Bard QW5S1, QW2S1, QW4S1, QW3S1 User Manual

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INSTALLATION

MIS-2736

INSTRUCTIONS

QW SERIES GEOTHERMAL R-410A STAGED CAPACITY PACKAGED HEAT PUMP

Models:

QW2S1 QW3S1 QW4S1 QW5S1

Earth Loop Fluid

Temperatures 25 – 110

Ground Water Temperature 45 – 75

Bard Manufacturing Company, Inc. Bryan, Ohio 43506

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

Manual No.: 2100-532B Supersedes: 2100-532A 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

Closed Loop (Earth Coupled Ground Loop Applications)

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

Manual 2100-532B Page 2 of 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-T 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

EC ERV ........................ 14

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

FOR MORE INFORMATION, CONTACT THESE PUBLISHERS:

ACCA Air Conditioning Contractors of America

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

ANSI American National Standards Institute

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

ASHRAE American Society of Heating Refrigerating,

and Air Conditioning Engineers, Inc.

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

NFPA National Fire Protection Association

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

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

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

Installation Guide

Manual 2100-532B Page 4 of 46

IGSHPA International Ground Source

Heat Pump Association

490 Cordell South Stillwater, OK 74078-8018

QW SERIES GEOTHERMAL R-410A STAGED CAPACITY GENERAL INFORMATION

QW MODEL NOMENCLATURE

QW 3 S 1 A 0Z B X 4 X C X

MODEL NUMBER |

Q-Tec™ Model

CAPACITY |

2 - 2 Ton 3 - 3 Ton 4 - 4 Ton 5 - 5 Ton

STEP CAPACITY |

SPECIALTY PRODUCTS

VOLTS & PHASE

A - 230/208/60/1

REVISION |

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.

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

0Z - OKW

TABLE 1

ELECTRICAL SPECIFICATIONS

FILTER OPTIONS

X - 2-Inch Pleated (MERV6)

COLOR

4 - Buckeye Gray paint X - Beige paint V - Platinum w/Slate Front (Vinyl)

CLIMATE CONTROL

Standard X - None D - Electronic/Prog/Man/Auto H - Electronic/Prog with CO

COIL OPTIONS

C - Copper (water) N - Cupronickel

INTERNAL CONTROLS

• High Pressure Switch

• Low Pressure Switch

• Compressor Control Module w/Time Delay

• Phase Monitor (3-PH)

control

TIUCRICELGNIS

MUMIXAM

LANRETXE

DETAR

zH,STLOV

LEDOM

Z0A-1S2WQ Z0B-1S2WQ Z0C-1S2WQ

Z0A-1S3WQ Z0B-1S3WQ Z0C-1S3WQ

Z0A-1S4WQ Z0B-1S4WQ Z0C-1S4WQ

Z0A-1S5WQ Z0B-1S5WQ Z0C-1S5WQ

1 Maximum size of the time delay fuse or HACR type circuit breaker for protection of field wiring conductors. 2 These “Minimum Circuit Ampacity” values are to be used for sizing the field power conductors. Refer to the National Electric

Code (latest revision), article 310 for power conductor sizing.

CAUTION: When more than one field power conductor circuit is run through one conduit, the conductors must be derated.

Pay special attention to Note 8 of Table 310 regarding Ampacity Adjustment Factors when more than three conductors are in a raceway.

ESAHP&

1-06-802/032

3-06-802/032

3-06-064

1-06-802/032

3-06-802/032

3-06-064

1-06-802/032

3-06-802/032

3-06-064

1-06-802/032

3-06-802/032

3-06-064

DLEIF.ON

REWOP

STIUCRIC

1 1 1

MUMINIM TIUCRIC

YTICAPMA

91 41

62 02

13 72 11

93 92 71

ROESUF

TIUCRIC

REKAERB

03 02 51

04 03 51

05 04 02

06 54 52

Manual 2100-532B Page 5 of 46

VENT

EXHAUST

VENT

INTAKE

5 1/4"

5 15/16"

33 9/16"

20"

MIS-2737 B

UNIT DIM. "A" DIM. "B" DIM. "C" DIM. "D"

QW2S, QW3S 8 5/8" 42" 30" 43"

QW4S, QW5S 8 3/4" 48" 40" 49"

FIGURE 1

ELECTRICAL ENTRANCE

UNIT DIMENSIONS

(OPTIONAL) HIGH VOLTAGE

2 15/16"

(OPTIONAL) LOW VOLTAGE

ELECTRICAL ENTRANCE

LOW VOLTAGE

ELECTRICAL ENTRANCE

(OPTIONAL) LOW VOLTAGE

6 3/4"

3 3/16"

7/8"

1 15/16"

3 3/8"

(OPTIONAL) HIGH VOLTAGE

ELECTRICAL ENTRANCE

3 3/8"

3 3/4"

(OPTIONAL)

PLENUM BOX

FREEBLOW

1 1/8"

1 11/16"

11 3/4"

CIRCUIT BREAKER

3 1/16"

(OPTIONAL) HIGH

ACCESS AND LOCKING

COVER

ACCESS

VOLTAGE

ENTRANCE

ELECTRICAL

GRILLE

RETURN AIR

FOR FLUID

CONNECTION FOR

DORFC PUMP

15 5/8"

6 7/8"

APPLICATION

68 3/4"

36 7/8"

19"

FLUID CONNECTION

POINTS FOR FACTORY

BACK VIEW

INSTALLED PUMP OPTIONS

3, 4, OR 5 (INLET ON LEFT,

OUTLET ON RIGHT AS VIEWED

FROM BACK OF UNIT)

RIGHT SIDE VIEW

1 3/4"

2 1/16"

2 7/16"

SUPPLY AIR OPENING

Manual 2100-532B Page 6 of 46

9 15/16"

(DUCT SIZE)

20 3/8"

"A"

24 15/16"

(DUCT SIZE)

TOP VIEW

(SHOWN WITHOUT

FREEBLOW PLENUM)

"B"

"C"

GRILLE

SUPPLY AIR

14"

THERMOSTAT

(OPTIONAL)

16 5/8"

FILTER

(OPTIONAL)

ACCESS

CO2 SENSOR

37 1/8"

104"

DOOR

"C"

"D"

FRONT VIEW

DOOR

CONDENSER

36 1/16"

SHIPPING DAMAGE

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

UNIT REMOVAL FROM SKID

WARNING

HANDLING UNIT AFTER REMOVAL FROM SKID

WARNING

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

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

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

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

REMOVAL OF UNIT FROM SKID

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

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

A SHIPPING BRACKETS

HOLD SKID DOWN

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)

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.

STRAP

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

INSTALLATION OF UNIT THROUGH WALL WITH WALL SLEEVE

QW2S, QW3S - 42.000" QW4S, QW5S - 48.000"

SUPPLY AIR

OPTIONAL FREE BLOW PLENUM BOX

HIGH VOLTAGE ELECTRICAL ENTRANCE (TOP-REAR-SIDE)

RETURN AIR

(X)

FIGURE 4

14" to 5"

18 9/16"

WALL SLEEVE

VENTILATION AIR DIVIDER

35"

29 1/2"

33 7/8"

28 7/8"

17 9/16"

6 1/8"

MIST ELIMINATOR

103 7/8"

84 1/4"

BOTTOM TRIM PIECE

33"

LOW VOLTAG E ELECTRICAL ACCESS (TOP-SIDE)

CIRCUIT BREAKER, ROTARY, OR TOGGLE DISCONNECT AND LOCKING COVER

PERMANENT ROLLERS

MIS-2739 A

Manual 2100-532B Page 9 of 46

FIGURE 5

INSTALLATION WITH FREE BLOW PLENUM

8 FT. - 8 IN.

25 IN.

MINIMUM

8 FT. - 9 IN.

MINIMUM REQUIRED

INSTALLATION HEIGHT

FLOOR

FIGURE 6

DUCTED APPLICATION

SUSPENDED CEILING

FIXED CEILING

12 IN.

MINIMUM

MIS-2740

DUCT

DUCT FLANGE

7 FT. - 6 IN.

UNIT HEIGHT

Manual 2100-532B Page 10 of 46

FLOOR

FROM DUCT FLANGE

TO DUCT BOTTOM

9 FT.

MINIMUM REQUIRED

INSTALLATION HEIGHT

2 IN. MINIMUM

8 FT. - 9 IN.

MINIMUM REQUIRED

INSTALLATION HEIGHT

MIS-2741

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

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.

ROOM SIDE OF QW UNIT

MIS-2742

DUCT FLANGE PROVIDED WITH UNIT

Manual 2100-532B Page 11 of 46

FLOOR

FIGURE 8A

CONDENSATE DRAIN

LOOP TO FORM A "P" TRAP

DRAIN HOSE

EXTERNAL DRAIN TUBE

ALTERNATE DRAINING OPTION

FRONT VIEW WITH CONDENSER DOOR REMOVED

MIS-2743

The drain can be routed through the floor or through the wall. If the drain is to be routed through an unconditioned space, it must be protected from freezing. The drain line must be able to be removed from the unit if it is necessary

to remove the unit from the wall.

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.

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.

SLEEVE

WATER TRAP

FIGURE 8C

REAR DRAIN (TOP VIEW)

DRAIN LINE

WALL (MAXIMUM 10” FOR REAR DRAIN)

COUPLINGS NOT SHOWN BUT RECOMMENDED FOR EASE OF REMOVABILITY

FOR SERVICE

WALL BRACKET

UNIT

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.

REMOVAL OF THE Q-TEC ENERGY RECOVERY VENTILATOR

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

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

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

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

FIGURE 9

Manual 2100-532B Page 14 of 46

MOUNTING SCREWS

POWER CONNECTORS

LOWER BLOWER ASSEMBLY POWER CONNECTOR

FRONT FILL

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.

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

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).

REMOVE SCREWS FROM WHEELS BEFORE ROLLING INTO PLACE

Manual 2100-532B Page 15 of 46

FIGURE 11

UNIT MOUNTING WITHOUT VENTILATION WALL SLEEVE

SIDE TRIM CUT TO LENGTH

WALL MOUNTING BRACKET

BASE TRIM

41"

ADJUSTABLE SIDE TRIM EXTENSION KIT -ORDERED SEPARATELY

SIDE TRIM EXTENSION

BASE TRIM EXTENSION

MIS-2744 A

Manual 2100-532B Page 16 of 46

FIGURE 12

COMPONENT LOCATION

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.

TABLE 2

OPERATING VOLTAGE RANGE

PATEGNAR

V042612-352 V802781-022

NOTE: The voltage should be measured at the field

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

The standard Climate Control Option X is a remote thermostat connection terminal block. See Figure 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 wiring diagram.

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.

WIRING – LOW VOLTAGE WIRING

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

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

WALL THERMOSTATS

tatsomrehTserutaeFtnanimoderP

060-3048

)544-0211(

GENERAL

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

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

CAUTION

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

TABLE 3

taeHegats3;looCegats3

cinortcelEelbammargorP-noN/elbammargorP

lanoitnevnoCroPH

revoegnahclaunaMrootuA

Manual 2100-532B Page 18 of 46

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 “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.

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.

BLOWER MOTOR LOW VOLTAGE

WIRE HARNESS PLUG

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

MIS-1285

Manual 2100-532B Page 19 of 46

Temp. and H umidity

Controller

Part #8403-060

FIGURE 14

REMOTE THERMOSTAT WIRING DIAGRAM

“X” OPTION

Low Voltage

Terminal Strip

W1/E

O/B

R C L

D/YO

CO2 Controller

Part #8403-056

24VAC

Analog

Out

A G

R C L

Red

Black

Yellow

Brown

Red/Yellow Purple Brown/White Orange Yellow Blue Brown Red/White Black/White Pink

Terminal

Strip

Red

Black Yellow Brown

Orange

Green

PLUG #2

1 2 3

4 5 6 7 8

9 10 11

PLUG #1

Manual 2100-532B Page 20 of 46

Orange

Green

Purple/White

4115-102 A

FIGURE 15

REMOTE THERMOSTAT WIRING DIAGRAM

“D” THERMOSTAT OPTION

Temp. and H umidity

Controller

D/YO W1/E

Y1Part #8403-060

O/B

R C L

Purple/White Red/Yellow Purple Brown/White Orange Yellow Blue Brown Red/White Black/White Pink

PLUG #2

1 2 3

4 5 6 7 8

9 10 11

4115-100 A

Manual 2100-532B Page 21 of 46

FIGURE 16

REMOTE THERMOSTAT PLUG CO

“H” THERMOSTAT OPTION

VENT CONTROL WIRING DIAGRAM

Temp. and H umidity

Controller

Part #8403-060

CO2 Controller

Part #8403-056

D/YO W1/E

O/B

R C L

24VAC

Analog

Out

Purple/White Red/Yellow Purple Brown/White Orange Yellow Blue Brown Red/White Black/White Pink

Red

Black

Yellow

Brown

Red

Black Yellow Brown

Orange

Green

PLUG #2

1 2 3

4 5 6 7 8

9 10 11

PLUG #1

Manual 2100-532B Page 22 of 46

Orange

Green

4115-101 A

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 LOCKOUT SEQUENCE

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

ALARM RELAY OUTPUT

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

Note: Both high and low pressure switch controls are

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

ADJUSTMENTS

ADJUSTABLE DELAY ON MAKE AND DELAY ON BREAK TIMER

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

. 1

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setunim0.4)sdnoces042(BOD=

setunim0.5)sdnoces003(BOD= MODsdnoces051

OPTIONAL CFM

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.

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Dsdnoces441

SERVICE HINTS

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

2. 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.

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.

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.

IMPORTANT INSTALLER NOTE

For improved start up performance, wash the indoor coil with dishwashing detergent.

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.

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.

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

PIPING ACCESS TO UNIT

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.

INDOOR BLOWER PERFORMANCE

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

DETAR

LEDOM

1S2WQ0.05.00080080090001 1S3WQ0.05.000800905010511 1S4WQ0.05.0009051152210531 1S6WQ0.05.0009052100310541

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

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.

3 Optional 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.

PSE

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

PSE.XAM

SUOUNITNOC

WOLFRIA

EGATSts1

LANOITPO EGATSdn2

EGATSdn2

Manual 2100-532B Page 25 of 46

FLUID CONNECTIONS ON UNIT WITH VENTILATION WALL SLEEVE

SIDE TRIM PEICES (SHIPPED WITH UNIT)

FLUID ACCESS FROM CEILING

SLEEVE

FIGURE 17

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

FLUID ACCESS FROM CEILING

FLUID ACCESS FROM EACH SIDE

66 1/2"

OPENING IN REAR OF UNIT 3" x 8"

TOP OF UNIT

BACK OF UNI T

34"

8" TO 14" EXTER IOR WALL

FLUID ACCESS FROM EACH SIDE

SLEEVE

WALL OPENING 35" x 29 1/2"

29"

MOUNTING BRACKETS (SHIPPED WITH UNIT)

FLUID ACCESS FROM FLOOR

Manual 2100-532B Page 26 of 46

23 1/2"

8 1/2"

33"

REF.

FLOOR

MIS-2746

FIGURE 18

FLUID CONNECTIONS ON UNIT WITHOUT VENTILATION WALL SLEEVE

TOP VIEW

WALL BRACKET

FLUID ACCESS FROM TOP

OPENING IN REAR OF UNIT 3" x 8"

WATER LINES

66 1/2"

BACK OF UNI T

WALL LOCATION

WALL BRACKET (LEFT BRACKET REMOVED FOR CLARITY)

FLOOR

23 1/2"

8 1/2"

FLUID ACCESS FROM FLOOR

MIS-2747

Manual 2100-532B Page 27 of 46

TABLE 5

PRESSURE TABLE

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S2WQ

S3WQ

S4WQ

S5WQ

ledoM

S2WQ S3WQ S4WQ S5WQ

riAnruteR

erutarepmeT

BD°57

BW°26

BD°08

BW°76

BD°58

BW°27

BD°57

BW°26

BD°08

BW°76

BD°58

BW°27

BD°57

BW°26

BD°08

BW°76

BD°58

BW°27

BD°57

BW°26

BD°08

BW°76

BD°58

BW°27

riAnruteR

erutarepmeT

BD°07

F°03 F°53 F°04 F°54 F°05 F°55 F°06 F°56 F°07 F°57 F°08 F°58 F°09 F°59 F°001 F°501

erusserP

ediSwoL

601

801

111

411

711

021

221

521

821

031

231

ediShgiH

131

641

161

671

191

602

122

632

252

ediSwoL

311

611

911

221

521

821

131

ediShgiH

431

051

561

181

691

ediSwoL

121

521

821

ediShgiH

931

ediSwoL ediShgiH

erusserP

ediSwoL ediShgiH

551

231

841

531

251

001

041

751

641

261

101

051

661

401

801

551

271

741

361

001

151

761

501

801

651

371

F°5 F°01 F°51 F°02 F°52 F°03 F°53 F°04 F°54 F°05 F°55 F°06 F°56 F°07 F°57 F°08 F°58

262

072

082

092

892

882

003

131

171

781

561

181

101

961

681

401

901

571

391

101

771

391

401

801

281

891

211

611

881

502

871

491

301

501

381

991

011

311

981

602

972

782

003

013

703

513

213

423

212

431

831

302

912

201

891

512

501

901

302

022

311

711

012

822

401

701

802

422

111

511

412

922

911

321

122

732

101

301

012

522

801

011

512

132

611

811

322

932

692

403

023

033

423

233

533

743

431

722

342

141

441

532

152

601

901

132

842

311

711

732

452

121

621

542

362

011

411

932

552

811

221

542

162

721

131

452

072

501

701

142

652

211

511

742

362

121

321

652

272

313

123

043

053

143

943

953

173

272

731

931

852

972

741

051

762

982

311

611

462

582

121

421

172

292

031

331

082

303

711

911

072

192

521

721

772

992

431

731

782

903

901

111

272

392

711

911

972

003

621

721

982

113

201

901

033

833

001

701

063

073

301

853

663

001

283

493

431

392

313

141

441

003

223

251

451

113

333

811

121

603

723

621

921

413

533

631

931

523

743

121

221

213

333

921

131

023

243

931

141

133

353

211

411

313

433

021

221

123

343

921

131

333

453

811

821

743

553

411

221

083

983

211

221

873

983

901

911

804

124

F°lioCretaWgniretnEerutarepmeTdiulF—GNILOOCDAOLLLUF

°011

631

831

041

241

433

553

641 343

751 553

321 743

231 653

241 963

421 453

331 363

341 673

511 553

321 463

231 673

573

841

051

463

583

951

161

773

893

621

821

863

983

431

731

873

993

441

741

193

314

621

821

573

693

531

731

583

604

541

741

893

024

611

811

573

693

521

621

583

604

431

531

893

024

441

693

714

251

451

604

724

461

661

024

244

131

331

014

134

041

241

024

244

051

351

534

754

031

231

714

834

931

141

824

944

941

251

244

564

911

121

614

734

821

921

724

844

731

931

244

464

F°lioCretaWgniretnEerutarepmeTdiulF—GNITAEHDAOLLLUF

731

641

551

561

463

273

921 993

131 104

821 534

183

631

341

804

814

041

941

214

424

731

641

844

264

471

983

893

151

851

724

734

951

861

534

744

651

561

574

984

ledoM

S2WQ

S3WQ

S4WQ

S5WQ

ledoM

S2WQ S3WQ S4WQ S5WQ

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BD°57

BW°26

BD°08

BW°76

BD°58

BW°27

BD°57

BW°26

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BW°26

BD°08

BW°76

BD°58

BW°27

BD°57

BW°26

BD°08

BW°76

BD°58

BW°27

riAnruteR

erutarepmeT

BD°07

F°03 F°53 F°04 F°54 F°05 F°55 F°06 F°56 F°07 F°57 F°08 F°58 F°09 F°59 F°001 F°501

erusserP

ediSwoL

501

901

311

711

121

521

921

331

731

ediShgiH

021

531

051

561

971

491

902

ediSwoL

211

611

121

521

031

ediShgiH

321

831

451

ediSwoL

021

ediShgiH ediSwoL

ediShgiH

erusserP

ediSwoL ediShgiH

521

721

341

201

421

931

501

901

721

341

311

711

131

741

401

701

921

441

111

511

231

841

911

321

731

351

801

011

331

841

611

811

631

251

521

721

141

751

F°5 F°01 F°51 F°02 F°52 F°03 F°53 F°04 F°54 F°05 F°55 F°06 F°56 F°07 F°57 F°08 F°58

232

042

052

062

262

962

172

082

961

031

531

951

571

601

011

451

961

311

711

851

471

221

621

461

081

111

511

951

471

911

321

361

971

821

231

961

581

211

411

361

871

021

221

761

381

921

131

371

981

842

652

072

082

772

482

092

992

431

481

991

931

441

091

602

411

711

481

991

221

621

981

502

131

531

691

212

811

221

091

502

721

031

591

012

631

041

102

712

511

711

491

902

421

521

991

412

331

531

502

222

462

272

092

003

292

992

903

813

422

831

341

512

032

941

351

222

832

121

521

512

032

031

431

022

632

931

441

822

442

621

921

022

532

431

831

622

142

441

841

432

052

911

121

422

932

721

921

032

542

731

931

832

452

082

882

001

013

023

703

413

823

733

931

932

952

741

941

542

662

851

061

452

572

921

031

542

562

831

931

152

272

841

941

062

282

331

431

152

172

241

341

752

872

351

451

662

882

221

421

452

572

131

331

162

282

141

241

072

292

501

611

692

403

801

711

033

043

501

311

223

923

301

011

743

653

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

FLOW RATE FOR VARIOUS FLUIDS

retawhserfrofMPGderiuqeretarwolF

lonahteM%51rofMPGderiuqeretarwolF

poolreliob/rewotgnilooc,MPGderiuqeretarwolF

Manual 2100-532B Page 28 of 46

S2WQS3WQS4WQS6WQ

5679 789 11

1.66.83.117.31

F°lioCretaWgniretnEerutarepmeTdiulF—GNILOOCDAOLTRAP

°011

141

341

441

641

841

941

972

992

913

933

151

351

682 261

692

131

682 041

392

151

303 431

292 441

992 451

903 521

592 431

203 441

313

451

703

723

461

661

713

833

231

331

603

723

141

241

413

533

251

351

523

743

531

631

213

233

541

023

143

551

651

133

353

721

821

513

533

631

731

323

443

641

741

433

653

953

651

851

843

863

861

071

063

183

431

531

743

863

341

441

653

773

451

551

863

093

731

353

373

641

741

263

383

751

851

573

693

921

131

553

573

931

041

463

583

941

151

773

893

151

973

993

061

261

983

904

271

471

204

324

631

731

883

904

541

641

893

914

651

751

214

434

831

931

493

414

841

941

404

524

951

061

814

044

231

431

693

614

241

341

604

624

251

451

024

144

F°lioCretaWgniretnEerutarepmeTdiulF—GNITAEHDAOLTRAP

521

531

441

351

261

271

113

813

523

233

721

731

053 221

833 021

763

741

163

173

131

041

743

553

921

931

873

883

933

751

761

183

193

941

851

463

373

841

851

993

014

181

643

353

771

781

204

214

761

671

283

093

761

771

124

134

S3WQ,S2WQ

tilibitapmoCtinU

S5WQ,S4WQ

.edishcaenoellirgnoitcefedyaw-2sulp,24BPQsaemaS

.edishcaenoellirgnoitcefedyaw-2sulp,84BPQsaemaS

S3WQ,S2WQ

S5WQ,S4WQ

snoitpOnoitalitneVhtiwnoitallatsnIhcaErofdesUebtsuM–seirosseccAlanoitpO

TABLE 6

OPTIONAL ACCESSORIES

:seveelSllaWnoitalitneV

:srevuoLnoitalitneV

24SVWQ.kcihtsehcni41otpusllawrofeveelsllawnoitalitneV :ETON .snoitallatsnillarofderedroebtsumtikmirtedis,deilppus-dleifeboterayehtsselnU

12-GLQnoitpotnevrofdezidonAeznorBmuideM

13-GLQnoitpotnevrofmunimulAdezidonAeznorBkraD

11-GLQnoitpotnevrofmunimulAdezidonAraelC

snoitacificepSboJybdenimreteDsasmetIlanoitiddA–seirosseccAlanoitpO

deilppuS-dleiFsselnUsnoitallatsnIllArofderiuqeR—stiKmirTediS

:sgnilieCotsexoBmunelPgnihsiniFrofsmetsySlliFpoT ytilibitapmoCtinU

:snoitacilppAdetcuDrofsnoisnetxEtenibaC ytilibitapmoCtinU

:sexoBmunelPhtiwslioCretaWtoH ytilibitapmoCtinU

lyniVmunitalP4-24BPQtniaPyarGX-24BPQtniaPegieBellirgnoitcelfedyaw-4,ylppuStnorF

lyniVmunitalP4-24SBPQtniaPyarGX-24SBPQtniaPegieB

lyniVmunitalP4-84BPQtniaPyarGX-84BPQtniaPegieBellirgnoitcelfedyaw-4,ylppuStnorF

lyniVmunitalP4-84SBPQtniaPyarGX-84SBPQtniaPegieB

lyniVmunitalP4-9-24XBPQtniaPyarGX-9-24XBPQtniaPegieB)"9'9otpusgniliecotstsujda(24SBPQro24BPQhtiwesU

lyniVmunitalP4-01-24XBPQtniaPyarGX-01-24XBPQtniaPegieB )"5'01otpusgniliecotstsujda(24SBPQro24BPQhtiwesU

lyniVmunitalP4-9-84XBPQtniaPyarGX-9-84XBPQtniaPegieB)"9'9otpusgniliecotstsujda(84SBPQro84BPQhtiwesU

lyniVmunitalP4-01-84XBPQtniaPyarGX-01-84XBPQtniaPegieB )"5'01otpusgniliecotstsujda(84SBPQro84BPQhtiwesU

lyniVmunitalP4-A01XCQtniaPyarGX-A01XCQtniaPegieB )sthgiehgniliecdehsinif"3'01ot"7'9rof9-24XBPQdda;"7'9otpusgniliecrofstsujda(thgieh"02 S3WQ,S2WQ

lyniVmunitalP4-A51XCQtniaPyarGX-A51XCQtniaPegieB )sthgiehgniliecdehsinif"3'01ot"7'9rof9-84XBPQdda;"7'9otpusgniliecrofstsujda(thgieh"02 S5WQ,S4WQ

lyniVmunitalP4-F-24WHBPQtniaPyarGX-F-24WHBPQtniaPegieBxobmunelpwolbeerF S3WQ,S2WQ

lyniVmunitalP4-F-84WHBPQtniaPyarGX-F-84WHBPQtniaPegieBxobmunelpwolbeerF S5WQ,S4WQ

lyniVmunitalP4-D-24WHBPQtniaPyarGX-D-24WHBPQtniaPegieBxobmunelpdetcuD S3WQ,S2WQ

lyniVmunitalP6-4-XTSQtniaPyarG6-X-XTSQtniaPegieB"6ot"4

lyniVmunitalP8-4-XTSQtniaPyarG8-X-XTSQtniaPegieB"8ot"6

lyniVmunitalP01-4-XTSQtniaPyarG01-X-XTSQtniaPegieB"01ot"8

lyniVmunitalP21-4-XTSQtniaPyarG21-X-XTSQtniaPegieB"21ot"01

:stiKnoisnetxEmirTediS

01-V-XTSQ

:ETON .htiwdesueblliwyehttahtledomSWQehtotdehctamsi)roloc(hsinifehtosdetcelesebtsumsmetiyrosseccagniwollofehT

6-V-XTSQ

ledoMroloCledoMroloCledoMroloCllawottinufokcabmorfecapS

21-V-XTSQ

8-V-XTSQ

:sexoBmunelPwolB-eerF ytilibitapmoCtinU

V-01-24XBPQ

V-24SBPQ

V-84BPQ

V-24BPQ

V-9-24XBPQ

V-84SBPQ

V-01-84XBPQ

V-9-84XBPQ

V-A01XCQ

V-F-24WHBPQ

V-A51XCQ

lyniVmunitalP4-D-84WHBPQtniaPyarGX-D-84WHBPQtniaPegieBxobmunelpdetcuD S5WQ,S4WQ

V-D-24WHBPQ

V-D-84WHBPQ

V-F-84WHBPQ

:ETON .sexobmunelpdradnatshtiwsasexobmunelpliocretawtohhtiwdesuebnacsnoisnetxetenibacdnametsysllifpotemasehT

Manual 2100-532B Page 29 of 46

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

CIRCULATION SYSTEM

FLEXIBLE HOSE

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

Manual 2100-532B Page 30 of 46

WATER

OUT

PUMP MODULE (See Spec Sheet for Model No.)

PIPE FROM GROUND LOOP

MIS-2748

PIPE TO GROUND LOOP

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,

the unit disconnect switch.

4. Check system air flow for obstructions.

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

Do not open

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.

Dial face pressure guage with guage adaptor

30 20 10

Thermometer

100 110

120

FIGURE 20

WATER TEMPERATURE and PRESSURE PROCEDURE

Retaining cap, hand t ighten only

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

Head (Feet)

0 5 10 15 20 25 30 35

Flow (GPM)

FIGURE 22

PERFORMANCE MODEL DORFC-2 LOOP PUMP MODULE

Manual 2100-532B Page 32 of 46

Head (Feet)

0 5 10 15 20 25 30 35

Flow (GPM)

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

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.

Solenoid

TABLE 7

CONSTANT FLOW VALVES

elbaliavA.niM

.oNtraP

-VFC5 51 1 5 6-VFC51 1 6 7-VFC51 1 7 9-VFC51 1 9

GISPerusserP

etaRwolF

MPG

1 The pressure drop through the constant flow valve will

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

Strainer (5) (7)

to collect foreign material which would clog the

installed upstream of

constant flow valve

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

CORROSION

Drain cock (12)

section.

provides access to the system to check

WATER

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

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.

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.

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.

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.

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:

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 (CO carbonate, is very soluble in water. It will remain

), the carbonate of calcium and magnesium

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.

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.

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

Pump

FIGURE 24

CLEANING WATER COIL

Hose Bib (B)

Isolation Valve

Hose Bib (A)

TO WATER COIL

FROM WATER COIL

MIS-2750

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.

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.

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.

Manual 2100-532B Page 36 of 46

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.

WELL CAP

ELECTRICAL LINE

TANK

PITLESS ADAPTER

TO PRESSURE

WATER SUPPLY

15' to 20'

LINE

DEEP

DROP PIPE

PERFORATED

PLASTIC CASING

SUBMERSIBLE

PUMP

FIGURE 25

WATER WELL SYSTEM

GRAVEL FILL

WATER LEVEL

LAKE

POND

12' to 15'

Manual 2100-532B Page 37 of 46

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.

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

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.

WATER FLOW AND PRESSURE DROP

&1S2WQ

1S3WQ1S4WQ1S6WQ

MPG

31.032.0

45.051.19.080.2

52.177.24.132.3

67.129.33.213.5

73.213.52.383.7216.4

81.351.71.464.95.277.5

91.464.91.577.112.383.7 01 11 21 31 41 51 61 71 81

GISP.dH.tFGISP.dH.tFGISP

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

dH.tF

1.670.419.300.9

1.783.617.448.01

2.829.815.596.21

4.996.124.667.41

6.0154.423.748.61

1.896.81

967.02

9.948.22

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

UNBRAZING SYSTEM COMPONENTS

SERVICE

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 • This is normal start-up for ECM when starting

Motor won’t start • Check blower turns by hand

• No movement

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

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

Motor starts, but runs erratically

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

or intermittent • Check low voltage connections

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

high CFM (speed) “puffing”?

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

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

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

• Blower won’t shut off •

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

• Air noise • High static creating high blower speed?

• Check power at motor

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

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

• Check for unseated pins in connectors on motor harness

• Test with a temporary jumper between R - G

• Check motor for tight shaft

• Perform motor/control replacement check

• Perform Moisture Check

• Make sure blower wheel is tight on shaft

• Perform motor/control replacement check

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

• Check “Bk” for erratic CFM command (in variable-speed applications)

• Check out system controls, Thermostat

• Perform Moisture Check

- Reduce restriction

- Reduce max airflow

delay complete

• “R” missing/not connected at motor

• Perform motor/control replacement check

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

• Perform motor/control replacement check

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

motor noise; interview customer, if necessary

- Is airflow set properly?

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

- Use low-pressure drop filter

- Check/correct duct restrictions

Symptom Cause/Procedure

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

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

Evidence of Moisture

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

• Evidence of moisture • Perform Moisture Check

present inside air mover

• High static creating high blower speed?

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

- Check for cabinet/duct deformation

“puffing”?

- Reduce restriction

- Reduce max. airflow

Perform Moisture Check

Do Don’t

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

wiring and connections thoroughly before replacing motor

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

water can’t get in positions

- Install “drip loops”

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

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

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

minimum: H20 drop!

- Recommend high • Use restricted returns

efficiency, low static filters

- Recommend keeping filters

clean.

- Design ductwork for min.

static, max. comfort

- Look for and recommend

ductwork improvement, where necessary

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

• Check orientation before • Plug in power connector backwards

inserting motor connectors • Force plugs

airflow

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?

½"

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 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. 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.

¼" hex head bolts at the rear of the control

Finish installing the replacement control per

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

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

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

new control to the motor's endshield, insert bolts, and tighten. DO NOT OVERTIGHTEN THE BOLTS.

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

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

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

NOT OVERTIGHTEN THE BOLTS.

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

Follow the manufacturer's suggested procedures.

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

Make sure the connector is properly seated and latched.

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

IMMEDIATE FAILURE OF THE CONTROL MODULE.

12.

Final installation check. Make sure the motor is installed as

follows:

a. Unit is as far INTO the blower housing as possible. b.Belly bands are not on the control module or covering vent

holes.

c. Motor connectors should be oriented between the 4 o’clock

and 8 o’clock positions when the blower is positioned in its final location and orientation.

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

motor by draining down the cables. Refer to Figure 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.

Back of Control

Figure 29

Figure 4

Winding Test

Motor OK when R > 100k ohm

Figure 30

Figure 5

Drip Loop

Connector Orientation

Between 4 and 8 o'clock

Drip Loop

Only remove Hex Head Bolts

ECM 2.0

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

Control Disassembly

Push until Latch Seats Over Ramp

ECM

2.3/2.5

Hex-head Screws

Figure 28

Figure 3

From Motor

Circuit

Board

Motor

Motor Connector (3-pin)

Control Connector

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

Motor Connector (3-pin)

Manual 2100-532B Page 43 of 46

AUX.

Heat Gen.

otor

ower

and Coil

oor

INDOOR SECTIONPOWER SUPPLY

ev.

Valve Water Coil

ater

Solenoid

WATER COIL SECTION

Line Voltage Control Circuit Compressor Refrigerant System

QUICK REFERENCE TROUBLESHOOTING CHART FOR WATER TO AIR HEAT PUMP

Auxillary Heat Upstream of Coil

Undersized or Restricted Ductwork

Air Filters Dirty

Air Volume Low

Motor Winding Defective

Fins Dirty or Plugged

Plugged or Restricted Metering Device (Clg)

Low Water Temperature (Htg)

Water Volume Low (Clg)

Water Volume Low (Htg)

Scaled or Plugged Coil (CLg)

Scaled or Plugged Coil (Htg)

Plugged or Restricted Metering Device (Htg)

Defective Valve or Coil

Leaking

Solenoid Valve Stuck Open (Htg or Clg)

Solenoid Valve Stuck Closed (Clg)

Solenoid Valve Stuck Closed (Htg)

Unequalized Pressures

Non-Condensables

Low Suction Pressure

High Suction Pressure

Low Head Pressure

High Head Pressure

Refrigerant Overcharge

Refrigerant Charge Low

Motor Wingings Defective

Valve Defective

Seized

Bearings Defective

Discharge Line Hitting Inside of Shell

Indoor Blower Relay

Pressure Controls (High or Low)

Contactor Coil



Thermostat

Low Voltage



Control Transformer

Loose Terminals

Faulty Wiring



Start Capacitor

Run Capacitor

Potential Relay

Compressor Overload

Defective Contacts in Contactor



Low Voltage

Loose Terminals

Faulty Wiring

Blown Fuse or Tripped Breaker

Power Failure

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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

Cycle

Heating or Cooling Cycles

Cooling

DENOTES COMMON CAUSE

DENOTES OCCASIONAL CAUSE





Manual 2100-532B Page 44 of 46

Ice in Water Coil

Heating Cycle

GROUND SOURCE HEAT PUMP

PERFORMANCE REPORT

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

DATE: TAKEN BY:

1. UNIT: Mfgr Model # S/N

THERMOSTAT: Mfgr Model # P/N

2. Person Reporting

3. Company Reporting

4. Installed By Date Installed

5. User’s (Owner’s) Name

Address

6. Unit Location

WATER SYSTEM INFORMATION

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

A. If Open Loop where is water discharged?

8. The following questions are for

Closed Loop systems only

A. Closed loop system designed by

B. Type of antifreeze used: % Solution

C. System type: Series Parallel

D. Pipe Material Nominal Size

E. Pipe Installed:

1. Horizontal Total length of pipe ft

No. pipes in trench Depth bottom pipe ft

2. Vertical Total length of bore hole ft

Manual 2100-532B 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

Bard QW5S1, QW2S1, QW4S1, QW3S1 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual