Bard QW 2S1, QW 3S1, QW 4S1, QW 5S1 geothermal heat pump Installation instructions

INSTALLATION
INSTRUCTIONS
QW SERIES
GEOTHERMAL R-410A
STAGED CAPACITY
PACKAGED HEAT PUMP
Models:
QW2S1
QW4S1
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.
QW3S1
QW5S1
MIS-2736
Manual No.:
Supersedes:
File:
Date:
2100-532C
2100-532B
Vol II Tab 14
11-08-10
Manual
Page
2100-532C
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 ..................................................
Wiring – Main Power .............................................
Wiring – Low Voltage Wiring .................................
General ..................................................................
Low Voltage Connections ......................................
15
18
18
18
19
Start Up
Description of Standard Equipment ....................... 23
Compressor Control Module .................................. 23
Adjustments ........................................................... 23
Optional CFM ........................................................ 24
Important Installer Note ......................................... 24
Phase Monitor ....................................................... 24
Service Hints ......................................................... 24
Sequence of Operation .................................. 24 & 25
Pressure Service Ports .......................................... 25
Pressure Tables ..................................................... 28
Optional Accessories ............................................. 29
Manual 2100-532C
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2 of 46
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
CONTENTS
Figures
Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8A
Figure 8B
Figure 8C
Figure 9
Figure 10
Figure 11
Figure 12
Figure 13
Figure 14
Figure 15
Figure 16
Figure 17
Figure 18
Figure 19
Figure 20
Figure 21
Figure 22
Figure 23
Figure 24
Figure 25
Figure 26
Figure 27
Figure 28
Figure 29
Figure 30
Unit Dimensions ..................................... 6
Removal of Unit From Skid .................... 7
Proper Handling of Unit After Removal
from Skid ................................................ 8
Installation of Unit w/Wall Sleeve .......... 9
Installation With Free Blow Plenum ..... 10
Ducted Application ............................... 10
Supply Duct Connections ..................... 11
Condensate Drain ................................ 12
Optional Rear Drain ............................. 12
Rear Drain (Top View) .......................... 13
Removal of Q-TEC ERV ........................ 14
Remove Locking Screws from Wheels 15
Unit Mounting Without Wall Sleeve ..... 16
Component Location ............................ 17
Low Voltage Wire Harness Plug .......... 19
Remote Thermostat Wiring "X" Option 20
Remote Thermostat Wiring "D" Option 21
Remote Thermostat Wiring "H" Option 22
Fluid Connections w/Ventilation
Wall Sleeve .......................................... 26
Fluid Connections w/o Ventilation
Wall Sleeve .......................................... 27
Circulation System ............................... 30
Water Temperature and Pressure
Test Procedure .................................. 31
Performance Model WGPM-1C ........... 32
Performance Model WGPM-2C ........... 32
Piping Diagram .................................... 33
Cleaning Water Coil ............................. 36
Water Well System .............................. 37
Water Source H/P Cooling Cycle ......... 39
Water Source H/P Heating Cycle ........ 40
Control Disassembly ............................ 43
Winding Test ........................................ 43
Drip Loop ............................................. 43
Tables
Table 1
Table 2
Table 3
Table 4
Table 5
Table 6
Table 7
Table 8
Electrical Specifications ........................... 5
Operating Voltage Range ....................... 18
Wall Thermostats ................................... 18
Indoor Blower Performance ................... 25
Pressures ............................................... 28
Optional Accessories ............................. 29
Constant Flow Valves ............................. 33
Water Flow and Pressure Drop .............. 38
Manual
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2100-532C
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.
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
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
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
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
Manual 2100-532C
Page
4 of 46
QW SERIES GEOTHERMAL R-410A STAGED CAPACITY GENERAL INFORMATION
QW MODEL NOMENCLATURE
QW
3
S
MODEL NUMBER |
Q-Tec™ Model
1
A
SPECIALTY
PRODUCTS
CAPACITY |
2 - 2 Ton
3 - 3 Ton
STEP CAPACITY |
4 - 4 Ton
5 - 5 Ton
0Z
B
4
X
C
X
COIL OPTIONS
C - Copper (water)
N - Cupronickel
FILTER OPTIONS
X - 2-Inch Pleated
(MERV6)
KW
0Z - OKW
VOLTS &
PHASE
A - 230/208/60/1
B - 230/208/60/3
C - 460/60/3
REVISION |
X
COLOR
4 - Buckeye Gray paint
X - Beige paint
V - Platinum w/Slate
Front (Vinyl)
INTERNAL CONTROLS
X • High Pressure Switch
• Low Pressure Switch
• Compressor Control Module
w/Time Delay
• Phase Monitor (3-PH)
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.
CLIMATE CONTROL
Standard X - None
D - Electronic/Prog/Man/Auto
H - Electronic/Prog with CO2 control
TABLE 1
ELECTRICAL SPECIFICATIONS
SINGLE CIRCUIT
2
1
1
NO. FIELD
POWER
CIRCUITS
MINIMUM
CIRCUIT
AMPACITY
MAXIMUM
EXTERNAL
FUSE OR
CIRCUIT
BREAKER
QW2S1-A0Z 230/208-60-1
QW2S1-B0Z 230/208-60-3
QW2S1-C0Z
460-60-3
1
1
1
19
14
7
30
20
15
QW3S1-A0Z 230/208-60-1
QW3S1-B0Z 230/208-60-3
QW3S1-C0Z
460-60-3
1
1
1
26
20
9
40
30
15
QW4S1-A0Z 230/208-60-1
QW4S1-B0Z 230/208-60-3
QW4S1-C0Z
460-60-3
1
1
1
31
27
11
50
40
20
QW5S1-A0Z 230/208-60-1
QW5S1-B0Z 230/208-60-3
QW5S1-C0Z
460-60-3
1
1
1
39
29
17
60
45
25
MODEL
RATED
VOLTS, Hz
& PHASE
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.
Manual
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2100-532C
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Manual 2100-532C
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SUPPLY AIR
GRILLE
CONDENSER
DOOR
36 1/16"
(OPTIONAL)
CO2 SENSOR
37 1/8"
FILTER
104"
ACCESS
DOOR
16 5/8" (OPTIONAL)
THERMOSTAT
14"
TOP VIEW
(SHOWN WITHOUT
FREEBLOW PLENUM)
9 15/16"
20 3/8" (DUCT SIZE)
2 1/16"
1 3/4"
"D"
FRONT VIEW
"C"
"B"
"C"
24 15/16"
(DUCT SIZE)
SUPPLY AIR OPENING
2 7/16"
"A"
36 7/8"
15 5/8"
68 3/4"
RETURN AIR
GRILLE
DIM. "A"
8 5/8"
8 3/4"
DIM. "B"
42"
48"
3 3/8"
19"
8"
MIS-2737 B
20"
33 9/16"
5 1/4"
5 15/16"
VENT
INTAKE
VENT
EXHAUST
DIM. "C" DIM. "D"
30"
43"
40"
49"
FLUID CONNECTION
POINTS FOR FACTORY
INSTALLED PUMP OPTIONS
BACK VIEW
3, 4, OR 5 (INLET ON LEFT,
OUTLET ON RIGHT AS VIEWED
FROM BACK OF UNIT)
3"
6 7/8"
1 15/16"
(OPTIONAL) HIGH VOLTAGE
ELECTRICAL ENTRANCE
(OPTIONAL) LOW VOLTAGE
ELECTRICAL ENTRANCE
UNIT
QW2S, QW3S
QW4S, QW5S
3 1/16"
(OPTIONAL) HIGH
VOLTAGE
ELECTRICAL
ENTRANCE
ACCESS
FOR FLUID
CONNECTION FOR
DORFC PUMP
APPLICATION
3 3/8"
RIGHT SIDE VIEW
3 3/4"
1 11/16"
FREEBLOW
PLENUM BOX
(OPTIONAL)
(OPTIONAL) LOW VOLTAGE
ELECTRICAL ENTRANCE
(OPTIONAL) HIGH VOLTAGE
ELECTRICAL ENTRANCE
LOW VOLTAGE
ELECTRICAL ENTRANCE
CIRCUIT BREAKER
ACCESS AND LOCKING
COVER
11 3/4"
1 1/8"
3 3/16"
7/8"
6 3/4"
2 15/16"
FIGURE 1
UNIT DIMENSIONS
SHIPPING DAMAGE
Upon receipt of equipment, the carton should be
checked for external signs of shipping damage. The
skid must remain attached to the unit until the unit is
ready for installation. If damage is found, the receiving
party must contact the last carrier immediately,
preferably in writing, requesting inspection by the
carrier’s agent.
UNIT REMOVAL FROM SKID
WARNING
This unit is heavy and requires more than one
person to handle and remove from the skid.
Check unit wheels to ensure that wheels are
locked before removing from skid. Extreme
caution must be taken to prevent injury to
personnel and damage to the unit.
It is recommended that the unit not be removed from the
skid with a forklift.
The shipping brackets on each side of the unit must be
removed and discarded. See Figure 2-A. The return air
grille panel can be removed to provide a place to hold
the unit. The unit can be slid forward on the skid until
the front wheels hang over the edge of the skid. See
Figure 2-B. The unit can be tipped forward and slid
down the edge of the skid until the front wheels touch
the ground. See Figure 2-C. The wheels will not roll.
They are shipped from the factory locked so they will
not roll. The back of the skid will have to be held down
to keep it from tipping up. The skid can be slid out from
under the unit. The unit can then be set upright.
HANDLING UNIT AFTER REMOVAL FROM
SKID
WARNING
Exercise extreme caution when pushing the
unit on the rollers. Handle and push from the
lower 1/3 of the unit. Insure that debris is not
on the floor where the unit is to be moved on
the rollers. Failure to do so could result in
the unit tipping over and causing bodily injury
and/or damage to the unit.
The unit will have to be turned sideways and removed
from the skid to fit through a 36" doorway. If the door
height allows, the unit can be slid sideways through the
door.
If the unit can not be slid through the door, then the unit
will have to be put on a cart and tipped down to roll
through the door. It is recommended that an appliance
cart be used with a strap to hold the unit on the cart.
The wheels of the unit must be locked. If the wheels
were allowed to roll, the unit could roll off the cart. The
unit should always be carted from the left side. This is
the side where the compressor is located. See Figure 3.
The blade of the appliance cart should be slid under the
wheels of the unit. The strap of the appliance cart
should be placed around the unit and strapped tightly.
Help will be required to tip the unit back onto the cart.
The unit can be leaned far enough back to be rolled
through the door. Be careful when setting the unit back
up to keep from damaging the unit.
FIGURE 2
REMOVAL OF UNIT FROM SKID
HOLD SKID DOWN
A SHIPPING BRACKETS
B FRONT WHEELS OVER EDGE
C FRONT WHEELS ON FLOOR
Manual
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2100-532C
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FIGURE 3
PROPER HANDLING OF UNIT
AFTER REMOVAL FROM SKID
Q-Tec UNIT
(RIGHT SIDE)
STRAP
APPLIANCE
CART
COMPRESSOR
REMOVAL OF WALL BRACKET FROM
SHIPPING LOCATION (UNITS WITH
BLANK OFF PLATE ONLY)
The wall brackets are attached to the back of the unit.
Remove and retain the wall brackets for use when
attaching the unit to the wall. In units equipped with a
ventilator a wall sleeve is required and these two wall
brackets are not included. A different style bracket is
supplied with the sleeve assembly.
GENERAL
The equipment covered in this manual is to be installed
by trained, experienced service and installation
technicians.
The unit is designed for use with or without duct work.
For use without duct work, Plenum Box QPB** is
recommended.
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
These instructions explain the recommended method to
install the water source self-contained unit and the
electrical wiring connections to the unit.
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.
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.
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 2100-532C
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FIGURE 4
INSTALLATION OF UNIT THROUGH WALL WITH WALL SLEEVE
14" to 5"
WALL SLEEVE
VENTILATION
AIR DIVIDER
QW2S, QW3S - 42.000"
QW4S, QW5S - 48.000"
33 7/8"
SUPPLY AIR
OPTIONAL FREE
BLOW PLENUM BOX
(X)
28 7/8"
18 9/16"
HIGH VOLTAGE
ELECTRICAL ENTRANCE
(TOP-REAR-SIDE)
17 9/16"
35"
6 1/8"
29 1/2"
MIST
ELIMINATOR
RETURN AIR
33"
84 1/4"
103 7/8"
LOW VOLTAGE
ELECTRICAL ACCESS
(TOP-SIDE)
BOTTOM
TRIM PIECE
CIRCUIT BREAKER, ROTARY,
OR TOGGLE DISCONNECT
AND LOCKING COVER
5"
PERMANENT
ROLLERS
MIS-2739 A
Manual
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2100-532C
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FIGURE 5
INSTALLATION WITH FREE BLOW PLENUM
8 FT. - 9 IN.
MINIMUM REQUIRED
INSTALLATION HEIGHT
8 FT. - 8 IN.
FLOOR
MIS-2740
FIGURE 6
DUCTED APPLICATION
SUSPENDED CEILING
FIXED CEILING
25 IN.
MINIMUM
DUCT
DUCT FLANGE
12 IN.
MINIMUM
2 IN. MINIMUM
FROM DUCT FLANGE
TO DUCT BOTTOM
9 FT.
MINIMUM REQUIRED
INSTALLATION HEIGHT
7 FT. - 6 IN.
UNIT HEIGHT
8 FT. - 9 IN.
MINIMUM REQUIRED
INSTALLATION HEIGHT
FLOOR
MIS-2741
Manual 2100-532C
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10 of 46
DUCT WORK
Any heat pump is more critical of proper operating
charge and an adequate duct system than a straight air
conditioning unit. All duct work must be properly sized
for the design airflow requirement of the equipment.
Air Conditioning Contractors of America (ACCA) is an
excellent guide to proper sizing. All duct work or
portions thereof not in the conditioned space should be
properly insulated in order to both conserve energy and
prevent condensation or moisture damage. When duct
runs through unheated spaces, it should be insulated
with a minimum of one inch of insulation. Use
insulation with a vapor barrier on the outside of the
insulation. Flexible joints should be used to connect the
duct work to the equipment in order to keep the noise
transmission to a minimum.
The Q-Tec Series heat pump has provision to attach a
supply air duct to the top of the unit. Duct connection
size is 12 inches x 20 inches. The duct work is field
supplied and must be attached in a manner to allow for
ease of removal when it becomes necessary to slide the
unit out from the wall for service. See Figure 7 for
suggested attachment method.
NOTE: Unit cabinet, supply air duct and free blow
plenum are approved for “0” clearance to
combustible material.
The Q-Tec Series heat pumps are designed for use with
free return (non-ducted) and either free blow with the
use of QPB Plenum Box or a duct supply air system.
The QPB Plenum Box mounts on top of the unit and has
both vertically and horizontally adjustable louvers on
the front discharge grille.
FIGURE 7
SUPPLY DUCT CONNECTIONS
SUPPLY DUCT TO
BE FIELD SUPPLIED
ATTACHMENT
SCREWS TO
BE FIELD
SUPPLIED
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.
DUCT FLANGE
PROVIDED WITH UNIT
ROOM SIDE
OF QW UNIT
MIS-2742
Manual
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2100-532C
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FIGURE 8A
CONDENSATE DRAIN
LOOP TO FORM
A "P" TRAP
DRAIN HOSE
EXTERNAL
DRAIN TUBE
ALTERNATE
DRAINING
OPTION
FLOOR
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 2100-532C
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12 of 46
The rear drain can be used with wall thickness of up to
10 inches where a water trap can be installed between
the unit and the interior wall. See Figure 8B. The trap
cannot extend beyond the edge of the unit or it will
interfere with the wall mounting bracket. The drain can
be routed through the floor or through the wall. If the
drain is routed through the wall, the drain line must be
positioned such that it will not interfere with the sleeve
flange or the grille. See Figure 8C. If the drain is to
be routed through an unconditioned space, it must
be protected from freezing.
FIGURE 8C
REAR DRAIN (TOP VIEW)
DRAIN LINE
WALL (MAXIMUM
10” FOR REAR
DRAIN)
SLEEVE
COUPLINGS NOT
SHOWN BUT
RECOMMENDED
FOR EASE OF
REMOVABILITY
FOR SERVICE
WALL BRACKET
WATER
TRAP
MIST ELIMINATOR SERVICE (Optional –
only used with one of the vent options)
A mist eliminator is supplied with the wall sleeve. The
mist eliminator is constructed of aluminum frame and
mesh. The mist eliminator is located in the top section
of the wall sleeve and can be removed from the inside of
the building without removing the unit from the wall.
This requires that the ventilation package must be
removed.
The steps necessary to remove each of the vent options
are listed following.
It is recommended that the mist eliminator be inspected
annually and serviced as required. The mist eliminator
can be inspected from the outside of the building by
looking through the outdoor grille. The mist eliminator
can be serviced from the outside. The outdoor grille
must be removed to do so.
The mist eliminator can be cleaned by washing with
soap and water. The excess water should be shaken off
the mist eliminator before it is reinstalled.
COMMERCIAL ROOM VENTILATOR OPTION
Before starting the removal make sure the power has
been turned off. The hinged return air grille panel must
be opened. The commercial room ventilator (CRV) can
be seen after the panel has been removed. The CRV
must be removed to gain access to the mist eliminator.
1. The two mounting screws in the front of the CRV
must be removed.
UNIT
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
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2100-532C
13 of 46
Q-TEC ENERGY RECOVERY VENTILATOR
OPTION
Before starting the removal make sure that the power
has been turned off. The hinged return air grille panel
must be opened. The energy recovery ventilator
(QERV) can be seen after the panel is opened. To gain
access to the mist eliminator, the QERV must be
removed. Refer to Figure 9.
1. The front fill plate of the QERV must be removed.
There is one screw on either side of the plate.
Remove these screws and remove the plate.
2. On either side of the QERV there are mounting
screws that hold the QERV in place. Remove both
of these screws.
3. Underneath the heat recovery cassette there is a
power connector for the lower blower assembly. To
disconnect this plug, the tabs on both sides of the
plug must be squeezed to release the plug. While
squeezing the tabs, pull the plug out of the socket.
4. The QERV is plugged into the unit on the right side
of the unit. Both of these plugs must be
disconnected to remove the QERV. Squeeze the
tabs on the sides of the connector and pull straight
out.
5. Slide the QERV assembly straight out of the unit
being careful not to let the cassette slide out of the
QERV.
The mist eliminator can be seen through the opening in
the back of the unit. The mist eliminator must be raised
up and the bottom can be pulled toward the front of the
unit and removed.
FIGURE 9
REMOVAL OF THE Q-TEC ENERGY RECOVERY VENTILATOR
POWER
CONNECTORS
MOUNTING
SCREWS
LOWER
BLOWER
ASSEMBLY
POWER
CONNECTOR
FRONT FILL
Manual 2100-532C
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14 of 46
INSTALLATION INSTRUCTIONS
MOUNTING THE UNIT
When installing a QW unit near an interior wall on the
left side, a minimum of 8 inches is required; 12 inches is
preferred.
When installing a QW unit near an interior wall on the
right side, a minimum of 12 inches is required as
additional space is required to connect the drain.
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.
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.
FIGURE 10
REMOVING LOCKING SCREWS FROM
WHEELS
NOTE: When a wall sleeve is to be used attach the unit
to the sleeve with bracket supplied with the
wall sleeve.
Following are the steps for mounting the QW units. For
reference see Figure 11.
1. Attach wall mounting bracket to the structure wall
with field supplied lag bolts. The fluid piping
connections are to be within the confines of this
bracket. See Figure 1 for cabinet openings and
location of fluid coil connection points.
2. Position the unit in front of the wall mounting
bracket.
3. Remove the locking screws from the wheels. Refer
to Figure 10.
4. Roll the unit up to the wall mounting bracket. The
unit must be level from side to side. If any
adjustments are necessary, shim up under the rollers
with sheets of steel or any substance that is not
affected by moisture.
5. Secure the unit to the wall bracket with provided #10
hex head sheet metal screws. There are prepunched
holes in the cabinet sides, and the bracket has slotted
holes to allow for some misalignment.
6. Position the bottom trim piece to the unit and attach
with provided screws (dark colored).
REMOVE SCREWS
FROM WHEELS
BEFORE ROLLING
INTO PLACE
Manual
Page
2100-532C
15 of 46
FIGURE 11
UNIT MOUNTING WITHOUT VENTILATION WALL SLEEVE
SIDE TRIM CUT
TO LENGTH
WALL MOUNTING
BRACKET
41"
ADJUSTABLE SIDE TRIM
EXTENSION KIT -ORDERED
SEPARATELY
BASE TRIM
SIDE TRIM
EXTENSION
BASE TRIM
EXTENSION
MIS-2744 A
Manual 2100-532C
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
Page
2100-532C
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.
TABLE 2
OPERATING VOLTAGE RANGE
TAP
RANGE
240V
253 - 216
208V
220 - 187
NOTE: The voltage should be measured at the field
power connection point in the unit and while
the unit is operating at full load (maximum
amperage operating condition).
The standard Climate Control Option X is a remote
thermostat connection terminal block. See Figure 14 for
wiring diagram. Compatible thermostats are listed in
Table 3.
The 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 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 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 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.
GENERAL
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.
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
CAUTION
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.
Do not plug in or unplug blower motor connectors while the power is on. Failure to do
so may result in motor failure.
TABLE 3
WALL THERMOSTATS
Thermostat
8403-060
(1120-445)
Manual 2100-532C
Page
18 of 46
Predominant Features
3 stage Cool; 3 stage Heat
Programmable/Non-Programmable Electronic
HP or Conventional
Auto or Manual changeover
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.
LOW VOLTAGE CONNECTIONS FOR
DDC CONTROL
Fan Only
Ventilation
Part Load Cooling
Full Load Cooling
Part Load HP Heating
Full Load HP Heating
Electric Heat
Dehumidification
Energize G
Energize G, A (any mode of operation)
Energize G, Y1, O
Energize G, Y1, Y2, O
Energize G, Y1
Energize G, Y1, Y2
Energize G, W2
Energize G, D, O
FIGURE 13
BLOWER MOTOR LOW VOLTAGE
WIRE HARNESS PLUG
MIS-1285
Manual
Page
2100-532C
19 of 46
FIGURE 14
REMOTE THERMOSTAT WIRING DIAGRAM
“X” OPTION
Temp. and Humidity
Controller
Part #8403-060
Low Voltage
Terminal Strip
W1/E
E
Red/Yellow
Y2
Y2
Purple
A
Brown/White
G
G
Orange
Y1
Y1
Yellow
O/B
O
Blue
W2
W2
Brown
R
R
Red/White
C
C
Black/White
L
L
Pink
A
PLUG #2
1
1
2
3
4
5
6
7
8
9
10
11
12
D/YO
Terminal
Strip
CO2 Controller
Part #8403-056
Red
24VAC
Black
Analog
Out
Yellow
Red
Black
Yellow
Brown
Orange
Green
PLUG #1
1
2
3
4
5
6
Brown
Orange
Green
Purple/White
1
FOR ENERGY RECOVERY VENTILATOR WITH CO2 CONTROL, DO NOT CONNECT "A"
OCCUPANCY INPUT BETWEEN THERMOSTAT AND LOW VOLTAGE TERMINAL STRIP.
DO MAKE THIS CONNECTION WHEN APPLYING A COMMERCIAL ROOM VENTILATOR
WITH CO2 CONTROL.
4115-102 B
Manual 2100-532C
Page
20 of 46
FIGURE 15
REMOTE THERMOSTAT WIRING DIAGRAM
“D” THERMOSTAT OPTION
Temp. and Humidity
Controller
Part #8403-060
D/YO
Purple/White
W1/E
Red/Yellow
Y2
Purple
A
Brown/White
G
Orange
Y1
Yellow
O/B
Blue
W2
Brown
R
Red/White
C
Black/White
L
Pink
PLUG #2
1
2
3
4
5
6
7
8
9
10
11
12
4115-100 A
Manual
Page
2100-532C
21 of 46
FIGURE 16
REMOTE THERMOSTAT PLUG CO2 VENT CONTROL WIRING DIAGRAM
“H” THERMOSTAT OPTION
D/YO
Purple/White
W1/E
Red/Yellow
Purple
Y2
A
Temp. and Humidity
Controller
Part #8403-060
CO2 Controller
Part #8403-056
PLUG #2
G
Orange
Y1
Yellow
O/B
Blue
W2
Brown
R
Red/White
C
Black/White
L
Pink
Red
24VAC
Black
Analog
Out
Yellow
1
2
3
4
5
6
7
8
9
10
11
12
Red
Black
Yellow
Brown
Orange
Green
PLUG #1
1
2
3
4
5
6
Brown
Orange
Green
4115-101 B
Manual 2100-532C
Page
22 of 46
START UP
DESCRIPTION OF STANDARD
EQUIPMENT
LOW PRESSURE SWITCH
NOTE: This unit is supplied with two low pressure
switches installed, a 45 PSIG and a 60 PSIG.
The 60 PSIG is wired into the system. This switch is
suitable for ground water (pump and dump), and water
loop (boiler/tower applications).
To avoid nuisance lockouts for ground loop application
with antifreeze, the 60 PSIG switch should be
disconnected and connect the 45 PSIG switch.
The leads for both switches are located in the lower
electrical connection panel. The switch bodies are
marked with pressure settings. The 60 PSIG switch has
blue leads. The 45 PSIG switch has yellow leads.
HIGH PRESSURE SWITCH
This unit is equipped with a high pressure switch that
will stop the compressor in the event of abnormal high
pressure occurrences.
The high and low pressure switches are included in a
lockout circuit that is resettable from the room
thermostat.
COMPRESSOR CONTROL MODULE
The compressor control module is standard on models
covered by this manual. The compressor control is an
anti-short cycle/lockout timer with high and low
pressure switch monitoring and alarm relay output.
ADJUSTABLE DELAY ON MAKE AND BREAK
TIMER
On initial power up or any time power is interrupted to
the unit, the delay on make period begins, which will be
2 minutes plus 10% of the delay on break setting. When
the delay on make is complete and the high pressure
switch (and low pressure switch, if employed) is closed,
the compressor contactor is energized. Upon shutdown,
the delay on break timer starts and prevents restart until
the delay on break and delay on make periods have
expired.
During routine operation of the unit with no power
interruptions the compressor will operate on demand
with no delay.
HIGH PRESSURE SWITCH AND LOCKOUT
SEQUENCE
If the high pressure switch opens, the compressor
contactor will de-energize immediately. The lockout
timer will go into a soft lockout and stay in soft lockout
until the high pressure switch closes and the delay on
break time has expired. If the high pressure switch
opens again in the same operating cycle, the unit will go
into manual lockout condition and the alarm relay
circuit will energize. Recycling the wall thermostat
resets the manual lockout.
LOW PRESSURE SWITCH, BYPASS AND
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
Page
2100-532C
23 of 46
DELAY ON MAKE TIMING
.05 minutes (30 seconds)
DOB = 123 seconds DOM
1.0 minutes (60 seconds)
DOB = 126 seconds DOM
2.0 minutes (120 Seconds) DOB = 132 seconds DOM
3.0 minutes (180 seconds) DOB = 138 seconds DOM
4.0 minutes (240 seconds) DOB = 144 seconds DOM
5.0 minutes (300 seconds) DOB = 150 seconds DOM
OPTIONAL CFM
SERVICE HINTS
All models covered by this Manual are factory set to
operate at rated CFM levels as shown in Table 4. Rated
CFM is required for ducted applications for maximum
performance ratings.
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.
For free blow applications where Full Load Rated CFM
is undesirable due to sound levels, there is an optional
CFM that can be obtained (-10%). This CFM level will
reduce the system capacity performance by
approximately 2% at the same energy efficiency.
For Full Load Optional CFM:
1. Disconnect all power to the unit. Failure to do so
may result in damage to the motor.
2. 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.
SEQUENCE OF OPERATION
3. Open control panel cover.
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.
4. Locate low voltage terminal strip and purple wire
with white trace that connects to terminal “Y2”.
Disconnect this wire from terminal “Y2” and tape
off end.
5. Reverse steps to reassemble.
IMPORTANT INSTALLER NOTE
For improved start up performance, wash the indoor coil
with dishwashing detergent.
PHASE MONITOR
All units with three phase scroll compressors are
equipped with a three phase line monitor to prevent
compressor damage due to phase reversal.
The phase monitor in this unit is equipped with two
LEDs. If the Y signal is present at the phase monitor
and phases are correct, the green LED will light and
contactor will energize. If phases are reversed, the red
fault LED will be lit and compressor operation is
inhibited.
If a fault condition occurs, reverse two of the supply
leads to the unit. Do not reverse any of the unit factory
wires as damage may occur.
Manual 2100-532C
Page
24 of 46
On a call for Part Load Cooling by the thermostat, it
completes a circuit from “R” to “Y1”, “O” and “G” for part
load cooling. “Y1” starts the compressor, “O” energizes
the reversing valve and “G” starts the indoor blower.
On a call for Full Load Cooling by the thermostat, it
completes the same as Part Load Cooling above, but also
includes a signal to “Y2”. Signal “Y2” energizes the staging
solenoid on the side of the compressor and the signal also
goes to the indoor blower to ramp-up the airflow.
HEATING – On a call for Part Load Heating by the
thermostat, it completes a circuit from “R” to “Y1” and
“G”. “Y1” starts the compressor and “G” starts the
indoor blower.
On a call for Full Load Heating by the thermostat, it
completes the same as Part Load Heating above, but also
includes a signal to “Y2”. Signal “Y2” energizes the staging
solenoid on the side of the compressor and the signal also
goes to the indoor blower to ramp-up the airflow.
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.
Water piping to and from the coaxial water coil is
intended to enter/exit the unit through the rectangular
hole (See Figures 1, 8A, 17 and 18). The connections on
the water coil are a double O-ring with a retainer nut
that secures it in place.
Various double O-ring fittings are available so you may
then connect to the coaxial coil with various methods
and materials. The methods include 1" barbed fittings
(straight and 90°), 1" MPT (straight and 90°), and 1¼"
hot fusion fitting with P/T fitting). (See Table 6.)
Note: All double O-ring fittings require “hand
tightening only”. Do not use a wrench or pliers as
retainer nut can be damaged with excessive force.
Avoid cross-threading the nut.
TABLE 4
INDOOR BLOWER PERFORMANCE
1
4
3
MOD EL
R ATED
ESP
MAX. ESP
C ON TIN U OU S
AIR FLOW
1st STAGE
OP TION AL
2nd STAGE
2nd STAGE
QW2S1
0.0
0.5
800
800
900
1000
QW3S1
0.0
0.5
800
900
1050
1150
QW4S1
0.0
0.5
900
120 0
1300
1450
QW5S1
0.0
0.5
900
1400
1500
1650
NOTE: These units are equipped with a variable speed (ECM) indoor motor that automatically
adjusts itself to maintain approximately the same rate of indoor airflow in both heating and
cooling, dry and wet coil conditions, and at both 230/208 or 460 volts.
1 Maximum ESP (inches WC) shown is with 2" MERV 6 pleated filter.
2 Rated CFM for ducted applications – required for maximum performance rating. To obtain full CFM on
models QW3S1, QW4S1 and QW5S1, locate pink wire that is secured to purple wire at low voltage terminal
strip in the control box, and attach it to the “Y2” terminal along with the purple wire.
3 Optional 2nd Stage CFM – the unit is factory shipped to operate on full 2nd Stage airflow. If the optional 2nd
Stage airflow is desired, it requires removal of gray wire form "Y2" terminal of low voltage terminal strip in unit
main control panel. This reduces system capacity performance by approximately 2% at the same energy
efficiency.
4 Continuous CFM the total airflow being circulated during continuous blower operation.
Manual
Page
2100-532C
25 of 46
FIGURE 17
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
SIDE TRIM PEICES
(SHIPPED WITH UNIT)
FLUID ACCESS
FROM CEILING
FLUID ACCESS FROM
CEILING
SLEEVE
TOP OF UNIT
FLUID ACCESS
FROM EACH SIDE
8" TO 14" EXTERIOR WALL
BACK OF UNIT
FLUID ACCESS
FROM EACH SIDE
SLEEVE
66 1/2"
WALL OPENING
35" x 29 1/2"
34"
29"
MOUNTING BRACKETS
(SHIPPED WITH UNIT)
OPENING IN
REAR OF UNIT
3" x 8"
FLUID ACCESS
FROM FLOOR
8 1/2"
33" REF.
23 1/2"
FLOOR
MIS-2746
Manual 2100-532C
Page
26 of 46
FIGURE 18
FLUID CONNECTIONS ON UNIT WITHOUT VENTILATION WALL SLEEVE
TOP VIEW
WALL BRACKET
WALL BRACKET
4"
WATER LINES
BACK OF UNIT
WALL LOCATION
FLUID ACCESS
FROM TOP
66 1/2"
OPENING IN
REAR OF UNIT
3" x 8"
WALL BRACKET
(LEFT BRACKET
REMOVED FOR
CLARITY)
8 1/2"
23 1/2"
FLOOR
FLUID ACCESS FROM FLOOR
MIS-2747
Manual
Page
2100-532C
27 of 46
TABLE 5
PRESSURE TABLE
Model
QW2S
QW3S
QW4S
QW5S
Model
Return Air
Temperature Pressure 30°F
75° D B
62° WB
80° D B
67° WB
85° D B
72° WB
75° D B
62° WB
80° D B
67° WB
85° D B
72° WB
75° D B
62° WB
80° D B
67° WB
85° D B
72° WB
75° D B
62° WB
80° D B
67° WB
85° D B
72° WB
70° D B
QW3S
70° D B
QW4S
70° D B
QW5S
70° D B
QW2S
QW3S
QW4S
QW5S
Model
106
131
113
134
121
139
83
132
89
135
96
140
91
146
97
150
104
155
92
147
98
151
105
156
Return Air
Temperature Pressure 5°F
QW2S
Model
Low S i de
High Side
Low S i de
High Side
Low S i de
High Side
Low S i de
High Side
Low S i de
High Side
Low S i de
High Side
Low S i de
High Side
Low S i de
High Side
Low S i de
High Side
Low S i de
High Side
Low S i de
High Side
Low S i de
High Side
Low S i de
High Side
Low S i de
High Side
Low S i de
High Side
Low S i de
High Side
46
262
40
280
36
290
37
288
Return Air
Temperature Pressure 30°F
75° D B
62° WB
80° D B
67° WB
85° D B
72° WB
75° D B
62° WB
80° D B
67° WB
85° D B
72° WB
75° D B
62° WB
80° D B
67° WB
85° D B
72° WB
75° D B
62° WB
80° D B
67° WB
85° D B
72° WB
Low S i de
High Side
Low S i de
High Side
Low S i de
High Side
Low S i de
High Side
Low S i de
High Side
Low S i de
High Side
Low S i de
High Side
Low S i de
High Side
Low S i de
High Side
Low S i de
High Side
Low S i de
High Side
Low S i de
High Side
105
120
112
123
120
127
98
124
105
127
113
131
104
129
111
132
119
137
108
133
116
136
125
141
Return Air
Temperature Pressure 5°F
QW2S
70° D B
QW3S
70° D B
QW4S
70° D B
QW5S
70° D B
Low S i de
High Side
Low S i de
High Side
Low S i de
High Side
Low S i de
High Side
15
232
38
250
39
262
43
271
FULL LOAD COOLING — Fluid Temperature Entering Water Coil °F
35°F
40°F
45°F
50°F
55°F
60°F
65°F
70°F
75°F
80°F
85°F
90°F
108
146
116
150
125
155
87
148
93
152
100
157
94
162
101
166
108
172
94
163
100
167
108
173
111
161
119
165
128
171
91
165
97
169
104
175
97
177
104
182
112
188
96
178
103
183
110
189
114
176
122
181
131
187
94
181
101
186
109
193
101
193
108
198
116
205
98
194
105
199
113
206
117
191
125
196
134
203
98
198
105
203
113
210
104
208
111
214
119
221
101
210
108
215
116
223
120
206
128
212
138
219
102
215
109
220
117
228
107
224
115
229
123
237
103
225
110
231
118
239
122
221
131
227
141
235
106
231
113
237
121
245
110
239
118
245
127
254
105
241
112
247
121
256
125
236
134
243
144
251
109
248
117
254
126
263
114
255
122
261
131
270
107
256
115
263
123
272
128
252
137
258
147
267
113
264
121
271
130
280
117
270
125
277
134
287
109
272
117
279
126
289
130
272
139
279
150
289
116
285
124
292
133
303
119
291
127
299
137
309
111
293
119
300
127
311
132
293
141
300
152
311
118
306
126
314
136
325
121
312
129
320
139
331
112
313
120
321
129
333
134
313
144
322
154
333
121
327
129
335
139
347
122
333
131
342
141
353
114
334
122
343
131
354
136
334
146
343
157
355
123
347
132
356
142
369
124
354
133
363
143
376
115
355
123
364
132
376
95°F 100°F 105°F 110°F
138
355
148
364
159
377
126
368
134
378
144
391
126
375
135
385
145
398
116
375
125
385
134
398
142
396
152
406
164
420
131
410
140
420
150
435
130
417
139
428
149
442
119
416
128
427
137
442
144
417
154
427
166
442
133
431
142
442
153
457
132
438
141
449
152
465
121
437
129
448
139
464
FULL LOAD HEATING — Fluid Temperature Entering Water Coil °F
10°F
15°F
20°F
25°F
30°F
35°F
40°F
45°F
50°F
55°F
60°F
65°F
70°F
75°F
80°F
85°F
53
270
47
290
43
298
44
300
60
279
55
300
51
307
51
312
67
287
62
310
58
315
58
324
74
296
70
320
66
324
65
335
81
304
77
330
73
332
72
347
88
313
85
340
81
341
79
359
95
321
92
350
88
349
86
371
102
330
100
360
96
358
93
382
109
338
107
370
103
366
100
394
118
347
114
380
112
378
109
408
128
355
122
389
122
389
119
421
137
364
129
399
131
401
128
435
146
372
136
408
140
412
137
448
155
381
143
418
149
424
146
462
165
389
151
427
159
435
156
475
174
398
158
437
168
447
165
489
35°F
40°F
45°F
50°F
55°F
60°F
65°F
70°F
75°F
80°F
85°F
90°F
109
135
116
138
125
143
102
139
109
143
117
147
107
144
115
148
123
153
110
148
118
152
127
157
113
150
121
154
130
159
106
154
113
158
122
164
111
159
119
163
128
169
112
163
120
167
129
173
117
165
125
169
135
175
110
169
117
174
126
180
115
174
123
179
132
185
114
178
122
183
131
189
121
179
130
184
139
190
114
184
122
189
131
196
118
190
127
195
136
201
115
194
124
199
133
205
125
194
134
199
144
206
117
199
126
205
135
212
122
205
130
210
140
217
117
209
125
214
135
222
129
209
138
215
149
222
121
215
130
220
139
228
126
220
134
226
144
234
119
224
127
230
137
238
133
224
143
230
153
238
125
230
134
236
144
244
129
235
138
241
148
250
121
239
129
245
139
254
137
239
147
245
158
254
129
245
138
251
148
260
133
251
142
257
153
266
122
254
131
261
141
270
139
259
149
266
160
275
130
265
139
272
149
282
134
271
143
278
154
288
124
275
133
282
142
292
141
279
151
286
162
296
131
286
140
293
151
303
134
292
144
299
154
309
125
295
134
302
144
313
143
299
153
307
164
317
132
306
141
314
152
325
135
312
145
320
155
331
127
315
136
323
146
334
144
319
154
327
166
338
133
327
142
335
153
347
136
332
145
341
156
353
128
335
137
344
147
356
PART LOAD COOLING — Fluid Temperature Entering Water Coil °F
95°F 100°F 105°F 110°F
146
339
156
348
168
360
134
347
143
356
154
368
137
353
146
362
157
375
129
355
139
364
149
377
148
359
158
368
170
381
135
368
144
377
155
390
137
373
147
383
158
396
131
375
140
385
151
398
149
379
160
389
172
402
136
388
145
398
156
412
138
394
148
404
159
418
132
396
142
406
152
420
151
399
162
409
174
423
137
409
146
419
157
434
139
414
149
425
160
440
134
416
143
426
154
441
PART LOAD HEATING — Fluid Temperature Entering Water Coil °F
10°F
15°F
20°F
25°F
30°F
35°F
40°F
45°F
50°F
55°F
60°F
65°F
70°F
75°F
80°F
85°F
26
240
47
260
47
269
50
280
37
248
56
270
55
277
58
290
49
256
65
280
64
284
65
299
60
264
73
290
72
292
73
309
71
272
82
300
80
299
80
318
82
280
91
310
88
307
88
328
94
288
100
320
97
314
95
337
105
296
108
330
105
322
103
347
116
304
117
340
113
329
110
356
125
311
127
350
122
338
120
367
135
318
137
361
131
347
129
378
144
325
147
371
140
355
139
388
153
332
157
381
149
364
148
399
162
339
167
391
158
373
158
410
172
346
177
402
167
382
167
421
181
353
187
412
176
390
177
431
The data in the above pressure chart is based on the following flow rates:
FLOW RATE FOR VARIOUS FLUIDS
QW2S
QW3S
QW4S
QW6S
Flow rate required GPM for fresh w ater
5
6
7
9
Flow rate required GPM for 15% Methanol
7
8
9
11
6.1
8.6
11.3
13.7
Flow rate required GPM, cooling tow er/boiler loop
Manual 2100-532C
Page
28 of 46
140
375
150
385
161
398
128
389
137
399
147
413
128
396
137
406
147
420
118
396
126
406
135
420
Manual
Page
2100-532C
29 of 46
Ventilation wall sleeve for walls up to 14 inches thick.
Medium Bronze Anodized for vent option
Dark Bronze Anodized Aluminum for vent option
QLG-21
QLG-31
NOTE: Unless they are to be field-supplied, side trim kit must be ordered for all installations.
Gray Paint
Gray Paint
Platinum Vinyl QSTX-4-8
Platinum Vinyl QSTX-4-10
Platinum Vinyl QSTX-4-12
QSTX-V-10
QSTX-V-12
QSTX-X-12
QSTX-X-10
QSTX-X-8
QSTX-X-6
Model
Beige Paint
Beige Paint
Beige Paint
Beige Paint
Color
10" to 12"
8" to 10"
6" to 8"
4" to 6"
Space from back of unit to w all
Platinum Vinyl QPBS42-4
Platinum Vinyl QPB48-4
Platinum Vinyl QPBS48-4
QPBS42-V
QPB48-V
QPBS48-V
Gray Paint
Gray Paint
Gray Paint
Gray Paint
Platinum Vinyl QPBX48-10-4
Platinum Vinyl QCX15A-4
QCX15A-V
Platinum Vinyl QPBHW48-F-4 Gray Paint
Platinum Vinyl QPBHW42-D-4 Gray Paint
Platinum Vinyl QPBHW48-D-4 Gray Paint
QPBHW48-F-V
QPBHW42-D-V
QPBHW48-D-V
Beige Paint
Beige Paint
Beige Paint
Beige Paint
Beige Paint
Beige Paint
QPBHW48-D-X Beige Paint
QPBHW42-D-X Beige Paint
QPBHW48-F-X Beige Paint
QPBHW42-F-X Beige Paint
QCX15A-X
QCX10A-X
QPBX48-10-X Beige Paint
QPBX48-9-X Beige Paint
QPBX42-10-X Beige Paint
QPBX42-9-X Beige Paint
QPBS48-X
QPB48-X
QPBS42-X
QPB42-X
Ducted plenum box
Ducted plenum box
Free blow plenum box
Free blow plenum box
20" height (adjusts for ceilings up to 9'7"; add QPBX48-9 for 9'7" to 10'3" finished ceiling heights)
20" height (adjusts for ceilings up to 9'7"; add QPBX42-9 for 9'7" to 10'3" finished ceiling heights)
Use with QPB48 or QPBS48 (adjusts to ceilings up to 10'5")
Use with QPB48 or QPBS48 (adjusts to ceilings up to 9'9")
Use with QPB42 or QPBS42 (adjusts to ceilings up to 10'5")
Use with QPB42 or QPBS42 (adjusts to ceilings up to 9'9")
Same as QPB48, plus 2-w ay defection grille on each side.
Front Supply, 4-way deflection grille
Same as QPB42, plus 2-w ay defection grille on each side.
Front Supply, 4-way deflection grille
NOTE: The same top fill system and cabinet extensions can be used w ith hot w ater coil plenum boxes as w ith standard plenum boxes.
Platinum Vinyl QPBHW42-F-4 Gray Paint
Gray Paint
Gray Paint
QPBHW42-F-V
Hot Water Coils w ith Plenum Boxes:
Platinum Vinyl QCX10A-4
QCX10A-V
Cabinet Extensions for Ducted Applications:
Gray Paint
Platinum Vinyl QPBX48-9-4
QPBX48-9-V
QPBX48-10-V
Gray Paint
Gray Paint
Platinum Vinyl QPBX42-10-4
QPBX42-10-V
Gray Paint
Platinum Vinyl QPBX42-9-4
QPBX42-9-V
Top Fill Systems for Finishing Plenum Boxes to Ceilings:
Platinum Vinyl QPB42-4
QPB42-V
Free-Blow Plenum Boxes:
Optional Accessories – Additional I tems as Determined by Job Specifications
Gray Paint
Gray Paint
QSTX-V-8
Color
Platinum Vinyl QSTX-4-6
QSTX-V-6
Model
Color
Model
Side Trim Extension Kits:
NOTE: The follow ing accessory items must be selected so the finish (color) is matched to the QWS model that they w ill be used w ith.
Side Trim Kits — Required for All I nstallations Unless Field-Supplied
Clear Anodized Aluminum for vent option
QLG-11
Ventilation Louvers:
QWVS42
Ventilation Wall Sleeves:
Optional Accessories – M ust be Used for Each I nstallation w ith Ventilation Options
TABLE 6
OPTIONAL ACCESSORIES
QW4S, QW5S
QW2S, QW3S
QW4S, QW5S
QW2S, QW3S
Unit Compatibility
QW4S, QW5S
QW2S, QW3S
Unit Compatibility
QW4S, QW5S
QW2S, QW3S
Unit Compatibility
QW4S, QW5S
QW2S, QW3S
Unit Compatibility
All
All
All
All
Unit Compatibility
CLOSED LOOP
(Earth Coupled Ground Loop Applications)
CIRCULATION SYSTEM DESIGN
Equipment room piping design is based on years of
experience with earth coupled heat pump systems. The
design eliminates most causes of system failure.
Surprisingly, the heat pump itself is rarely the cause.
Most problems occur because designers and installers
forget that a closed loop earth coupled heat pump
system is not like a household plumbing system.
Most household water systems have more than enough
water pressure either from the well pump of the
municipal water system to overcome the pressure of
head loss in 1/2 inch or 3/4 inch household plumbing.
A closed loop earth coupled heat pump system,
however, is separated from the pressure of the
household supply and relies on a small, low wattage
pump to circulate the water and antifreeze solution
through the earth coupling, heat pump and equipment
room components.
The small circulator keeps the operating costs of the
system to a minimum. However, the performance of the
circulator must be closely matched with the pressure of
head loss of the entire system in order to provide the
required flow through the heat pump. Insufficient flow
through the heat exchanger is one of the most common
causes of system failure. Proper system piping design
and circulator selection will eliminate this problem.
Bard supplies a work sheet to simplify head loss
calculations and circulator selection. Refer to
“Circulating Pump Work sheet” section in manual
2100-099. Loop pump performance data can be seen in
Figures 21 and 22.
COPPER WATER COIL APPLICATION
Copper water coils are available as a factory installed
option. The unit model number will indicate the coil
option as the next to last character; “C” represents a
water coil constructed of copper material and “N”
represents a water coil constructed of cupronickel.
The cupronickel coil is suitable for all applications.
The copper coil is suitable for applications using
ground loop and cooling tower only and is not
recommended for open well application.
FIGURE 19
CIRCULATION SYSTEM
FLEXIBLE HOSE
PUMP MODULE
(See Spec Sheet
for Model No.)
PIPE FROM
GROUND LOOP
PIPE TO
GROUND
LOOP
WATER
OUT
MIS-2748
Manual 2100-532C
Page
30 of 46
START UP PROCEDURE FOR CLOSED
LOOP SYSTEM
1. Be sure main power to the unit is OFF at disconnect.
2. Set thermostat system switch to OFF, fan switch to
AUTO.
3. Move main power disconnect to ON. Except as
required for safety while servicing, Do not open
the unit disconnect switch.
4. Check system air flow for obstructions.
A. Move thermostat fan switch to ON. Blower runs.
B. Be sure all registers and grilles are open.
C. Move thermostat fan switch to AUTO. Blowing
should stop.
5. Flush, fill and pressurize the closed loop system as
outlined in manual 2100-099.
6. Fully open the manual inlet and outlet valves. Start
the loop pump module circulator(s) and check for
proper operation. If circulator(s) are not operating,
turn off power and diagnose the problem.
7. Check fluid flow using a direct reading flow meter
or a single water pressure gauge, measure the
pressure drop at the pressure/temperature plugs
across the water coil. Compare the measurement
with flow versus pressure drop table to determine
the actual flow rate. If the flow rate is too low,
recheck the selection of the loop pump module
model for sufficient capacity. If the module
selection is correct, there is probably trapped air or a
restriction in the piping circuit.
8. Start the unit in cooling mode by moving the
thermostat switch to cool. Fan should be set for
AUTO.
9. Check the system refrigerant pressures against the
cooling refrigerant pressure table in the installation
manual for rated water flow and entering water
temperatures. If the refrigerant pressures do not
match, check for airflow problem then refrigeration
system problem.
10. Switch the unit to the heating mode by moving the
thermostat switch to heat. Fan should be set for
AUTO.
11. Check the refrigerant system pressures against the
heating refrigerant pressure table in installation
manual. Once again, if they do not match, check for
airflow problems and then refrigeration system
problems.
NOTE: If a charge problem is determined (high or low):
A. Check for possible refrigerant leaks.
B. Recover all remaining refrigerant from unit and
repair leak.
C. Evacuate unit down to 29 inches of vacuum
D. Recharge the unit with refrigerant by weight.
This is the only way to insure a proper charge.
FIGURE 20
WATER TEMPERATURE and PRESSURE PROCEDURE
Thermometer
Dial face pressure guage
with guage adaptor
50
40
30
20
60
70
Retaining cap, hand tighten only
80
90
100
10
110
0
120
Pete's test plug
Test plug cap
Barbed 90° adapter
MIS-2622
Manual
Page
2100-532C
31 of 46
FIGURE 21
PERFORMANCE MODEL DORFC-1 LOOP PUMP MODULE
35
30
Head (Feet)
25
20
15
10
5
0
0
5
10
15
20
25
30
35
Flow (GPM)
FIGURE 22
PERFORMANCE MODEL DORFC-2 LOOP PUMP MODULE
70
60
Head (Feet)
50
40
30
20
10
0
0
5
10
15
20
Flow (GPM)
Manual 2100-532C
Page
32 of 46
25
30
35
OPEN LOOP
(Well System Applications)
TABLE 7
CONSTANT FLOW VALVES
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.
1
Part No.
Min. Available
Pressure PSIG
Flow Rate
GPM
CFV-5
15 1
5
CFV-6
15 1
6
CFV-7
15 1
7
CFV-9
15 1
9
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) installed upstream of constant flow valve
(7) to collect foreign material which would clog the
flow valve orifice.
Figure 22 shows the use of shutoff valves (9) and (11),
on the in and out water lines to permit isolation of the
unit from the plumbing system should future service
work require this. Globe valves should not be used as
shutoff valves because of the excessive pressure drop
inherent in the valve design. Instead use gate or ball
valves as shut-offs so as to minimize pressure drop.
Drain cock (8) and (10), and tees have been included
to permit acid cleaning the refrigerant-to-water coil
should such cleaning be required. See WATER
CORROSION section.
Refer to piping, Figure 23. Slow closing Solenoid
Valve (6) with a 24V coil provides on/off control of the
water flow to the unit. Refer to the wiring diagram for
correct hookup of the valve solenoid coil.
Constant Flow Valve (7) provides correct flow of
water to the unit regardless of variations in water
pressure. Observe the water flow direction indicated by
the arrow on the side of the valve body. Table 7 is a
table showing the flow rate of each valve. Two
constant flow rate valves may be installed in parallel to
increase the flow. For example, when a 8603-007 (6
GPM) and 8603-011 (5 GPM) are installed in parallel
the total flow will be 11 GPM.
Drain cock (12) provides access to the system to check
water flow through the constant flow valve to insure
adequate water flow through the unit. A water meter is
used to check the water flow rate.
FIGURE 23
PIPING DIAGRAM
8
9
10
11
6
7
12
MIS-2749
Manual
Page
2100-532C
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.
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.
SYSTEM START UP PROCEDURE FOR
OPEN LOOP APPLICATIONS
B. Recover all remaining refrigerant from unit and
repair leak.
1. Be sure main power to the unit is OFF at disconnect.
C. Evacuate unit down to 29 inches of vacuum.
2. Set thermostat system switch to OFF, fan switch to
AUTO.
3. Move main power disconnect to ON. Except as
required for safety while servicing – do not open the
unit disconnect switch.
4. Check system airflow for obstructions.
A. Move thermostat fan switch to ON. Blower runs.
B. Be sure all registers and grilles are open.
C. Move thermostat fan switch to AUTO. Blower
should stop.
5. Fully open the manual inlet and outlet valves.
6. Check water flow.
Manual 2100-532C
Page
34 of 46
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 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.
4. Scale Formation. Of all the water problems, the
formation of scale by ground water is by far the most
common. Usually this scale is due to the formation
of calcium carbonate, but magnesium carbonate or
calcium sulfate may also be present. Carbon dioxide
gas (CO2), the carbonate of calcium and magnesium
carbonate, is very soluble in water. It will remain
dissolved in the water until some outside factor
upsets the balance. This outside influence may be a
large change in water temperature or pressure.
When this happens, enough carbon dioxide gas
combines with dissolved calcium or magnesium in
the water and falls out of solution until a new
balance is reached. The change in temperature that
this heat pump produces is usually not high enough
to cause the dissolved gas to fall out of solution.
Likewise, if pressure drops are kept to a reasonable
level, no precipitation of carbon dioxide should
occur.
REMEDIES OF WATER PROBLEMS
Water Treatment. Water treatment can usually be
economically justified for close loop systems.
However, because of the large amounts of water
involved with a ground water heat pump, water
treatment is generally too expensive.
Acid Cleaning the Water Coil or Heat Pump
Recovery Unit. If scaling of the coil is strongly
suspected, the coil can be cleaned up with a solution of
Phosphoric Acid (food grade acid). Follow the
manufacturer’s directions for mixing, use, etc. Refer to
the “Cleaning Water Coil”, Figure 24. The acid
solution can be introduced into the heat pump coil
through the hose bib A. Be sure the isolation valves are
closed to prevent contamination of the rest of the system
by the coil. The acid should be pumped from a bucket
into the hose bib and returned to the bucket through the
other hose bib B. Follow the manufacturer’s directions
for the product used as to how long the solution is to be
circulated, but it is usually circulated for a period of
several hours.
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.
Manual
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2100-532C
35 of 46
FIGURE 24
CLEANING WATER COIL
Hose Bib (B)
Isolation Valve
Hose Bib (A)
TO WATER COIL
Pump
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.
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.
The following is a list of recommendations to follow
when installing this type of system (Refer to Figure 25):
H. Most installers use 4-inch filed tile (rigid plastic or
corrugated) for water return to the lake or pond.
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).
I. The drain line discharge should be located at least
100 feet from the dry well location.
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 2100-532C
Page
36 of 46
J. The drain line should be installed with a slope of 2
inches per 10 feet of run to provide complete
drainage of the line when the ground water heat
pump is not operating. This gradient should also
help prevent freezing of the discharge where the
pipe terminates above the frost line.
K. Locate the discharge high enough above high water
level so the water will not back up and freeze inside
the drain pipe.
L. Where the local conditions prevent the use of a
gravity drainage system to a lake or pond, you can
instead run standard plastic piping out into the pond
below the frost and low water level.
Manual
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2100-532C
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12' to 15'
LAKE
or
POND
WATER LEVEL
GRAVEL FILL
FIGURE 25
WATER WELL SYSTEM
SUBMERSIBLE
PUMP
PERFORATED
PLASTIC CASING
DROP PIPE
WATER SUPPLY
LINE
TO PRESSURE
TANK
PITLESS ADAPTER
ELECTRICAL LINE
WELL CAP
15' to 20'
DEEP
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.
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.
CAUTION
Water piping exposed to extreme low ambient
temperatures are subject to freezing.
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.
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.
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.
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.
It is imperative that all air be eliminated from the source
closed loop side of the heat exchanger to insure against
fouling.
TABLE 8
WATER FLOW AND PRESSURE DROP
QW2S1 &
QW3S1
GPM
PSIG
Ft. Hd.
3
0.1
0.23
4
0.5
5
PSIG
Ft. Hd.
1.15
0.9
2.08
1.2
2.77
1.4
3.23
6
1.7
3.92
2.3
5.31
7
2.3
5.31
3.2
8
3.1
7.15
9
4.1
9.46
QW6S1
PSIG
Ft. Hd.
7.38
2
4.61
4.1
9.46
2.5
5.77
5.1
11.77
3.2
7.38
10
6.1
14.07
3.9
9.00
11
7.1
16.38
4.7
10.84
12
8.2
18.92
5.5
12.69
13
9.4
21.69
6.4
14.76
14
10.6
24.45
7.3
16.84
15
8.1
18.69
16
9
20.76
17
9.9
22.84
18
Manual 2100-532C
Page
38 of 46
QW4S1
FIGURE 26
WATER SOURCE HEAT PUMP
Manual
Page
2100-532C
39 of 46
FIGURE 27
WATER SOURCE HEAT PUMP
Manual 2100-532C
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40 of 46
SERVICE
UNBRAZING SYSTEM COMPONENTS
If the refrigerant charge is removed from a scroll
equipped unit by bleeding the high side only, it is
sometimes possible for the scrolls to seal, preventing
pressure equalization through the compressor. This may
leave low side shell and suction line tubing pressurized.
If the brazing torch is then applied to the low side while
the low side shell and suction line contains pressure, the
pressurized refrigerant and oil mixture could ignite
when it escapes and contacts the brazing flame. To
prevent this occurrence, it is important to check both the
high and low side with manifold gauges before
unbrazing.
WARNING
Both the high and low side of the scroll
compressor must be checked with manifold
gauges before unbrazing system
components. Failure to do so could cause
pressurized refrigerant and oil mixture to
ignite if it escapes and contacts the brazing
flame causing property damage, bodily harm
or death.
Manual
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2100-532C
41 of 46
TROUBLESHOOTING GE ECM™ MOTORS
CAUTION:
Symptom
Cause/Procedure
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.
• Noisy blower or cabinet
• Check for loose blower housing, panels, etc.
• High static creating high blower speed?
- Check for air whistling through seams in
ducts, cabinets or panels
- Check for cabinet/duct deformation
• “Hunts” or “puffs” at
high CFM (speed)
• Does removing panel or filter reduce
“puffing”?
- Reduce restriction
- Reduce max. airflow
Symptom
Cause/Procedure
Motor rocks slightly
when starting
• This is normal start-up for ECM
Motor won’t start
• No movement
• Check blower turns by hand
• Check power at motor
• Check low voltage (24 Vac R to C) at motor
• Check low voltage connections
(G, Y, W, R, C) at motor
• Check for unseated pins in connectors on
motor harness
• Test with a temporary jumper between R - G
• Check motor for tight shaft
• Perform motor/control replacement check
• Perform Moisture Check
• Motor rocks,
but won’t start
• Check for loose or compliant motor mount
• Make sure blower wheel is tight on shaft
• Perform motor/control replacement check
Motor oscillates up
& down while being
tested off of blower
• It is normal for motor to oscillate with no load
on shaft
Motor starts, but
runs erratically
• Varies up and down
or intermittent
• Check line voltage for variation or “sag”
• Check low voltage connections
(G, Y, W, R, C) at motor, unseated pins in
motor harness connectors
• Check “Bk” for erratic CFM command (in
variable-speed applications)
• Check out system controls, Thermostat
• Perform Moisture Check
Evidence of Moisture
• Motor failure or
malfunction has occurred
and moisture is present
• Replace motor and Perform Moisture Check
• Evidence of moisture
present inside air mover
• Perform Moisture Check
Do
Don’t
• Check out motor, controls,
wiring and connections
thoroughly before replacing
motor
• Orient connectors down so
water can’t get in
- Install “drip loops”
• Use authorized motor and
model #’s for replacement
• Keep static pressure to a
minimum:
- Recommend high
efficiency, low static filters
- Recommend keeping filters
clean.
- Design ductwork for min.
static, max. comfort
- Look for and recommend
ductwork improvement,
where necessary
• Automatically assume the motor is bad.
• Locate connectors above 7 and 4 o’clock
positions
• Replace one motor or control model # with
another (unless an authorized replacement)
• Use high pressure drop filters some have ½"
H20 drop!
• Use restricted returns
• Size the equipment wisely
• “Hunts” or “puffs” at
high CFM (speed)
• Does removing panel or filter reduce
“puffing”?
- Reduce restriction
- Reduce max airflow
• Stays at low CFM
despite system call
for cool or heat CFM
• Check low voltage (Thermostat) wires and
connections
• Verify fan is not in delay mode; wait until
delay complete
• “R” missing/not connected at motor
• Perform motor/control replacement check
• Stays at high CFM
• “R” missing/not connected at motor
• Is fan in delay mode? - wait until delay time
complete
• Perform motor/control replacement check
• Oversize system, then compensate with low
airflow
• Check orientation before
• Plug in power connector backwards
inserting motor connectors • Force plugs
Moisture Check
• Blower won’t shut off
• Current leakage from controls into G, Y or W?
Check for Triac switched thermostat or solidstate relay
Excessive noise
• Determine if it’s air noise, cabinet, duct or
motor noise; interview customer, if necessary
• High static creating high blower speed?
- Is airflow set properly?
- Does removing filter cause blower to slow
down? Check filter
- Use low-pressure drop filter
- Check/correct duct restrictions
• Air noise
Manual 2100-532C
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42 of 46
• 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?
TROUBLESHOOTING GE ECM™ MOTORS CONT’D.
Replacing ECM Control Module
To replace the control module for the GE variable-speed indoor blower
motor you need to take the following steps:
1. You MUST have the correct replacement module. The controls are
factory programmed for specific operating modes. Even though they look
alike, different modules may have completely different functionality.
USING THE WRONG CONTROL MODULE VOIDS ALL PRODUCT
WARRANTIES AND MAY PRODUCE UNEXPECTED RESULTS.
2. Begin by removing AC power from the furnace or air handler being
serviced. DO NOT WORK ON THE MOTOR WITH AC POWER
APPLIED. To avoid electric shock from the motor’s capacitors, disconnect
power and wait at least 5 minutes before opening motor.
3. It is usually not necessary to remove the motor from the blower
assembly. However, it is recommended that the whole blower assembly,
with the motor, be removed from the furnace/air handler. (Follow the
manufacturer’s procedures). Unplug the two cable connectors to the motor.
There are latches on each connector. DO NOT PULL ON THE WIRES.
The plugs remove easily when properly released.
4. Locate the two standard ¼" hex head bolts at the rear of the control
housing (at the back end of the control opposite the shaft end). Refer
to Figure 28. Remove these two bolts from the motor and control
assembly while holding the motor in a way that will prevent the motor
or control from falling when the bolts are removed. If an ECM2.0
control is being replaced (recognized by an aluminum casting rather
that a deep-drawn black steel can housing the electronics), remove
only the hex-head bolts. DO NOT REMOVE THE TORX-HEAD
SCREWS.
5. The control module is now free of mechanical attachment to the
motor endshield but is still connected by a plug and three wires inside
the control. Carefully rotate the control to gain access to the plug at
the control end of the wires. With thumb and forefinger, reach the
latch holding the plug to the control and release it by squeezing the
latch tab and the opposite side of the connector plug and gently pulling
the plug out of the connector socket in the control. DO NOT PULL
ON THE WIRES. GRIP THE PLUG ONLY.
6. The control module is now completely detached from the motor.
Verify with a standard ohmmeter that the resistance from each motor
lead (in the motor plug just removed) to the motor shell is >100K ohms.
Refer to Figure 29. (Measure to unpainted motor end plate.) If any
motor lead fails this test, do not proceed to install the control module.
THE MOTOR IS DEFECTIVE AND MUST BE REPLACED.
Installing the new control module will cause it to fail also.
7. Verify that the replacement control is correct for your
application. Refer to the manufacturer's authorized replacement list.
USING THE WRONG CONTROL WILL RESULT IN
IMPROPER OR NO BLOWER OPERATION. Orient the control
module so that the 3-wire motor plug can be inserted into the socket in
the control. Carefully insert the plug and press it into the socket until
it latches. A SLIGHT CLICK WILL BE HEARD WHEN
PROPERLY INSERTED. Finish installing the replacement control per
one of the three following paragraphs, 8a, 8b or 8c.
8a. IF REPLACING AN ECM 2.0 CONTROL (control in cast
aluminum can with air vents on the back of the can) WITH AN ECM
2.3 CONTROL (control containing black potting for water protection in
black deep-drawn steel case with no vents in the bottom of the can),
locate the two through-bolts and plastic tab that are packed with the
replacement control. Insert the plastic tab into the slot at the perimeter
of the open end of the can so that the pin is located on the inside of the
perimeter of the can. Rotate the can so that the tab inserts into the tab
locater hole in the endshield of the motor. Using the two through-bolts
provided with the replacement control, reattach the can to the motor.
8b. IF REPLACING AN ECM 2.3 CONTROL WITH AN ECM
2.3 CONTROL, the plastic tab and shorter through-bolts are not
needed. The control can be oriented in two positions 180° apart.
MAKE SURE THE ORIENTATION YOU SELECT FOR
REPLACING THE CONTROL ASSURES THE CONTROL'S
CABLE CONNECTORS WILL BE LOCATED DOWNWARD IN
THE APPLICATION SO THAT WATER CANNOT RUN DOWN
THE CABLES AND INTO THE CONTROL. Simply orient the
new control to the motor's endshield, insert bolts, and tighten. DO
NOT OVERTIGHTEN THE BOLTS.
8c. IF REPLACING AN ECM 2.0 CONTROL WITH AN ECM
2.0 CONTROL (It is recommended that ECM 2.3 controls be used for
all replacements), the new control must be attached to the motor using
through bolts identical to those removed with the original control. DO
NOT OVERTIGHTEN THE BOLTS.
9. Reinstall the blower/motor assembly into the HVAC equipment.
Follow the manufacturer's suggested procedures.
10. Plug the 16-pin control plug into the motor. The plug is keyed.
Make sure the connector is properly seated and latched.
11. Plug the 5-pin power connector into the motor. Even though the
plug is keyed, OBSERVE THE PROPER ORIENTATION. DO
NOT FORCE THE CONNECTOR. It plugs in very easily when
properly oriented. REVERSING THIS PLUG WILL CAUSE
IMMEDIATE FAILURE OF THE CONTROL MODULE.
12. Final installation check. Make sure the motor is installed as
follows:
a. Unit is as far INTO the blower housing as possible.
b.Belly bands are not on the control module or covering vent
holes.
c. Motor connectors should be oriented between the 4 o’clock
and 8 o’clock positions when the blower is positioned in its
final location and orientation.
d.Add a drip loop to the cables so that water cannot enter the
motor by draining down the cables. Refer to Figure 30.
The installation is now complete. Reapply the AC power to the
HVAC equipment and verify that the new motor control module is
working properly. Follow the manufacturer's procedures for
disposition of the old control module.
Figure 429
Figure
Winding Test
Figure
Figure28
3
Control Disassembly
Motor Connector
(3-pin)
Only remove
From Motor
Hex Head Bolts Push until
Latch Seats
Over Ramp
Circuit
Board
Motor
ECM 2.0
Motor OK when
R > 100k ohm
Note:
Use the shorter
bolts and
alignment pin
supplied when
replacing an
ECM 2.0
control.
Figure
Figure30
5
Drip Loop
ECM
2.3/2.5
Motor Connector
(3-pin)
Back of
Control
Connector Orientation
Between 4 and 8 o'clock
Control Connector
(16-pin)
Power Connector
(5-pin)
Hex-head Screws
Drip Loop
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.
Manual
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2100-532C
43 of 46
Loose Terminals
Faulty Wiring
Blown Fuse or Tripped Breaker
Power Failure
Low Voltage
Compressor Overload
Start Capacitor
Run Capacitor
Potential Relay
Thermostat
Low Voltage
Control Transformer
Loose Terminals
Faulty Wiring
Indoor Blower Relay
Discharge Line Hitting Inside of Shell
Contactor Coil
Excessive Operation Costs
Ice in Water Coil
Aux. Heat on I.D. Blower Off
Liquid Refrigerant Flooding Back
To Compressor
Reversing Valve Does Not Shift
Compressor Runs Continuously
– No Cooling
Liquid Refrigerant Flooding Back
To Compressor
Compressor Runs Continuously
– No Heating
Excessive Water Usage
High Compressor Amps
I.D. Coil Frosting or Icing
I.D. Blower Will Not Start
Suction Pressure Too Low
Motor Wingings Defective
Refrigerant Charge Low
Refrigerant Overcharge
Low Head Pressure
High Suction Pressure
Low Suction Pressure
Non-Condensables
Unequalized Pressures
Solenoid Valve Stuck Closed (Htg)
Solenoid Valve Stuck Closed (Clg)
Solenoid Valve Stuck Open (Htg or Clg)
Leaking
Plugged or Restricted Metering Device (Htg)
Water Coil
Scaled or Plugged Coil (CLg)
Water Volume Low (Htg)
Water Volume Low (Clg)
Scaled or Plugged Coil (Htg)
Rev.
Valve
Defective Valve or Coil
WATER COIL SECTION
Water
Solenoid
Refrigerant System
High Head Pressure
Pressure Controls (High or Low)
Compressor
Bearings Defective
Suction Pressure Too High
Control Circuit
Seized
Defective Contacts in Contactor
POWER SUPPLY
Air Volume Low
Motor Winding Defective
Fins Dirty or Plugged
Plugged or Restricted Metering Device (Clg)
Air Filters Dirty
Undersized or Restricted Ductwork
INDOOR SECTION
AUX.
Indoor Blower Motor
and Coil
Heat Gen.
Auxillary Heat Upstream of Coil
Line Voltage
Low Water Temperature (Htg)
QUICK REFERENCE TROUBLESHOOTING CHART FOR WATER TO AIR HEAT PUMP
Valve Defective
Head Pressure Too Low
Head Pressure Too High
Compressor Noisy
Thermostat Check Light
Lite-Lockout Relay
Compressor Off on High
Pressure Control
Compressor Off on Low
Pressure Control
Compressor Cycles on Overload
Compressor Will Not Run
No Power at Contactor
Compressor Will Not Run
Power at Contactor
Compressor "Hums"
But Will Not Start
DENOTES COMMON CAUSE
DENOTES OCCASIONAL CAUSE
Heating or Cooling Cycles
Cooling
Cycle
Heating Cycle
Manual 2100-532C
Page
44 of 46
GROUND SOURCE HEAT PUMP
PERFORMANCE REPORT
This performance check report should be filled out by installer and retained with unit.
DATE:
TAKEN BY:
1. UNIT:
Mfgr
Model #
THERMOSTAT:
Mfgr
S/N
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:
C. System type:
D. Pipe Material
% Solution
Series
Parallel
Nominal Size
E. Pipe Installed:
1.
Horizontal
No. pipes in trench
2.
Vertical
Total length of pipe
ft
Depth bottom pipe
ft
Total length of bore hole
ft
Manual
Page
2100-532C
45 of 46
THE FOLLOWING INFORMATION IS NEEDED
TO CHECK PERFORMANCE OF UNIT
FLUID SIDE DATA
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
** Heating
Entering fluid temperature
Leaving fluid temperature
Entering fluid pressure
Leaving fluid pressure
Pressure drop through coil
Gallons per minute through the water coil
Liquid or discharge line pressure
Suction line pressure
Voltage at compressor (unit running)
Amperage draw at line side of contactor
Amperage at compressor common terminal
* Suction line temperature 6” from compressor
* Superheat at compressor
* Liquid line temperature at metering device
* Coil subcooling
INDOOR SIDE DATA
24.
25.
26.
27.
28.
29.
30.
Cooling
F
F
PSIG
PSIG
PSIG
GPM
PSIG
PSIG
V
A
A
F
F
F
F
Cooling
** Heating
Dry bulb temperature at air entering indoor coil
Wet bulb temperature of air entering indoor coil
Dry bulb temperature of air leaving indoor coil
Wet bulb temperature of air leaving indoor coil
* Supply air static pressure (packaged unit)
* Return air static pressure (packaged unit)
Other information about installation
** When performing a heating test insure that second stage heat is not activated.
* Items that are optional
Manual 2100-532C
Page
46 of 46
F
F
F
F
WC
WC
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