Bard QW3S1, QW4S1, QW2S1, QW5S1 User Manual

QW SERIES

GEOTHERMAL R-410A

INSTALLATION

STAGED CAPACITY

INSTRUCTIONS

PACKAGED HEAT PUMP

Models:

QW2S1 QW3S1

QW4S1 QW5S1

Earth Loop Fluid

Temperatures 25 – 110

Ground Water Temperature 45 – 75

MIS-2736

Bard Manufacturing Company, Inc.	Manual No.:		2100-532B
Bryan, Ohio 43506	Supersedes:		2100-532A
Since 1914...Moving ahead, just as planned.	File:		Vol II Tab 14
	Date:		07-19-10
		Manual 2100-532B
		Page	1 of 46

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 & 14
Installation Instructions
Mounting the Unit ..................................................		15
Wiring – Main Power .............................................		18
Wiring – Low Voltage Wiring .................................		18
General ..................................................................		18
Low Voltage Connections ......................................		19
Start Up
Description of Standard Equipment .......................		23
Compressor Control Module ..................................		23
Adjustments ...........................................................		23
Optional CFM ........................................................		24
Important Installer Note .........................................		24
Phase Monitor .......................................................		24
Service Hints .........................................................		24
Sequence of Operation..................................	24 & 25
Pressure Service Ports ..........................................		25
Pressure Tables .....................................................		28
Optional Accessories .............................................		29

Manual 2100-532B

Page 2 of 46

Closed Loop (Earth Coupled Ground LoopApplications)
Circulation System Design ....................................	30
Copper Water Coil Application...............................	30
Start Up Procedure for Closed Loop System .........	31
Open Loop (Well System Applications)
Water Connections ................................................	33
Well Pump Sizing ..................................................	34
Start Up Procedure for Open Loop System ...	34 & 35
Water Corrosion ....................................................	35
Remedies of Water Problems ................................	35
Lake and Pond Installations ..................................	36
Cooling Tower / Boiler Application .........................	38
Service
Unbrazing System Components ............................	41
Troubleshooting GE ECM™ Blower Motors ...	42-43
Quick Reference Troubleshooting Chart for
Water to Air Heat Pump..........................................	44
Ground Source Heat Pump
Performance Report ..........................................	45-46

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 8A	Condensate Drain ................................	12
Figure 8B	Optional Rear Drain .............................	12
Figure 8C	Rear Drain (Top View)..........................	13
Figure 9	Removal of Q-TEC ERV ........................	14
Figure 10	Remove Locking Screws from Wheels 15
Figure 11	Unit Mounting Without Wall Sleeve .....	16
Figure 12	Component Location............................	17
Figure 13	Low Voltage Wire Harness Plug ..........	19
Figure 14	Remote Thermostat Wiring "X" Option	20
Figure 15	Remote Thermostat Wiring "D" Option	21
Figure 16	Remote Thermostat Wiring "H" Option	22
Figure 17	Fluid Connections w/Ventilation
	Wall Sleeve ..........................................	26
Figure 18	Fluid Connections w/o Ventilation
	Wall Sleeve ..........................................	27
Figure 19	Circulation System ...............................	30
Figure 20	Water Temperature and Pressure
	Test Procedure..................................	31
Figure 21	Performance Model WGPM-1C ...........	32
Figure 22	Performance Model WGPM-2C ...........	32
Figure 23	Piping Diagram ....................................	33
Figure 24	Cleaning Water Coil .............................	36
Figure 25	Water Well System ..............................	37
Figure 26	Water Source H/P Cooling Cycle .........	39
Figure 27	Water Source H/P Heating Cycle ........	40
Figure 28	Control Disassembly ............................	43
Figure 29	Winding Test ........................................	43
Figure 30	Drip Loop .............................................	43

Tables
Table 1	Electrical Specifications ...........................	5
Table 2 Operating Voltage Range .......................		18
Table 3	Wall Thermostats ...................................	18
Table 4 Indoor Blower Performance ...................		25
Table 5	Pressures ...............................................	28
Table 6	Optional Accessories .............................	29
Table 7 Constant Flow Valves.............................		33
Table 8 Water Flow and Pressure Drop ..............		38

Manual	2100-532B
Page	3 of 46

GETTING OTHER INFORMATION AND PUBLICATIONS

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

National Electrical Code ......................	ANSI/NFPA 70
Standard for the Installation ..............	ANSI/NFPA 90A
of Air Conditioning and Ventilating Systems
Standard for Warm Air ......................	ANSI/NFPA 90B
Heating and Air Conditioning Systems
Load Calculation for Residential .......	ACCA Manual J
Winter and Summer Air Conditioning
Duct Design for Residential .............	ACCA Manual D
Winter and Summer Air Conditioning and Equipment
Selection
Closed-Loop/Ground Source Heat Pump ........		IGSHPA
Systems Installation Guide
Grouting Procedures for Ground-Source .........		IGSHPA
Heat Pump Systems
Soil and Rock Classification for the Design ....		IGSHPA
of Ground-Coupled Heat Pump Systems
Ground Source Installation Standards	.............	IGSHPA
Closed-Loop Geothermal Systems – Slinky ....		IGSHPA
Installation Guide

FOR MORE INFORMATION, CONTACT THESE PUBLISHERS:

ACCA	Air Conditioning Contractors of America
	1712 New Hampshire Avenue
	Washington, DC 20009
	Telephone: [phone]
	Fax: [phone]
ANSI	American National Standards Institute
	11 West Street, 13th Floor
	New York, NY 10036
	Telephone: [phone]
	Fax: [phone]
ASHRAE	American Society of Heating Refrigerating,
	and Air Conditioning Engineers, Inc.
	1791 Tullie Circle, N.E.
	Atlanta, GA 30329-2305
	Telephone: [phone]
	Fax: [phone]
NFPA	National Fire Protection Association
	Batterymarch Park
	P.O. Box 9101
	Quincy, MA 02269-9901
	Telephone: [phone]
	Fax: [phone]
IGSHPA	International Ground Source
	Heat Pump Association
	490 Cordell South
	Stillwater, OK 74078-8018

Manual	2100-532B
Page	4 of 46

QW SERIES GEOTHERMAL R-410A STAGED CAPACITY GENERAL INFORMATION

QW MODEL NOMENCLATURE

QW 3 S

MODEL NUMBER |

Q-Tec™ Model

CAPACITY |

2 - 2 Ton

3 - 3 Ton STEP CAPACITY |

4 - 4 Ton

5 - 5 Ton

REVISION |

1 A 0Z B

KW

SPECIALTY 0Z - OKW

PRODUCTS

VOLTS &

PHASE

A - 230/208/60/1

B - 230/208/60/3

C - 460/60/3

VENTILATION OPTIONS

B - Blank-off Plate

V - Commercial Room Ventilator w/Multi-Position Control. Can also be modulating with CO2 control.

R- Energy Recovery Ventilator w/Independent Intake/Exhaust Control.

X

4

X

C

X

COIL OPTIONS

FILTER OPTIONS

X - 2-Inch Pleated

C - Copper (water)

(MERV6)

N - Cupronickel

INTERNAL CONTROLS

COLOR

X • High Pressure Switch

4 - Buckeye Gray paint

• Low Pressure Switch

X - Beige paint

• Compressor Control Module

V - Platinum w/Slate

w/Time Delay

Front (Vinyl)

• Phase Monitor (3-PH)

CLIMATE CONTROL

Standard -

X - None

D - Electronic/Prog/Man/Auto

H - Electronic/Prog with CO2 control

TABLE 1

ELECTRICALSPECIFICATIONS

SINGLE CIRCUIT

		2	1	1
				MAXIMUM
				EXTERNAL
	RATED	NO. FIELD	MINIMUM	FUSE OR
	VOLTS, Hz	POWER	CIRCUIT	CIRCUIT
MODEL	& PHASE	CIRCUITS	AMPACITY	BREAKER
QW2S1-A0Z 230/208-60-1		1	19	30
QW2S1-B0Z 230/208-60-3		1	14	20
QW2S1-C0Z 460-60-3		1	7	15
QW3S1-A0Z 230/208-60-1		1	26	40
QW3S1-B0Z 230/208-60-3		1	20	30
QW3S1-C0Z 460-60-3		1	9	15
QW4S1-A0Z 230/208-60-1		1	31	50
QW4S1-B0Z 230/208-60-3		1	27	40
QW4S1-C0Z 460-60-3		1	11	20
QW5S1-A0Z 230/208-60-1		1	39	60
QW5S1-B0Z 230/208-60-3		1	29	45
QW5S1-C0Z	460-60-3	1	17	25

1Maximum size of the time delay fuse or HACR type circuit breaker for protection of field wiring conductors.

2These “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	2100-532B
Page	5 of 46

Page	Manual
46 of 6	532B-2100

FIGURE 1

UNIT DIMENSIONS

	SUPPLY AIR OPENING	2 1/16"		UNIT	DIM. "A"	DIM. "B"	DIM. "C"	DIM. "D"
	2 7/16"		2 15/16"
				QW2S, QW3S	8 5/8"	42"	30"	43"
		1 3/4"
			(OPTIONAL) HIGH VOLTAGE	QW4S, QW5S	8 3/4"	48"	40"	49"
	9 15/16"		ELECTRICAL ENTRANCE

20 3/8"	(DUCT SIZE)			LOW VOLTAGE
			6 3/4"	ELECTRICAL ENTRANCE
				(OPTIONAL) LOW VOLTAGE
		24 15/16"	7/8"	ELECTRICAL ENTRANCE
	TOP VIEW	(DUCT SIZE)
(SHOWN WITHOUT			3 3/16"		(OPTIONAL) LOW VOLTAGE
FREEBLOW PLENUM)		"A"
					ELECTRICAL ENTRANCE
				FREEBLOW	(OPTIONAL) HIGH VOLTAGE
		"B"	1 1/8"	PLENUM BOX	ELECTRICAL ENTRANCE
				(OPTIONAL)
		"C"			1 15/16"
	SUPPLY AIR			1 11/16"
14"			11 3/4"
	GRILLE

3 3/4"

3 3/8"

3 3/8"

16 5/8"	(OPTIONAL)	CIRCUIT BREAKER
	THERMOSTAT
		ACCESS AND LOCKING
		COVER

		(OPTIONAL)
	CO2 SENSOR		RETURN AIR
37 1/8"		FILTER	GRILLE
104"
		ACCESS
		DOOR	15 5/8"
			68 3/4"
			"C"
36 1/16"			36 7/8"
	CONDENSER
		DOOR
			"D"
			FRONT VIEW

3 1/16"

(OPTIONAL) HIGH VOLTAGE ELECTRICAL ENTRANCE

ACCESS FOR FLUID

CONNECTION FOR DORFC PUMP APPLICATION

6 7/8"

3"

FLUID CONNECTION POINTS FOR FACTORY

RIGHT SIDE VIEW INSTALLED PUMP OPTIONS 3, 4, OR 5 (INLET ON LEFT,

OUTLET ON RIGHT AS VIEWED FROM BACK OF UNIT)

8"

19"

BACK VIEW

VENT EXHAUST

VENT

INTAKE

5 15/16"

5 1/4"

33 9/16"

20"

MIS-2737 B

SHIPPING DAMAGE

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

UNIT REMOVAL FROM SKID

WARNING

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

It is recommended that the unit not be removed from the skid with a forklift.

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

HANDLING UNIT AFTER REMOVAL FROM SKID

WARNING

Exercise extreme caution when pushing the unit on the rollers. Handle and push from the lower 1/3 of the unit. Insure that debris is not on the floor where the unit is to be moved on the rollers. Failure to do so could result in the unit tipping over and causing bodily injury and/or damage to the unit.

The unit will have to be turned sideways and removed from the skid to fit through a 36" doorway. If the door height allows, the unit can be slid sideways through the door.

If the unit can not be slid through the door, then the unit will have to be put on a cart and tipped down to roll through the door. It is recommended that an appliance cart be 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

REMOVAL OF UNIT FROM SKID

HOLD SKID DOWN

A SHIPPING BRACKETS

B FRONT WHEELS OVER EDGE

C FRONT WHEELS ON FLOOR

Manual	2100-532B
Page	7 of 46

FIGURE 3

PROPER HANDLING OF UNIT

AFTER REMOVAL FROM SKID

Q-Tec UNIT

(RIGHT SIDE)

STRAP

APPLIANCE CART

COMPRESSOR

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. 9 in. This provides enough clearance for the plenum to be removed. See Figure 5.

The minimum installation height for ducted applications is 8 ft. 9 in. This provides enough clearance to install the duct work. See Figure 6.

Manual	2100-532B
Page	8 of 46

FIGURE 4

INSTALLATION OF UNIT THROUGH WALL WITH WALL SLEEVE

14" to 5"

QW2S, QW3S - 42.000"

QW4S, QW5S - 48.000"

SUPPLY AIR
OPTIONAL FREE	(X)	18 9/16"

BLOW PLENUM BOX

HIGH VOLTAGE ELECTRICAL ENTRANCE (TOP-REAR-SIDE)

RETURN AIR

84 1/4"

103 7/8"

BOTTOM

TRIM PIECE

5"

PERMANENT ROLLERS

WALL SLEEVE

VENTILATION

AIR DIVIDER

33 7/8"

28 7/8"

17 9/16"

35"

6 1/8"

29 1/2"

MIST ELIMINATOR

33"

LOW VOLTAGE ELECTRICAL ACCESS (TOP-SIDE)

CIRCUIT BREAKER, ROTARY,

OR TOGGLE DISCONNECT

AND LOCKING COVER

MIS-2739 A

Manual	2100-532B
Page	9 of 46

FIGURE 5

INSTALLATION WITH FREE BLOW PLENUM

8 FT. - 9 IN.

8 FT. - 8 IN. MINIMUM REQUIRED INSTALLATION HEIGHT

FLOOR

MIS-2740

FIGURE 6

DUCTEDAPPLICATION

SUSPENDED CEILING

	FIXED CEILING	DUCT
25 IN.
MINIMUM		DUCT FLANGE
	12 IN.
	MINIMUM
	2 IN. MINIMUM
	FROM DUCT FLANGE
	TO DUCT BOTTOM

	7 FT. - 6 IN.					9 FT.			8 FT. - 9 IN.
				MINIMUM REQUIRED					MINIMUM REQUIRED
	UNIT HEIGHT
				INSTALLATION HEIGHT					INSTALLATION HEIGHT

FLOOR

MIS-2741

Manual	2100-532B
Page	10 of 46

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 Q-Tec 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 Q-Tec 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.

FIGURE 7

SUPPLY DUCT CONNECTIONS

SUPPLY DUCT TO

BE FIELD SUPPLIED

ATTACHMENT

SCREWS TO

BE FIELD

SUPPLIED

DUCT FLANGE

PROVIDED WITH UNIT

ROOM SIDE

OF QW UNIT

MIS-2742

When used with a ducted supply, a QCX Cabinet Extension can be used to conceal the duct work above the unit to the ceiling. This extends 20" above the unit for a total height above the floor of 10'-7/8". The unit is equipped with a variable speed indoor blower motor which increases in speed with an increase in duct static pressure. The unit will therefore deliver proper rated 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 2-inch pleated filters are supplied with each unit. The filters fit into a fixed rack.

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

The internal filter brackets are adjustable to accommodate 1-inch filters. The tabs for the 1-inch filters must be bent up to allow the 1-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.

If the drain is to be hard plumbed, there is a 3/4 inch FPT pipe connection located on the cabinet rear panel. In these installations, the drain tube is to be slipped over the pipe connection inside of the cabinet; this is how it is shipped from the factory. (See Figure 8C.)

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. (See Figure 8A.)

NOTE: Whichever type of drain connection is used a “P” trap must be formed. See Figure 8A.

Manual	2100-532B
Page	11 of 46

FIGURE 8A

CONDENSATEDRAIN

LOOP TO FORM

A "P" TRAP

DRAIN HOSE

EXTERNAL

DRAIN TUBE

ALTERNATE

FLOOR DRAINING OPTION

FRONT VIEW WITH CONDENSER DOOR REMOVED

MIS-2743

Thedraincanberoutedthroughthefloororthroughthewall. Ifthedrainistoberoutedthroughanunconditioned space, it must be protected from freezing. The drain line must be able to be removed from the unit if it is necessary to remove the unit from the wall.

FIGURE 8B

OPTIONAL REAR DRAIN

Manual	2100-532B
Page	12 of 46

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	COUPLINGS NOT
	SHOWN BUT
	RECOMMENDED
	FOR EASE OF
	REMOVABILITY
	FOR SERVICE
	WALL BRACKET
WATER
TRAP
	UNIT

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.

COMMERCIAL ROOM VENTILATOR OPTION

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

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

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

3.Slide the CRV straight out of the unit.

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

Manual	2100-532B
Page	13 of 46

Q-TEC 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 9.

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

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

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

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

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

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

FIGURE 9

REMOVAL OF THE Q-TEC ENERGY RECOVERY VENTILATOR

POWER

CONNECTORS

MOUNTING

SCREWS

LOWER

BLOWER

ASSEMBLY POWER CONNECTOR

FRONT FILL

Manual	2100-532B
Page	14 of 46

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 11.

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

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

3.Remove the locking screws from the wheels. Refer to Figure 10.

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

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

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

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

FIGURE 10

REMOVING LOCKING SCREWS FROM

WHEELS

REMOVE SCREWS

FROM WHEELS

BEFORE ROLLING

INTO PLACE

Manual	2100-532B
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FIGURE 11

UNIT MOUNTING WITHOUT VENTILATION WALL SLEEVE

SIDE TRIM CUT

TO LENGTH

WALL MOUNTING

BRACKET

41"

ADJUSTABLE SIDE TRIM EXTENSION KIT -ORDERED

SEPARATELY

BASE TRIM

SIDE TRIM

EXTENSION

BASE TRIM

EXTENSION

MIS-2744 A

Manual	2100-532B
Page	16 of 46

FIGURE 12

COMPONENTLOCATION

SIDE FIELD

WIRE ENTRANCE

REMOTE THERMOSTAT

TERMINAL BLOCK

INDOOR DUAL BLOWERS

CONTROL BOX/ CIRCUIT

BREAKER PANEL

MIS-2745

Manual	2100-532B
Page	17 of 46

WIRING – MAIN POWER

Refer to the unit rating plate and/or Table 2 for wire sizing information and maximum fuse or “HACR Type” circuit breaker size. Each unit is marked with a “Minimum Circuit Ampacity”. This means that the field wiring used must be sized to carry that amount of current. Depending on the installed KW of electric heat, there may be two field power circuits required. If this is the case, the unit serial plate will so indicate. All models are suitable only for connection with copper wire. Each unit and/or wiring diagram will be marked “Use Copper Conductors Only”. These instructions must be adhered to. Refer to the National Electrical Code (NEC) for complete current carrying capacity data on the various insulation grades of wiring material. All wiring must conform to NEC and all local codes.

The electrical data lists fuse and wire sizes (75°C copper) for all models, including the most commonly used heater sizes. Also shown are the number of field power circuits required for the various models with heaters.

The unit rating plate lists a “Maximum Time Delay Relay Fuse” or “HACR Type” circuit breaker that is to be used with the equipment. The correct size must be used for proper circuit protection, and also to assure that 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.

TABLE 2

OPERATING VOLTAGE RANGE

TAP	RANGE
240V	253 - 216
208V	220 - 187

NOTE: The voltage should be measured at the field power connection point in the unit and while the unit is operating at full load (maximum amperage operating condition).

The standard Climate Control Option X is a remote thermostat connection terminal block. See Figure 14 for wiring diagram. Compatible thermostats are listed in Table 3.

The Climate Control Option D is an electronic, programmable thermostat. The subbase of the thermostat is factory wired to the front panel of the unit. See Figure 15 for wiring diagram. Compatible for use with Energy Recovery Ventilator or Economizer.

The Climate Control Option H is an electronic, programmable thermostat and CO2 controller. The subbase of the thermostat and CO2 controller are factory wired to the front panel of the unit. See Figure 16 for wiringdiagram.

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.

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
	WALL THERMOSTATS
Thermostat	Predominant Features
	3 stage Cool; 3 stage Heat
8403-060	Programmable/Non-Programmable Electronic
(1120-445)	HP or Conventional
	Auto or Manual changeover

Manual	2100-532B
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LOW VOLTAGE CONNECTIONS

The “R” terminal is the 24 VAC hot terminal and is supplied through Pin #10 of Plug P2.

The “C” terminal is the 24 VAC common/grounded terminal and feeds through Pin #11 of Plug P2.

The “G” terminal is the indoor blower input signal and feeds through Pin #6 of Plug P2.

The “Y1” terminal is the compressor starting signal and feeds through Pin #7 of Plug P2.

The “Y2” terminal is the compressor staging solenoid signal and feeds through Pin #4 of Plug P2.

The “O” terminal is the reversing valve signal and feeds through Pin #8 of Plug P2.

The “A” terminal is the ventilation demand signal and outputs a signal for ventilation during occupied programming conditions, and feeds through Pin #5 of Plug P2.

The “W2” terminal is the electric heat signal and feeds through Pin #9 of Plug P2.

The “W1/E” terminal is the emergency heat signal and feeds through Pin #3 of Plug P2.

The “L” terminal is used as an input terminal when a CS2000 infrared occupancy device is used. It feeds through Pin #12 of Plug P2.

The “D” terminal is used only of dehumidification models and feeds through Pin #1 of Plug P2.

LOW VOLTAGE CONNECTIONS FOR

DDC CONTROL

Fan Only	Energize G
Ventilation	Energize G, A (any mode of operation)
Part Load Cooling	Energize G, Y1, O
Full Load Cooling	Energize G, Y1, Y2, O
Part Load HP Heating	Energize G, Y1
Full Load HP Heating	Energize G, Y1, Y2
Electric Heat	Energize G, W2
Dehumidification	Energize G, D, O

FIGURE 13

BLOWER MOTOR LOW VOLTAGE

WIRE HARNESS PLUG

MIS-1285

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Page	19 of 46

FIGURE 14

REMOTE THERMOSTAT WIRING DIAGRAM

“X” OPTION

Temp. and Humidity
Controller	Low Voltage
Part #8403-060	Terminal Strip
W1/E	E
Y2	Y2
A	A
G	G
Y1	Y1
O/B	O
W2	W2
R	R
C	C
L	L
D/YO
CO2 Controller
Part #8403-056
	Red
24VAC
	Black
Analog	Yellow
Out
	Brown
	Orange
	Green

Red/Yellow

Purple

Brown/White

Orange

Yellow

Blue

Brown

Red/White

Black/White

Pink

Terminal

Strip

Red

Black

Yellow

Brown

Orange

Green

Purple/White

PLUG #2 1 2 3 4 5 6 7 8 9 10 11 12

PLUG #1 1 2 3 4 5 6

4115-102 A

Manual	2100-532B
Page	20 of 46

FIGURE 15

REMOTE THERMOSTAT WIRING DIAGRAM

“D” THERMOSTAT OPTION

	D/YO	Purple/White
	W1/E	Red/Yellow
	Y2	Purple
	A	Brown/White
Temp. and Humidity	G	Orange
Controller		Yellow
Part #8403-060	Y1
	O/B	Blue
	W2	Brown
	R	Red/White
	C	Black/White
	L	Pink

PLUG #2 1 2 3 4 5 6 7 8 9 10 11 12

4115-100 A

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Page	21 of 46

FIGURE 16

REMOTE THERMOSTAT PLUG CO2 VENT CONTROL WIRING DIAGRAM

“H” THERMOSTAT OPTION

	D/YO
	W1/E
	Y2
	A
Temp. and Humidity	G
Controller
Part #8403-060	Y1
	O/B
	W2
	R
	C
	L

CO2 Controller

Part #8403-056

24VAC

Analog

Out

Purple/White

Red/Yellow

Purple

Brown/White

Orange

Yellow

Blue

Brown

Red/White

Black/White

Pink

Red

Black

Yellow

Brown

Orange

Green

PLUG #2 1 2 3 4 5 6 7 8 9 10 11 12

		PLUG #1
	Red	1
		2
	Black
		3
	Yellow
		4
	Brown
		5
	Orange
		6
	Green

4115-101 A

Manual	2100-532B
Page	22 of 46

START UP

DESCRIPTION OF STANDARD

EQUIPMENT

LOW PRESSURE SWITCH

NOTE: This unit is supplied with two low pressure switches installed, a 45 PSIG and a 60 PSIG.

The 60 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 60 PSIG switch should be disconnected and connect the 45 PSIG switch.

The leads for both switches are located in the lower electrical connection panel. The switch bodies are marked with pressure settings. The 60 PSIG switch has blue leads. The 45 PSIG switch has yellow 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.

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 standard on 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

LOCKOUTSEQUENCE

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 24.

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

Manual	2100-532B
Page	23 of 46

	DELAY ON MAKE TIMING
.05 minutes	(30 seconds)	DOB	= 123 seconds DOM
1.0 minutes	(60 seconds)	DOB	= 126 seconds DOM
2.0 minutes	(120 Seconds)	DOB	= 132 seconds DOM
3.0 minutes	(180 seconds)	DOB	= 138 seconds DOM
4.0 minutes	(240 seconds)	DOB	= 144 seconds DOM
5.0 minutes	(300 seconds)	DOB	= 150 seconds DOM

OPTIONAL CFM SERVICE HINTS

All models covered by this Manual are factory set to operate at rated CFM levels as shown in Table 4. Rated CFM is required for ducted applications for maximum performance ratings.

For free blow applications where Full Load Rated CFM is undesirable due to sound levels, there is an optional CFM that can be obtained (-10%). This CFM level will reduce the system capacity performance by approximately 2% at the same energy efficiency.

For Full Load Optional CFM:

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

2.Open hinged return air grille service panel.

3.Open control panel cover.

4.Locate low voltage terminal strip and purple wire with white trace that connects to terminal “Y2”. Disconnect this wire from terminal “Y2” and tape off end.

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.

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.

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

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

SEQUENCE OF OPERATION

COOLING – A 24V solenoid coil on the reversing valve controls the cooling cycle operation. There are two different thermostat options. 1.) Allows for “Auto” changeover from cycle to cycle. 2.) The other (Manual changeover). The Auto changeover mode will cause the reversing valve solenoid to cycle with each cooling call and may cause a “swooshing sound” with refrigerant equalization at the end of each cycle.

On a call for Part Load Cooling by the thermostat, it completes a circuit from “R” to “Y1”, “O” and “G” for part load cooling. “Y1” starts the compressor, “O” energizes the reversing valve and “G” starts the indoor blower.

On a call for Full Load Cooling by the thermostat, it completes the same as Part Load Cooling above, but also includes a signal to “Y2”. Signal “Y2” energizes the staging solenoid on the side of the compressor and the signal also goes to the indoor blower to ramp-up the airflow.

HEATING – On a call for Part Load Heating by the thermostat, it completes a circuit from “R” to “Y1” and “G”. “Y1” starts the compressor and “G” starts the indoor blower.

On a call for Full Load Heating by the thermostat, it completes the same as Part Load Heating above, but also includes a signal to “Y2”. Signal “Y2” energizes the staging solenoid on the side of the compressor and the signal also goes to the indoor blower to ramp-up the airflow.

Manual	2100-532B
Page	24 of 46

PRESSURE SERVICE PORTS

High and low pressure service ports are installed on all units so that the system operating pressures can be observed. Pressure charts are located on the backside of the units lower service door, as well as later in this Manual (Table 5). It is imperative to match the correct pressure chart to the unit by model number. All upper service doors must be attached to obtain proper reading. The service ports are in the lower compressor section on the tubing adjacent to the compressor.

PIPING ACCESS TO UNIT

Water piping to and from the coaxial water coil is intended to enter/exit the unit through the rectangular hole (See Figures 1, 8A, 17 and 18). The connections on the water coil are a double O-ring with a retainer nut that secures it in place.

Various double O-ring fittings are available so you may then connect to the coaxial coil with various methods and materials. The methods include 1" barbed fittings (straight and 90°), 1" MPT (straight and 90°), and 1¼" hot fusion fitting with P/T fitting). (See Table 6.)

Note: All double O-ring fittings require “hand tightening only”. Do not use a wrench or pliers as retainer nut can be damaged with excessive force. Avoid cross-threading the nut.

TABLE 4

INDOOR BLOWER PERFORMANCE

		1	4		3
MODEL	RATED		CONTINUOUS	1st STAGE	OPTIONAL	2nd STAGE
	ESP	MAX. ESP	AIRFLOW		2nd STAGE
QW2S1	0.0	0.5	800	800	900	1000
QW3S1	0.0	0.5	800	900	1050	1150
QW4S1	0.0	0.5	900	1150	1225	1350
QW6S1	0.0	0.5	900	1250	1300	1450

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

1 Maximum ESP (inches WC) shown is with 2" MERV 6 pleated filter.

2 Rated CFM for ducted applications – required for maximum performance rating. To obtain full CFM on models QW3S1, QW4S1 and QW5S1, locate pink wire that is secured to purple wire at low voltage terminal strip in the control box, and attach it to the “Y2” terminal along with the purple wire.

3Optional 2nd Stage 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 CFM the total airflow being circulated during continuous blower operation.

Manual	2100-532B
Page	25 of 46

FIGURE 17

FLUID CONNECTIONS ON UNIT WITH VENTILATION WALL SLEEVE

SIDE TRIM PEICES (SHIPPED WITH UNIT)

FLUID ACCESS

FROM CEILING

SLEEVE
FLUID ACCESS	TOP OF UNIT
FROM EACH SIDE	BACK OF UNIT

66 1/2"
	34"
	29"
OPENING IN
REAR OF UNIT
3" x 8"
FLUID ACCESS	8 1/2"
FROM FLOOR
23 1/2"

SIDE TRIM PIECES (SHIPPED WITH UNIT) IF THE WALL THICKNESS IS LESS THAN 14" BUT GREATER THAN 8", A SIDE TRIM EXTENSION KIT QSTX42 IS REQUIRED. REFER TO UNIT SPEC. SHEET FOR PROPER COLOR

FLUID ACCESS FROM

CEILING

8" TO 14" EXTERIOR WALL

FLUID ACCESS

FROM EACH SIDE

SLEEVE

WALL OPENING 35" x 29 1/2"

MOUNTING BRACKETS (SHIPPED WITH UNIT)

33" REF.

FLOOR

MIS-2746

Manual	2100-532B
Page	26 of 46

FIGURE 18

FLUID CONNECTIONS ON UNIT WITHOUT VENTILATION WALL SLEEVE

TOP VIEW

WALL BRACKET

WALL BRACKET

	4"
WATER LINES	WALL LOCATION
BACK OF UNIT

FLUID ACCESS

FROM TOP

66 1/2"

OPENING IN REAR OF UNIT 3" x 8"

8 1/2"

23 1/2"

WALL BRACKET (LEFT BRACKET REMOVED FOR CLARITY)

FLOOR

MIS-2747

FLUID ACCESS FROM FLOOR

Manual	2100-532B
Page	27 of 46

TABLE 5

PRESSURE TABLE

		Return Air					FULL LOAD COOLING — Fluid Temperature Entering Water Coil °F
	Model	Temperature Pressure		30°F	35°F	40°F	45°F	50°F	55°F	60°F	65°F	70°F	75°F	80°F	85°F	90°F	95°F	100°F	105°F	110°F
		75° DB	Low Side	106	108	111	114	117	120	122	125	128	130	132	134	136	138	140	142	144
		62° WB	High Side	131	146	161	176	191	206	221	236	252	272	293	313	334	355	375	396	417
	QW2S	80° DB	Low Side	113	116	119	122	125	128	131	134	137	139	141	144	146	148	150	152	154
		67° WB	High Side	134	150	165	181	196	212	227	243	258	279	300	322	343	364	385	406	427
		85° DB	Low Side	121	125	128	131	134	138	141	144	147	150	152	154	157	159	161	164	166
		72° WB	High Side	139	155	171	187	203	219	235	251	267	289	311	333	355	377	398	420	442
		75° DB	Low Side	83	87	91	94	98	102	106	109	113	116	118	121	123	126	128	131	133
		62° WB	High Side	132	148	165	181	198	215	231	248	264	285	306	327	347	368	389	410	431
	QW3S	80° DB	Low Side	89	93	97	101	105	109	113	117	121	124	126	129	132	134	137	140	142
		67° WB	High Side	135	152	169	186	203	220	237	254	271	292	314	335	356	378	399	420	442
		85° DB	Low Side	96	100	104	109	113	117	121	126	130	133	136	139	142	144	147	150	153
		72° WB	High Side	140	157	175	193	210	228	245	263	280	303	325	347	369	391	413	435	457
		75° DB	Low Side	91	94	97	101	104	107	110	114	117	119	121	122	124	126	128	130	132
		62° WB	High Side	146	162	177	193	208	224	239	255	270	291	312	333	354	375	396	417	438
	QW4S	80° DB	Low Side	97	101	104	108	111	115	118	122	125	127	129	131	133	135	137	139	141
		67° WB	High Side	150	166	182	198	214	229	245	261	277	299	320	342	363	385	406	428	449
		85° DB	Low Side	104	108	112	116	119	123	127	131	134	137	139	141	143	145	147	149	152
		72° WB	High Side	155	172	188	205	221	237	254	270	287	309	331	353	376	398	420	442	465
		75° DB	Low Side	92	94	96	98	101	103	105	107	109	111	112	114	115	116	118	119	121
		62° WB	High Side	147	163	178	194	210	225	241	256	272	293	313	334	355	375	396	416	437
	QW5S	80° DB	Low Side	98	100	103	105	108	110	112	115	117	119	120	122	123	125	126	128	129
		67° WB	High Side	151	167	183	199	215	231	247	263	279	300	321	343	364	385	406	427	448
		85° DB	Low Side	105	108	110	113	116	118	121	123	126	127	129	131	132	134	135	137	139
		72° WB	High Side	156	173	189	206	223	239	256	272	289	311	333	354	376	398	420	442	464

		Return Air						FULL LOAD HEATING — Fluid Temperature Entering Water Coil °F
	Model
		Temperature Pressure			5°F	10°F	15°F	20°F	25°F	30°F	35°F	40°F	45°F	50°F	55°F	60°F	65°F	70°F	75°F	80°F	85°F
	QW2S	70° DB	Low Side		46	53	60	67	74	81	88	95	102	109	118	128	137	146	155	165	174
			High Side		262	270	279	287	296	304	313	321	330	338	347	355	364	372	381	389	398
	QW3S	70° DB	Low Side		40	47	55	62	70	77	85	92	100	107	114	122	129	136	143	151	158
			High Side		280	290	300	310	320	330	340	350	360	370	380	389	399	408	418	427	437
	QW4S	70° DB	Low Side		36	43	51	58	66	73	81	88	96	103	112	122	131	140	149	159	168
			High Side		290	298	307	315	324	332	341	349	358	366	378	389	401	412	424	435	447
	QW5S	70° DB	Low Side		37	44	51	58	65	72	79	86	93	100	109	119	128	137	146	156	165
			High Side		288	300	312	324	335	347	359	371	382	394	408	421	435	448	462	475	489

		Return Air					PART LOAD COOLING — Fluid Temperature Entering Water Coil °F
	Model			30°F	35°F	40°F	45°F	50°F	55°F	60°F	65°F	70°F	75°F	80°F	85°F	90°F	95°F	100°F	105°F	110°F
		Temperature Pressure
		75° DB	Low Side	105	109	113	117	121	125	129	133	137	139	141	143	144	146	148	149	151
		62° WB	High Side	120	135	150	165	179	194	209	224	239	259	279	299	319	339	359	379	399
	QW2S	80° DB	Low Side	112	116	121	125	130	134	138	143	147	149	151	153	154	156	158	160	162
		67° WB	High Side	123	138	154	169	184	199	215	230	245	266	286	307	327	348	368	389	409
		85° DB	Low Side	120	125	130	135	139	144	149	153	158	160	162	164	166	168	170	172	174
		72° WB	High Side	127	143	159	175	190	206	222	238	254	275	296	317	338	360	381	402	423
		75° DB	Low Side	98	102	106	110	114	117	121	125	129	130	131	132	133	134	135	136	137
		62° WB	High Side	124	139	154	169	184	199	215	230	245	265	286	306	327	347	368	388	409
	QW3S	80° DB	Low Side	105	109	113	117	122	126	130	134	138	139	140	141	142	143	144	145	146
		67° WB	High Side	127	143	158	174	189	205	220	236	251	272	293	314	335	356	377	398	419
		85° DB	Low Side	113	117	122	126	131	135	139	144	148	149	151	152	153	154	155	156	157
		72° WB	High Side	131	147	164	180	196	212	228	244	260	282	303	325	347	368	390	412	434
		75° DB	Low Side	104	107	111	115	118	122	126	129	133	134	134	135	136	137	137	138	139
		62° WB	High Side	129	144	159	174	190	205	220	235	251	271	292	312	332	353	373	394	414
	QW4S	80° DB	Low Side	111	115	119	123	127	130	134	138	142	143	144	145	145	146	147	148	149
		67° WB	High Side	132	148	163	179	195	210	226	241	257	278	299	320	341	362	383	404	425
		85° DB	Low Side	119	123	128	132	136	140	144	148	153	154	154	155	156	157	158	159	160
		72° WB	High Side	137	153	169	185	201	217	234	250	266	288	309	331	353	375	396	418	440
		75° DB	Low Side	108	110	112	114	115	117	119	121	122	124	125	127	128	129	131	132	134
		62° WB	High Side	133	148	163	178	194	209	224	239	254	275	295	315	335	355	375	396	416
	QW5S	80° DB	Low Side	116	118	120	122	124	125	127	129	131	133	134	136	137	139	140	142	143
		67° WB	High Side	136	152	167	183	199	214	230	245	261	282	302	323	344	364	385	406	426
		85° DB	Low Side	125	127	129	131	133	135	137	139	141	142	144	146	147	149	151	152	154
		72° WB	High Side	141	157	173	189	205	222	238	254	270	292	313	334	356	377	398	420	441

		Return Air						PART LOAD HEATING — Fluid Temperature Entering Water Coil °F
	Model
		Temperature Pressure			5°F	10°F	15°F	20°F	25°F	30°F	35°F	40°F	45°F	50°F	55°F	60°F	65°F	70°F	75°F	80°F	85°F
	QW2S	70° DB	Low Side		15	26	37	49	60	71	82	94	105	116	125	135	144	153	162	172	181
			High Side		232	240	248	256	264	272	280	288	296	304	311	318	325	332	339	346	353
	QW3S	70° DB	Low Side		38	47	56	65	73	82	91	100	108	117	127	137	147	157	167	177	187
			High Side		250	260	270	280	290	300	310	320	330	340	350	361	371	381	391	402	412
	QW4S	70° DB	Low Side		39	47	55	64	72	80	88	97	105	113	122	131	140	149	158	167	176
			High Side		262	269	277	284	292	299	307	314	322	329	338	347	355	364	373	382	390
	QW5S	70° DB	Low Side		43	50	58	65	73	80	88	95	103	110	120	129	139	148	158	167	177
			High Side		271	280	290	299	309	318	328	337	347	356	367	378	388	399	410	421	431

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

FLOW RATE FOR VARIOUS FLUIDS		QW2S	QW3S	QW4S	QW6S
	Flow rate required GPM for fresh water	5	6	7	9
	Flow rate required GPM for 15% Methanol	7	8	9	11
	Flow rate required GPM, cooling tower/boiler loop	6.1	8.6	11.3	13.7

Manual	2100-532B
Page	28 of 46

									TABLE 6
								OPTIONALACCESSORIES
			Optional Accessories – Must be Used for Each Installation with Ventilation Options
			Ventilation Wall Sleeves:
			QWVS42	Ventilation wall sleeve for walls up to 14 inches thick.				NOTE: Unless they are to be field-supplied, side trim kit must be ordered for all installations.
			Ventilation Louvers:
			QLG-11	Clear Anodized Aluminum for vent option
			QLG-21	Medium Bronze Anodized for vent option
			QLG-31	Dark Bronze Anodized Aluminum for vent option
			Side Trim Kits — Required for All Installations Unless Field-Supplied
			NOTE: The following accessory items must be selected so the finish (color) is matched to the QWS model that they will be used with.
			Side Trim Extension Kits:							Unit Compatibility
			Model	Color	Model	Color	Model	Color	Space from back of unit to wall
			QSTX-V-6	Platinum Vinyl	QSTX-4-6	Gray Paint	QSTX-X-6	Beige Paint	4" to 6"	All
			QSTX-V-8	Platinum Vinyl	QSTX-4-8	Gray Paint	QSTX-X-8	Beige Paint	6" to 8"	All
			QSTX-V-10	Platinum Vinyl	QSTX-4-10	Gray Paint	QSTX-X-10	Beige Paint	8" to 10"	All
			QSTX-V-12	Platinum Vinyl	QSTX-4-12	Gray Paint	QSTX-X-12	Beige Paint	10" to 12"	All
			Optional Accessories – Additional Items as Determined by Job Specifications
			Free-Blow Plenum Boxes:							Unit Compatibility
			QPB42-V	Platinum Vinyl	QPB42-4	Gray Paint	QPB42-X	Beige Paint	Front Supply, 4-way deflection grille	QW2S, QW3S
			QPBS42-V	Platinum Vinyl	QPBS42-4	Gray Paint	QPBS42-X	Beige Paint	Same as QPB42, plus 2-way defection grille on each side.
			QPB48-V	Platinum Vinyl	QPB48-4	Gray Paint	QPB48-X	Beige Paint	Front Supply, 4-way deflection grille	QW4S, QW5S
			QPBS48-V	Platinum Vinyl	QPBS48-4	Gray Paint	QPBS48-X	Beige Paint	Same as QPB48, plus 2-way defection grille on each side.
			Top Fill Systems for Finishing Plenum Boxes to Ceilings:							Unit Compatibility
			QPBX42-9-V	Platinum Vinyl	QPBX42-9-4	Gray Paint	QPBX42-9-X	Beige Paint	Use with QPB42 or QPBS42 (adjusts to ceilings up to 9'9")	QW2S, QW3S
			QPBX42-10-V	Platinum Vinyl	QPBX42-10-4	Gray Paint	QPBX42-10-X	Beige Paint	Use with QPB42 or QPBS42 (adjusts to ceilings up to 10'5")
			QPBX48-9-V	Platinum Vinyl	QPBX48-9-4	Gray Paint	QPBX48-9-X	Beige Paint	Use with QPB48 or QPBS48 (adjusts to ceilings up to 9'9")	QW4S, QW5S
			QPBX48-10-V	Platinum Vinyl	QPBX48-10-4	Gray Paint	QPBX48-10-X	Beige Paint	Use with QPB48 or QPBS48 (adjusts to ceilings up to 10'5")
			Cabinet Extensions for Ducted Applications:							Unit Compatibility
	Page	Manual	QCX10A-V	Platinum Vinyl	QCX10A-4	Gray Paint	QCX10A-X	Beige Paint	20" height (adjusts for ceilings up to 9'7"; add QPBX42-9 for 9'7" to 10'3" finished ceiling heights)	QW2S, QW3S
			QCX15A-V	Platinum Vinyl	QCX15A-4	Gray Paint	QCX15A-X	Beige Paint	20" height (adjusts for ceilings up to 9'7"; add QPBX48-9 for 9'7" to 10'3" finished ceiling heights)	QW4S, QW5S
			Hot Water Coils with Plenum Boxes:							Unit Compatibility
	29	-2100	QPBHW42-F-V	Platinum Vinyl	QPBHW42-F-4	Gray Paint	QPBHW42-F-X	Beige Paint	Free blow plenum box	QW2S, QW3S
			QPBHW48-F-V	Platinum Vinyl	QPBHW48-F-4	Gray Paint	QPBHW48-F-X	Beige Paint	Free blow plenum box	QW4S, QW5S
	46of	532B	QPBHW42-D-V	Platinum Vinyl	QPBHW42-D-4	Gray Paint	QPBHW42-D-X	Beige Paint	Ducted plenum box	QW2S, QW3S
			QPBHW48-D-V	Platinum Vinyl	QPBHW48-D-4	Gray Paint	QPBHW48-D-X	Beige Paint	Ducted plenum box	QW4S, QW5S

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 not like a household plumbing system.

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 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. Loop pump performance data can be seen in Figures 21 and 22.

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; “C” represents a water coil constructed of copper material and “N” represents a water coil constructed of cupronickel.

The cupronickel coil is suitable for all applications.

The copper coil is suitable for applications using ground loop and cooling tower only and is not recommended for open well application.

FIGURE 19

CIRCULATION SYSTEM

FLEXIBLE HOSE

PUMP MODULE (See Spec Sheet for Model No.)

PIPE FROM

GROUND LOOP

PIPE TO

GROUND

LOOP

WATER

OUT

MIS-2748

Manual	2100-532B
Page	30 of 46

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, Do not open the unit disconnect switch.

4.Check system air flow 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 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.

FIGURE 20

WATER TEMPERATURE and PRESSURE PROCEDURE

Thermometer

Dial face pressure guage with guage adaptor

50	60	70	Retaining cap, hand tighten only
40		80
30			90
20			100
10			110
0			120

Pete's test plug

Test plug cap

Barbed 90° adapter

MIS-2622

Manual	2100-532B
Page	31 of 46

FIGURE 21

PERFORMANCE MODEL DORFC-1 LOOP PUMP MODULE

	35
	30
	25
(Feet)	20
Head	15
	10
	5
	0
	0	5	10	15	20	25	30	35

Flow (GPM)

FIGURE 22

PERFORMANCE MODEL DORFC-2 LOOP PUMP MODULE

	70
	60
	50
(Feet)	40
Head	30
	20
	10
	0
	0	5	10	15	20	25	30	35

Flow (GPM)

Manual	2100-532B
Page	32 of 46

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 23. Slow closing Solenoid 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 7 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.

TABLE 7

CONSTANT FLOW VALVES

	Min. Available	Flow Rate
Part No.	Pressure PSIG	GPM
CFV-5	15 1	5
CFV-6	15 1	6
CFV-7	15 1	7
CFV-9	15 1	9

1The 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.

Strainer (5) installed upstream of constant flow valve

(7) to collect foreign material which would clog the flow valve orifice.

Figure 22 shows the use of shutoff valves (9) and (11), 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) and (10), and tees have been included to permit acid cleaning the refrigerant-to-water coil should such cleaning be required. See WATER CORROSION section.

Drain cock (12) provides access to the system to check 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.

FIGURE 23

PIPING DIAGRAM

8

9

10

11

6

7

12

MIS-2749

Manual	2100-532B
Page	33 of 46

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 ensure 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.

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

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

A.Check for possible refrigerant loss.

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 proper charge.

Manual	2100-532B
Page	34 of 46

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 low 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, but 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 24. 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	2100-532B
Page	35 of 46

FIGURE 24

CLEANING WATER COIL

Hose Bib (B)

Isolation Valve

Hose Bib (A)

TO WATER COIL

Pump

FROM WATER COIL

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 25):

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.

MIS-2750

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	2100-532B
Page	36 of 46

FIGURE 25

WATER WELL SYSTEM

GRAVEL FILL

LAKE	WATER LEVEL
or
POND

12' to 15'

Page	Manual
46 of 37	532B-2100

WELL CAP

ELECTRICAL LINE

PITLESS ADAPTER

TO PRESSURE

TANK

WATER SUPPLY

LINE

15' to 20'

DEEP

DROP PIPE

PERFORATED

PLASTIC CASING

SUBMERSIBLE

PUMP

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 ensure 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 double O-ring (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 8 for water flow and pressure drop information.

TABLE 8

WATER FLOW AND PRESSURE DROP

		QW2S1 &
		QW3S1		QW4S1		QW6S1
	GPM	PSIG	Ft. Hd.	PSIG	Ft. Hd.	PSIG	Ft. Hd.
	3	0.1	0.23
	4	0.5	1.15	0.9	2.08
	5	1.2	2.77	1.4	3.23
	6	1.7	3.92	2.3	5.31
	7	2.3	5.31	3.2	7.38	2	4.61
	8	3.1	7.15	4.1	9.46	2.5	5.77
	9	4.1	9.46	5.1	11.77	3.2	7.38
	10			6.1	14.07	3.9	9.00
	11			7.1	16.38	4.7	10.84
	12			8.2	18.92	5.5	12.69
	13			9.4	21.69	6.4	14.76
	14			10.6	24.45	7.3	16.84
	15					8.1	18.69
	16					9	20.76
	17					9.9	22.84
	18

Manual	2100-532B
Page	38 of 46

FIGURE 26

WATER SOURCE HEAT PUMP

Manual	2100-532B
Page	39 of 46

FIGURE 27

WATER SOURCE HEAT PUMP

Manual	2100-532B
Page	40 of 46

SERVICE

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	2100-532B
Page	41 of 46

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 when starting

Motor won’t start

• No movement

•This is normal start-up for ECM

•Check blower turns by hand

•Check power at motor

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

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

•Check for unseated pins in connectors on motor harness

•Test with a temporary jumper between R - G

•Check motor for tight shaft

•Perform motor/control replacement check

•Perform Moisture Check

• Motor rocks,	• Check for loose or compliant motor mount
but won’t start	• Make sure blower wheel is tight on shaft
	• Perform motor/control replacement check
Motor oscillates up	• It is normal for motor to oscillate with no load
& down while being	on shaft
tested off of blower
Motor starts, but
runs erratically
• Varies up and down	• Check line voltage for variation or “sag”
or intermittent	• Check low voltage connections
	(G, Y, W, R, C) at motor, unseated pins in
	motor harness connectors
	• Check “Bk” for erratic CFM command (in
	variable-speed applications)
	• Check out system controls, Thermostat
	• Perform Moisture Check
• “Hunts” or “puffs” at	• Does removing panel or filter reduce
high CFM (speed)	“puffing”?
	- Reduce restriction
	- Reduce max airflow
• Stays at low CFM	• Check low voltage (Thermostat) wires and
despite system call	connections
for cool or heat CFM	• Verify fan is not in delay mode; wait until
	delay complete
	• “R” missing/not connected at motor
	• Perform motor/control replacement check
• Stays at high CFM	• “R” missing/not connected at motor
	• Is fan in delay mode? - wait until delay time
	complete
	• Perform motor/control replacement check
• Blower won’t shut off	• Current leakage from controls into G, Y or W?
	Check for Triac switched thermostat or solid-
	state relay
Excessive noise	• Determine if it’s air noise, cabinet, duct or
	motor noise; interview customer, if necessary
• Air noise	• High static creating high blower speed?
	- Is airflow set properly?
	- Does removing filter cause blower to slow
	down? Check filter
	- Use low-pressure drop filter
	- Check/correct duct restrictions

Symptom Cause/Procedure

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

•High static creating high blower speed?

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

-Check for cabinet/duct deformation

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

high CFM (speed)	“puffing”?
	- Reduce restriction
	- Reduce max. airflow
Evidence of Moisture
• Motor failure or	• Replace motor and Perform Moisture Check
malfunction has occurred
and moisture is present
• Evidence of moisture	• Perform Moisture Check
present inside air mover
Do	Don’t

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

•Orient connectors down so water can’t get in

-Install “drip loops”

•Use authorized motor and model #’s for replacement

•Keep static pressure to a minimum:

-Recommend high efficiency, low static filters

-Recommend keeping filters clean.

-Design ductwork for min. static, max. comfort

-Look for and recommend ductwork improvement, where necessary

•Size the equipment wisely

•Check orientation before inserting motor connectors

•Automatically assume the motor is bad.

•Locate connectors above 7 and 4 o’clock positions

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

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

•Use restricted returns

•Oversize system, then compensate with low airflow

•Plug in power connector backwards

•Force plugs

Moisture Check

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

•Arrange harness with “drip loop” under motor

•Is condensate drain plugged?

•Check for low airflow (too much latent capacity)

•Check for undercharged condition

•Check and plug leaks in return ducts, cabinet

Comfort Check

•Check proper airflow settings

•Low static pressure for lowest noise

•Set low continuous-fan CFM

•Use humidistat and 2-speed cooling units

•Use zoning controls designed for ECM that regulate CFM

•Thermostat in bad location?

Manual	2100-532B
Page	42 of 46

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 28. 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 29. (Measure to unpainted motor end plate.) If any motor lead fails this test, do not proceed to install the control module.

THE MOTOR IS DEFECTIVE AND MUST BE REPLACED.

Installing the new control module will cause it to fail also.

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

USING THE WRONG CONTROL WILL RESULT IN IMPROPER OR NO BLOWER OPERATION. Orient the control module so that the 3-wire motor plug can be inserted into the socket in the control. Carefully insert the plug and press it into the socket until it latches. A SLIGHT CLICK WILL BE HEARD WHEN PROPERLY INSERTED. Finish installing the replacement control per one of the three following paragraphs, 8a, 8b or 8c.

8a. IF REPLACING AN ECM 2.0 CONTROL (control in cast aluminum can with air vents on the back of the can) WITH AN ECM 2.3 CONTROL (control containing black potting for water protection in black deep-drawn steel case with no vents in the bottom of the can), locate the two through-bolts and plastic tab that are packed with the replacement control. Insert the plastic tab into the slot at the perimeter of the open end of the can so that the pin is located on the inside of the perimeter of the can. Rotate the can so that the tab inserts into the tab locater hole in the endshield of the motor. Using the two 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.

8b. IF REPLACING AN ECM 2.3 CONTROL WITH AN ECM 2.3 CONTROL, the plastic tab and shorter through-bolts are not needed. The control can be oriented in two positions 180° apart.

MAKE SURE THE ORIENTATION YOU SELECT FOR REPLACING THE CONTROL ASSURES THE CONTROL'S CABLE CONNECTORS WILL BE LOCATED DOWNWARD IN THE APPLICATION SO THAT WATER CANNOT RUN DOWN THE CABLES AND INTO THE CONTROL. Simply orient the new control to the motor's endshield, insert bolts, and tighten. DO NOT OVERTIGHTEN THE BOLTS.

8c. IF REPLACING AN ECM 2.0 CONTROL WITH AN ECM 2.0 CONTROL (It is recommended that ECM 2.3 controls be used for all replacements), the new control must be attached to the motor using through bolts identical to those removed with the original control. DO NOT OVERTIGHTEN THE BOLTS.

9.Reinstall the blower/motor assembly into the HVAC equipment. Follow the manufacturer's suggested procedures.

10.Plug the 16-pin control plug into the motor. The plug is keyed. Make sure the connector is properly seated and latched.

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

12.Final installation check. Make sure the motor is installed as follows:

a. Unit is as far INTO the blower housing as possible.

b.Belly bands are not on the control module or covering vent holes.

c.Motor connectors should be oriented between the 4 o’clock and 8 o’clock positions when the blower is positioned in its final location and orientation.

d.Add a drip loop to the cables so that water cannot enter the motor by draining down the cables. Refer to Figure 30.

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.

			Figure 28		Figure 29
			Figure 3		Figure 4
		Control Disassembly			Winding Test
				Motor Connector
	Only remove		From Motor	(3-pin)
	Hex Head Bolts	Push until
		Latch Seats
		Over Ramp
			Circuit
			Board
	ECM 2.0		Motor
					Motor OK when
	Note:				R > 100k ohm
	Use the shorter
	bolts and
	alignment pin				FigureFigure305
	supplied when
	replacing an				Drip Loop
	ECM 2.0		Motor Connector
	control.				Connector Orientation
			(3-pin)	Back of
	ECM			Control	Between 4 and 8 o'clock
	2.3/2.5		Control Connector
			(16-pin)
			Power Connector
			(5-pin)
			Hex-head Screws		Drip Loop

Manual	2100-532B
Page	43 of 46

	AUX.		Heat Gen.
HEAT PUMP	INDOOR SECTION	Indoor Blower Motor	Water Coil and Coil
AIR		Rev.	Valve
QUICK REFERENCE TROUBLESHOOTING CHART FOR WATER TO	POWER SUPPLY WATER COIL SECTION	Water	Line Voltage Control Circuit Compressor Refrigerant System Solenoid

AuxillaryHeatUpstreamofCoil

UndersizedorRestrictedDuctwork

AirFiltersDirty

AirVolumeLow

MotorWindingDefective

FinsDirtyorPlugged

PluggedorRestrictedMeteringDevice(Clg)

LowWaterTemperature(Htg)

WaterVolumeLow(Clg)

WaterVolumeLow(Htg)

ScaledorPluggedCoil(CLg)

ScaledorPluggedCoil(Htg)

PluggedorRestrictedMeteringDevice(Htg)

DefectiveValveorCoil

Leaking

SolenoidValveStuckOpen(HtgorClg)

SolenoidValveStuckClosed(Clg)

SolenoidValveStuckClosed(Htg)

UnequalizedPressures

Non-Condensables

LowSuctionPressure

HighSuctionPressure

LowHeadPressure

HighHeadPressure

RefrigerantOvercharge

RefrigerantChargeLow

MotorWingingsDefective

ValveDefective

Seized

BearingsDefective

DischargeLineHittingInsideofShell

IndoorBlowerRelay

PressureControls(HighorLow)

ContactorCoil

Thermostat

LowVoltage

ControlTransformer

LooseTerminals

FaultyWiring

StartCapacitor

RunCapacitor

PotentialRelay

CompressorOverload

DefectiveContactsinContactor

LowVoltage

LooseTerminals

FaultyWiring

BlownFuseorTrippedBreaker

PowerFailure

COMMON CAUSE	OCCASIONAL CAUSE
DENOTES	DENOTES

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

Aux. Heat on I.D. Blower Off

Excessive Operation Costs

Ice in Water Coil

HeatingorCoolingCycles

Cycle

HeatingCycle

Cooling

Manual	2100-532B
Page	44 of 46

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	2100-532B
Page	45 of 46

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	2100-532B
Page	46 of 46