Bard QW 242, QW 361, QW 481, QW 302, QW 421, QW 601 Water Source Heat Pump Installation Instructions
Below you will find brief information for Water Source Heat Pump QW 242, Water Source Heat Pump QW 361, Water Source Heat Pump QW 481, Water Source Heat Pump QW 302, Water Source Heat Pump QW 421, Water Source Heat Pump QW 601. This document provides step-by-step instructions for installing your water source heat pump, including information on mounting the unit, wiring main power and low voltage, and starting up your new system.
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INSTALLATION
INSTRUCTIONS
QW SERIES
WATER SOURCE
PACKAGED HEAT PUMP
Models:
QW242 QW302
QW361 QW421
QW481 QW601
Earth Loop Fluid
Temperatures 25 – 110
Ground Water Temperature 45 – 75
Bard Manufacturing Company
Bryan, Ohio 43506
Since 1914...Moving ahead, just as planned.
Manual No.: 2100-419D
Supersedes: 2100-419C
File:
Date:
Vol II Tab 14
06-02-04
© Copyright 2004
i
CONTENTS
Getting Other Information and Publications
For more information, contact these publishers: ...... 1
QW General Information
QW Model Nomenclature ........................................ 2
Shipping Damage .................................................... 4
Unit Removal From Skid .......................................... 4
Handling Unit After Removal From Skid .................. 4
Removal of Wall Bracket from Shipping Location ... 5
General .................................................................... 5
Minimum Installation Height ..................................... 5
Duct Work ................................................................ 8
Filters ....................................................................... 8
Condensate Drain .................................................... 8
Mist Eleminator Service ......................................... 10
Installation Instructions
Mounting the Unit .................................................. 13
Wiring – Main Power ............................................. 16
Wiring – Low Voltage Wiring ................................. 16
General .................................................................. 16
Low Voltage Connections ...................................... 17
Start Up
Description of Standard Equipment ....................... 21
Compressor Control Module .................................. 21
Adjustments ........................................................... 21
Optional CFM ........................................................ 22
Important Installer Note ......................................... 22
Phase Monitor ....................................................... 22
Service Hints ......................................................... 22
Sequence of Operation .......................................... 22
Pressure Service Ports .......................................... 23
Pressure Tables ................................................ 26-27
Optional Accessories ............................................. 28
Closed Loop (Earth Coupled
Ground Loop Applications)
Circulation System Design .................................... 29
Copper Water Coil Application ............................... 29
Start Up Procedure for Closed Loop System ......... 30
Open Loop (Well System Applications)
Water Connections ................................................ 32
Copper Water Coil Limitations ............................... 32
Well Pump Sizing .................................................. 33
Start Up Procedure for Open Loop System ........... 33
Water Corrosion .................................................... 34
Remedies of Water Problems ................................ 34
Lake and Pond Installations .................................. 35
Cooling Tower / Boiler Application ......................... 37
Service
Service Hints ......................................................... 40
Un-brazing System Components ........................... 40
Troubleshooting ECM Blower Motors ............. 41-42
Quick Referance Troupbleshooting Chart for
Water to Air Heat Pump .......................................... 43
Ground Source Heat Pump
Performance Report .......................................... 44-45
CONTENTS
Figures
Figure 1 Unit Dimensions ..................................... 3
Figure 2 Removal of Unit From Skid .................... 4
Figure 3 Proper Handling of Unit After Removal from Skid ................................................ 5
Figure 4 Installation of Unit w/Wall Sleeve .......... 6
Figure 5 Installation With Free Blow Plenum ....... 7
Figure 6 Ducted Application ................................. 7
Figure 7 Supply Duct Connections ...................... 8
Figure 8 Condensate Drain .................................. 9
Figure 8A Side Drain (Side View) ........................... 9
Figure 8B Optional Rear Drain ............................... 9
Figure 8C Rear Drain (Top View) .......................... 10
Figure 9 Fresh Air Damper Removal ................... 11
Figure 10 Removal of QT
EC
ERV ......................... 12
Figure 11 Remove Locking Screws from Wheels 13
Figure 12 Unit Mounting Without Wall Sleeve ..... 14
Figure 13 Component Location ............................ 15
Figure 14 Low Voltage Wire Harness Plug .......... 17
Figure 15 Remote Thermostat Wiring "X" Option 18
Figure 16 Remote Thermostat Wiring "A" Option 19
Figure 17 Remote Thermostat Wiring "D" Option 20
Figure 18 Fluid Connections w/Ventilation
Wall Sleeve .......................................... 24
Figure 19 Fluid Connections w/o Ventilation
Wall Sleeve .......................................... 25
Figure 20 Circulation System ............................... 29
Figure 21 Water Temperature and Pressure
Test Procedure .................................. 30
Figure 22 Performance Model WGPM-1C ........... 31
Figure 23 Performance Model WGPM-2C ........... 31
Figure 24 Piping Diagram .................................... 32
Figure 25 Cleaning Water Coil ............................. 35
Figure 26 Water Well System .............................. 36
Figure 27 Water Source H/P Cooling Cycle ......... 38
Figure 28 Water Source H/P Heating Cycle ........ 39
Tables
Table 1 Electrical Specifications ........................... 2
Table 2 Operating Voltage Range ....................... 16
Table 3 Wall Thermostats and Subbase
Combinations ......................................... 16
Table 4 Indoor Blower Performance ................... 23
Table 5 Cooling Pressure Table .......................... 26
Table 6 Heating Pressure ................................... 27
Table 7 Optional Accessories ............................. 28
Table 8 Constant Flow Valves ............................. 32
Table 9 Water Flow and Pressure Drop .............. 37 ii
GETTING OTHER INFORMATION AND PUBLICATIONS
These publications can help you install the air conditioner or heat pump. You can usually find these at your local library or purchase them directly from the publisher. Be sure to consult current edition of each standard.
National Electrical Code ...................... ANSI/NFPA 70
Standard for the Installation .............. ANSI/NFPA 90A of Air Conditioning and
Ventilating Systems
Standard for Warm Air ...................... ANSI/NFPA 90B
Heating and Air
Conditioning Systems
Load Calculation for Residential ....... ACCA Manual J
Winter and Summer
Air Conditioning
Duct Design for Residential ............. ACCA Manual D
Winter and Summer Air Conditioning and Equipment Selection
Closed-Loop/Ground Source Heat Pump ........ IGSHPA
Systems Installation Guide
Grouting Procedures for Ground-Source ......... IGSHPA
Heat Pump Systems
Soil and Rock Classification for the Design .... IGSHPA of Ground-Coupled Heat Pump Systems
Ground Source Installation Standards ............. IGSHPA
Closed-Loop Geothermal Systems – Slinky .... IGSHPA
Installation Guide
FOR MORE INFORMATION, CONTACT
THESE PUBLISHERS:
ACCA
ANSI
Air Conditioning Contractors of America
1712 New Hampshire Avenue
Washington, DC 20009
Telephone: (202) 483-9370
Fax: (202) 234-4721
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
IGSHPA International Ground Source
Heat Pump Association
490 Cordell South
Stillwater, OK 74078-8018
Manual 2100-419
Page 1
QW SERIES WATER SOURCE GENERAL INFORMATION
QW MODEL NOMENCLATURE
MODEL NUMBER
QW - QT
EC
Model
Water Source
Heat Pump
CAPACITY
24 - 2 Ton
30 - 2-1/2 Ton
36 - 3 Ton
42 - 3-1/2 Ton
48 - 4 Ton
60 - 5 Ton
REVISION
QW 36 1 - A 0Z B X V X X X
VOLTS & PHASE
A - 2630/208-60-1
B - 2308208-60-3
C - 460-60-3
KW
0Z - None
VENTILATION OPTIONS
B - Blank-off Plate
X - Barometric Fresh Air
Damper
V - Commercial Ventilator -
Motorized Spring Return w/Exhaust
P - Commercial Ventilator -
Motorized power return w/Exhaust
R - Energy Recovery
Ventilator w/Exhaust
INTERNAL CONTROLS
X - Standard
• High Pressure Switch
• Low Pressure Switch
• Compressor Time Delay
COLOR OPTIONS
V - Platinum w/Slate
Front (Vinyl)
4 - Gray (Painted)
FILTER OPTIONS
X - 1 Inch Fiberglass
(Standard)
F - 2 Inch Fiberglass
P - 2 Inch Pleated
COIL OPTIONS
X - Standard Cupronickel
Water Coil
4 - Copper Water Coil
CLIMATE CONTROL OPTIONS
X - None
A - Electronic/Non Prog/Man/Auto
D - Electronic/Prog/Man/Auto
M O D E L
Q W 2 4 2 A 0 Z
Q W 2 4 2 B 0 Z
Q W 2 4 2 C 0 Z
Q W 3 0 2 A 0 Z
Q W 3 0 2 B 0 Z
Q W 3 0 2 C 0 Z
Q W 3 6 1 A 0 Z
Q W 3 6 1 B 0 Z
Q W 3 6 1 C 0 Z
Q W 4 2 1 A 0 Z
Q W 4 2 1 B 0 Z
Q W 4 2 1 C 0 Z
Q W 4 8 1 A 0 Z
Q W 4 8 1 B 0 Z
Q W 4 8 1 C 0 Z
Q W 6 0 1 A 0 Z
Q W 6 0 1 B 0 Z
Q W 6 0 1 C 0 Z
V
R A T
O L T
E D
S &
P H A S E
2 3 0 / 2 0 8 1
2 3 0 / 2 0 8 3
4 6 0 3
2 3 0 / 2 0 8 1
2 3 0 / 2 0 8 3
4 6 0 3
2 3 0 / 2 0 8 -
2 3 0 / 2 0 8 -
1
3
4 6 0 3
2 3 0 / 2 0 8 1
2 3 0 / 2 0 8 -
4 6 0 3
3
2 3 0 / 2 0 8 -
2 3 0 / 2 0 8 -
1
3
4 6 0 3
2 3 0 / 2 0 8 1
2 3 0 / 2 0 8 3
4 6 0 3
N O
P
.
O
F I E
W E
L D
R
C I R C U I T S
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
TABLE 1
ELECTRICAL SPECIFICATIONS
S I N G L E C I R C U I T
3
M I N I M U M
A
C I R C U I T
M P A C I T Y
2 7
2 0
1 1
3 1
2 4
1 2
1 9
1 4
8
2 1
1 6
1 0
2 4
1 9
1 0
4 5
3 4
1 6
1
M A X I M U M
E X T
F U
E R
S E
N
O
A
R
L
B
C I R
R E
C U I T
A K E R
4 0
3 0
1 5
4 5
3 5
1 5
2 5
2 0
1 5
3 0
2 0
1 5
3 5
2 5
1 5
6 0
4 5
2 0
2
F I E L D
W
P O W E R
I R E S I Z E
8
1 0
1 4
8
8
1 4
1 0
1 2
1 4
1 0
1 2
1 4
1 0
1 0
1 4
8
8
1 2
2
G R O U N D
W I R E S I Z E
1 0
1 0
1 4
1 0
1 0
1 4
1 0
1 2
1 4
1 0
1 2
1 4
1 0
1 0
1 4
1 0
1 0
1 2
!
"
#
Maximum size of the time delay fuse or HACR type circuit breaker for protection of field wiring conductors.
Based on 75° C copper wire. All wiring must conform to the National Electrical Code and all local codes.
These “Minimum Circuit Ampacity” values are to be used for sizing the field power conductors. Refer to the
National Electric Code (latest revision), article 310 for power conductor sizing. CAUTION: When more than one field power conductor circuit is run through one conduit, the conductors must be derated. Pay special attention to Note 8 of Table 310 regarding Ampacity Adjustment Factors when more than three conductors are in a raceway.
Manual 2100-419
Page 2
Manual 2100-419
Page 3
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
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.
caution must be taken to prevent injury to personnel and damage to the unit.
If the unit can not be slid through the door, then the unit
It is recommended that the unit not be removed from the skid with a fork lift.
will have to be put on a cart and tipped down to roll through the door. It is recommended that an appliance cart by used with a strap to hold the unit on the cart.
The wheels of the unit must be locked. If the wheels
The shipping brackets on each side of the unit must be removed and discarded. See Figure 2-A on Page 5. 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 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.
will not roll. The back of the skid will have to be held down to keep it from tipping up. The skid can be slid out from under the unit. The unit can then be set upright.
FIGURE 2
REMOVAL OF UNIT FROM SKID
HOLD SKID DOWN
MIS-1603
A SHIPPING BRACKETS B FRONT WHEELS OVER EDGE C FRONT WHEELS ON FLOOR
Manual 2100-419
Page 4
FIGURE 3
PROPER HANDLING OF UNIT
AFTER REMOVAL FROM SKID
QT
EC
UNIT
(RIGHT SIDE)
STRAP
APPLIANCE
CART
COMPRESSOR
MIS-1555
REMOVAL OF WALL BRACKET FROM
SHIPPING LOCATION (UNITS WITH
BLANK OFF PLATE ONLY)
The wall brackets are attached to the back of the unit.
Remove and retain the wall brackets for use when attaching the unit to the wall. In units equipped with a ventilator a wall sleeve is required and these two wall brackets are not included. A different style bracket is supplied with the sleeve assembly.
GENERAL
The equipment covered in this manual is to be installed by trained, experienced service and installation technicians.
The unit is designed for use with or without duct work.
For use without duct work, Plenum Box QPB** is recommended.
These instructions explain the recommended method to install the water source self-contained unit and the electrical wiring connections to the unit.
These instructions and any instructions packaged with any separate equipment required to make up the entire air conditioning system should be carefully read before beginning the installation. Note particularly “Start
Procedure” and any tags and/or labels attached to the equipment.
While these instructions are intended as a general recommended guide, they do not supersede any national and/or local codes in any way. Authorities having jurisdiction should be consulted before the installation is made. See Page 1 for information on codes and standards.
Size of unit for a proposed installation should be based on heat loss calculation made according to methods of
Air Conditioning Contractors of America (ACCA). The air duct should be installed in accordance with the
Standards of the National Fire Protection Systems of
Other Than Residence Type, NFPA No. 90A, and
Residence Type Warm Air Heating and Air
Conditioning Systems, NFPA No. 90B. Where local regulations are at a variance with instructions, installer should adhere to local codes.
MINIMUM INSTALLATION HEIGHT
The minimum installation height of the unit with a Free
Blow Plenum is 8 ft. 6 in. This provides enough clearance for the plenum to be removed. See Figure 5.
The minimum installation height for ducted applications is 8 ft. 4-1/2 in. This provides enough clearance to install the duct work. See Figure 6.
Manual 2100-419
Page 5
FIGURE 4
INSTALLATION OF UNIT THRU WALL WITH WALL SLEEVE
MIS-1564
Manual 2100-419
Page 6
FIGURE 5
INSTALLATION WITH FREE BLOW PLENUM
CEILING
20 IN.
MINIMUM
FLOOR
FIGURE 6
DUCTED APPLICATION
SUSPENDED
CEILING
FIXED CEILING
MIS-1558
DUCT
DUCT FLANGE
Manual 2100-419
Page 7
FLOOR
MIS-1559
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 air flow requirement of the equipment.
Air Conditioning Contractors of America (ACCA) is an excellent guide to proper sizing. All duct work or portions thereof not in the conditioned space should be properly insulated in order to both conserve energy and prevent condensation or moisture damage. When duct runs through unheated spaces, it should be insulated with a minimum of one inch of insulation. Use insulation with a vapor barrier on the outside of the insulation. Flexible joints should be used to connect the duct work to the equipment in order to keep the noise transmission to a minimum.
The QT
EC
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.
FIGURE 7
SUPPLY DUCT CONNECTIONS
ROOM SIDE
OF QW UNIT
SUPPLY DUCT
TO BE FIELD
SUPPLIED
ATTACHMENT
SCREWS TO BE
FIELD SUPPLIED
DUCT FLANGE
PROVIDED WITH UNIT
MIS-978
The QT
EC
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. See Optional Accessories,
Page 18, for the correct Plenum Box model number.
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”. See
Optional Accessories, Page 18 for the correct Cabinet
Extension model number. The unit is equipped with a variable speed indoor blower motor which increases in speed with an increase in duct static pressure. The unit will therefore deliver proper rated air flow up to the
Maximum ESP shown in Table 5. However, for quiet operation of the air system, the duct static should be kept as low as practical, within the guidelines of good duct design.
FILTERS
Two 1 inch throw away filters are supplied with each unit. The filters fit into a fixed rack.
The filters are serviced from the inside of the building .
To gain access to the filters release the latch on the circuit breaker door and one 1/4 turn fastener near the bottom of the door. This door is hinged on the left so it will swing open.
The internal filter brackets are adjustable to accommodate 2 inch filters. The tabs for the 1 inch filters must be bent down to allow the 2 inch filters to slide in place.
CONDENSATE DRAIN
The condensate drain hose is routed down from the evaporator drain pan on the right side of the unit into the compressor compartment. There are three locations that the drain can exit the cabinet. For a stand pipe type of drain, the drain hose can exit the rear of the cabinet. There is adequate hose length to reach the floor on the right hand side of the unit.
If the drain is to be hard plumbed, there is a 3/4 inch pipe connection located on the right hand cabinet side near the rear and one on the cabinet rear panel.
In these installations the drain tube is to be slipped over the pipe connection inside of the cabinet.
See Figures 8A, 8B and 8C.
NOTE: Whichever type of drain connection is used a “P” trap must be formed. See Figure 8.
Manual 2100-419
Page 8
FIGURE 8
CONDENSATE DRAIN
MIS-1568
The side drain requires a water trap for proper drainage. See Figure 8A. The drain can be routed through the floor or through the wall. 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 8A
SIDE DRAIN (SIDE VIEW)
FIGURE 8B
OPTIONAL REAR DRAIN
QT
EC
UNIT
MIS-976
Manual 2100-419
Page 9
MIS-974
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.
SLEEVE
WATER
TRAP
MIS-977
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
MIST ELIMINATOR SERVICE (Optional –
only used with one of the vent options)
A mist eliminator is supplied with the wall sleeve. The mist eliminator is constructed of aluminum frame and mesh. The mist eliminator is located in the top section of the wall sleeve and can be removed from the inside of the building without removing the unit from the wall.
This requires that the ventilation package must be removed.
The steps necessary to remove each of the vent options are listed following.
It is recommended that the mist eliminator be inspected annually and serviced as required. The mist eliminator can be inspected from the outside of the building by looking through the outdoor grille. The mist eliminator can be serviced from the outside. The outdoor grille must be removed to do so.
The mist eliminator can be cleaned by washing with soap and water. The excess water should be shaken off the mist eliminator before it is reinstalled.
BAROMETRIC FRESH AIR DAMPER
(Optional)
Before start to remove make sure the power has been turned off. The hinged return air grille panel must be opened. The fresh air damper assembly can be seen on the back of the unit.
Refer to Figure 9.
1. The fresh air damper is attached to the back of the unit with one screw on either side of the assembly. Both of the screws must be removed.
2. Once the mounting screws are removed, tilt the assembly down and lift it out.
The mist eliminator can be seen through the opening. The mist eliminator must be raised up and the bottom can be pulled toward the front of the unit.
Manual 2100-419
Page 10
COMMERCIAL ROOM VENTILATOR OPTION
Before stating the removal make sure the power has been turned off. The hinged return air grille must be opened. The commercial room ventilator (CRV) can be seen after the panel has been removed. The CRV must be removed to gain access to the mist eliminator.
1. The two mounting screws in the front of the CRV must be removed.
2. The power connectors for the CRV (located on the right side of the unit) must be disconnected.
Squeeze the tabs on the sides of the connector and pull straight out. Unplug both of the connectors.
3. Slide the CRV straight out of the unit.
The mist eliminator can be seen through the opening in the back of the unit. The mist eliminator must be raised up and the bottom can be pulled toward the front of the unit and removed.
FIGURE 9
FRESH AIR DAMPER REMOVAL
MOUNTING SCREW
MIS-1627
Manual 2100-419
Page 11
QTEC ENERGY RECOVERY VENTILATOR
OPTION
Before starting the removal make sure that the power has been turned off. The hinged return air grille panel must be opened. The energy recovery ventilator
(QERV) can be seen after the panel is opened. To gain access to the mist eliminator, the QERV must be removed. Refer to Figure 10
1. The front fill plate of the QERV must be removed.
There is one screw on either side of the plate.
Remove these screws and remove the plate.
2. On either side of the QERV there are mounting screws that hold the QERV in place. Remove both of these screws.
3. Underneath the heat recovery cassette there is a power connector for the lower blower assembly. To disconnect this plug, the tabs on both sides of the plug must be squeezed to release the plug. While squeezing the tabs, pull the plug out of the socket.
4. The QERV is plugged into the unit on the right side of the unit. Both of these plugs must be disconnected to remove the QERV. Squeeze the tabs on the sides of the connector and pull straight out.
5. Slide the QERV assembly straight out of the unit being careful not to let the cassette slide out of the
QERV.
The mist eliminator can be seen through the opening in the back of the unit. The mist eliminator must be raised up and the bottom can be pulled toward the front of the unit and removed.
FIGURE 10
REMOVAL OF THE QTEC ENERGY RECOVERY VENTILATOR
MOUNTING
SCREWS
FRONT FILL
POWER
CONNECTORS
LOWER BLOWER
ASSEMBLY POWER
CONNECTOR
MIS-1605
Manual 2100-419
Page 12
INSTALLATION INSTRUCTIONS
MOUNTING THE UNIT
When installing a QW unit near an interior wall on the left side, a minimum of 8 inches is required; 12 inches is preferred.
When installing a QW unit near an interior wall on the right side, a minimum of 12 inches is required as additional space is required to connect the drain.
This clearance is required to allow for the attachment of the unit to the wall mounting brackets and the side trim pieces to the wall.
This unit is to be secured to the wall when there is not a vent sleeve used with the wall mounting brackets provided. (NOTE: Wall mounting brackets are only
shipped on units with no vent inside.) The unit itself, the supply duct, and the free blow plenum are suitable for “0” clearance to combustible material.
NOTE: When a wall sleeve is to be used attach the unit to the sleeve with bracket supplied with the wall sleeve.
Following are the steps for mounting the QW units for reference see Figure 12 on page 14.
1. Attach wall mounting bracket to the structure wall with field supplied lag bolts. The fluid piping connections are to be within the confines of this bracket. See Figure 1 for cabinet openings and location of fluid coil connection points.
2. Position the unit in front of the wall mounting bracket.
3. Remove the locking screws from the wheels. Refer to Figure 11.
4. Roll the unit up to the wall mounting bracket. The unit must be level from side to side. If any adjustments are necessary, shim up under the rollers with sheets of steel or any substance that is not affected by moisture.
5. Secure the unit to the wall bracket with provided #10 hex head sheet metal screws. There are prepunched holes in the cabinet sides, and the bracket has slotted holes to allow for some misalignment.
6. Position the bottom trim piece to the unit and attach with provided screws (dark colored).
7. Position side trim pieces to the wall and attach with field supplied screws. There are two long and two short pieces supplied. The long pieces are to enclose the gap behind the unit. The short pieces are to fill the gap behind the cabinet extension or the free blow plenum box. They may be cut to suit the ceiling height or overlap the unit side trim. There is sufficient length to trim up to a 10’2” ceiling.
FIGURE 11
REMOVING LOCKING SCREWS FROM
WHEELS
REMOVE SCREWS
FROM WHEELS
BEFORE ROLLING
INTO PLACE
MIS-1523
Manual 2100-419
Page 13
FIGURE 12
UNIT MOUNTING WITHOUT VENTILATION WALL SLEEVE
(REFER TO MOUNTING INSTRUCTIONS ON PAGE 13)
SIDE TRIM
(2 PIECES)
SIDE TRIM (2
PIECES)
WALL MOUNTING
BRACKET
BOTTOM TRIM PIECE BOTTOM TRIM
EXTENSION
MIS-1557
Manual 2100-419
Page 14
Manual 2100-419
Page 15
FIGURE 13
COMPONENT LOCATION
SIDE FIELD
WIRE ENTRANCE
REMOTE THERMOSTAT
TERMINAL BLOCK
INDOOR BLOWER
CONTROL BOX/ CIRCUIT
BREAKER PANEL
ELECTRICAL
CONNECTION PANEL
MIS-1556
WIRING – MAIN POWER
Refer to the unit rating plate and/or Table 2 for wire sizing information and maximum fuse or “HACR Type” circuit breaker size. Each unit is marked with a
“Minimum Circuit Ampacity”. This means that the field wiring used must be sized to carry that amount of current. Depending on the installed KW of electric heat, there may be two field power circuits required. If this is the case, the unit serial plate will so indicate. All models are suitable only for connection with copper wire. Each unit and/or wiring diagram will be marked
“Use Copper Conductors Only”. These instructions
must be adhered to. Refer to the National Electrical
Code (NEC) for complete current carrying capacity data on the various insulation grades of wiring material. All wiring must conform to NEC and all local codes.
The electrical data lists fuse and wire sizes (75° C copper) for all models, including the most commonly used heater sizes. Also shown are the number of field power circuits required for the various models with heaters.
The unit rating plate lists a “Maximum Time Delay
Relay Fuse” or “HACR Type” circuit breaker that is to be used with the equipment. The correct size must be used for proper circuit protection, and also to assure that there will be no nuisance tripping due to the momentary high starting current of the compressor motor.
The disconnect access door on this unit may be locked to prevent unauthorized access to the disconnect.
The field wiring connections are located behind the top panel in the circuit breaker panel. The return air panel must be removed first. This panel is equipped with a door switch which shuts the unit down when it is removed. The filter rack must be removed next.
TABLE 2
OPERATING VOLTAGE RANGE
T A P R A N G E
2 4 0 V
2 0 8 V
2 5 3 2 1 6
2 2 0 1 8 7
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 17 for wiring diagram. Compatible thermostats are listed in
Table 3.
The Climate Control Option A is an electronic, nonprogrammable manual or auto changeover thermostat.
The subbase of the thermostat is factory wired to the front panel of the unit. Compatible for use with Bard
CS2000 Controller and Energy Recovery Ventilator.
The Climate Control Option D is an electronic, programmable thermostat. The subbase of the thermostat is factory wired to the front panel of the unit.
Compatible for use with Energy Recovery Ventilator or
Economizer.
GENERAL
This unit is equipped with a variable speed ECM motor.
The motor is designed to maintain rated airflow up to the maximum static allowed. It is important that the blower motor plugs are not plugged in or unplugged while the power is on. Failure to remove power prior to unplugging or plugging in the motor could result in motor failure.
WIRING – LOW VOLTAGE WIRING
230/208V, 1 PHASE AND 3 PHASE EQUIPMENT
DUAL PRIMARY VOLTAGE TRANSFORMERS
All equipment leaves the factory wired on 240V tap.
For 208V operation, reconnect from 240V to 208V tap.
The acceptable operating voltage range for the 240 and
208V taps are as noted in Table 2.
CAUTION
Do not plug in or unplug blower motor connectors while the power is on. Failure to do so may result in motor failure.
TABLE 3
WALL THERMOSTATS AND SUBBASE COMBINATIONS
T h e r m o s t a t
8 4 0 4 0 1 7
( T 8 7 4 R 1 1 2 9 )
8 4 0 3 0 1 8
( T 8 7 4 N 2 0 2 4 )
8 4 0 3 0 4 2
( T 8 5 1 1 G 1 0 7 0 )
5 4 0 3 0 3 4
( I F 9 4 8 0 )
S u b b a s e
8 4 0 4 0 0 9
( Q 6 7 4 1 2 6 1 )
8 4 0 4 0 1 0
( Q 6 7 4 1 2 6 1 )
N / A
N / A
P r e d o m i n a n t F e a t u r e s
H e a t
N o A o r u t o
C o o l
A
C u t o m a h a n g e it c H o v e r e
P a t o
/ s i
C o o l it o n
M a n u
N o n P a l / r o g
A u t o / r a m m
H e a t a b l e
/ C o o l
E l e c t r o n i c
M a n u a l
P r o g r a
/ A m m u t o a b l e
/ H e a t / C o o l
E l e c t r o n i c
Manual 2100-419
Page 16
LOW VOLTAGE CONNECTIONS
These units use a grounded 24 volt AC low voltage circuit.
The “R” terminal is the hot terminal and the “C” terminal is grounded.
“G” terminal or pins 6 and 1 of P2 are the fan inputs.
Both must be energized for proper fan operation. This is done automatically in the factory installed climate control options. If the climate control option is abandoned and connections are made directly to P2 both pins 6 and 1 of P2 must be energized for proper operation.
“Y” terminal or pin 7 of P2 is the compressor input.
“B” terminal or pin 8 of P2 is the reversing valve input.
The reversing valve must be energized for heating mode.
“R” terminal or pin 10 of P2 is 24 VAC hot.
“C” terminal or pin 11 of P2 is 24 VAC grounded.
“L” terminal or pin 12 of P2 is compressor lockout
output. This terminal is activated on a high or low pressure trip by the compressor control module. This is a 24 VAC output.
“W2” terminal or pin 9 of P2 is second stage heat (if equipped). If the unit is equipped with an optional hot water coil plenum box the water valve will be connected to this terminal.
“O1” terminal of pin 5 of P2 is the ventilation input.
This terminal energizes any factory installed ventilation option.
L O W V O L T
D
A G
D
E
C
C
C
O
O
N N
N T
E
R
C
O
T
L
I O N S F O R
F a n O n l y
C o o il n g M o d e
H e a t P u m p H e a it n g
(
2 n d fi e
S t m p a g l o e H y e d ) e a it n g
V e n t li a it o n
E n e r g i z e G
E n e r g i z e Y , G
E n e r g i z e Y , G , B
E n e r g i z e G , W 2
E n e r g i z e G , O 1
FIGURE 14
BLOWER MOTOR LOW VOLTAGE
WIRE HARNESS PLUG
VIEWED FROM PIN END VIEWED FROM PIN END
MIS-1285
Manual 2100-419
Page 17
FIGURE 15
REMOTE THERMOSTAT WIRING DIAGRAM
“X” OPTION
Manual 2100-419
Page 18
FIGURE 16
REMOTE THERMOSTAT WIRING DIAGRAM
“A” THERMOSTAT OPTION
Manual 2100-419
Page 19
4102-021A
FIGURE 17
REMOTE THERMOSTAT WIRING DIAGRAM
“D” THERMOSTAT OPTION
4102-022C
Manual 2100-419
Page 20
START UP
DESCRIPTION OF STANDARD
EQUIPMENT
LOW PRESSURE SWITCH
NOTE: This unit is supplied with two low pressure switches installed, a 15 PSIG and a 27 PSIG.
The 27 PSIG is wired into the system. This switch is suitable for ground water (pump and dump), and water loop (boiler/tower applications).
To avoid nuisance lockouts for ground loop application with antifreeze, the 27 PSIG switch should be disconnected and connect the 15 PSIG switch.
The leads for both switches are located in the lower electrical connection panel. The switch bodies are marked with pressure settings. The 27 PSIG switch has yellow leads. The 15 PSIG switch has blue leads.
HIGH PRESSURE SWITCH
This unit is equipped with a high pressure switch that will stop the compressor in the event of abnormal high pressure occurrences.
The high and low pressure switches are included in a lockout circuit that is resettable from the room thermostat.
COMPRESSOR CONTROL MODULE
The compressor control module is optional on the models covered by this manual. The compressor control is an anti-short cycle/lockout timer with high and low pressure switch monitoring and alarm relay output.
ADJUSTABLE DELAY ON MAKE AND BREAK
TIMER
On initial power up or any time power is interrupted to the unit the delay on make period begins which will be 2 minutes plus 10% of the delay on break setting. When the delay on make is complete and the high pressure switch (and low pressure switch, if employed) is closed, the compressor contactor is energized. Upon shutdown the delay on break timer starts and prevents restart until the delay on break and delay on make periods have expired.
During routine operation of the unit with no power interruptions the compressor will operate on demand with no delay.
HIGH PRESSURE SWITCH AND LOCKOUT
SEQUENCE
If the high pressure switch opens, the compressor contactor will de-energize immediately. The lockout timer will go into a soft lockout and stay in soft lockout until the high pressure switch closes and the delay on break time has expired. If the high pressure switch opens again in the same operating cycle the unit will go into manual lockout condition and the alarm relay circuit will energize. Recycling the wall thermostat resets the manual lockout.
LOW PRESSURE SWITCH, BYPASS AND
LOCKOUT SEQUENCE
If the low pressure switch opens for more than 120 seconds, the compressor contactor will de-energize and go into a soft lockout. Regardless the state of the low pressure switch, the contactor will reenergize after the delay on make time delay has expired. I the low pressure switch remains open, of 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 22.
During routine operation of the unit with no power interruptions the compressor will operate on demand with no delay.
Manual 2100-419
Page 21
DELAY ON MAKE TIMING
.
0 5 m i n u t e s
1 .
0 m i n u t e s
2 .
0 m i n u t e s
3 .
0 m i n u t e s
4 .
0 m i n u t e s
5 .
0 m i n u t e s
( 3 0 s e c o n d s )
( 6 0 s e c o n d s )
( 1 2 0 S e c o n d s )
( 1 8 0 s e c o n d s )
( 2 4 0 s e c o n d s )
( 3 0 0 s e c o n d s )
D
D
D
D
D
O
O
O
B
O B
O B
B
B
=
=
=
=
=
1 2 3 s e c o n d s D O M
1 2 6 s e c o n d s D O M
1 3 2
1 3 8
1 4 4 s e c o n d s s e c o n d s s e c o n d s
D O M
D O M
D O M
D O B = 1 5 0 s e c o n d s D O M
OPTIONAL CFM
This option is not available for QW241 or QW301.
These units are shipped from the factory set to operate at the optional CFM level shown in Table 4. This provides lower operating sound levels for non-ducted, free discharge applications. This CFM level will reduce the system capacity performance by approximately 2% at the same energy efficiency.
Rated CFM is required for ducted applications for maximum performance rating. To obtain full CFM on these models, connect jumper wire as follows:
1. Disconnect all power to the unit. Failure to do so may result in damage to the motor.
2. Open hinged return air grille panel
3. Open control panel cover.
4. Locate low voltage terminal strip. There is a pink jumper wire with both ends attached to terminal marked “G2”. Move one end of this jumper to terminal “Y”.
5. Reverse steps to reassemble.
IMPORTANT INSTALLER NOTE
For improved start up performance, wash the indoor coil with dishwashing detergent.
PHASE MONITOR
All units with three phase scroll compressors are equipped with a three phase line monitor to prevent compressor damage due to phase reversal.
The phase monitor in this unit is equipped with two
LEDs. If the Y signal is present at the phase monitor and phases are correct, the green LED will light and contactor will energize. If phases are reversed, the red fault LED will be lit and compressor operation is inhibited.
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.
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 air flow through the system which shortens equipment service life as well as increasing operating costs and noise levels.
2. The heat pump wall thermostats perform multiple functions. Be sure that all function switches are correctly set for the desired operating mode before trying to diagnose any reported service problems.
SEQUENCE OF OPERATION
COOLING – Circuit R-Y makes the thermostat pull in the compressor contactor starting the compressor. The
G (indoor motor) circuit is automatically completed on any call for cooling operation, or can be energized by manual fan switch on subbase for constant air circulation.
Manual 2100-419
Page 22
HEATING – A 24V solenoid coil on reversing valve controls heating cycle operation. Two thermostat options, one allowing “Auto” change over from cycle to cycle and the other constantly energizing solenoid coil during heating season and thus eliminating pressure equalization noise, are to be used. On “Auto” option, a circuit is completed for R-W1 and R-Y on each heating
“on” cycle, energizing reversing valve solenoid and pulling in compressor contactor starting compressor.
R-G also makes starting indoor blower motor. Heat pump heating cycle now in operation.
The second option has no “Auto” change over position, but instead energizes the reversing valve solenoid constantly whenever the system switch on subbase is placed in “Heat” position, the “B” terminal being constantly energized from R. A thermostat demand for heat completes R-Y circuit pulling in compressor contactor starting compressor. R-G also make starting indoor blower motor.
PRESSURE SERVICE PORTS
High and low pressure service ports are installed on all units so that the system operating pressures can be observed. Pressure charts can be found later in the manual covering all models on both cooling and heating cycles. It is imperative to match the correct pressure chart to the unit by model number. All service doors must be attached to obtain proper reading. The service ports are located behind the center door on the left hand side of the unit above the air filters.
M O D E L
Q W 2 4 2
Q W 3 0 2
Q W 3 6 1
Q W 4 2 1
Q W 4 8 1
Q W 6 0 1
R A
E
T E D
S P
0 .
0
0 .
0
0 .
0
0 .
0
0 .
0
0 .
0
TABLE 4
INDOOR BLOWER PERFORMANCE
1 2
M A X .
E S P
0 .
5
0 .
8
0 .
8
0 .
8
0 .
8
0 .
8
R A T E D C F M
8 0 0
1 0 0 0
1 2 0 0
1 2 0 0
1 4 0 0
1 5 5 0
3
O P T I O N A L
C F M
N / A
N / A
1 0 0 0
1 0 0 0
1 1 0 0
1 2 5 0
4
C O N T I N U O U S
C F M
8 0 0
1 0 0 0
1 0 0 0
1 0 0 0
1 1 0 0
1 2 5 0
C F M @ M A X .
E S P
7 0 0
9 1 0
1 1 7 5
1 1 7 5
1 1 7 5
1 4 0 0
NOTE: These units are equipped with a variable speed (ECM) indoor motor that automatically adjusts itself to maintain approximately the same rate of indoor air flow in both heating and cooling, dry and wet coil conditions, and at both 230/208 or 460 volts.
1 Maximum ESP (inches WC) shown is with 1” thick disposable filter (reduced by .2 for 2” filter).
2 Rated CFM for ducted applications – required for maximum performance rating. To obtain full CFM on models QW361, QW421, QW481 and QW601 locate low voltage terminal strip in the circuit breaker box.
There is a pink jumper wire with both ends attached to terminal marked “G2”. Move one end of the jumper to terminal “Y”.
3 Optional CFM – the unit is shipped from the factory set to operate at the optional CFM level shown.
This provides lower operating sound levels for non-ducted, free discharge applications. This reduces system capacity performance by approximately 2% at the same energy efficiency.
4 Continuous fan CFM is the total air being circulated during continuous fan mode.
Manual 2100-419
Page 23
SIDE TRIM PEICES
(SHIPPED WITH UNIT)
FLUID ACCESS
FROM CEILING
SLEEVE
FLUID ACCESS
FROM EACH SIDE
FIGURE 18
FLUID CONNECTIONS ON UNIT WITH VENTILATION WALL SLEEVE
SIDE TRIM PIECES (SHIPPED
WITH UNIT) IF THE WALL
THICKNESS IS LESS THAN
14" BUT GREATER THAN 8",
A SIDE TRIM EXTENSION KIT
QSTX42 IS REQUIRED. REFER
TO UNIT SPEC. SHEET FOR
PROPER COLOR
FLUID ACCESS FROM
CEILING
TOP OF UNIT
BACK OF UNIT
63 1/2"
34"
29"
8" TO 14" EXTERIOR WALL
FLUID ACCESS
FROM EACH SIDE
SLEEVE
WALL OPENING
35" x 29 1/2"
MOUNTING BRACKETS
(SHIPPED WITH WALL
SLEEVE)
OPENING IN
REAR OF UNIT
3" x 8"
FLUID ACCESS
FROM FLOOR
8 1/2"
23 1/2"
33" REF.
FLOOR
MIS-1602
1-18-01
MIS-1602
Manual 2100-419
Page 24
FIGURE 19
FLUID CONNECTIONS ON UNIT WITHOUT VENTILATION WALL SLEEVE
TOP VIEW
WALL BRACKET
WALL BRACKET
4"
WATER LINES
WALL LOCATION
BACK OF UNIT
FLUID ACCESS
FROM TOP
63 1/2"
OPENING IN
REAR OF UNIT
3" x 8"
8 1/2"
23 1/2"
FLOOR
WALL BRACKET
(LEFT BRACKET
REMOVED FOR
CLARITY)
FLUID ACCESS FROM FLOOR
MIS-1601
11/10/00
MIS-1601
Manual 2100-419
Page 25
TABLE 5
PRESSURE TABLE
COOLING
M o d e l
Q W 2 4 2
Q W 3 0 2
Q W 3 6 1
Q W 4 2 1
Q W 4 8 1
Q W 6 0 1
Fluid Temperature Entering Water Coil Degree F
R e t u r n
T e m p e r a t
A i r u r e
7
8
8
7
8
8
7
8
8
7
8
8
7
8
8
7
8
8
5
0
5
5
0
5
5
0
5
5
0
5
5
0
5
5
0
5 /
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/ 6
6
7
6
6
7
6
6
7
6
6
7
6
6
7
6
6
7
2
7
2
2
7
2
2
7
2
2
7
2
2
7
2
2
7
2
P r e s s u r e
L o w
H i g h
S i
S i d e d e
L o w
H i g h
S i d e
S i d e
L o w
H i g h
S i
S i d e d e
L o w
H i g h
S i
S i d e d e
L o w
H i g h
S i d e
S i d e
L o w
H i g h
S i d e
S i d e
L o w
H i g h
S i d e
S i d e
L o w
H i g h
S i d e
S i d e
L o w
H i g h
S i d e
S i d e
L o w
H i g h
S i d e
S i d e
L o w
H i g h
S i d e
S i d e
L o w
H i g h
S i d e
S i d e
L o w
H i g h
S i d e
S i d e
L o w
H i g h
S i d e
S i d e
L o w
H i g h
S i d e
S i d e
L o w
H i g h
S i d e
S i d e
L o w
H i g h
S i d e
S i d e
L o w
H i g h
S i d e
S i d e
5 5
6 8
1 4 5
7 3
1 4 9
7 6
1 5 4
6 5
1 4 6
6 9
1 5 0
7 1
1 5 5
6 9
1 4 0
7 4
1 4 4
7 7
1 4 9
7 1
1 6 2
7 3
1 6 8
6 9
1 5 1
7 4
1 5 5
7 7
1 6 0
6 0
6 9
1 5 5
7 4
1 5 9
7 7
1 6 5
6 6
1 5 8
6 5
1 4 4
6 9
1 4 8
7 1
1 5 3
6 5
1 4 0
7 1
1 4 8
7 1
1 4 9
6 2
1 4 1
6 6
1 4 5
6 8
1 5 0
6 5
1 5 4
7 0
1 5 8
7 2
1 6 4
6 6
1 5 2
7 2
1 5 8
7 2
1 5 9
6 2
1 5 4
6 6
1 5 8
6 8
1 6 4
6 3
1 3 5
6 7
1 3 8
6 9
1 4 3
6 4
1 3 1
6 9
1 3 6
7 0
1 4 4
6 3
1 3 0
6 7
1 3 3
6 9
1 3 8
6 7
1 3 7
6 9
1 4 2
6 8
1 2 9
7 3
1 3 2
7 6
1 3 7
5 0
6 8
1 3 6
7 3
1 3 9
7 6
1 4 4
6 3
1 3 4
6 1
1 2 5
6 5
1 2 8
6 7
1 3 2
6 3
1 2 1
6 7
1 2 6
6 9
1 3 3
6 3
1 1 8
6 7
1 2 1
6 9
1 2 5
6 6
1 2 5
6 8
1 2 9
6 7
1 1 9
7 2
1 2 2
7 6
1 2 6
4 5
6 8
1 2 7
7 3
1 3 0
7 6
1 3 5
6 2
1 2 2
7 0
1 9 1
7 5
1 9 6
7 8
2 0 3
6 9
1 8 8
7 6
1 9 6
7 6
1 9 7
6 3
1 9 4
6 7
1 9 9
6 9
2 0 6
7 6
2 0 3
7 9
2 1 0
7 1
1 9 0
7 6
1 9 5
7 9
2 0 2
7 5
7 0
1 9 1
7 5
1 9 6
7 8
2 0 3
7 1
1 9 8
6 7
1 6 6
7 2
1 7 0
7 5
1 7 6
6 7
1 6 4
7 4
1 6 9
7 3
1 7 6
7 5
1 8 2
7 0
1 6 4
7 5
1 6 8
7 8
1 7 4
6 5
6 9
1 6 7
7 4
1 7 1
7 7
1 7 7
6 8
1 7 2
7 3
1 7 0
6 2
1 6 7
6 6
1 7 1
6 8
1 7 7
7 4
1 8 5
6 3
1 8 0
6 7
1 8 5
6 9
1 9 1
7 0
6 9
1 7 8
7 4
1 8 3
7 7
1 8 9
6 9
1 8 4
6 8
1 7 8
7 3
1 8 3
7 6
1 8 9
6 8
1 7 6
7 5
1 8 4
7 4
1 8 9
7 7
1 9 6
7 1
1 7 6
7 6
1 8 1
7 9
1 8 7
7 1
2 0 5
7 6
2 1 0
7 9
2 1 7
7 0
2 0 0
7 6
2 1 5
7 8
2 1 9
6 4
2 0 8
6 8
2 1 3
7 0
2 2 0
7 7
2 1 7
8 0
2 2 5
7 2
2 0 4
7 7
2 0 9
8 0
2 1 6
8 0
7 0
2 0 6
7 5
2 1 1
7 8
2 1 8
7 2
2 1 2
7 2
2 1 9
7 7
2 2 5
8 0
2 3 3
7 2
2 1 9
7 7
2 2 5
7 9
2 3 4
6 5
2 2 2
6 9
2 2 8
7 1
2 3 6
7 9
2 3 1
8 2
2 3 9
7 2
2 1 9
7 7
2 2 5
8 0
2 3 3
8 5
7 1
2 2 0
7 6
2 2 6
7 9
2 3 4
7 4
2 2 5
9 0
7 1
2 3 6
7 6
2 4 2
7 9
2 5 0
7 5
2 4 0
9 5
7 1
2 5 3
7 6
2 5 9
7 9
2 6 8
7 6
2 5 4
1 0 0
7 4
2 5 2
7 9
2 5 8
8 2
2 6 7
7 4
2 5 2
7 8
2 5 8
8 1
2 6 0
6 6
2 5 2
7 1
2 5 8
7 3
2 6 7
7 3
2 3 5
7 8
2 4 1
8 1
2 4 9
7 3
2 3 5
7 7
2 4 1
8 0
2 4 7
6 5
2 3 7
7 0
2 4 3
7 2
2 5 2
8 0
2 4 6
8 3
2 5 5
7 3
2 3 4
7 8
2 4 0
8 1
2 4 8
8 1
2 6 1
8 4
2 7 0
7 3
2 5 1
7 8
2 5 7
8 1
2 6 6
8 2
2 7 6
8 5
2 8 6
7 4
2 6 7
7 9
2 7 4
8 2
2 8 4
7 5
2 6 9
8 0
2 7 6
8 3
2 8 6
7 5
2 6 9
7 9
2 7 6
8 2
2 8 0
6 7
2 6 7
7 2
2 7 4
7 5
2 8 4
7 2
2 7 0
7 7
2 7 7
8 0
2 8 7
7 7
2 6 9
1 0 5
7 2
2 8 9
7 7
2 9 6
8 0
3 0 6
7 8
2 8 4
7 5
2 8 8
8 0
2 9 5
8 3
3 0 5
7 5
2 8 7
7 9
2 9 5
8 3
2 9 1
8 6
3 0 1
7 4
2 8 5
7 9
2 9 2
8 2
3 0 2
8 2
3 0 2
6 9
2 8 4
7 4
2 9 1
7 7
3 0 1
8 3
3 2 2
7 1
2 9 9
7 6
3 0 7
7 9
3 1 8
7 6
3 0 6
8 1
3 1 4
8 4
3 2 5
7 6
3 0 4
8 0
3 1 4
8 5
3 0 7
8 8
3 1 8
7 5
3 0 2
8 0
3 1 0
8 3
3 2 1
1 1 0
7 2
3 0 8
7 7
3 1 6
8 0
3 2 7
7 9
2 9 9
The data in the above pressure chart is based on the following flow rates:
FLOW RATE FOR VARIOUS FLUIDS
F l o w r a t e r e q u i r e d G P M f r e s h w a t e r
F l o w r a t e r e q u i r e d G P M 1 5 % S o d i u m C h l o r i d e
F l o w r a t e r e q u i r e d G P M 2 5 % G S 4
Q W 2 4 2
3
4
4
Q W 3 0 2
4
6
6
Q W 3 6 1
5
7
7
Q W 4 2 1
6
8
8
Q W 4 8 1
6
8
8
Q W 6 0 1
9
1 1
1 1
Manual 2100-419
Page 26
TABLE 6
PRESSURE TABLE
HEATING
M o d e l
Q W 2 4 2
Q W 3 0 2
Q W 3 6 1
Q W 4 2 1
Q W 4 8 1
Q W 6 0 1
Fluid Temperature Entering Water Coil Degree F
T
R e e m t u p r e n r a t
A i r u r e
6
6
6
6
6
6
8
8
8
8
8
8
P r e s s u r e
L o w
H i g h
S i d e
S i d e
L o w
H i g h
S i d e
S i d e
L o w
H i g h
S i d e
S i d e
L o w
H i g h
S i d e
S i d e
L o w
H i g h
S i d e
S i d e
L o w
H i g h
S i d e
S i d e
2 5
4 0
1 7 5
3 5
1 7 4
3 6
1 7 1
3 3
1 7 4
3 1
1 7 6
3 3
2 1 4
3 0
4 1
1 7 6
3 9
1 7 8
3 5
4 3
1 7 7
4 3
1 8 3
3 8
1 7 5
3 7
1 7 9
3 5
1 8 1
3 7
2 1 6
4 1
1 8 1
4 1
1 8 5
3 9
1 8 7
4 2
2 1 9
4 0
4 4
1 7 8
4 7
1 8 7
4 5
1 8 7
4 5
1 9 2
4 3
1 9 4
4 6
2 2 3
5 0
4 6
1 8 0
5 6
1 9 8
5 4
1 9 9
5 5
2 0 5
5 2
2 0 7
5 6
2 3 6
4 5
4 5
1 7 9
5 1
1 9 3
4 9
1 9 3
5 0
1 9 8
4 7
2 0 0
5 1
2 2 9
6 0
4 8
1 8 2
6 7
2 1 1
6 6
2 1 3
6 5
2 1 9
6 2
2 2 2
6 7
2 5 4
5 5
4 7
1 8 1
6 1
2 0 5
5 9
2 0 6
6 0
2 1 2
5 6
2 1 5
6 2
2 4 5
7 0
5 0
1 8 5
7 9
2 2 5
8 0
2 2 8
7 7
2 3 4
7 3
2 3 8
7 9
2 7 8
6 5
4 9
1 8 4
7 3
2 1 8
7 2
2 2 1
7 1
2 2 6
6 7
2 3 0
7 3
2 6 5
8 0
5 1
1 8 8
9 2
2 4 1
9 7
2 4 5
9 0
2 4 9
8 5
2 5 6
9 3
3 0 6
7 5
5 1
1 8 6
8 5
2 3 3
8 8
2 3 7
8 4
2 4 1
7 9
2 4 7
8 6
2 9 1
The data in the above pressure chart is based on the following flow rates:
FLOW RATE FOR VARIOUS FLUIDS
F l o w r a t e r e q u i r e d G P M f r e s h w a t e r
F l o w r a t e r e q u i r e d G P M 1 5 % S o d i u m C h l o r i d e
F l o w r a t e r e q u i r e d G P M 2 5 % G S 4
Q W 2 4 2
3
4
4
Q W 3 0 2
4
6
6
Q W 3 6 1
5
7
7
Q W 4 2 1
6
8
8
Q W 4 8 1
6
8
8
Q W 6 0 1
9
1 1
1 1
Manual 2100-419
Page 27
Manual 2100-419
Page 28
CLOSED LOOP
(Earth Coupled Ground Loop Applications)
CIRCULATION SYSTEM DESIGN
Equipment room piping design is based on years of experience with earth coupled heat pump systems. The design eliminates most causes of system failure.
Surprisingly, the heat pump itself is rarely the cause.
Most problems occur because designers and installers forget that a closed loop earth coupled heat pump system is not like a household plumbing system.
Most household water systems have more than enough water pressure either from the well pump of the municipal water system to overcome the pressure of head loss in 1/2 inch or 3/4 inch household plumbing.
A closed loop earth coupled heat pump system, however, is separated from the pressure of the household supply and relies on a small, low wattage pump to circulate the water and antifreeze solution through the earth coupling, heat pump and equipment room components.
The small circulator keeps the operating costs of the system to a minimum. However, the performance of the circulator must be closely matched with the pressure of head loss of the entire system in order to provide the required flow through the heat pump.
Insufficient flow through the heat exchanger is one of the most common causes of system failure. Proper system piping design and circulator selection will eliminate this problem
Bard supplies a work sheet to simplify head loss calculations and circulator selection. Refer to
“Circulating Pump Work sheet” section in manual
2100-099.
COPPER WATER COIL APPLICATION
Copper water coils are available as a factory installed option. The unit model number will indicate the coil option as the next to last character; “X” is for standard coil constructed of Cupronickel material and “4” is fro a water coil constructed of copper.
The Cupronickel coil is suitable for all applications.
The copper coil is suitable for applications using ground loop and cooling tower only and is never to be used in an open well application.
FIGURE 20
CIRCULATION SYSTEM
PIPE TO GROUND LOOP
PIPE FROM GROUND LOOP
PUMP MODULE
(See Spec Sheet for Model No.)
UNIONS
1” FLEXIBLE HOSE
Manual 2100-419
Page 29
START UP PROCEDURE FOR CLOSED
LOOP SYSTEM
1. Be sure main power to the unit is OFF at disconnect.
2. Set thermostat system switch to OFF, fan switch to
AUTO.
3. Move main power disconnect to ON. Except as required for safety while servicing, Do not open the unit disconnect switch.
4. Check system air flow for obstructions.
A. Move thermostat fan switch to ON. Blower runs.
B. Be sure all registers and grilles are open.
C. Move thermostat fan switch to AUTO. Blowing should stop.
5. Flush, fill and pressurize the closed loop system as outlined in manual 2100-099.
6. Fully open the manual inlet and outlet valves. Start the loop pump module circulator(s) and check for proper operation. If circulator(s) are not operating, turn off power and diagnose the problem.
7. Check fluid flow using a direct reading flow meter or a single water pressure gauge, measure the pressure drop at the pressure/temperature plugs across the water coil. Compare the measurement with flow versus pressure drop table to determine the actual flow rate. If the flow rate is too low, recheck the selection of the loop pump module model for sufficient capacity. If the module selection is correct, there is probably trapped air or a restriction in the piping circuit.
8. Start the unit in cooling mode. By moving the thermostat switch to cool, fan should be set for
AUTO.
9. Check the system refrigerant pressures against the cooling refrigerant pressure table in the installation manual for rated water flow and entering water temperatures. If the refrigerant pressures do not match, check for air flow 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 air flow problems and then refrigeration system problems.
NOTE: If a charge problem is determined (high
or low):
A. Check for possible refrigerant leaks.
B. Recover all remaining refrigerant from unit and repair leak.
C. Evacuate unit down to 29 inches of vacuum
D. Recharge the unit with refrigerant by weight.
This is the only way to insure a proper charge.
FIGURE 21
WATER TEMPERATURE and PRESSURE PROCEDURE
THERMOMETER
DIAL FACE PRESSURE GAUGE
WITH GAUGE ADAPTOR
WATER COIL CONNECTION
AT HEAT PUMP
TEST PLUG CAP
PETE’S TEST PLUG
UNION
MIS-1637
Manual 2100-419
Page 30
Manual 2100-419
Page 31
35
30
25
20
15
10
5
0
0
FIGURE 22
PERFORMANCE MODEL WGPM-1C LOOP PUMP MODULE
5 10 15 20
Flow (GPM)
25 30 35
70
FIGURE 23
PERFORMANCE MODEL WGPM-2C LOOP PUMP MODULE
60
50
40
30
20
10
0
0 5 10 15 20
Flow (GPM)
25 30 35
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 24. Slow closing Solenoid
Valve (6) with a 24 V 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 8 is a table showing the flow rate of each valve. Two constant flow rate valves may be installed in parallel to increase the flow. For example, when a 8603-007 (6 GPM) and
8603-011 (5 GPM) are installed in parallel the total flow will be 11 GPM.
TABLE 8
CONSTANT FLOW VALVES
P a r t N o .
8 6 0 3 0 0 7
8 6 0 3 0 0 8
8 6 0 3 0 1 0
8 6 0 3 0 1 1
8 6 0 3 0 1 9
M i n .
A v a
P r e s s u r e li a b
P S l e
I G
1 5 1
1 5 1
1 5 1
1 5 1
1 5 1
F l o w R a t e
G P M
6
5
3
8
4
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.
COPPER WATER COIL LIMITATIONS
Copper water coils are available as a factory installed option. The unit model number will indicate the coil option as the next to last character; “X” is for standard coil constructed of Cupronickel material and “4” is fro a water coil constructed of copper.
The Cupronickel coil is suitable for all applications.
The copper coil is suitable for applications using ground loop and cooling tower only and is never to be used in an open well application.
FIGURE 24
PIPING DIAGRAM
MIS-1569
TO WATER COIL
FROM WATER COIL
Manual 2100-419
Page 32
Strainer (5) installed upstream of constant flow valve
(7) to collect foreign material which would clog the flow valve orifice.
Figure 22 on preceding page 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 us gate or ball valves as shut-offs so as to minimize pressure drop.
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 us gate or ball valves as shut-offs so as to minimize pressure drop.
Drain cock (8) and (10), and tees have been included to permit acid cleaning the refrigerant-to-water coil should such cleaning be required. See WATER
CORROSION section on page 34.
Drain cock (12) provides access to the system to check water flow through the constant flow valve to insure adequate water flow through the unit. A water meter is used to check the water flow rate.
WELL PUMP SIZING
Strictly speaking, sizing the well pump is the responsibility of the well drilling contractor. It is important, however, that the HVAC contractor be familiar with the factors that determine what size pump will be required. Rule of thumb estimates will invariably lead to under or oversized well pumps.
Undersizing the pump will result in inadequate water to the whole plumbing system but with especially bad results to the heat pump – NO HEAT / NO COOL calls will result. Oversized pumps will short cycle and could cause premature pump motor or switch failures.
The well pump must be capable of supplying enough water and at an adequate pressure to meet competing demands of water fixtures. The well pump must be sized in such a way that three requirements are met:
1. Adequate flow rate in GPM.
2. Adequate pressure at the fixture.
3. Able to meet the above from the depth of the well-feet of lift.
The pressure requirements put on the pump are directly affected by the diameter of pipe being used, as well as, by the water flow rate through the pipe. The work sheet included in manual 2110-078 should guarantee that the well pump has enough capacity. It should also ensure that the piping is not undersized which would create too much pressure due to friction loss. High pressure losses due to undersized pipe will reduce efficiency and require larger pumps and could also create water noise problems.
SYSTEM START UP PROCEDURE FOR
OPEN LOOP APPLICATIONS
1. Be sure main power to the unit is OFF at disconnect.
2. Set thermostat system switch to OFF, fan switch to
AUTO.
3. Move main power disconnect to ON. Except as required for safety while servicing – do not open the unit disconnect switch.
4. Check system air low for obstructions.
A. Move thermostat fan switch to ON. Blower runs.
B. Be sure all registers and grilles are open.
C. Move thermostat fan switch to AUTO. Blower should stop.
5. Fully open the manual inlet and outlet valves.
6. Check water flow.
A. Connect a water flow meter to the drain cock between the constant flow valve and the solenoid valve. Run a hose from the flow meter to a drain or sink. Open the drain cock.
B. Check the water flow rate through constant flow valve to be sure it is the same as the unit is rated for.
C. When water flow is okay, close drain cock and remove the water flow meter. The unit is now ready to start.
7. Start the unit in cooling mode. By moving the thermostat switch to cool, fan should be set for
AUTO.
A. Check to see the solenoid valve opened.
8. Check the system refrigerant pressures against the cooling refrigerant pressure table in the installation manual for rated water flow and entering water temperatures. If the refrigerant pressures do not match, check for air flow problem that refrigeration system problem.
9. Switch the unit to the heat mode. By moving the thermostat switch to heat, fan should be set for
AUTO.
A. Check to see the solenoid valve opened again.
Manual 2100-419
Page 33
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. Discharge all remaining refrigerant from unit.
C. Evacuate unit down to 29 inches of vacuum.
D. Recharge the unit with refrigerant by weight.
This is the only way to insure proper charge.
WATER CORROSION
Two concerns will immediately come to light when considering a water source heat pump, whether for ground water or for a closed loop application: Will there be enough water? And, how will the water quality affect the system?
Water quantity is an important consideration and one which is easily determined. The well driller must perform a pump down test on the well according to methods described by the Nation Well Water
Association. This test, if performed correctly, will provide information on the rate of low and on the capacity of the well. It is important to consider the overall capacity of the well when thinking about a water source heat pump because the heat pump may be required to run for extended periods of time.
The second concern, about water quality, is equally important. Generally speaking, if the water is not offensive for drinking purposes, it should pose no problem for the heat pump. The well driller or local water softening company can perform tests which will determine the chemical properties of the well water.
Water quality problems will show up in the heat pump in one of more of the following ways:
1. Decrease in water flow through the unit.
2. Decreased heat transfer of the water coil (entering to leaving water temperature difference is less).
There are four main water quality problems associated with ground water. These are:
1. Biological Growth. This is the growth of microscopic organisms in the water and will shop 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
Cupro nickel coil) through the water system will reduce corrosion problems significantly.
4. Scale Formation. Of all the water problems, the formation of scale by ground water is by far the most common. Usually this scale is due to the formation of calcium carbonate by magnesium carbonate or calcium sulfate may also be present. Carbon dioxide gas (CO
2
), the carbonate of calcium and magnesium carbonate, is very soluble in water. It will remain dissolved in the water until some outside factor upsets the balance. This outside influence may be a large change in water temperature or pressure.
When this happens, enough carbon dioxide gas combines with dissolved calcium or magnesium in the water and falls out of solution until a new balance is reached. The change in temperature that this heat pump produces is usually not high enough to cause the dissolved gas to fall out of solution.
Likewise, if pressure drops are kept to a reasonable level, no precipitation of carbon dioxide should occur.
REMEDIES OF WATER PROBLEMS
Water Treatment. Water treatment can usually be economically justified for close loop systems. However, because of the large amounts of water involved with a ground water heat pump, water treatment is generally too expensive.
Acid Cleaning the Water Coil or Heat Pump
Recovery Unit. If scaling of the coil is strongly suspected, the coil can be cleaned up with a solution of
Phosphoric Acid (food grade acid). Follow the manufacturer’s directions for mixing, use, etc. Refer to the “Cleaning Water Coil”, Figure 25 on page 35. 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 solutionis to be circulated, but it is usually circulated for a period of several hours.
Manual 2100-419
Page 34
FIGURE 25
CLEANING WATER COIL
HOSE BIB (A)
ISOLATION VALVE
HOSE BIB (B)
ISOLATION VALVE
TO WATER COIL
FROM WATER COIL
PUMP
MIS-1570
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 26 on page 36):
A. A lake or pond should be at least 1 acre (40,000 a square feet) in surface area for each 50,000 BTUs of ground water heat pump capacity or have 2 times the cubic feet size of the dwelling that you are trying to heat (includes basement if heated).
B. The average water depth should be a least 4 feet and there should be an area where the water depth is at least 12 to 15 feet deep.
C. If possible, use a submersible pump suspended in the dry well casing. Jet pumps and other types of suction pumps normally consume more electrical energy than similarly sized submersible pumps.
Pipe the unit the same as a water well system.
Manual 2100-419
Page 35
D. Size the pump to provide necessary GPM for the ground water heat pump. A 12 GPM or greater water flow rate is required on all modes when used on this type system.
E. A pressure tank should be installed in dwelling to be heated adjacent to the ground water heat pump. A pressure switch should be installed at the tank for pump control.
F. All plumbing should be carefully sized to compensate for friction losses, etc., particularly if the pond or lake is over 200 feet from the dwelling to be heated or cooled.
G. Keep all water lines below low water level and below the frost line.
H. Most installers use 4 inch filed tile (rigid plastic or corrugated) for water return to the lake or pond.
I. The drain line discharge should be located at least
100 feet from the dry well location.
J. The drain line should be installed with a slope of 2 inches per 10 feet of run to provide complete drainage of the line when the ground water heat pump is not operating. This gradient should also help prevent freezing of the discharge where the pipe terminates above the frost line.
K. Locate the discharge high enough above high water level so the water will not back up and freeze inside the drain pipe.
Manual 2100-419
Page 36
G P M
3
8
9
1 0
1 1
1 2
6
7
4
5
1 3
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.
WARNING
Thin ice may result in the vicinity of the discharge line.
For complete information on water well systems and lake and pond applications, refer to Manual 2100-078 available from your distributor.
COOLING TOWER / BOILER
APPLICATION
The cooling tower and boiler water loop temperature is usually maintained between 50° F to 100° F to assure adequate cooling and heating performance.
In the cooling mode, heat is rejected from the unit into the source water loop. A cooling tower provides evaporative cooling to the loop water thus maintaining a constant supply temperature to the unit. When utilizing open cooling towers chemical water treatment is mandatory to ensure the water is free from corrosive minerals.
It is imperative that all air be eliminated from the source closed loop side of the heat exchanger to insure against fouling.
In the heating mode, heat is absorbed from the source water loop. A boiler can be utilized to maintain the loop at the desired temperature. In milder climates a
“flooded tower” concept is often used. This concept involves adding makeup water to the cooling tower sump to maintain the desired loop temperature.
CAUTION
Water piping exposed to extreme low ambient temperatures are subject to freezing.
Units are equipped with 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 9 for water flow and pressure drop information.
-
-
-
-
-
1 .
4 2
1 .
8 3
2 .
2 4
2 .
6 6
-
P S I G
1 .
0 0
Q W 2 4 2
F t .
2
H d .
.
3 1
-
-
-
-
-
3 .
2 8
4 .
2 2
5 .
1 7
6 .
1 4
-
TABLE 9
WATER FLOW AND PRESSURE DROP
2 .
7 3
-
-
-
-
-
P S I G
Q W 3 0 2
F t .
H d .
-
1 .
0 0
1 .
4 3
1 .
8 6
2 .
3 0
-
2 .
3 1
3 .
3 0
4 .
2 9
5 .
3 1
6 .
3 0
-
-
-
-
-
6 .
2 6
7 .
7 5
9 .
2 4
-
-
-
Q W 3 6 1 , Q W 4 2 1 ,
Q W 4 8 1
P S I G F t .
H d .
-
-
1 .
8 0
3 .
2 8
4 .
7 7 1
-
-
-
-
4 .
1 5
7 .
5 7
1 .
0 1
1 4 .
4 6
1 7 .
9 0
2 1 .
3 4
-
-
-
P S I G
Q W 6 0 1
F t .
H d .
-
-
-
-
-
3 .
3 0
4 .
3 0
5 .
0 0
6 .
0 0
7 .
0 0
8 .
2 0
7 .
6 3
9 .
9 4
1 1 .
5 5
1 3 .
8 6
1 6 .
1 7
1 8 .
9 5
-
-
-
-
-
Manual 2100-419
Page 37
FIGURE 27
WATER SOURCE HEAT PUMP
COOLING CYCLE
MIS-329
Manual 2100-419
Page 38
FIGURE 28
WATER SOURCE HEAT PUMP
HEATING CYCLE
Manual 2100-419
Page 39
MIS-328
SERVICE
SERVICE HINTS
1. Maintain clean air filters at tall times. Also, do not to needlessly close off supply and return air registers. This reduces air flow through the system, which shortens equipment service life as well as increasing operating costs.
2. Check all power fuses or circuit breakers to be sure that they are the correct rating.
UN-BRAZING SYSTEM COMPONENTS
If the refrigerant charge is removed from a scroll equipped unit by bleeding the high side only, it is sometimes possible for the scrolls to seal, preventing pressure equalization through the compressor. This may leave low side shell and suction line tubing pressurized.
If the brazing torch is then applied to the low side while the low side shell and suction line contains pressure, the pressurized refrigerant and oil mixture could ignite when it escapes and contacts the brazing flame. To prevent this occurrence, it is important to check both the high and low side with manifold gauges before unbrazing.
WARNING
Both the high and low side of the scroll compressor must be checked with manifold gauges before un-brazing 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 2100-419
Page 40
TROUBLESHOOTING ECM BLOWER MOTORS
CAUTION
Disconnect power from unit before removing or replacing connectors, or servicing motor. Wait at least 5 minutes after disconnection power before opening motor.
S Y M P T O M
M o t o r r o c k s s il g h t l y w h e n s t a r t i n g .
M o
% t o r w o n ' t s t a r t
N o m o v e m e n t
C A U
% T
S E h i s
/ i s
P R O C E n o r m a l
D U R E s t a r t u p f o r I C M
%
M o t e s t t o r e d
%
%
M o t o r r o c k s , b u t
N o i o o s c i f f ll a t e s o f b l o u p w e r a n d s y b l o w
" H u n t s " o r e r o f c w o n t' s t a r t a b i n e t d o w n w h li e b e i n g
" p u ff s " a t h i g h C F M ( s p e e d )
%
%
%
%
%
%
%
C h e c k p o w e r a t m o t o r
C h e c k l o w v o tl a g e ( 2 4 V A C R t o C ) a t m o t o r
C h e c k l o w v o tl a g e c o n n e c it o n s ( G , Y , W , R , C ) a t m o t o r
C h e c k f o r u n s e a t e d p i n s i n c o n n e c t o r s o n m o t o r h a r n e s s
T e s t w ti h a t e m p o r a r y j u m p e r b e t w e e n R G
C h e c k m o t o r f o r it g h t s h a tf
R u n M o s i t u r e C h e c k
%
%
C h e c k f o r l o o s e o r c o m p il a n t m o t o r m o u n t
M a k e s u r e b l o w e r w h e e l i s it g h t o n s h a tf
% tI i s n o r m a l f o r m o t o r t o o s c i ll a t e w ti h n o l o a d o n s h a f .t
%
%
C h e c k f o r l o o s e b l o w e r h o u s i n g , p a n e l s , e t c .
H i g h
– s t a it c c r e a it n g h i g h b
C h e c a b i c k n e t f o r s o r a i r p w a n h i s t e l s .
il n g l o w e r t h r o u s p g h e e d ?
s e a m s
– C h e c k f o r c a b i n e t / d u c t d e f o r m a it o n i n d u c t s ,
% D o e s r e m o v i n g p a n e l o r
–
–
R e d u c e r e s it c it o n
R e d u c e m a x i m u m a i r if tl e r lf o w r e d u c e " p u f if n g " ?
E v i d e n c e o f
%
%
M m o o i t o r f a s t u r e
E v i d e n c e li i u
M o i s t u r e s r e o f o f m a p r e s e n t m o i s t u r fl u n c e p r it o n e s e h n t a s i n o c c u r e d s i d e a i r a n d m o v e r
D O
%
%
%
%
C h e c k o u t m o t o ,r t h
O o r ir e o u n t g h c l y o n n b e f o e c t o r e r s c o n t r o l s , r e p d o l a c w n i n g s o w i ir n g a n d m w a t o t e r o r c a n t' c o n n e c g e t i n ; i n
U s s t a e ll a u t
" d ir h o p ir l o o p z e d s " m o t o r f
K o r e e r e p p s l a t c e a it c m e n t p r e s s u r e a t o n d a c m i o n n i t r o m u l m m : o d e l n u m it b o e r n s s
–
–
–
–
R e c o m m e n d h i g h e f if c i e n c y , l o w s t a it c if tl e r s
R e c o m m e n d k e e p i n g if tl e r s c l e a n
D e s i g n d u c t w o r k f o r m i n i m u m s t a it c , i m a x i
L o o k m f o r u m c a n d m p r o v e m e o m r n ,t e c o m w f o r t h e r e m e n d d u c t n e c e s s a r y , w o r k i n r e p l a c e m e n .t
Manual 2100-419
Page 41
% R e p l a c e m o t o r a n d p e r f o r m M o i s t u r e C h e c k
% P e r f o r m M o i s t u r e C h e c k
D O N ' T
% A u t o m a it c a ll y a s s u m e t h e m o t o r i s b a d
% L o c a t e c o n n e c t o r s a b o v e 7 a n d 4 o ' c l o s k p o s it o n s
%
%
%
(
R e p l a c e u n l e s s a o n n e a u t m o t o r h o ir z o e d f c o n t r o l m o d e l r e p l a c e m e n t )
U s e h i g h p r e s s u r e d r o p if tl e r s .
S o m e n u m b e r h a v e 1 / w
2 " ti h
H
2 a n
O o t h e r d r o p !
U s e r e s t ir c t e d r e t u r n s
S
M o t o
%
%
%
Y M P r
T O M s t a r t s
V a r i e s u p
B l o w e r b u t r u n s e r r w o n ' t s h u t o f f a t i c a l l y a n d d o w n o r i n t e r m i t t e n t
" H u n t s " o r p u f f s " a t h i g h C R M ( s p e e d )
%
S t a y s a t l o w h e a t C F M
C F M d e s p i t e s y s s t e m c a ll f o r c o o l o r
% S t a y s a t h i g h C F M
C A U S E / P R O C E D U R E
%
%
%
%
%
C h e c k il n e v o l t a g e f o r v a r i a t i o n o r " s a g "
C h e c k l o w v o l t a g e c o n n e c t i o n s ( G , Y , W , R , C ) u n s e a t e d
C h e c k p
" B k " i n s f o r i n m o t o r e r r a t i c h a r n
C F M e c s s o m c o n n e m a n d c
( t o r s i n v a r i a b l e s p e e d a p p il c a t i o n s a t m o t o r ;
C h e c k o u t s y s t e m c o n t r o l s t h e r m o s t a t ?
P e r f o r m M o i s t u r e C h e c k
% D o e s r e m o v i n g p a n e l o r f i l t e r r e d u c e " p u f f i n g " ?
– R e d u c e r e s t r i c t i o n
– R e d u c e m a x i m u m a i r f l o w
%
C h e c k l o w v o l t a g e ( t h e r m o s t a t ) w i r e s a n d c o n n e c t i o n s
%
%
V e r i f y f a n i s c o m p l e t e n o t i n d a l a y m o d e w a i t u n t i l d e l a y i s
" R " m i s s i n g / n o t c o n n e c t e d a t m o t o r
P e r f o r m m o t o r / c o n t r o l r e p l a c e m e n t c h e c k
%
%
" R " m i s s i n g / n o t c o n n e c t e d a t m o t o r
I s f a n i n d a l a y m o d e ?
w a i t u n t i l d e l a y t i m e c o m p l e t e
% C u r r e n t l e a k a g e f r o m c o n t r o l s i n t o G , Y o r W ?
– C h e r e l a y c k f o r T r i a c s w i t c h e d t h e r m o s t a t o r s o il d s t a t e
S
%
%
%
Y M
D O
P
E x c e s
A i r
T O N s i v e
S i z e n o
N o i s e i s e t h e e q u p m e n t
C h e c k o r i e c o n n e c t o r s n t a t i o n w i s e l y b e f o r e i n s e r t i n g m o t o r
C A U S E
% D e t
/ P e r m i
R O n e i
C E D U f i t i s a i
R E r n o i s e , c a b i n e t , d u c t o r m o t o r n o i s e .
I n t e r v i e w c u s t o m e r i f n e c e s s r y .
%
H i g h s t a t i c c r e a t i n g h i g h b l o w e r s p e e d ?
–
–
–
I s a i r f l o w s e t p r o p e r l y ?
D o e s
C h e c k r e
/ m o v i n g r e p l a c e f i l t e r f i l t e r c a u s e b l o w e r t o s l o w d o w n ?
U s e l o w p r e s s u r e d r o p f i l t e r
– C h e c k / c o r r e c t d u c t r e s t i r c t i o n s
D O N ' T
%
%
O v e r s i z e s y s t e m t h e n c o m p e n s a t e
P l u g i n p o w e r c o n n e c t o r b a c k w a r d s w i t h l o w a i r f l o w
% F o r c e p l u g s
M O I S T U R E C H E C K P R O C E D U R E
% C o n n e c t o r s a r e o r i e n t e d " d o w n "
%
%
%
%
%
A
C
C
C
C r r o h h h a n g e n e e e d c c c e k k k n f f a s o o h r r t a r e n d l n e d p l r o w u n d a s s i n a i r e r u g l e s p l w i t h u g f l o w c h a e a k s g e
( t i
" d r i p d ?
o o r g e d n l u t r n o o m u c h c o n r e d i t i d p " u l a t e n t o n u c t s n d e r m o t c a p a c i o r t y ) a n d c a b i n e t
C O M F O R T C H E C K P R O C E D U R E
% C h e c k p r o p e r a i r f l o w s e t t i n g s
%
%
L o w s t a t i c p r e s s u r e f o r l o w e s t n o i s e
S e t l o w c o n t i n u o u s f a n C F M
%
%
%
U s e h u m i d i s t a t a n d 2 s p e e d c o o il n g u n i t s
U s e z o n i n g c o n t r o l s d e s i g n e d f o r I C M t h a t r e g u l a t e C F M
T h e r m o s t a t i n b a d l o c a t i o n ?
Manual 2100-419
Page 42
lg) (C ice tg) (H ice g) hell tg or Cl k
Low)
Clg)
Htg) tor er oil ed Ductwor ing Dev ing Dev
of C e (Htg)
Htg) ed Meter ed Meter e
CLg)
Htg) l ( l (
Coil
Clg) ng Defectiv am re ict ict em lugged Coi lugged Coi me Low ( me Low ( ict peratur
Restr pst
Plugged y t U ea irt y or me Low zed or rs D lte olu
Windi
Dirt ry H ter T olu olu ed or P ed or P
Restr
Restr ve or e Val ter V ter V pen (H ng Inside of S osed ( osed ( e tiv es k O k Cl k Cl tuc tuc sur ge e re su sur e e sur sur res res char res ables e Stuc alve S alv alve S ed Pres tion P ant Over ant Charge Low uction P ngs Defec ctive fe De
Wingi
High or e Defectiv ne Hitti
Relay ls ( Contro lower re su d ings harge Li
Coil er form s inal rans tat tage l T erm iring mos ty W t Capacitor enoid V enoid V enoid V
Loose T
Contro
Low Vol
Ther
Contactor
Pres
Indoor B
Refriger
Refriger
High Head P
Low Head Pres
High S
Low Suc
Non-Condens
Unequaliz
Faul
Star
Sol
Sol
Sol
Valve
Seize
Bear
Disc
Motor
Run Capacitor
Leaking
Defectiv
Low Wa
Undersi
Auxilla
Air V
Motor
Fins
Plugged or
Air Fi
Wa
Wa
Scal
Plugged or
Scal reak
in Contac load lay
Over l Re essor e Contacts
Tripped B s re inal iring use or ilu erm tage er Fa ty W ntia
Loose T
Low Vol
Defectiv
Compr
Pote
Faul
Blown F
Pow
Manual 2100-419
Page 43 cles Cooling Cy Heating or
Cycle
Cooling cle Heating Cy
GROUND SOURCE HEAT PUMP
PERFORMANCE REPORT
This performance check report should be filled out by installer and retained with unit.
DATE:
1. UNIT:
Mfgr
THERMOSTAT:
Mfgr
E.
1. Horizontal
No. pipes in trench
2. Vertical
S/N
P/N
4. Installed By
5. User’s (Owner’s) Name
Address
6. Unit Location
Date Installed
WATER SYSTEM INFORMATION
7. Open Loop System (Water Well)
A. If Open Loop where is water discharged?
Closed Loop System
8. The following questions are for Closed Loop systems only
A. Closed loop system designed by
B. Type of antifreeze used: % Solution
C. System Series Parallel
Total length of pipe
Depth bottom pipe
Total length of bore hole ft ft ft
Manual 2100-419
Page 44
THE FOLLOWING INFORMATION IS NEEDED
TO CHECK PERFORMANCE OF UNIT
FLUID SIDE DATA Cooling ** Heating
9. Entering fluid temperature
10. Leaving fluid temperature
11. Entering fluid pressure
12. Leaving fluid pressure
13. Pressure drop through coil
14. Gallons per minute through the water coil
15. Liquid or discharge line pressure
17. Voltage at compressor (unit running)
18. Amperage draw at line side of contactor
19. Amperage at compressor common terminal
20. * Suction line temperature 6” from compressor
21. * Superheat at compressor
22. * Liquid line temperature at metering device
INDOOR SIDE DATA
24. Dry bulb temperature at air entering indoor coil
25. Wet bulb temperature of air entering indoor coil
26. Dry bulb temperature of air leaving indoor coil
27. Wet bulb temperature of air leaving indoor coil
28. * Supply air static pressure (packaged unit)
29. * Return air static pressure (packaged unit)
30. Other information about installation
Cooling ** Heating
F
F
F
F
WC
WC
F
F
PSIG
PSIG
PSIG
A
A
F
F
GPM
PSIG
PSIG
V
F
F
** When performing a heating test insure that second stage heat is not activated.
* Items that are optional
Manual 2100-419
Page 45

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Key features
- Water source heat pump
- Multiple models
- Installation instructions
- Mounting and wiring
- Start-up procedure
- Closed and open loop applications
- Service hints
- Troubleshooting chart
- Performance report