Bard QW4S1 2100 532(B) (2010 07) User Manual To The 844e3e6d B1ca 49be B9b3 F97d6997d5b6

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Manual 2100-532B

Page 1 of 46

QW SERIES

GEOTHERMAL R-410A

STAGED CAPACITY

PACKAGED HEAT PUMP

INSTALLATION

INSTRUCTIONS

Models:

QW2S1 QW3S1

QW4S1 QW5S1

Manual No.: 2100-532B

Supersedes: 2100-532A

File: Vol II Tab 14

Date: 07-19-10

Bard Manufacturing Company, Inc.

Bryan, Ohio 43506

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

MIS-2736

Earth Loop Fluid

Temperatures 25 – 110

Ground Water Temperature 45 – 75

Manual 2100-532B

Page 2 of 46

CONTENTS

Getting Other Information and Publications

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

QW General Information

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

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

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

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

Removal of Wall Bracket from Shipping Location ... 8

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

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

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

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

Condensate Drain ........................................... 11 – 13

Mist Eliminator Service .................................. 13 & 14

Installation Instructions

Mounting the Unit .................................................. 15

Wiring – Main Power ............................................. 18

Wiring – Low Voltage Wiring ................................. 18

General .................................................................. 18

Low Voltage Connections ...................................... 19

Start Up

Description of Standard Equipment ....................... 23

Compressor Control Module .................................. 23

Adjustments ........................................................... 23

Optional CFM ........................................................ 24

Important Installer Note ......................................... 24

Phase Monitor ....................................................... 24

Service Hints ......................................................... 24

Sequence of Operation .................................. 24 & 25

Pressure Service Ports .......................................... 25

Pressure Tables ..................................................... 28

Optional Accessories ............................................. 29

Closed Loop (Earth Coupled Ground Loop Applications)

Circulation System Design .................................... 30

Copper Water Coil Application ............................... 30

Start Up Procedure for Closed Loop System ......... 31

Open Loop (Well System Applications)

Water Connections ................................................ 33

Well Pump Sizing .................................................. 34

Start Up Procedure for Open Loop System ... 34 & 35

Water Corrosion .................................................... 35

Remedies of Water Problems ................................ 35

Lake and Pond Installations .................................. 36

Cooling Tower / Boiler Application ......................... 38

Service

Unbrazing System Components ............................ 41

Troubleshooting GE ECM™ Blower Motors ... 42-43

Quick Reference Troubleshooting Chart for

Water to Air Heat Pump.......................................... 44

Ground Source Heat Pump

Performance Report .......................................... 45-46

Manual 2100-532B

Page 3 of 46

Figures

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

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

Figure 3 Proper Handling of Unit After Removal

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

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

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

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

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

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

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

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

Figure 9 Removal of Q-TEC ERV ........................ 14

Figure 10 Remove Locking Screws from Wheels 15

Figure 11 Unit Mounting Without Wall Sleeve ..... 16

Figure 12 Component Location ............................ 17

Figure 13 Low Voltage Wire Harness Plug .......... 19

Figure 14 Remote Thermostat Wiring "X" Option 20

Figure 15 Remote Thermostat Wiring "D" Option 21

Figure 16 Remote Thermostat Wiring "H" Option 22

Figure 17 Fluid Connections w/Ventilation

Wall Sleeve .......................................... 26

Figure 18 Fluid Connections w/o Ventilation

Wall Sleeve .......................................... 27

Figure 19 Circulation System ............................... 30

Figure 20 Water Temperature and Pressure

Test Procedure .................................. 31

Figure 21 Performance Model WGPM-1C ........... 32

Figure 22 Performance Model WGPM-2C ........... 32

Figure 23 Piping Diagram .................................... 33

Figure 24 Cleaning Water Coil ............................. 36

Figure 25 Water Well System .............................. 37

Figure 26 Water Source H/P Cooling Cycle ......... 39

Figure 27 Water Source H/P Heating Cycle ........ 40

Figure 28 Control Disassembly ............................ 43

Figure 29 Winding Test ........................................ 43

Figure 30 Drip Loop ............................................. 43

Tables

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

Table 2 Operating Voltage Range ....................... 18

Table 3 Wall Thermostats ................................... 18

Table 4 Indoor Blower Performance ................... 25

Table 5 Pressures ............................................... 28

Table 6 Optional Accessories ............................. 29

Table 7 Constant Flow Valves ............................. 33

Table 8 Water Flow and Pressure Drop .............. 38

CONTENTS

Manual 2100-532B

Page 4 of 46

GETTING OTHER INFORMATION AND PUBLICATIONS

These publications can help you install the air

conditioner or heat pump. You can usually find these at

your local library or purchase them directly from the

publisher. Be sure to consult current edition of each

standard.

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

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

of Air Conditioning and Ventilating Systems

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

Heating and Air Conditioning Systems

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

Winter and Summer Air Conditioning

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

Winter and Summer Air Conditioning and Equipment

Selection

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

Systems Installation Guide

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

Heat Pump Systems

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

of Ground-Coupled Heat Pump Systems

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

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

Installation Guide

FOR MORE INFORMATION, CONTACT

THESE PUBLISHERS:

ACCA Air Conditioning Contractors of America

1712 New Hampshire Avenue

Washington, DC 20009

Telephone: (202) 483-9370

Fax: (202) 234-4721

ANSI American National Standards Institute

11 West Street, 13th Floor

New York, NY 10036

Telephone: (212) 642-4900

Fax: (212) 302-1286

ASHRAE American Society of Heating Refrigerating,

and Air Conditioning Engineers, Inc.

1791 Tullie Circle, N.E.

Atlanta, GA 30329-2305

Telephone: (404) 636-8400

Fax: (404) 321-5478

NFPA National Fire Protection Association

Batterymarch Park

P.O. Box 9101

Quincy, MA 02269-9901

Telephone: (800) 344-3555

Fax: (617) 984-7057

IGSHPA International Ground Source

Heat Pump Association

490 Cordell South

Stillwater, OK 74078-8018

Manual 2100-532B

Page 5 of 46

QW SERIES GEOTHERMAL R-410A STAGED CAPACITY GENERAL INFORMATION

QW MODEL NOMENCLATURE

FILTER OPTIONS

X - 2-Inch Pleated

(MERV6)

STEP CAPACITY |

CAPACITY |

2 - 2 Ton

3 - 3 Ton

4 - 4 Ton

5 - 5 Ton

MODEL NUMBER |

Q-Tec™ Model

REVISION |

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)

VOLTS &

PHASE

A - 230/208/60/1

B - 230/208/60/3

C - 460/60/3

COIL OPTIONS

C - Copper (water)

N - Cupronickel

KW

0Z - OKW

CLIMATE CONTROL

Standard -

X - None

D - Electronic/Prog/Man/Auto

H - Electronic/Prog with CO2 control

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

SPECIALTY

PRODUCTS

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

2These “Minimum Circuit Ampacity” values are to be used for sizing the field power conductors. Refer to the National Electric

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

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

Pay special attention to Note 8 of Table 310 regarding Ampacity Adjustment Factors when more than three

conductors are in a raceway.

VENTILATION OPTIONS

B - Blank-off Plate

V - Commercial Room Ventilator w/Multi-Position Control.

Can also be modulating with CO

2

control.

R - Energy Recovery Ventilator w/Independent Intake/Exhaust

Control.

TABLE 1

ELECTRICAL SPECIFICATIONS

LEDOM

DETAR zH,STLOV ESAHP&

TIUCRICELGNIS

2

DLEIF.ON REWOP STIUCRIC

1

MUMINIM TIUCRIC YTICAPMA

1

MUMIXAM LANRETXE ROESUF TIUCRIC REKAERB

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

1-06-802/032 3-06-802/032 3-06-064

1

1

1

9141

7

030251

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

1-06-802/032 3-06-802/032 3-06-064

1

1

1

6202

9

040351

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

1-06-802/032 3-06-802/032 3-06-064

1

1

1

137211

050402

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

1-06-802/032 3-06-802/032 3-06-064

1

1

1

939271

065452

Manual 2100-532B

Page 6 of 46

FIGURE 1

UNIT DIMENSIONS

36 1/16" 36 7/8"

68 3/4"

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

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

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

MIS-2737 B

(OPTIONAL)

FILTER

ACCESS

DOOR

SUPPLY AIR

THERMOSTAT

RETURN AIR

CO2 SENSOR GRILLE

GRILLE

(OPTIONAL)

DOOR

CONDENSER

CIRCUIT BREAKER

ACCESS AND LOCKING

COVER

FRONT VIEW

16 5/8"

14"

"D"

15 5/8"

"C"

11 3/4"

"C"

104"

37 1/8"

1 1/8"

"B" (OPTIONAL)

PLENUM BOX

RIGHT SIDE VIEW

(OPTIONAL) HIGH VOLTAGE

ELECTRICAL ENTRANCE

BACK VIEW

FREEBLOW

(OPTIONAL) LOW VOLTAGE

ELECTRICAL ENTRANCE

1 11/16"

3 3/4"

3 1/16"

3 3/8"

VENT

(OPTIONAL) HIGH

INTAKE

VOLTAGE

VENT

EXHAUST

ENTRANCE

ELECTRICAL

ACCESS

FOR FLUID

CONNECTION FOR

DORFC PUMP

APPLICATION

20"

5 1/4"

3"

5 15/16"

19"

1 15/16"

8"

6 7/8"

3 3/8"

33 9/16"

FLUID CONNECTION

POINTS FOR FACTORY

INSTALLED PUMP OPTIONS

3, 4, OR 5 (INLET ON LEFT,

OUTLET ON RIGHT AS VIEWED

FROM BACK OF UNIT)

ELECTRICAL ENTRANCE

SUPPLY AIR OPENING

ELECTRICAL ENTRANCE

FREEBLOW PLENUM)

(SHOWN WITHOUT

(OPTIONAL) LOW VOLTAGE

(OPTIONAL) HIGH VOLTAGE

TOP VIEW

LOW VOLTAGE

ELECTRICAL ENTRANCE

(DUCT SIZE)

(DUCT SIZE)

"A"

24 15/16"

3 3/16"

2 1/16" 2 15/16"

1 3/4"

6 3/4"

7/8"

20 3/8" 9 15/16"

2 7/16"

Manual 2100-532B

Page 7 of 46

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.

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.

FIGURE 2

REMOVAL OF UNIT FROM SKID

The unit will have to be turned sideways and removed

from the skid to fit through a 36" doorway. If the door

height allows, the unit can be slid sideways through the

door.

If the unit can not be slid through the door, then the unit

will have to be put on a cart and tipped down to roll

through the door. It is recommended that an appliance

cart be used with a strap to hold the unit on the cart.

The wheels of the unit must be locked. If the wheels

were allowed to roll, the unit could roll off the cart. The

unit should always be carted from the left side. This is

the side where the compressor is located. See Figure 3.

The blade of the appliance cart should be slid under the

wheels of the unit. The strap of the appliance cart

should be placed around the unit and strapped tightly.

Help will be required to tip the unit back onto the cart.

The unit can be leaned far enough back to be rolled

through the door. Be careful when setting the unit back

up to keep from damaging the unit.

UNIT REMOVAL FROM SKID

HANDLING UNIT AFTER 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.

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.

HOLD SKID DOWN

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

Manual 2100-532B

Page 8 of 46

REMOVAL OF WALL BRACKET FROM

SHIPPING LOCATION (UNITS WITH

BLANK OFF PLATE ONLY)

The wall brackets are attached to the back of the unit.

Remove and retain the wall brackets for use when

attaching the unit to the wall. In units equipped with a

ventilator a wall sleeve is required and these two wall

brackets are not included. A different style bracket is

supplied with the sleeve assembly.

GENERAL

The equipment covered in this manual is to be installed

by trained, experienced service and installation

technicians.

The unit is designed for use with or without duct work.

For use without duct work, Plenum Box QPB** is

recommended.

These instructions explain the recommended method to

install the water source self-contained unit and the

electrical wiring connections to the unit.

These instructions and any instructions packaged with

any separate equipment required to make up the entire

air conditioning system should be carefully read before

beginning the installation. Note particularly “Start

Procedure” and any tags and/or labels attached to the

equipment.

While these instructions are intended as a general

recommended guide, they do not supersede any national

and/or local codes in any way. Authorities having

jurisdiction should be consulted before the installation is

made. See Page 4 for information on codes and

standards.

Size of unit for a proposed installation should be based

on heat loss calculation made according to methods of

Air Conditioning Contractors of America (ACCA). The

air duct should be installed in accordance with the

Standards of the National Fire Protection Systems of

Other Than Residence Type, NFPA No. 90A, and

Residence Type Warm Air Heating and Air

Conditioning Systems, NFPA No. 90B. Where local

regulations are at a variance with instructions, installer

should adhere to local codes.

MINIMUM INSTALLATION HEIGHT

The minimum installation height of the unit with a Free

Blow Plenum is 8 ft. 9 in. This provides enough

clearance for the plenum to be removed. See Figure 5.

The minimum installation height for ducted applications

is 8 ft. 9 in. This provides enough clearance to install

the duct work. See Figure 6.

FIGURE 3

PROPER HANDLING OF UNIT

AFTER REMOVAL FROM SKID

APPLIANCE

CART

COMPRESSOR

Q-Tec UNIT

(RIGHT SIDE)

STRAP

Manual 2100-532B

Page 9 of 46

MIS-2739 A

AIR DIVIDER

ELIMINATOR

5"

WALL SLEEVE

MIST

TRIM PIECE

SUPPLY AIR

ROLLERS

BOTTOM

RETURN AIR

CIRCUIT BREAKER, ROTARY,

OR TOGGLE DISCONNECT

ELECTRICAL ACCESS

BLOW PLENUM BOX

(TOP-SIDE)

AND LOCKING COVER

LOW VOLTAGE

OPTIONAL FREE

ELECTRICAL ENTRANCE

(TOP-REAR-SIDE)

VENTILATION

PERMANENT

HIGH VOLTAGE

QW2S, QW3S - 42.000"

QW4S, QW5S - 48.000"

28 7/8"

33 7/8"

103 7/8"

84 1/4"

(X) 18 9/16"

35"

29 1/2"

33"

6 1/8"

17 9/16"

14" to 5"

FIGURE 4

INSTALLATION OF UNIT THROUGH WALL WITH WALL SLEEVE

Manual 2100-532B

Page 10 of 46

FIGURE 6

DUCTED APPLICATION

INSTALLATION HEIGHT

8 FT. - 9 IN.

MINIMUM REQUIRED

MIS-2740

FLOOR

8 FT. - 8 IN.

INSTALLATION HEIGHT

9 FT.

MINIMUM REQUIRED

UNIT HEIGHT

7 FT. - 6 IN.

MINIMUM

25 IN.

TO DUCT BOTTOM

2 IN. MINIMUM

FROM DUCT FLANGE

INSTALLATION HEIGHT

8 FT. - 9 IN.

MINIMUM REQUIRED

MINIMUM

12 IN.

MIS-2741

FLOOR

DUCT

FIXED CEILING

DUCT FLANGE

SUSPENDED CEILING

FIGURE 5

INSTALLATION WITH FREE BLOW PLENUM

Manual 2100-532B

Page 11 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.

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.

FIGURE 7

SUPPLY DUCT CONNECTIONS

OF QW UNIT

ROOM SIDE

DUCT FLANGE

PROVIDED WITH UNIT

SUPPLY DUCT TO

BE FIELD SUPPLIED

ATTACHMENT

SCREWS TO

BE FIELD

SUPPLIED

MIS-2742

Manual 2100-532B

Page 12 of 46

FIGURE 8A

CONDENSATE DRAIN

FIGURE 8B

OPTIONAL REAR DRAIN

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.

MIS-2743

FLOOR OPTION

DRAINING

EXTERNAL

DRAIN TUBE

DRAIN HOSE

FRONT VIEW WITH CONDENSER DOOR REMOVED

ALTERNATE

LOOP TO FORM

A "P" TRAP

Manual 2100-532B

Page 13 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)

WALL BRACKET

MIST ELIMINATOR SERVICE (Optional –

only used with one of the vent options)

A mist eliminator is supplied with the wall sleeve. The

mist eliminator is constructed of aluminum frame and

mesh. The mist eliminator is located in the top section

of the wall sleeve and can be removed from the inside of

the building without removing the unit from the wall.

This requires that the ventilation package must be

removed.

The steps necessary to remove each of the vent options

are listed following.

It is recommended that the mist eliminator be inspected

annually and serviced as required. The mist eliminator

can be inspected from the outside of the building by

looking through the outdoor grille. The mist eliminator

can be serviced from the outside. The outdoor grille

must be removed to do so.

The mist eliminator can be cleaned by washing with

soap and water. The excess water should be shaken off

the mist eliminator before it is reinstalled.

COMMERCIAL ROOM VENTILATOR OPTION

Before starting the removal make sure the power has

been turned off. The hinged return air grille panel must

be opened. The commercial room ventilator (CRV) can

be seen after the panel has been removed. The CRV

must be removed to gain access to the mist eliminator.

1. The two mounting screws in the front of the CRV

must be removed.

2. The power connectors for the CRV (located on the

right side of the unit) must be disconnected.

Squeeze the tabs on the sides of the connector and

pull straight out. Unplug both of the connectors.

3. Slide the CRV straight out of the unit.

The mist eliminator can be seen through the opening in

the back of the unit. The mist eliminator must be raised

up and the bottom can be pulled toward the front of the

unit and removed.

WALL (MAXIMUM

10” FOR REAR

DRAIN)

DRAIN LINE

COUPLINGS NOT

SHOWN BUT

RECOMMENDED

FOR EASE OF

REMOVABILITY

FOR SERVICE

SLEEVE

WATER

TRAP

UNIT

Manual 2100-532B

Page 14 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.

FIGURE 9

REMOVAL OF THE Q-TEC ENERGY RECOVERY VENTILATOR

3. Underneath the heat recovery cassette there is a

power connector for the lower blower assembly. To

disconnect this plug, the tabs on both sides of the

plug must be squeezed to release the plug. While

squeezing the tabs, pull the plug out of the socket.

4. The QERV is plugged into the unit on the right side

of the unit. Both of these plugs must be

disconnected to remove the QERV. Squeeze the

tabs on the sides of the connector and pull straight

out.

5. Slide the QERV assembly straight out of the unit

being careful not to let the cassette slide out of the

QERV.

The mist eliminator can be seen through the opening in

the back of the unit. The mist eliminator must be raised

up and the bottom can be pulled toward the front of the

unit and removed.

FRONT FILL

MOUNTING

SCREWS LOWER

BLOWER

ASSEMBLY

POWER

CONNECTOR

POWER

CONNECTORS

Manual 2100-532B

Page 15 of 46

INSTALLATION INSTRUCTIONS

MOUNTING THE UNIT

When installing a QW unit near an interior wall on the

left side, a minimum of 8 inches is required; 12 inches is

preferred.

When installing a QW unit near an interior wall on the

right side, a minimum of 12 inches is required as

additional space is required to connect the drain.

This clearance is required to allow for the attachment of

the unit to the wall mounting brackets and the side trim

pieces to the wall.

This unit is to be secured to the wall when there is not a

vent sleeve used with the wall mounting brackets

provided. (NOTE: Wall mounting brackets are only

shipped on units with no vent inside.) The unit itself,

the supply duct, and the free blow plenum are suitable

for “0” clearance to combustible material.

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

to the sleeve with bracket supplied with the

wall sleeve.

Following are the steps for mounting the QW units. For

reference see Figure 11.

1. Attach wall mounting bracket to the structure wall

with field supplied lag bolts. The fluid piping

connections are to be within the confines of this

bracket. See Figure 1 for cabinet openings and

location of fluid coil connection points.

2. Position the unit in front of the wall mounting

bracket.

3. Remove the locking screws from the wheels. Refer

to Figure 10.

4. Roll the unit up to the wall mounting bracket. The

unit must be level from side to side. If any

adjustments are necessary, shim up under the rollers

with sheets of steel or any substance that is not

affected by moisture.

5. Secure the unit to the wall bracket with provided #10

hex head sheet metal screws. There are prepunched

holes in the cabinet sides, and the bracket has slotted

holes to allow for some misalignment.

6. Position the bottom trim piece to the unit and attach

with provided screws (dark colored).

7. Position side trim pieces to the wall and attach with

field supplied screws. There are two long and two

short pieces supplied. The long pieces are to enclose

the gap behind the unit. The short pieces are to fill

the gap behind the cabinet extension or the free blow

plenum box. They may be cut to suit the ceiling

height or overlap the unit side trim. There is

sufficient length to trim up to a 10'2" ceiling.

FIGURE 10

REMOVING LOCKING SCREWS FROM

WHEELS

REMOVE SCREWS

FROM WHEELS

BEFORE ROLLING

INTO PLACE

Manual 2100-532B

Page 16 of 46

FIGURE 11

UNIT MOUNTING WITHOUT VENTILATION WALL SLEEVE

BRACKET

WALL MOUNTING

BASE TRIM

SIDE TRIM CUT

TO LENGTH

41"

ADJUSTABLE SIDE TRIM

EXTENSION KIT -ORDERED

SEPARATELY

SIDE TRIM

EXTENSION

MIS-2744 A

BASE TRIM

EXTENSION

Manual 2100-532B

Page 17 of 46

FIGURE 12

COMPONENT LOCATION

WIRE ENTRANCE

SIDE FIELD

TERMINAL BLOCK

REMOTE THERMOSTAT

INDOOR DUAL BLOWERS

CONTROL BOX/ CIRCUIT

BREAKER PANEL

MIS-2745

Manual 2100-532B

Page 18 of 46

WIRING – MAIN POWER

Refer to the unit rating plate and/or Table 2 for wire

sizing information and maximum fuse or “HACR Type”

circuit breaker size. Each unit is marked with a

“Minimum Circuit Ampacity”. This means that the

field wiring used must be sized to carry that amount of

current. Depending on the installed KW of electric heat,

there may be two field power circuits required. If this is

the case, the unit serial plate will so indicate. All

models are suitable only for connection with copper

wire. Each unit and/or wiring diagram will be marked

“Use Copper Conductors Only”. These instructions

must be adhered to. Refer to the National Electrical

Code (NEC) for complete current carrying capacity data

on the various insulation grades of wiring material. All

wiring must conform to NEC and all local codes.

The electrical data lists fuse and wire sizes (75°C copper)

for all models, including the most commonly used heater

sizes. Also shown are the number of field power circuits

required for the various models with heaters.

The unit rating plate lists a “Maximum Time Delay

Relay Fuse” or “HACR Type” circuit breaker that is to

be used with the equipment. The correct size must be

used for proper circuit protection, and also to assure that

there will be no nuisance tripping due to the momentary

high starting current of the compressor motor.

The disconnect access door on this unit may be locked

to prevent unauthorized access to the disconnect.

The field wiring connections are located behind the top

panel in the circuit breaker panel. The return air panel

must be removed first. This panel is equipped with a

door switch, which shuts the unit down when it is

removed. The filter rack must be removed next.

WIRING – LOW VOLTAGE WIRING

230/208V, 1 PHASE AND 3 PHASE EQUIPMENT

DUAL PRIMARY VOLTAGE TRANSFORMERS

All equipment leaves the factory wired on 240V tap.

For 208V operation, reconnect from 240V to 208V tap.

The acceptable operating voltage range for the 240 and

208V taps are as noted in Table 2.

The standard Climate Control Option X is a remote

thermostat connection terminal block. See Figure 14 for

wiring diagram. Compatible thermostats are listed in

Table 3.

The Climate Control Option D is an electronic,

programmable thermostat. The subbase of the

thermostat is factory wired to the front panel of the unit.

See Figure 15 for wiring diagram. Compatible for use

with Energy Recovery Ventilator or Economizer.

The Climate Control Option H is an electronic,

programmable thermostat and CO

2

controller. The

subbase of the thermostat and CO

2

controller are factory

wired to the front panel of the unit. See Figure 16 for

wiring diagram.

GENERAL

This unit is equipped with a variable speed ECM motor.

The motor is designed to maintain rated airflow up to

the maximum static allowed. It is important that the

blower motor plugs are not plugged in or unplugged

while the power is on. Failure to remove power prior

to unplugging or plugging in the motor could result in

motor failure.

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).

TABLE 2

OPERATING VOLTAGE RANGE

PATEGNAR

V042612-352

V802781-022

TABLE 3

WALL THERMOSTATS

tatsomrehTserutaeFtnanimoderP

060-3048 )544-0211(

taeHegats3;looCegats3 cinortcelEelbammargorP-noN/elbammargorP lanoitnevnoCroPH revoegnahclaunaMrootuA

CAUTION

Do not plug in or unplug blower motor con-

nectors while the power is on. Failure to do

so may result in motor failure.

Manual 2100-532B

Page 19 of 46

LOW VOLTAGE CONNECTIONS

The “R” terminal is the 24 VAC hot terminal and is

supplied through Pin #10 of Plug P2.

The “C” terminal is the 24 VAC common/grounded

terminal and feeds through Pin #11 of Plug P2.

The “G” terminal is the indoor blower input signal and

feeds through Pin #6 of Plug P2.

The “Y1” terminal is the compressor starting signal and

feeds through Pin #7 of Plug P2.

The “Y2” terminal is the compressor staging solenoid

signal and feeds through Pin #4 of Plug P2.

The “O” terminal is the reversing valve signal and

feeds through Pin #8 of Plug P2.

The “A” terminal is the ventilation demand signal and

outputs a signal for ventilation during occupied

programming conditions, and feeds through Pin #5 of

Plug P2.

The “W2” terminal is the electric heat signal and feeds

through Pin #9 of Plug P2.

The “W1/E” terminal is the emergency heat signal and

feeds through Pin #3 of Plug P2.

The “L” terminal is used as an input terminal when a

CS2000 infrared occupancy device is used. It feeds

through Pin #12 of Plug P2.

The “D” terminal is used only of dehumidification

models and feeds through Pin #1 of Plug P2.

LOW VOLTAGE CONNECTIONS FOR

DDC CONTROL

Fan Only Energize G

Ventilation Energize G, A (any mode of operation)

Part Load Cooling Energize G, Y1, O

Full Load Cooling Energize G, Y1, Y2, O

Part Load HP Heating Energize G, Y1

Full Load HP Heating Energize G, Y1, Y2

Electric Heat Energize G, W2

Dehumidification Energize G, D, O

FIGURE 13

BLOWER MOTOR LOW VOLTAGE

WIRE HARNESS PLUG

MIS-1285

Manual 2100-532B

Page 20 of 46

10

6

5

4

3

2

1

1

2

3

4

5

6

7

8

9

11

12

Blue

Pink

Purple

Purple/White

Yellow

Yellow

W1/E

L

G

L

Part #8403-056

4115-102 A

CO2 Controller

24VAC

O/B

Out

Part #8403-060

C

Y2

A

Y1

R

G

Analog

Controller Terminal Strip

E

W2

O

C

Y2

A

W2

Y1

R

Temp. and Humidity Low Voltage

D/YO

Orange

Orange

Orange

Yellow

Green

Green

Brown/White

Brown

Brown

Brown

Red/Yellow

Red/White

Red

PLUG #2

PLUG #1

Red

Black/White

Black

Black

Terminal

Strip

FIGURE 14

REMOTE THERMOSTAT WIRING DIAGRAM

“X” OPTION

Manual 2100-532B

Page 21 of 46

FIGURE 15

REMOTE THERMOSTAT WIRING DIAGRAM

“D” THERMOSTAT OPTION

Blue

Pink

Purple

L

O/B

W1/E

Y1Part #8403-060

C

Y2

A

W2

G

R

Temp. and Humidity

Controller

D/YO

Orange

Yellow

Brown/White

Brown

9

8

11

10

PLUG #2

Red/Yellow

Red/White

1

2

3

4

5

6

7

12

Black/White

Purple/White

4115-100 A

Manual 2100-532B

Page 22 of 46

10

6

5

4

3

2

1

1

2

3

4

5

6

7

8

9

11

12

Blue

Pink

Purple

Yellow

Yellow

R

Y1

O/B

Part #8403-056 24VAC

G

W1/E

L

CO2 Controller

Out

C

Y2

A

W2

Analog

Temp. and Humidity

Controller

Part #8403-060

Orange

Orange

Orange

Yellow

Green

Green

Brown

Brown

Brown/White

Brown

Red/White

PLUG #1

Red/Yellow

PLUG #2

Red Red

Black

Black/White

Black

D/YO Purple/White

4115-101 A

FIGURE 16

REMOTE THERMOSTAT PLUG CO

2

VENT CONTROL WIRING DIAGRAM

“H” THERMOSTAT OPTION

Manual 2100-532B

Page 23 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 2100-532B

Page 24 of 46

OPTIONAL CFM

All models covered by this Manual are factory set to

operate at rated CFM levels as shown in Table 4. Rated

CFM is required for ducted applications for maximum

performance ratings.

For free blow applications where Full Load Rated CFM

is undesirable due to sound levels, there is an optional

CFM that can be obtained (-10%). This CFM level will

reduce the system capacity performance by

approximately 2% at the same energy efficiency.

For Full Load Optional CFM:

1. Disconnect all power to the unit. Failure to do so

may result in damage to the motor.

2. Open hinged return air grille service panel.

3. Open control panel cover.

4. Locate low voltage terminal strip and purple wire

with white trace that connects to terminal “Y2”.

Disconnect this wire from terminal “Y2” and tape

off end.

5. Reverse steps to reassemble.

IMPORTANT INSTALLER NOTE

For improved start up performance, wash the indoor coil

with dishwashing detergent.

PHASE MONITOR

All units with three phase scroll compressors are

equipped with a three phase line monitor to prevent

compressor damage due to phase reversal.

The phase monitor in this unit is equipped with two

LEDs. If the Y signal is present at the phase monitor

and phases are correct, the green LED will light and

contactor will energize. If phases are reversed, the red

fault LED will be lit and compressor operation is

inhibited.

If a fault condition occurs, reverse two of the supply

leads to the unit. Do not reverse any of the unit factory

wires as damage may occur.

SERVICE HINTS

1. Caution user to maintain clean air filters at all times.

Also, not to needlessly close off supply air registers.

This may reduce airflow through the system which

shortens equipment service life as well as increasing

operating costs and noise levels.

2. Check all power fuses or circuit breakers to be sure

that they are the correct rating.

3. The heat pump wall thermostats perform multiple

functions. Be sure that all function switches are

correctly set for the desired operating mode before

trying to diagnose any reported service problems.

SEQUENCE OF OPERATION

COOLING – A 24V solenoid coil on the reversing

valve controls the cooling cycle operation. There are

two different thermostat options. 1.) Allows for “Auto”

changeover from cycle to cycle. 2.) The other (Manual

changeover). The Auto changeover mode will cause the

reversing valve solenoid to cycle with each cooling call

and may cause a “swooshing sound” with refrigerant

equalization at the end of each cycle.

On a call for Part Load Cooling by the thermostat, it

completes a circuit from “R” to “Y1”, “O” and “G” for part

load cooling. “Y1” starts the compressor, “O” energizes

the reversing valve and “G” starts the indoor blower.

On a call for Full Load Cooling by the thermostat, it

completes the same as Part Load Cooling above, but also

includes a signal to “Y2”. Signal “Y2” energizes the staging

solenoid on the side of the compressor and the signal also

goes to the indoor blower to ramp-up the airflow.

HEATING – On a call for Part Load Heating by the

thermostat, it completes a circuit from “R” to “Y1” and

“G”. “Y1” starts the compressor and “G” starts the

indoor blower.

On a call for Full Load Heating by the thermostat, it

completes the same as Part Load Heating above, but also

includes a signal to “Y2”. Signal “Y2” energizes the staging

solenoid on the side of the compressor and the signal also

goes to the indoor blower to ramp-up the airflow.

DELAY ON MAKE TIMING

setunim50

.

)sdnoces03(BOD= MODsdnoces321

setunim0.

1

)sdnoces06(BOD= MODsdnoces621

setunim0.2)sdnoceS021(BOD= MODsdnoces231

setunim0.3)sdnoces081(BOD= MODsdnoces831

setunim0.4)sdnoces042(BOD= MO

Dsdnoces441

setunim0.5)sdnoces003(BOD= MODsdnoces051

Manual 2100-532B

Page 25 of 46

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

2Rated CFM for ducted applications – required for maximum performance rating. To obtain full CFM on

models QW3S1, QW4S1 and QW5S1, locate pink wire that is secured to purple wire at low voltage terminal

strip in the control box, and attach it to the “Y2” terminal along with the purple wire.

3Optional 2nd Stage CFM – the unit is shipped from the factory set to operate at the optional CFM level shown.

This provides lower operating sound levels for non-ducted, free discharge applications. This reduces

system capacity performance by approximately 2% at the same energy efficiency.

4Continuous CFM the total airflow being circulated during continuous blower operation.

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.

TABLE 4

INDOOR BLOWER PERFORMANCE

LEDOM DETAR PSE

1

PSE.XAM

4

SUOUNITNOC WOLFRIA EGATSts1

3

LANOITPO EGATSdn2 EGATSdn2

1S2WQ0.05.00080080090001

1S3WQ0.05.000800905010511

1S4WQ0.05.0009051152210531

1S6WQ0.05.0009052100310541

PRESSURE SERVICE PORTS

High and low pressure service ports are installed on all

units so that the system operating pressures can be

observed. Pressure charts are located on the backside of

the units lower service door, as well as later in this

Manual (Table 5). It is imperative to match the correct

pressure chart to the unit by model number. All upper

service doors must be attached to obtain proper reading.

The service ports are in the lower compressor section on

the tubing adjacent to the compressor.

PIPING ACCESS TO UNIT

Water piping to and from the coaxial water coil is

intended to enter/exit the unit through the rectangular

hole (See Figures 1, 8A, 17 and 18). The connections on

the water coil are a double O-ring with a retainer nut

that secures it in place.

Various double O-ring fittings are available so you may

then connect to the coaxial coil with various methods

and materials. The methods include 1" barbed fittings

(straight and 90°), 1" MPT (straight and 90°), and 1¼"

hot fusion fitting with P/T fitting). (See Table 6.)

Note: All double O-ring fittings require “hand

tightening only”. Do not use a wrench or pliers as

retainer nut can be damaged with excessive force.

Avoid cross-threading the nut.

Manual 2100-532B

Page 26 of 46

FIGURE 17

FLUID CONNECTIONS ON UNIT WITH VENTILATION WALL SLEEVE

23 1/2"

33"

8 1/2"

66 1/2"

TO UNIT SPEC. SHEET FOR

FROM CEILING

SIDE TRIM PEICES

FLUID ACCESS

8" TO 14" EXTERIOR WALL

PROPER COLOR

(SHIPPED WITH UNIT)

CEILING

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

FLUID ACCESS FROM

SLEEVE

TOP OF UNIT

SLEEVE

FLUID ACCESS

3" x 8"

FLUID ACCESS

REAR OF UNIT

BACK OF UNIT

MIS-2746

FROM FLOOR

35" x 29 1/2"

FLOOR

FROM EACH SIDE

FLUID ACCESS

WALL OPENING

FROM EACH SIDE

OPENING IN

MOUNTING BRACKETS

(SHIPPED WITH UNIT)

REF.

34"

29"

Manual 2100-532B

Page 27 of 46

FIGURE 18

FLUID CONNECTIONS ON UNIT WITHOUT VENTILATION WALL SLEEVE

23 1/2"

8 1/2"

66 1/2"

4"

(LEFT BRACKET

REMOVED FOR

FLOOR

FLUID ACCESS FROM FLOOR

FLUID ACCESS

FROM TOP

CLARITY)

WALL BRACKET

OPENING IN

REAR OF UNIT

3" x 8"

BACK OF UNIT

MIS-2747

WATER LINES

WALL BRACKET

TOP VIEW

WALL BRACKET

WALL LOCATION

Manual 2100-532B

Page 28 of 46

TABLE 5

PRESSURE TABLE

S2WQS3WQS4WQS6WQ

retawhserfrofMPGderiuqeretarwolF 5679

lonahteM%51rofMPGderiuqeretarwolF 789 11

poolreliob/rewotgnilooc,MPGderiuqeretarwolF 1.66.83.117.31

FLOW RATE FOR VARIOUS FLUIDS

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

ledoM riAnruteR erutarepmeT erusserP

F°lioCretaWgniretnEerutarepmeTdiulF—GNILOOCDAOLLLUF

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

F

°011

S2WQ

BD°57 BW°26 ediSwoL ediShgiH 601 131 801 641 111 161 411 671 711 191 021 602 221 122 521 632 821 252 031 272 231 392 431 313 631 433 831 553 041 573 241 693 441 714

BD°08 BW°76 ediSwoL ediShgiH 311 431 611 051 911 561 221 181 521 691 821 212 131 722 431 342 731 852 931 972 141 003 441 223 641 343 841 463 051 583 251 604 451 724

BD°58 BW°27 ediSwoL ediShgiH 121 931 521 551 821 171 131 781 431 302 831 912 141 532 441 152 741 762 051 982 251 113 451 333 751 553 951 773 161 893 461 024 661 244

S3WQ

BD°57 BW°26 ediSwoL ediShgiH 38 231 78 841 19 561 49 181 89 891 201 512 601 132 901 842 311 462 611 582 811 603 121 723 321 743 621 863 821 983 131 014 331 134

BD°08 BW°76 ediSwoL ediShgiH 98 531 39 251 79 961 101 681 501 302 901 022 311 732 711 452 121 172 421 292 621 413 921 533 231 653 431 873 731 993 041 024 241 244

BD°58 BW°27 ediSwoL ediShgiH 69 041 001 751 401 571 901 391 311 012 711 822 121 542 621 362 031 082 331 303 631 523 931 743 241 963 441 193 741 314 051 534 351 754

S4WQ

BD°57 BW°26 ediSwoL ediShgiH 19 641 49 261 79 771 101 391 401 802 701 422 011 932 411 552 711 072 911 192 121 213 221 333 421 453 621 573 821 693 031 714 231 834

BD°08 BW°76 ediSwoL ediShgiH 79 051 101 661 401 281 801 891 111 412 511 922 811 542 221 162 521 772 721 992 921 023 131 243 331 363 531 583 731 604 931 824 141 944

BD°58 BW°27 ediSwoL ediShgiH 401 551 801 271 211 881 611 502 911 122 321 732 721 452 131 072 431 782 731 903 931 133 141 353 341 673 541 893 741 024 941 244 251 564

S5WQ

BD°57 BW°26 ediSwoL ediShgiH 29 741 49 361 69 871 89 491 101 012 301 522 501 142 701 652 901 272 111 392 211 313 411 433 511 553 611 573 811 693 911 614 121 734

BD°08 BW°76 ediSwoL ediShgiH 89 151 001 761 301 381 501 991 801 512 011 132 211 742 511 362 711 972 911 003 021 123 221 343 321 463 521 583 621 604 821 724 921 844

BD°58 BW°27 ediSwoL ediShgiH 501 651 801 371 011 981 311 602 611 322 811 932 121 652 321 272 621 982 721 113 921 333 131 453 231 673 431 893 531 024 731 244 931 464

ledoM riAnruteR erutarepmeT erusserP

F°lioCretaWgniretnEerutarepmeTdiulF—GNITAEHDAOLLLUF

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

S2WQ

BD°07 ediSwoL ediShgiH 64 262 35 072 06 972 76 782 47 692 18 403 88 313 59 123 201 033 901 833 811 743 821 553 731 463 641 273 551 183 561 983 471 893

S3WQ

BD°07 ediSwoL ediShgiH 04 082 74 092 55 003 26 013 07 023 77 033 58 043 29 053 001 063 701 073 411 083 221 983 921 993 631 804 341 814 151 724 851 734

S4WQ

BD°07 ediSwoL ediShgiH 63 092 34 892 15 703 85 513 66 423 37 233 18 143 88 943 69 853 301 663 211 873 221 983 131 104 041 214 941 424 951 534 861 744

S5WQ

BD°07 ediSwoL ediShgiH 73 882 44 003 15 213 85 423 56 533 27 743 97 953 68 173 39 283 001 493 901 804 911 124 821 534 731 844 641 264 651 574 561 984

ledoM riAnruteR erutarepmeT erusserP

F°lioCretaWgniretnEerutarepmeTdiulF—GNILOOCDAOLTRAP

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

F

°011

S2WQ

BD°57 BW°26 ediSwoL ediShgiH 501 021 901 531 311 051 711 561 121 971 521 491 921 902 331 422 731 932 931 952 141 972 341 992 441 913 641 933 841 953 941 973 151 993

BD°08 BW°76 ediSwoL ediShgiH 211 321 611 831 121 451 521 961 031 481 431 991 831 512 341 032 741 542 941 662 151 682 351 703 451 723 651 843 851 863 061 983 261 904

BD°58 BW°27 ediSwoL ediShgiH 021 721 521 341 031 951 531 571 931 091 441 602 941 222 351 832 851 452 061 572 261 692 461 713 661 833 861 063 071 183 271 204 471 324

S3WQ

BD°57 BW°26 ediSwoL ediShgiH 89 421 201 931 601 451 011 961 411 481 711 991 121 512 521 032 921 542 031 562 131 682 231 603 331 723 431 743 531 863 631 883 731 904

BD°08 BW°76 ediSwoL ediShgiH 501 721 901 341 311 851 711 471 221 981 621 502 031 022 431 632 831 152 931 272 041 392 141 413 241 533 341 653 441 773 541 893 641 914

BD°58 BW°27 ediSwoL ediShgiH 311 131 711 741 221 461 621 081 131 691 531 212 931 822 441 442 841 062 941 282 151 303 251 523 351 743 451 863 551 093 651 214 751 434

S4WQ

BD°57 BW°26 ediSwoL ediShgiH 401 921 701 441 111 951 511 471 811 091 221 502 621 022 921 532 331 152 431 172 431 292 531 213 631 233 731 353 731 373 831 493 931 414

BD°08 BW°76 ediSwoL ediShgiH 111 231 511 841 911 361 321 971 721 591 031 012 431 622 831 142 241 752 341 872 441 992 541 023 541 143 641 263 741 383 841 404 941 524

BD°58 BW°27 ediSwoL ediShgiH 911 731 321 351 821 961 231 581 631 102 041 712 441 432 841 052 351 662 451 882 451 903 551 133 651 353 751 573 851 693 951 814 061 044

S5WQ

BD°57 BW°26 ediSwoL ediShgiH 801 331 011 841 211 361 411 871 511 491 711 902 911 422 121 932 221 452 421 572 521 592 721 513 821 533 921 553 131 573 231 693 431 614

BD°08 BW°76 ediSwoL ediShgiH 611 631 811 251 021 761 221 381 421 991 521 412 721 032 921 542 131 162 331 282 431 203 631 323 731 443 931 463 041 583 241 604 341 624

BD°58 BW°27 ediSwoL ediShgiH 521 141 721 751 921 371 131 981 331 502 531 222 731 832 931 452 141 072 241 292 441 313 641 433 741 653 941 773 151 893 251 024 451 144

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

S2WQ

BD°07 ediSwoL ediShgiH 51 232 62 042 73 842 94 652 06 462 17 272 28 082 49 882 501 692 611 403 521 113 531 813 441 523 351 233 261 933 271 643 181 353

S3WQ

BD°07 ediSwoL ediShgiH 83 052 74 062 65 072 56 082 37 092 28 003 19 013 001 023 801 033 711 043 721 053 731 163 741 173 751 183 761 193 771 204 781 214

S4WQ

BD°07 ediSwoL ediShgiH 93 262 74 962 55 772 46 482 27 292 08 992 88 703 79 413 501 223 311 923 221 833 131 743 041 553 941 463 851 373 761 283 671 093

S5WQ

BD°07 ediSwoL ediShgiH 34 172 05 082 85 092 56 992 37 903 08 813 88 823 59 733 301 743 011 653 021 763 921 873 931 883 841 993 851 014 761 124 771 134

Manual 2100-532B

Page 29 of 46

TABLE 6

OPTIONAL ACCESSORIES

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:stiKnoisnetxEmirTediS

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6-V-XTSQ

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ll

A

8-V-XTSQ

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ll

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01-V-XTSQ

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ll

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21-V-XTSQ

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ll

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V-84BPQ

lyniVmunitalP4-84BPQtniaPyarGX-84BPQtniaPegieBellirgnoitcelfedyaw-4,ylppuStnorF S5WQ,S4WQ

V-84SBPQ

lyniVmunitalP4-84SBPQtniaPyarGX-84SBPQtniaPegieB .edishcaenoellirgnoitcefedyaw-2sulp,84BPQsaemaS

:sgnilieCotsexoBmunelPgnihsiniFrofsmetsySlliFpoT ytilibitapmoCtinU

V-9-24XBPQ

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V-01-24XBPQ

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V-9-84XBPQ

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V-01-84XBPQ

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V-A51XCQ

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V-F-84WHBPQ

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V-D-24WHBPQ

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V-D-84WHBPQ

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Manual 2100-532B

Page 30 of 46

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

FIGURE 19

CIRCULATION SYSTEM

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.

CLOSED LOOP

(Earth Coupled Ground Loop Applications)

OUT

MIS-2748

for Model No.)

(See Spec Sheet

FLEXIBLE HOSE

PIPE FROM

GROUND LOOP

PUMP MODULE

PIPE TO

GROUND

LOOP

WATER

Manual 2100-532B

Page 31 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

10

120

110

100

90

80

70

60

50

40

30

20

0

Pete's test plug

Retaining cap, hand tighten only

Test plug cap

Barbed 90° adapter

MIS-2622

with guage adaptor

Dial face pressure guage

Thermometer

Manual 2100-532B

Page 32 of 46

0

10

20

30

40

50

60

70

0 5 10 15 20 25 30 35

Flow (GPM)

Head (Feet)

FIGURE 22

PERFORMANCE MODEL DORFC-2 LOOP PUMP MODULE

0

5

10

15

20

25

30

35

0 5 10 15 20 25 30 35

Flow (GPM)

Head (Feet)

FIGURE 21

PERFORMANCE MODEL DORFC-1 LOOP PUMP MODULE

Manual 2100-532B

Page 33 of 46

6

10

11

8

9

12

7

MIS-2749

OPEN LOOP

(Well System Applications)

WATER CONNECTIONS

It is very important that an adequate supply of clean,

noncorrosive water at the proper pressure be provided

before the installation is made. Insufficient water, in

the heating mode for example, will cause the low

pressure switch to trip, shutting down the heat pump. In

assessing the capacity of the water system, it is

advisable that the complete water system be evaluated

to prevent possible lack of water or water pressure at

various household fixtures whenever the heat pump

turns on. All plumbing to and from the unit is to be

installed in accordance with local plumbing codes. The

use of plastic pipe, where permissible, is recommended

to prevent electrolytic corrosion of the water pipe.

Because of the relatively cold temperatures encountered

with well water, it is strongly recommended that the

water lines connecting the unit be insulated to prevent

water droplets form condensing on the pipe surface.

Refer to piping, Figure 23. Slow closing

Solenoid

Valve (6)

with a 24V coil provides on/off control of the

water flow to the unit. Refer to the wiring diagram for

correct hookup of the valve solenoid coil.

Constant Flow Valve (7)

provides correct flow of

water to the unit regardless of variations in water

pressure. Observe the water flow direction indicated by

the arrow on the side of the valve body. Table 7 is a

table showing the flow rate of each valve. Two

constant flow rate valves may be installed in parallel to

increase the flow. For example, when a 8603-007 (6

GPM) and 8603-011 (5 GPM) are installed in parallel

the total flow will be 11 GPM.

FIGURE 23

PIPING DIAGRAM

TABLE 7

CONSTANT FLOW VALVES

1The pressure drop through the constant flow valve will

vary depending on the available pressure ahead of the

valve. Unless minimum of 15 psig is available

immediately ahead of the valve, no water will flow.

.oNtraP elbaliavA.niM GISPerusserP etaRwolF MPG

-VFC5 5115

6-VFC5116

7-VFC5117

9-VFC5119

Strainer (5)

installed upstream of

constant flow valve

(7)

to collect foreign material which would clog the

flow valve orifice.

Figure 22 shows the use of

shutoff valves (9)

and

(11)

,

on the in and out water lines to permit isolation of the

unit from the plumbing system should future service

work require this. Globe valves should not be used as

shutoff valves because of the excessive pressure drop

inherent in the valve design. Instead use gate or ball

valves as shut-offs so as to minimize pressure drop.

Drain cock (8)

and

(10)

, and tees have been included

to permit acid cleaning the refrigerant-to-water coil

should such cleaning be required. See

WATER

CORROSION

section.

Drain cock (12)

provides access to the system to check

water flow through the constant flow valve to insure

adequate water flow through the unit. A water meter is

used to check the water flow rate.

Manual 2100-532B

Page 34 of 46

WELL PUMP SIZING

Strictly speaking, sizing the well pump is the

responsibility of the well drilling contractor. It is

important, however, that the HVAC contractor be

familiar with the factors that determine what size pump

will be required. Rule of thumb estimates will

invariably lead to under or oversized well pumps.

Undersizing the pump will result in inadequate water to

the whole plumbing system but with especially bad

results to the heat pump – NO HEAT / NO COOL calls

will result. Oversized pumps will short cycle and could

cause premature pump motor or switch failures.

The well pump must be capable of supplying enough

water and at an adequate pressure to meet competing

demands of water fixtures. The well pump must be

sized in such a way that three requirements are met:

1. Adequate flow rate in GPM.

2. Adequate pressure at the fixture.

3. Able to meet the above from the depth of the

well-feet of lift.

The pressure requirements put on the pump are directly

affected by the diameter of pipe being used, as well as,

by the water flow rate through the pipe. The work sheet

included in manual 2110-078 should guarantee that the

well pump has enough capacity. It should also ensure

that the piping is not undersized which would create too

much pressure due to friction loss. High pressure losses

due to undersized pipe will reduce efficiency and

require larger pumps and could also create water noise

problems.

SYSTEM START UP PROCEDURE FOR

OPEN LOOP APPLICATIONS

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

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

AUTO.

3. Move main power disconnect to ON. Except as

required for safety while servicing – do not open the

unit disconnect switch.

4. Check system airflow for obstructions.

A.

Move thermostat fan switch to ON. Blower runs.

B. Be sure all registers and grilles are open.

C. Move thermostat fan switch to AUTO. Blower

should stop.

5. Fully open the manual inlet and outlet valves.

6. Check water flow.

A. Connect a water flow meter to the drain cock

between the constant flow valve and the

solenoid valve. Run a hose from the flow meter

to a drain or sink. Open the drain cock.

B. Check the water flow rate through constant flow

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

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

remove the water flow meter. The unit is now

ready to start.

7. Start the unit in cooling mode by moving the

thermostat switch to cool. Fan should be set for

AUTO.

A. Check to see the solenoid valve opened.

8. Check the system refrigerant pressures against the

cooling refrigerant pressure table in the installation

manual for rated water flow and entering water

temperatures. If the refrigerant pressures do not

match, check for airflow problem that refrigeration

system problem.

9. Switch the unit to the heat mode by moving the

thermostat switch to heat. Fan should be set for

AUTO.

A. Check to see the solenoid valve opened again.

10. Check the refrigerant system pressures against the

heating refrigerant pressure table in installation

manual. Once again, if they do not match, check for

air flow problems and then refrigeration system

problems.

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

A. Check for possible refrigerant loss.

B. Recover all remaining refrigerant from unit and

repair leak.

C. Evacuate unit down to 29 inches of vacuum.

D. Recharge the unit with refrigerant by weight.

This is the only way to insure proper charge.

Manual 2100-532B

Page 35 of 46

WATER CORROSION

Two concerns will immediately come to light when

considering a water source heat pump, whether for

ground water or for a closed loop application: Will

there be enough water? And, how will the water quality

affect the system?

Water quantity is an important consideration and one

which is easily determined. The well driller must

perform a pump down test on the well according to

methods described by the Nation Well Water

Association. This test, if performed correctly, will

provide information on the rate of low and on the

capacity of the well. It is important to consider the

overall capacity of the well when thinking about a water

source heat pump because the heat pump may be

required to run for extended periods of time.

The second concern, about water quality, is equally

important. Generally speaking, if the water is not

offensive for drinking purposes, it should pose no

problem for the heat pump. The well driller or local

water softening company can perform tests which will

determine the chemical properties of the well water.

Water quality problems will show up in the heat pump

in one of more of the following ways:

1. Decrease in water flow through the unit.

2. Decreased heat transfer of the water coil (entering to

leaving water temperature difference is less).

There are four main water quality problems associated

with ground water. These are:

1. Biological Growth. This is the growth of

microscopic organisms in the water and will show

up as a slimy deposit throughout the water system.

Shock treatment of the well is usually required and

this is best left up to the well driller. The treatment

consists of injecting chlorine into the well casing

and flushing the system until all growth is removed.

2. Suspended Particles in the Water. Filtering

will usually remove most suspended particles (fine

sand, small gravel) from the water. The problem

with suspended particles in the water is that it will

erode metal parts, pumps, heat transfer coils, etc. So

long as the filter is cleaned and periodically

maintained, suspended particles should pose no

serious problem. Consult with your well driller.

3. Corrosion of Metal. Corrosion of metal parts

results from either highly corrosive water (acid

water, generally not the case with ground water) of

galvanic reaction between dissimilar metals in the

presence of water. By using plastic plumbing or

dielectric unions galvanic reaction is eliminated.

The use of corrosion resistant materials (such as the

Cupronickel coil) through the water system will

reduce corrosion problems significantly.

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

formation of scale by ground water is by far the most

common. Usually this scale is due to the formation

of calcium carbonate, but magnesium carbonate or

calcium sulfate may also be present. Carbon dioxide

gas (CO

2

), the carbonate of calcium and magnesium

carbonate, is very soluble in water. It will remain

dissolved in the water until some outside factor

upsets the balance. This outside influence may be a

large change in water temperature or pressure.

When this happens, enough carbon dioxide gas

combines with dissolved calcium or magnesium in

the water and falls out of solution until a new

balance is reached. The change in temperature that

this heat pump produces is usually not high enough

to cause the dissolved gas to fall out of solution.

Likewise, if pressure drops are kept to a reasonable

level, no precipitation of carbon dioxide should

occur.

REMEDIES OF WATER PROBLEMS

Water Treatment. Water treatment can usually be

economically justified for close loop systems.

However, because of the large amounts of water

involved with a ground water heat pump, water

treatment is generally too expensive.

Acid Cleaning the Water Coil or Heat Pump

Recovery Unit. If scaling of the coil is strongly

suspected, the coil can be cleaned up with a solution of

Phosphoric Acid (food grade acid). Follow the

manufacturer’s directions for mixing, use, etc. Refer to

the “Cleaning Water Coil”, Figure 24. The acid

solution can be introduced into the heat pump coil

through the hose bib A. Be sure the isolation valves are

closed to prevent contamination of the rest of the system

by the coil. The acid should be pumped from a bucket

into the hose bib and returned to the bucket through the

other hose bib B. Follow the manufacturer’s directions

for the product used as to how long the solution is to be

circulated, but it is usually circulated for a period of

several hours.

Manual 2100-532B

Page 36 of 46

MIS-2750

Hose Bib (A)

Hose Bib (B)

Pump

Isolation Valve

TO WATER COIL

FROM WATER COIL

LAKE AND POND INSTALLATIONS

Lakes and ponds can provide a low cost source of water

for heating and cooling with a ground water heat pump.

Direct usage of the water without some filtration is not

recommended as algae and turbid water can foul the

water to freon heat exchanger. Instead, there have been

very good results using a dry well dug next to the water

line or edge. Normal procedure in installing a dry well

is to backhoe a 15 to 20 foot hole adjacent to the body of

water (set backhoe as close to the water’s edge as

possible). Once excavated, a perforated plastic casing

should be installed with gravel backfill placed around

the casing. The gravel bed should provide adequate

filtration of the water to allow good performance of the

ground water heat pump.

The following is a list of recommendations to follow

when installing this type of system (Refer to Figure 25):

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

square feet) in surface area for each 50,000 BTUs of

ground water heat pump capacity or have 2 times the

cubic feet size of the dwelling that you are trying to

heat (includes basement if heated).

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

there should be an area where the water depth is at

least 12 to 15 feet deep.

C. If possible, use a submersible pump suspended in the

dry well casing. Jet pumps and other types of

suction pumps normally consume more electrical

energy than similarly sized submersible pumps.

Pipe the unit the same as a water well system.

D. Size the pump to provide necessary GPM for the

ground water heat pump. A 12 GPM or greater

water flow rate is required on all modes when used

on this type system.

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

heated adjacent to the ground water heat pump. A

pressure switch should be installed at the tank for

pump control.

F. All plumbing should be carefully sized to

compensate for friction losses, etc., particularly if

the pond or lake is over 200 feet from the dwelling

to be heated or cooled.

G. Keep all water lines below low water level and

below the frost line.

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

corrugated) for water return to the lake or pond.

I. The drain line discharge should be located at least

100 feet from the dry well location.

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

inches per 10 feet of run to provide complete

drainage of the line when the ground water heat

pump is not operating. This gradient should also

help prevent freezing of the discharge where the

pipe terminates above the frost line.

K. Locate the discharge high enough above high water

level so the water will not back up and freeze inside

the drain pipe.

L. Where the local conditions prevent the use of a

gravity drainage system to a lake or pond, you can

instead run standard plastic piping out into the pond

below the frost and low water level.

FIGURE 24

CLEANING WATER COIL

Manual 2100-532B

Page 37 of 46

FIGURE 25

WATER WELL SYSTEM

12' to 15'

LAKE

or

POND

WATER LEVEL

GRAVEL FILL

WELL CAP

ELECTRICAL LINE

PITLESS ADAPTER

TO PRESSURE

TANK

SUBMERSIBLE

PUMP

PERFORATED

PLASTIC CASING

DROP PIPE

WATER SUPPLY

LINE

15' to 20'

DEEP

Manual 2100-532B

Page 38 of 46

For complete information on water well systems and

lake and pond applications, refer to Manual 2100-078

available from your distributor.

COOLING TOWER / BOILER

APPLICATION

The cooling tower and boiler water loop temperature is

usually maintained between 50°F to 100°F to assure

adequate cooling and heating performance.

In the cooling mode, heat is rejected from the unit into

the source water loop. A cooling tower provides

evaporative cooling to the loop water thus maintaining a

constant supply temperature to the unit. When utilizing

open cooling towers chemical water treatment is

mandatory to ensure the water is free from corrosive

minerals.

It is imperative that all air be eliminated from the source

closed loop side of the heat exchanger to insure against

fouling.

TABLE 8

WATER FLOW AND PRESSURE DROP

MPG

&1S2WQ 1S3WQ1S4WQ1S6WQ

GISP.dH.tFGISP.dH.tFGISP

.

dH.tF

31.032.0

45.051.19.080.2

52.177.24.132.3

67.129.33.213.5

73.213.52.383.7216.4

81.351.71.464.95.277.5

91.464.91.577.112.383.7

01 1.670.419.300.9

11 1.783.617.448.01

21 2.829.815.596.21

31 4.996.124.667.41

41 6.0154.423.748.61

51 1.896.81

61 967.02

71 9.948.22

81

WARNING

Thin ice may result in the vicinity of the

discharge line.

CAUTION

Water piping exposed to extreme low ambient

temperatures are subject to freezing.

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.

Units are equipped with double O-ring (female pipe

thread) fittings. Consult the specification sheets for sizes.

Teflon tape sealer should be used when connection to the

unit to insure against leaks and possible condenser

fouling. Do not overtighten the connections. Flexible

hoses should be used between the unit and the rigid

system to avoid possible vibration. Ball valves should be

installed in the supply and return lines for unit isolation

and unit water flow rate balancing.

Pressure / temperature ports are recommended in both

supply and return lines for system flow balancing. Water

flow can be accurately set by measuring the refrigerant to

water heat exchangers water side pressure drop. See

Table 8 for water flow and pressure drop information.

Manual 2100-532B

Page 39 of 46

FIGURE 26

WATER SOURCE HEAT PUMP

Manual 2100-532B

Page 40 of 46

FIGURE 27

WATER SOURCE HEAT PUMP

Manual 2100-532B

Page 41 of 46

SERVICE

UNBRAZING SYSTEM COMPONENTS

If the refrigerant charge is removed from a scroll

equipped unit by bleeding the high side only, it is

sometimes possible for the scrolls to seal, preventing

pressure equalization through the compressor. This may

leave low side shell and suction line tubing pressurized.

If the brazing torch is then applied to the low side while

the low side shell and suction line contains pressure, the

pressurized refrigerant and oil mixture could ignite

when it escapes and contacts the brazing flame. To

prevent this occurrence, it is important to check both the

high and low side with manifold gauges before

unbrazing.

WARNING

Both the high and low side of the scroll

compressor must be checked with manifold

gauges before unbrazing system

components. Failure to do so could cause

pressurized refrigerant and oil mixture to

ignite if it escapes and contacts the brazing

flame causing property damage, bodily harm

or death.

Manual 2100-532B

Page 42 of 46

TROUBLESHOOTING GE ECM™ MOTORS

CAUTION:

Disconnect power from unit before removing or replacing

connectors, or servicing motor. To avoid electric shock from

the motor’s capacitors, disconnect power and wait at least 5

minutes before opening motor.

Symptom Cause/Procedure

Motor rocks slightly • This is normal start-up for ECM

when starting

Motor won’t start • Check blower turns by hand

• No movement • Check power at motor

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

• Check low voltage connections

(G, Y, W, R, C) at motor

• Check for unseated pins in connectors on

motor harness

• Test with a temporary jumper between R - G

• Check motor for tight shaft

• Perform motor/control replacement check

• Perform Moisture Check

• Motor rocks, • Check for loose or compliant motor mount

but won’t start • Make sure blower wheel is tight on shaft

• Perform motor/control replacement check

Motor oscillates up • It is normal for motor to oscillate with no load

& down while being on shaft

tested off of blower

Motor starts, but

runs erratically

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

or intermittent • Check low voltage connections

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

motor harness connectors

• Check “Bk” for erratic CFM command (in

variable-speed applications)

• Check out system controls, Thermostat

• Perform Moisture Check

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

high CFM (speed) “puffing”?

- Reduce restriction

- Reduce max airflow

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

despite system call connections

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

delay complete

• “R” missing/not connected at motor

• Perform motor/control replacement check

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

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

complete

• Perform motor/control replacement check

• Blower won’t shut off •

Current leakage from controls into G, Y or W?

Check for Triac switched thermostat or solid-

state relay

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

motor noise; interview customer, if necessary

• Air noise • High static creating high blower speed?

- Is airflow set properly?

- Does removing filter cause blower to slow

down? Check filter

- Use low-pressure drop filter

- Check/correct duct restrictions

Symptom Cause/Procedure

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

• High static creating high blower speed?

- Check for air whistling through seams in

ducts, cabinets or panels

- Check for cabinet/duct deformation

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

high CFM (speed) “puffing”?

- Reduce restriction

- Reduce max. airflow

Evidence of Moisture

• Motor failure or • Replace motor and

Perform Moisture Check

malfunction has occurred

and moisture is present

• Evidence of moisture • Perform Moisture Check

present inside air mover

Do Don’t

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

wiring and connections

thoroughly before replacing

motor

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

water can’t get in positions

- Install “drip loops”

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

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

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

½"

minimum: H20 drop!

- Recommend high • Use restricted returns

efficiency, low static filters

- Recommend keeping filters

clean.

- Design ductwork for min.

static, max. comfort

- Look for and recommend

ductwork improvement,

where necessary

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

airflow

• Check orientation before • Plug in power connector backwards

inserting motor connectors • Force plugs

Moisture Check

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

manufacturer)

• Arrange harness with “drip loop” under motor

• Is condensate drain plugged?

• Check for low airflow (too much latent capacity)

• Check for undercharged condition

• Check and plug leaks in return ducts, cabinet

Comfort Check

• Check proper airflow settings

• Low static pressure for lowest noise

• Set low continuous-fan CFM

• Use humidistat and 2-speed cooling units

• Use zoning controls designed for ECM that regulate CFM

• Thermostat in bad location?

Manual 2100-532B

Page 43 of 46

TROUBLESHOOTING GE ECM™ MOTORS CONT’D.

Motor

Motor OK when

R > 100k ohm

ECM 2.0

Only remove

Hex Head Bolts

Connector Orientation

Between 4 and 8 o'clock

Drip Loop

Back of

Control

Figure 5

Winding Test

Figure 4

Note:

Use the shorter

bolts and

alignment pin

supplied when

replacing an

ECM 2.0

control.

Figure 3

ECM

2.3/2.5

Power Connector

(5-pin)

Control Connector

(16-pin)

Hex-head Screws

Motor Connector

(3-pin)

Motor Connector

(3-pin)

Control Disassembly

Drip Loop

Push until

Latch Seats

Over Ramp

From Motor

Circuit

Board

Replacing ECM Control Module

To replace the control module for the GE variable-speed indoor blower

motor you need to take the following steps:

1. You MUST have the correct replacement module. The controls are

factory programmed for specific operating modes. Even though they look

alike, different modules may have completely different functionality.

USING THE WRONG CONTROL MODULE VOIDS ALL PRODUCT

WARRANTIES AND MAY PRODUCE UNEXPECTED RESULTS.

2. Begin by removing AC power from the furnace or air handler being

serviced. DO NOT WORK ON THE MOTOR WITH AC POWER

APPLIED. To avoid electric shock from the motor’s capacitors, disconnect

power and wait at least 5 minutes before opening motor.

3. It is usually not necessary to remove the motor from the blower

assembly. However, it is recommended that the whole blower assembly,

with the motor, be removed from the furnace/air handler. (Follow the

manufacturer’s procedures). Unplug the two cable connectors to the motor.

There are latches on each connector. DO NOT PULL ON THE WIRES.

The plugs remove easily when properly released.

4. Locate the two standard

¼" hex head bolts at the rear of the control

housing (at the back end of the control opposite the shaft end). Refer

to Figure 28. Remove these two bolts from the motor and control

assembly while holding the motor in a way that will prevent the motor

or control from falling when the bolts are removed. If an ECM2.0

control is being replaced (recognized by an aluminum casting rather

that a deep-drawn black steel can housing the electronics), remove

only the hex-head bolts. DO NOT REMOVE THE TORX-HEAD

SCREWS.

5. The control module is now free of mechanical attachment to the

motor endshield but is still connected by a plug and three wires inside

the control. Carefully rotate the control to gain access to the plug at

the control end of the wires. With thumb and forefinger, reach the

latch holding the plug to the control and release it by squeezing the

latch tab and the opposite side of the connector plug and gently pulling

the plug out of the connector socket in the control. DO NOT PULL

ON THE WIRES. GRIP THE PLUG ONLY.

6. The control module is now completely detached from the motor.

Verify with a standard ohmmeter that the resistance from each motor

lead (in the motor plug just removed) to the motor shell is >100K ohms.

Refer to Figure 29. (Measure to unpainted motor end plate.) If any

motor lead fails this test, do not proceed to install the control module.

THE MOTOR IS DEFECTIVE AND MUST BE REPLACED.

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

7. Verify that the replacement control is correct for your

application. Refer to the manufacturer's authorized replacement list.

USING THE WRONG CONTROL WILL RESULT IN

IMPROPER OR NO BLOWER OPERATION. Orient the control

module so that the 3-wire motor plug can be inserted into the socket in

the control. Carefully insert the plug and press it into the socket until

it latches. A SLIGHT CLICK WILL BE HEARD WHEN

PROPERLY INSERTED.

Finish installing the replacement control per

one of the three following paragraphs, 8a, 8b or 8c.

8a. IF REPLACING AN ECM 2.0 CONTROL (control in cast

aluminum can with air vents on the back of the can) WITH AN ECM

2.3 CONTROL (control containing black potting for water protection in

black deep-drawn steel case with no vents in the bottom of the can),

locate the two through-bolts and plastic tab that are packed with the

replacement control. Insert the plastic tab into the slot at the perimeter

of the open end of the can so that the pin is located on the inside of the

perimeter of the can. Rotate the can so that the tab inserts into the tab

locater hole in the endshield of the motor. Using the two through-bolts

provided with the replacement control, reattach the can to the motor.

THE TWO THROUGH-BOLTS PROVIDED WITH THE

REPLACEMENT ECM 2.3 CONTROL ARE SHORTER THAN

THE BOLTS ORIGINALLY REMOVED FROM THE ECM 2.0

CONTROL AND MUST BE USED IF SECURE ATTACHMENT

OF THE CONTROL TO THE MOTOR IS TO BE ACHIEVED.

DO NOT OVERTIGHTEN THE BOLTS.

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

2.3 CONTROL, the plastic tab and shorter through-bolts are not

needed. The control can be oriented in two positions 180° apart.

MAKE SURE THE ORIENTATION YOU SELECT FOR

REPLACING THE CONTROL ASSURES THE CONTROL'S

CABLE CONNECTORS WILL BE LOCATED DOWNWARD IN

THE APPLICATION SO THAT WATER CANNOT RUN DOWN

THE CABLES AND INTO THE CONTROL. Simply orient the

new control to the motor's endshield, insert bolts, and tighten. DO

NOT OVERTIGHTEN THE BOLTS.

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

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

all replacements), the new control must be attached to the motor using

through bolts identical to those removed with the original control. DO

NOT OVERTIGHTEN THE BOLTS.

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

Follow the manufacturer's suggested procedures.

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

Make sure the connector is properly seated and latched.

11. Plug the 5-pin power connector into the motor. Even though the

plug is keyed, OBSERVE THE PROPER ORIENTATION. DO

NOT FORCE THE CONNECTOR. It plugs in very easily when

properly oriented. REVERSING THIS PLUG WILL CAUSE

IMMEDIATE FAILURE OF THE CONTROL MODULE.

12.

Final installation check. Make sure the motor is installed as

follows:

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

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

holes.

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

and 8 o’clock positions when the blower is positioned in its

final location and orientation.

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

motor by draining down the cables. Refer to Figure 30.

The installation is now complete. Reapply the AC power to the

HVAC equipment and verify that the new motor control module is

working properly. Follow the manufacturer's procedures for

disposition of the old control module.

Figure 29

Figure 28

Figure 30

Manual 2100-532B

Page 44 of 46

Heat Gen.

Power Failure

Blown Fuse or Tripped Breaker

Faulty Wiring

Loose Terminals

Low Voltage

Defective Contacts in Contactor

Compressor Overload

Potential Relay

Run Capacitor

Start Capacitor

Faulty Wiring

Loose Terminals

Control Transformer

Low Voltage

Thermostat

Contactor Coil

Pressure Controls (High or Low)

Indoor Blower Relay

Discharge Line Hitting Inside of Shell

Bearings Defective

Seized

Valve Defective

Motor Wingings Defective

Refrigerant Charge Low

Refrigerant Overcharge

High Head Pressure

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

Defective Valve or Coil

Plugged or Restricted Metering Device (Htg)

Scaled or Plugged Coil (Htg)

Scaled or Plugged Coil (CLg)

Water Volume Low (Htg)

Water Volume Low (Clg)

Low Water Temperature (Htg)

Plugged or Restricted Metering Device (Clg)

Fins Dirty or Plugged

Motor Winding Defective

Air Volume Low

Air Filters Dirty

Undersized or Restricted Ductwork

Auxillary Heat Upstream of Coil

Compressor Will Not Run

No Power at Contactor   

Compressor Will Not Run

Power at Contactor    

Compressor "Hums"

But Will Not Start    

Compressor Cycles on Overload  





Thermostat Check Light

Lite-Lockout Relay 

Compressor Off on High

Pressure Control 

 

Compressor Off on Low

Pressure Control  

Compressor Noisy 

Head Pressure Too High 

 

Head Pressure Too Low   

Suction Pressure Too High  

Suction Pressure Too Low 

I.D. Blower Will Not Start   

I.D. Coil Frosting or Icing  

High Compressor Amps  

   

Excessive Water Usage 

Compressor Runs Continuously

– No Cooling   



Liquid Refrigerant Flooding Back

To Compressor  

Compressor Runs Continuously

– No Heating    



Reversing Valve Does Not Shift   

Liquid Refrigerant Flooding Back

To Compressor    

Aux. Heat on I.D. Blower Off    

Excessive Operation Costs       

Ice in Water Coil  



Heating Cycle

AUX.

Cooling

Cycle Heating or Cooling Cycles

I

n

d

oor

Bl

ower

M

otor

and Coil

INDOOR SECTIONPOWER SUPPLY

W

ater

Solenoid

R

ev.

Valve Water Coil

WATER COIL SECTION

Line Voltage Control Circuit Compressor Refrigerant System

QUICK REFERENCE TROUBLESHOOTING CHART FOR WATER TO AIR HEAT PUMP





DENOTES COMMON CAUSE

DENOTES OCCASIONAL CAUSE

Manual 2100-532B

Page 45 of 46

GROUND SOURCE HEAT PUMP

PERFORMANCE REPORT

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

DATE: TAKEN BY:

1. UNIT:

Mfgr Model # S/N

THERMOSTAT:

Mfgr Model # P/N

2. Person Reporting

3. Company Reporting

4. Installed By Date Installed

5. User’s (Owner’s) Name

Address

6. Unit Location

WATER SYSTEM INFORMATION

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

A. If Open Loop where is water discharged?

8. The following questions are for Closed Loop systems only

A. Closed loop system designed by

B. Type of antifreeze used: % Solution

C. System type: Series Parallel

D. Pipe Material Nominal Size

E. Pipe Installed:

1. Horizontal Total length of pipe ft

No. pipes in trench Depth bottom pipe ft

2. Vertical Total length of bore hole ft

Manual 2100-532B

Page 46 of 46

THE FOLLOWING INFORMATION IS NEEDED

TO CHECK PERFORMANCE OF UNIT

FLUID SIDE DATA Cooling ** Heating

9. Entering fluid temperature F

10. Leaving fluid temperature F

11. Entering fluid pressure PSIG

12. Leaving fluid pressure PSIG

13. Pressure drop through coil PSIG

14. Gallons per minute through the water coil GPM

15. Liquid or discharge line pressure PSIG

16. Suction line pressure PSIG

17. Voltage at compressor (unit running) V

18. Amperage draw at line side of contactor A

19. Amperage at compressor common terminal A

20. * Suction line temperature 6” from compressor F

21. * Superheat at compressor F

22. * Liquid line temperature at metering device F

23. * Coil subcooling F

INDOOR SIDE DATA Cooling ** Heating

24. Dry bulb temperature at air entering indoor coil F

25. Wet bulb temperature of air entering indoor coil F

26. Dry bulb temperature of air leaving indoor coil F

27. Wet bulb temperature of air leaving indoor coil F

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

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

30. Other information about installation

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

* Items that are optional