensions can be used with hot water coil plenum boxes as with standard plenum boxes.

CLOSED LOOP (Earth Coupled Ground Loop Applications)

CIRCULATION SYSTEM DESIGN

Equipment room piping design is based on years of experience with earth coupled heat pump systems. The design eliminates most causes of system failure.

Surprisingly, the heat pump itself is rarely the cause. Most problems occur because designers and installers forget that a closed loop earth coupled heat pump system is

Most household water systems have more than enough water pressure either from the well pump of the municipal water system to overcome the pressure of head loss in 1/2 inch or 3/4 inch household plumbing. A closed loop earth coupled heat pump system, however, is separated from the pressure of the household supply and relies on a small, low wattage pump to circulate the water and antifreeze solution through the earth coupling, heat pump and equipment room components.

The small circulator keeps the operating costs of the system to a minimum. However, the performance of the circulator must be closely matched with the

not

like a household plumbing system.

FIGURE 22

CIRCULATION SYSTEM

pressure of head loss of the entire system in order to provide the required flow through the heat pump. Insufficient flow through the heat exchanger is one of the most common causes of system failure. Proper system piping design and circulator selection will eliminate this problem

Bard supplies a work sheet to simplify head loss calculations and circulator selection. Refer to “Circulating Pump Work sheet” section in Manual 2100-099.

COPPER WATER COIL APPLICATION

Copper water coils are available as a factory installed option. The unit model number will indicate the coil option as the next to last character; “X” is for standard coil constructed of Cupronickel material and “4” is from a water coil constructed of copper.

The Cupronickel coil is suitable for all applications.

The copper coil is suitable for applications using ground loop and cooling tower only and is never to be used in an open well application.

PIPE FROM GROUND LOOP

PUMP MODULE (See Spec Sheet for Model No.)

UNIONS

PIPE TO GROUND LOOP

1" FLEXIBLE HOSE

Manual 2100-418F Page 35 of 49

START UP PROCEDURE FOR CLOSED LOOP SYSTEM

1. Be sure main power to the unit is OFF at disconnect.

2. Set thermostat system switch to OFF, fan switch to AUTO.

3. Move main power disconnect to ON. Except as required for safety while servicing,

unit disconnect switch.

4. Check system airflow for obstructions.

A. Move thermostat fan switch to ON. Blower

runs.

B. Be sure all registers and grilles are open.

C. Move thermostat fan switch to AUTO. Blowing

should stop.

5. Flush, fill and pressurize the closed loop system as outlined in Manual 2100-099.

6. Fully open the manual inlet and outlet valves. Start the loop pump module circulator(s) and check for proper operation. If circulator(s) are not operating, turn off power and diagnose the problem.

7. Check fluid flow using a direct reading flow meter or a single water pressure gauge, measure the pressure drop at the pressure/temperature plugs across the water coil. Compare the measurement with flow versus pressure drop table to determine the actual flow rate. If the flow rate is too low, recheck the selection of the loop pump module model for sufficient capacity. If the module

do not open the

selection is correct, there is probably trapped air or a restriction in the piping circuit.

8. Start the unit in cooling mode. By moving the thermostat switch to cool, fan should be set for AUTO.

9. Check the system refrigerant pressures against the cooling refrigerant pressure table in the installation manual for rated water flow and entering water temperatures. If the refrigerant pressures do not match, check for airflow problem then refrigeration system problem.

10. Switch the unit to the heating mode. By moving the thermostat switch to heat, fan should be set for AUTO.

11. Check the refrigerant system pressures against the heating refrigerant pressure table in installation manual. Once again, if they do not match, check for airflow problems and then refrigeration system problems.

NOTE: If a charge problem is determined (high or low):

A. Check for possible refrigerant leaks.

B. Recover all remaining refrigerant from unit and

repair leak.

C. Evacuate unit down to 29 inches of vacuum.

D. Recharge the unit with refrigerant by weight.

This is the only way to insure a proper charge.

WATER TEMPERATURE and PRESSURE PROCEDURE

DIAL FACE PRESSURE GAUGE WITH GAUGE ADAPTOR

Manual 2100-418F Page 36 of 49

THERMOMETER

FIGURE 23

WATER COIL CONNECTION AT HEAT PUMP

TEST PLUG CAP

PETE’S TEST PLUG

UNION

FIGURE 24

PERFORMANCE MODEL WGPM-1C LOOP PUMP MODULE

Head (Feet)

0 5 10 15 20 25 30 35

Flow (GPM)

FIGURE 25

PERFORMANCE MODEL WGPM-2C LOOP PUMP MODULE

Head (Feet)

0 5 10 15 20 25 30 35

Flow (GPM)

Manual 2100-418F Page 37 of 49

OPEN LOOP (Well System Applications)

WATER CONNECTIONS

It is very important that an adequate supply of clean, noncorrosive water at the proper pressure be provided before the installation is made. Insufficient water, in the heating mode for example, will cause the low pressure switch to trip, shutting down the heat pump. In assessing the capacity of the water system, it is advisable that the complete water system be evaluated to prevent possible lack of water or water pressure at various household fixtures whenever the heat pump turns on. All plumbing to and from the unit is to be installed in accordance with local plumbing codes. The use of plastic pipe, where permissible, is recommended to prevent electrolytic corrosion of the water pipe. Because of the relatively cold temperatures encountered with well water, it is strongly recommended that the water lines connecting the unit be insulated to prevent water droplets form condensing on the pipe surface.

Refer to piping, Figure 26. Slow closing

Valve (6)

with a 24V coil provides on/off control of the water flow to the unit. Refer to the wiring diagram for correct hookup of the valve solenoid coil.

Constant Flow Valve (7)

provides correct flow of water to the unit regardless of variations in water pressure. Observe the water flow direction indicated by the arrow on the side of the valve body. Table 9 is a table showing the flow rate of each valve. Two constant flow rate valves may be installed in parallel to increase the flow. For example, when a 8603-007 (6 GPM) and 8603-011 (5 GPM) are installed in parallel the total flow will be 11 GPM.

Solenoid

TABLE 9

CONSTANT FLOW VALVES

elbaliavA.niM

.oNtraP

700-3068)1(516 800-3068)1(518 010-3068)1(514 110-3068)1(515 910-3068)1(513

(1) The pressure drop through the constant flow

valve will vary depending on the available pressure ahead of the valve. Unless minimum of 15 psig is available immediately ahead of the valve, no water will flow.

GISPerusserP

etaRwolF

MPG

COPPER WATER COIL LIMITATIONS

The Cupronickel coil is suitable for all applications.

The copper coil is suitable for applications using ground loop and cooling tower only and is never to be used in an open well application.

Manual 2100-418F Page 38 of 49

FIGURE 26

PIPING DIAGRAM

Strainer (5) (7)

to collect foreign material, which would clog the

flow valve orifice.

Figure 26 on preceding page shows the use of

valves (9)

permit isolation of the unit from the plumbing system should future service work require this. Globe valves should not be used as shutoff valves because of the excessive pressure drop inherent in the valve design. Instead, use gate or ball valves as shut-offs so as to minimize pressure drop.

Figure 26 shows the use of on the in and out water lines to permit isolation of the unit from the plumbing system should future service work require this. Globe valves should not be used as shutoff valves because of the excessive pressure drop inherent in the valve design. Instead, use gate or ball valves as shut-offs so as to minimize pressure drop.

Drain cock (8)

to permit acid cleaning the refrigerant-to-water coil should such cleaning be required. See

CORROSION

Drain cock (12)

water flow through the constant flow valve to insure adequate water flow through the unit. A water meter is used to check the water flow rate.

installed upstream of

and

(11)

, on the in and out water lines to

constant flow valve

shutoff valves (9)

and

(10)

, and tees have been included

WATER

section on page 40.

provides access to the system to check

shutoff

and

(11)

WELL PUMP SIZING

Strictly speaking, sizing the well pump is the responsibility of the well drilling contractor. It is important, however, that the HVAC contractor be familiar with the factors that determine what size pump will be required. Rule of thumb estimates will invariably lead to under or oversized well pumps. Undersizing the pump will result in inadequate water to the whole plumbing system but with especially bad results to the heat pump – NO HEAT / NO COOL calls will result. Oversized pumps will short cycle and could cause premature pump motor or switch failures.

The well pump must be capable of supplying enough water and at an adequate pressure to meet competing demands of water fixtures. The well pump must be sized in such a way that three requirements are met:

1. Adequate flow rate in GPM.

2. Adequate pressure at the fixture.

3. Able to meet the above from the depth of the well-feet of lift.

The pressure requirements put on the pump are directly affected by the diameter of pipe being used, as well as, by the water flow rate through the pipe. The work sheet included in Manual 2110-078 should guarantee that the

well pump has enough capacity. It should also insure that the piping is not undersized, which would create too much pressure due to friction loss. High pressure losses due to undersized pipe will reduce efficiency and require larger pumps and could also create water noise problems.

SYSTEM START UP PROCEDURE FOR OPEN LOOP APPLICATIONS

1. Be sure main power to the unit is OFF at disconnect.

2. Set thermostat system switch to OFF, fan switch to

AUTO.

3. Move main power disconnect to ON. Except as required for safety while servicing – do not open the

unit disconnect switch.

4. Check system airflow for obstructions.

A. Move thermostat fan switch to ON. Blower

runs.

B. Be sure all registers and grilles are open.

C. Move thermostat fan switch to AUTO. Blower

should stop.

5. Fully open the manual inlet and outlet valves.

6. Check water flow.

A. Connect a water flow meter to the drain cock

between the constant flow valve and the solenoid valve. Run a hose from the flow meter to a drain or sink. Open the drain cock.

B. Check the water flow rate through constant flow

valve to be sure it is the same as the unit is rated for.

C. When water flow is okay, close drain cock and

remove the water flow meter. The unit is now ready to start.

7. Start the unit in cooling mode. By moving the thermostat switch to cool, fan should be set for AUTO.

A. Check to see the solenoid valve opened.

8. Check the system refrigerant pressures against the cooling refrigerant pressure table in the installation manual for rated water flow and entering water temperatures. If the refrigerant pressures do not match, check for airflow problem that refrigeration system problem.

9. Switch the unit to the heat mode. By moving the thermostat switch to heat, fan should be set for AUTO.

A. Check to see the solenoid valve opened again.

Manual 2100-418F Page 39 of 49

10. Check the refrigerant system pressures against the heating refrigerant pressure table in installation manual. Once again, if they do not match, check for airflow problems and then refrigeration system problems.

NOTE: If a charge problem is determined (high

or low):

A. Check for possible refrigerant loss.

B. Discharge all remaining refrigerant from unit.

C. Evacuate unit down to 29 inches of vacuum.

D. Recharge the unit with refrigerant by weight.

This is the only way to insure proper charge.

WATER CORROSION

Two concerns will immediately come to light when considering a water source heat pump, whether for ground water or for a closed loop application: Will there be enough water? And, how will the water quality affect the system?

Water quantity is an important consideration and one which is easily determined. The well driller must perform a pump down test on the well according to methods described by the Nation Well Water Association. This test, if performed correctly, will provide information on the rate of flow and on the capacity of the well. It is important to consider the overall capacity of the well when thinking about a water source heat pump because the heat pump may be required to run for extended periods of time.

The second concern, about water quality, is equally important. Generally speaking, if the water is not offensive for drinking purposes, it should pose no problem for the heat pump. The well driller or local water softening company can perform tests, which will determine the chemical properties of the well water.

Water quality problems will show up in the heat pump in one of more of the following ways:

1. Decrease in water flow through the unit.

2. Decreased heat transfer of the water coil (entering to leaving water temperature difference is less).

There are four main water quality problems associated with ground water. These are:

1. Biological Growth. This is the growth of microscopic organisms in the water and will show up as a slimy deposit throughout the water system. Shock treatment of the well is usually required and this is best left up to the well driller. The treatment consists of injecting chlorine into the well casing and flushing the system until all growth is removed.

2. Suspended Particles in the Water. Filtering

will usually remove most suspended particles (fine sand, small gravel) from the water. The problem with suspended particles in the water is that it will erode metal parts, pumps, heat transfer coils, etc. So long as the filter is cleaned and periodically maintained, suspended particles should pose no serious problem. Consult with your well driller.

3. Corrosion of Metal. Corrosion of metal parts

results from either highly corrosive water (acid water, generally not the case with ground water) of galvanic reaction between dissimilar metals in the presence of water. By using plastic plumbing or dielectric unions galvanic reaction is eliminated. The use of corrosion resistant materials such as the Cupronickel coil through the water system will reduce corrosion problems significantly.

4. Scale Formation. Of all the water problems, the

formation of scale by ground water is by far the most common. Usually this scale is due to the formation of calcium carbonate by magnesium carbonate or calcium sulfate may also be present. Carbon dioxide gas (CO2), the carbonate of calcium and magnesium carbonate, is very soluble in water. It will remain dissolved in the water until some outside factor upsets the balance. This outside influence may be a large change in water temperature or pressure. When this happens, enough carbon dioxide gas combines with dissolved calcium or magnesium in the water and falls out of solution until a new balance is reached. The change in temperature that this heat pump produces is usually not high enough to cause the dissolved gas to fall out of solution. Likewise, if pressure drops are kept to a reasonable level, no precipitation of carbon dioxide should occur.

REMEDIES OF WATER PROBLEMS

Water Treatment. Water treatment can usually be economically justified for close loop systems. However, because of the large amounts of water involved with a ground water heat pump, water treatment is generally too expensive.

Acid Cleaning the Water Coil or Heat Pump Recovery Unit. If scaling of the coil is strongly

suspected, the coil can be cleaned up with a solution of Phosphoric Acid (food grade acid). Follow the manufacturer’s directions for mixing, use, etc. Refer to the “Cleaning Water Coil”, Figure 27 on page 41. The acid solution can be introduced into the heat pump coil through the hose bib A. Be sure the isolation valves are closed to prevent contamination of the rest of the system by the coil. The acid should be pumped from a bucket into the hose bib and returned to the bucket through the other hose bib B. Follow the manufacturer’s directions for the product used as to how long the solution is to be circulated, but it is usually circulated for a period of several hours.

Manual 2100-418F Page 40 of 49

PUMP

FIGURE 27

CLEANING WATER COIL

HOSE BIB (A)

ISOLATION VALVE

HOSE BIB (B)

ISOLATION VALVE

LAKE AND POND INSTALLATIONS

Lakes and ponds can provide a low cost source of water for heating and cooling with a ground water heat pump. Direct usage of the water without some filtration is not recommended as algae and turbid water can foul the water to Freon heat exchanger. Instead, there have been very good results using a dry well dug next to the water line or edge. Normal procedure in installing a dry well is to backhoe a 15 to 20 foot hole adjacent to the body of water (set backhoe as close to the water’s edge as possible). Once excavated, a perforated plastic casing should be installed with gravel backfill placed around the casing. The gravel bed should provide adequate filtration of the water to allow good performance of the ground water heat pump.

The following is a list of recommendations to follow when installing this type of system (Refer to Figure 28 on page 42):

A. A lake or pond should be at least 1 acre (40,000 a

square feet) in surface area for each 50,000 BTUs of ground water heat pump capacity or have 2 times the cubic feet size of the dwelling that you are trying to heat (includes basement if heated).

B. The average water depth should be a least 4 feet and

there should be an area where the water depth is at least 12 to 15 feet deep.

C. If possible, use a submersible pump suspended in

the dry well casing. Jet pumps and other types of suction pumps normally consume more electrical energy than similarly sized submersible pumps. Pipe the unit the same as a water well system.

D. Size the pump to provide necessary GPM for the

ground water heat pump. A 12 GPM or greater water flow rate is required on all modes when used on this type system.

E. A pressure tank should be installed in dwelling to be

heated adjacent to the ground water heat pump. A pressure switch should be installed at the tank for pump control.

F. All plumbing should be carefully sized to

compensate for friction losses, etc., particularly if the pond or lake is over 200 feet from the dwelling to be heated or cooled.

G. Keep all water lines below low water level and

below the frost line.

H. Most installers use 4-inch filed tile (rigid plastic or

corrugated) for water return to the lake or pond.

I. The drain line discharge should be located at least

100 feet from the dry well location.

J. The drain line should be installed with a slope of 2

inches per 10 feet of run to provide complete drainage of the line when the ground water heat pump is not operating. This gradient should also help prevent freezing of the discharge where the pipe terminates above the frost line.

K. Locate the discharge high enough above high water

level so the water will not back up and freeze inside the drain pipe.

L. Where the local conditions prevent the use of a

gravity drainage system to a lake or pond, you can instead run standard plastic piping out into the pond below the frost and low water level.

Manual 2100-418F Page 41 of 49

LINE

15' to 20'

DEEP

WELL CAP

FIGURE 28

WATER WELL SYSTEM

ELECTRICAL LINE

TANK

PITLESS ADAPTER

TO PRESSURE

WATER SUPPLY

PUMP

SUBMERSIBLE

DROP PIPE

GRAVEL FILL

PERFORATED

PLASTIC CASING

Manual 2100-418F Page 42 of 49

WATER LEVEL

LAKE

POND

12' to 15'

WARNING

Thin ice may result in the vicinity of the discharge line.

For complete information on water well systems and lake and pond applications, refer to Manual 2100-078 available from your distributor.

COOLING TOWER / BOILER APPLICATION

The cooling tower and boiler water loop temperature is usually maintained between 50°F to 100°F to assure adequate cooling and heating performance.

In the cooling mode, heat is rejected from the unit into the source water loop. A cooling tower provides evaporative cooling to the loop water thus maintaining a constant supply temperature to the unit. When utilizing open cooling towers chemical water treatment is mandatory to insure the water is free from corrosive minerals.

It is imperative that all air be eliminated from the source closed loop side of the heat exchanger to insure against fouling.

In the heating mode, heat is absorbed from the source water loop. A boiler can be utilized to maintain the loop at the desired temperature. In milder climates a “flooded tower” concept is often used. This concept involves adding makeup water to the cooling tower sump to maintain the desired loop temperature.

CAUTION

Water piping exposed to extreme low ambient temperatures are subject to freezing.

Units are equipped with female pipe thread fittings. Consult the specification sheets for sizes. Teflon tape sealer should be used when connection to the unit to insure against leaks and possible condenser fouling. Do not overtighten the connections. Flexible hoses should be used between the unit and the rigid system to avoid possible vibration. Ball valves should be installed in the supply and return lines for unit isolation and unit water flow rate balancing.

Pressure / temperature ports are recommended in both supply and return lines for system flow balancing. Water flow can be accurately set by measuring the refrigerant to water heat exchangers water side pressure drop. See Table 10 for water flow and pressure drop information.

TABLE 10

WATER FLOW AND PRESSURE DROP

,D124WQ,D163WQ

D242WQD203WQ

MPG

300.113.2

424.182.300.113.2

538.122.434.103.308.151.4

642.271.568.192.482.375.7

766.241.603.213.577.410.11

837.203.662.664.4103.336.7

957.709.7103.449.9

0142.943.1200.555.11 11 00.668.31 21 00.771.61 31 02.859.81

GISP.dH.tFGISP.dH.tFGISP.dH.tFGISP.dH.tF

D184WQD106WQ

Manual 2100-418F Page 43 of 49

SERVICE

SERVICE HINTS

1. Maintain clean air filters at all times. Also, do not needlessly close off supply and return air registers. This reduces airflow through the system, which shortens equipment service life as well as increasing operating costs.

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

UNBRAZING SYSTEM COMPONENTS

If the refrigerant charge is removed from a scroll equipped unit by bleeding the high side only, it is sometimes possible for the scrolls to seal, preventing pressure equalization through the compressor. This may leave low side shell and suction line tubing pressurized. If the brazing torch is then applied to the low side while the low side shell and suction line contains pressure, the pressurized refrigerant and oil mixture could ignite when it escapes and contacts the brazing flame. To prevent this occurrence, it is important to check both the high and low side with manifold gauges before unbrazing.

WARNING

Both the high and low side of the scroll compressor must be checked with manifold gauges before unbrazing system components. Failure to do so could cause pressurized refrigerant and oil mixture to ignite if it escapes and contacts the brazing flame causing property damage, bodily harm or death.

Manual 2100-418F Page 44 of 49

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 •

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

• Air noise • High static creating high blower speed?

• 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

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

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?

Manual 2100-418F Page 45 of 49

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 29. 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 30. (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 through-bolts 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.

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 8o’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 31.

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 30

Figure 4

Winding Test

R > 100k ohm

Figure 31

Figure 5

Drip Loop

Connector Orientation

Between 4 and 8 o'clock

Drip Loop

Motor OK when

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 29

Figure 3

From Motor

Circuit Board

Motor

Motor Connector (3-pin)

Control Connector

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

Motor Connector (3-pin)

Manual 2100-418F Page 46 of 49

AUX.

Heat Gen.

otor

ower

and Coil

oor

INDOOR SECTIONPOWER SUPPLY

ev.

Valve Water Coil

ater

Solenoid

WATER COIL SECTION

Line Voltage Control Circuit Compressor Refrigerant System

QUICK REFERENCE TROUBLESHOOTING CHART FOR WATER TO AIR HEAT PUMP

Auxillary Heat Upstream of Coil

Undersized or Restricted Ductwork

Air Filters Dirty

Air Volume Low

Motor Winding Defective

Fins Dirty or Plugged

Plugged or Restricted Metering Device (Clg)

Low Water Temperature (Htg)

Water Volume Low (Clg)

Water Volume Low (Htg)

Scaled or Plugged Coil (CLg)

Scaled or Plugged Coil (Htg)

Plugged or Restricted Metering Device (Htg)

Defective Valve or Coil

Leaking

Solenoid Valve Stuck Open (Htg or Clg)

Solenoid Valve Stuck Closed (Clg)

Solenoid Valve Stuck Closed (Htg)

Unequalized Pressures

Non-Condensables

Low Suction Pressure

High Suction Pressure

Low Head Pressure

High Head Pressure

Refrigerant Overcharge

Refrigerant Charge Low

Motor Wingings Defective

Valve Defective

Seized

Bearings Defective

Discharge Line Hitting Inside of Shell

Indoor Blower Relay

Pressure Controls (High or Low)

Contactor Coil



Thermostat

Low Voltage



Control Transformer

Loose Terminals

Faulty Wiring



Start Capacitor

Run Capacitor

Potential Relay

Compressor Overload

Defective Contacts in Contactor



Low Voltage

Loose Terminals

Faulty Wiring

Blown Fuse or Tripped Breaker

Power Failure



 



 











   







 







































 







 























  

 





 

 











 



  





 







 



 

 



DENOTES COMMON CAUSE

DENOTES OCCASIONAL CAUSE





Compressor Will Not Run

No Power at Contactor

Compressor Will Not Run

Power at Contactor

Compressor "Hums"

But Will Not Start

Compressor Cycles on Overload

Thermostat Check Light

Lite-Lockout RelayCompressor Off on High

Pressure Control

Compressor Off on Low

Pressure Control

Compressor Noisy

Head Pressure Too High

Head Pressure Too Low

Suction Pressure Too High

Suction Pressure Too Low

I.D. Blower Will Not Start

I.D. Coil Frosting or Icing

High Compressor Amps

Excessive Water Usage

Compressor Runs Continuously

– No Cooling

Liquid Refrigerant Flooding Back

To Compressor

Compressor Runs Continuously

– No Heating

Reversing Valve Does Not Shift

Liquid Refrigerant Flooding Back

To Compressor

Cycle

Heating or Cooling Cycles

Cooling

Aux. Heat on I.D. Blower Off

Manual 2100-418F Page 47 of 49

Excessive Operation Costs

Ice in Water Coil

Heating Cycle

GROUND SOURCE HEAT PUMP

PERFORMANCE REPORT

This performance check report should be filled out by installer and retained with unit.

DATE: TAKEN BY:

1. UNIT: Mfgr Model # S/N

THERMOSTAT: Mfgr Model # P/N

2. Person Reporting

3. Company Reporting

4. Installed By Date Installed

5. User’s (Owner’s) Name

Address

6. Unit Location

WATER SYSTEM INFORMATION

7. Open Loop System (Water Well) Closed Loop System

A. If Open Loop where is water discharged?

8. The following questions are for

Closed Loop systems only

A. Closed loop system designed by

B. Type of antifreeze used: % Solution

C. System type: Series Parallel

D. Pipe Material Nominal Size

E. Pipe Installed:

1. Horizontal Total length of pipe ft

No. pipes in trench Depth bottom pipe ft

2. Vertical Total length of bore hole ft

Manual 2100-418F Page 48 of 49

THE FOLLOWING INFORMATION IS NEEDED

TO CHECK PERFORMANCE OF UNIT

FLUID SIDE DATA Cooling ** Heating

9. Entering fluid temperature F

10. Leaving fluid temperature F

11. Entering fluid pressure PSIG

12. Leaving fluid pressure PSIG

13. Pressure drop through coil PSIG

14. Gallons per minute through the water coil GPM

15. Liquid or discharge line pressure PSIG

16. Suction line pressure PSIG

17. Voltage at compressor (unit running) V

18. Amperage draw at line side of contactor A

19. Amperage at compressor common terminal A

20. * Suction line temperature 6” from compressor F

21. * Superheat at compressor F

22. * Liquid line temperature at metering device F

23. * Coil subcooling F

INDOOR SIDE DATA Cooling ** Heating

24. Dry bulb temperature at air entering indoor coil F

25. Wet bulb temperature of air entering indoor coil F

26. Dry bulb temperature of air leaving indoor coil F

27. Wet bulb temperature of air leaving indoor coil F

28. * Supply air static pressure (packaged unit) WC

29. * Return air static pressure (packaged unit) WC

30. Other information about installation

** When performing a heating test insure that second stage heat is not activated. * Items that are optional

Manual 2100-418F Page 49 of 49

Bard QW242D, QW481D, QW601D, QW302D, QW361D Installation Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual