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Bard QW5S1 manual

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Table of contents for the manual

  • Page 1

    Manual 2100-532B Page 1 of 46 QW SERIES GEOTHERMAL R-410A ST AGED CAP ACITY P ACKAGED HEA T PUMP INST ALLA TION INSTRUCTIONS Models: QW2S1 QW3S1 QW4S1 QW5S1 Manual No.: 2100-532B Supersedes: 2100-532A File: V ol II T ab 14 Date: 07-19-10 Bard Manufacturing Company , Inc. Bryan, Ohio 43506 Since 1914...Moving ahead, just as planned. MIS-2736 Earth L[...]

  • Page 2

    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 .............................[...]

  • Page 3

    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/W all Sleeve .......... 9 Figure 5 Inst allation [...]

  • Page 4

    Manual 2100-532B Page 4 of 46 GETTING OTHER INFORMA TION AND PUBLICA TIONS 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 Electri cal Code ...................... ANSI[...]

  • Page 5

    Manual 2100-532B Page 5 of 46 QW SERIES GEOTHERMAL R-410A ST AGED CAP ACITY GENERAL INFORMA TION 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) I[...]

  • Page 6

    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" 4 3" QW4S, QW5S 8 3/4" 48" 40" 4 9" MIS-2737 B (OPTIONAL) FILTER ACCESS DOOR SUPPLY AIR THERMOSTAT RETURN AI[...]

  • Page 7

    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 inspecti[...]

  • Page 8

    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 incl[...]

  • Page 9

    Manual 2100-532B Page 9 of 46 MIS -2739 A AIR DIVIDER ELIMINATO R 5" WAL L SL EEVE MIST TRIM PIECE SUPPLY AIR ROLLERS BOTTOM RETURN AIR CIRCUIT BREAKER, ROTARY, OR TOGGLE DISCONNECT ELECTRICAL ACCESS BLOW PLENUM BOX (TOP-SIDE) AND LOCKING CO VER LOW VO LTA GE OPTIONAL FREE ELECTRICAL ENTRANCE (TOP-REAR-SIDE) VENTILATIO N PERMANENT HIGH VOL TAG[...]

  • Page 10

    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 RE QU I R E D 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 RE QU I R E D MINIMUM 12 IN. M[...]

  • Page 11

    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 duc[...]

  • Page 12

    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 th[...]

  • Page 13

    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 w[...]

  • Page 14

    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 Fig[...]

  • Page 15

    Manual 2100-532B Page 15 of 46 INST ALLA TION 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[...]

  • Page 16

    Manual 2100-532B Page 16 of 46 FIGURE 11 UNIT MOUNTING WITHOUT VENTILATION WALL SLEEVE BRACKET WALL MO U NT I NG BASE TRIM SIDE TRIM CUT TO LE NGTH 41" ADJUSTABLE SIDE TRIM EXTENSION KIT -ORDERED SEPARATELY SIDE TRIM EXTENSION MIS -2744 A BASE TRIM EXTENSION[...]

  • Page 17

    Manual 2100-532B Page 17 of 46 FIGURE 12 COMPONENT LOCATION WIRE ENTRANCE SIDE FIELD TERMINAL BL OCK REMOTE THERMO STAT INDOOR DUAL BLOWERS CONTROL BOX/ CIRCUIT BREAKER PANEL MIS -2745[...]

  • Page 18

    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 inst[...]

  • Page 19

    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?[...]

  • Page 20

    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 Pur ple Purple/White Yellow Yellow W1/E L G L Part #8403- 056 411 5-1 02 A CO2 Contro lle r 24 VAC O/B Out Part #8403- 060 C Y2 A Y1 R G Analog Controller Termi nal S trip E W2 O C Y2 A W2 Y1 R Te mp. and H umi dit y Low Vo l t a ge D/YO Or a nge Orange Or a nge Yellow [...]

  • Page 21

    Manual 2100-532B Page 21 of 46 FIGURE 15 REMOTE THERMOSTAT WIRING DIAGRAM “D” THERMOSTAT OPTION Blue Pink Pur ple L O/B W1/E Y1 Part #8403- 060 C Y2 A W2 G R Te mp. and H umi dit y Controller D/YO Orange Yellow Brown/Whi te Bro wn 9 8 11 10 PLUG #2 Red/Yell ow Red/White 1 2 3 4 5 6 7 12 Black/White Pur ple /Wh ite 411 5-1 00 A[...]

  • Page 22

    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 Pur ple Yellow Yellow R Y1 O/B Part #8403- 056 24 VAC G W1/E L CO2 Contro lle r Out C Y2 A W2 Analog Te mp. and H umi dit y Controller Part #8403- 060 Or a nge Orange Or a nge Yellow Green Green Bro wn Bro wn Brown/Whi te Bro wn Red/White PLUG #1 Red/Yell ow PLUG #2 Red[...]

  • Page 23

    Manual 2100-532B Page 23 of 46 ST ART UP DESCRIPTION OF STANDARD EQUIPMENT LOW PRESSURE SWITCH NOTE: Thi s un it i s 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[...]

  • Page 24

    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[...]

  • Page 25

    Manual 2100-532B Page 25 of 46 1 Maximum ESP (inches WC) shown is with 2" MER V 6 pleated filter . 2 Rated CFM for ducted applications – required for maximum performance rating. T o 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[...]

  • Page 26

    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 UN IT SPEC. SHEET FO R FR OM CE ILIN G SID E TRIM PEIC ES FLUID ACCES S 8" TO 1 4" EXTERI OR WALL PROPER C OLOR (SHI PPED WITH U NIT ) CE ILIN G SID E TRIM PIEC ES (SH I PPED WITH UNI T) IF THE [...]

  • Page 27

    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 BR ACKET REMOVED FOR FLOOR FLU I D ACC ESS F R OM FLO O R FLUID ACCES S FROM TOP CLARITY) WALL BRAC KET OP E NIN G IN REAR OF UNI T 3" x 8" BACK OF U NIT MIS-274 7 WA TE R LINES WALL BRAC K[...]

  • Page 28

    Manual 2100-532B Page 28 of 46 TABLE 5 PRESSURE TABLE S 2 W QS 3 W QS 4 W QS 6 W Q r e t a w h s e r f r o f M P G d e r i u q e r e t a r w o l F 5679 l o n a h t e M % 5 1 r o f M P G d e r i u q e r e t a r w o l F 789 1 1 p o o l r e l i o b / r e w o t g n i l o o c , M P G d e r i u q e r e t a r w o l F 1 . 66 . 83 . 1 17 . 3 1 FLOW RATE FOR[...]

  • Page 29

    Manual 2100-532B Page 29 of 46 TABLE 6 OPTIONAL ACCESSORIES s n o i t p O n o i t a l i t n e V h t i w n o i t a l l a t s n I h c a E r o f d e s U e b t s u M – s e i r o s s e c c A l a n o i t p O : s e v e e l S l l a W n o i t a l i t n e V 2 4 S V W Q. k c i h t s e h c n i 4 1 o t p u s l l a w r o f e v e e l s l l a w n o i t a l i t n[...]

  • Page 30

    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 [...]

  • Page 31

    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 obstruct[...]

  • Page 32

    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[...]

  • Page 33

    Manual 2100-532B Page 33 of 46 6 10 11 8 9 12 7 MIS-2749 OPEN LOOP (W ell 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[...]

  • Page 34

    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. [...]

  • Page 35

    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 determine[...]

  • Page 36

    Manual 2100-532B Page 36 of 46 MIS-2750 Hose Bib (A) Hose Bib (B) Pump Isol ati on Val ve TO WATER COIL FROM W ATER 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 wa[...]

  • Page 37

    Manual 2100-532B Page 37 of 46 FIGURE 25 WATER WELL SYSTEM 12' to 15' LAKE or POND W A TER LEVEL GRA VEL FILL WELL CAP ELECTRICAL LINE PITLESS ADAPTER TO PRESSURE T ANK SUBMERSIBLE PUMP PERFORA TED PLASTIC CASING DROP PIPE W A TER SUPPL Y LINE 15' to 20' DEEP[...]

  • Page 38

    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 performanc[...]

  • Page 39

    Manual 2100-532B Page 39 of 46 FIGURE 26 WATER SOURCE HEAT PUMP[...]

  • Page 40

    Manual 2100-532B Page 40 of 46 FIGURE 27 WATER SOURCE HEAT PUMP[...]

  • Page 41

    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 brazi[...]

  • Page 42

    Manual 2100-532B Page 42 of 46 TROUBLESHOOTING GE ECM ™ MOT ORS 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 s[...]

  • Page 43

    Manual 2100-532B Page 43 of 46 TROUBLESHOOTING GE ECM ™ MOT ORS 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 W i nding Test Figure 4 Note: Use the shorter bolts and alignment pin supplied when replacing an ECM 2.0 control. Fig[...]

  • Page 44

    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) Indoo[...]

  • Page 45

    Manual 2100-532B Page 45 of 46 GROUND SO URCE H EAT PUMP PERFORMANCE R EPORT This performance check report should be f illed out by installer and retained w it h unit. DATE : TAKEN BY: 1. UNIT: Mfgr Model # S/N THE RMOST AT: Mfgr Model # P/N 2. Person Reporti ng 3. Company Reporting 4. Installed By Date Installe d 5. User’s (Ow ner’s) Name Addr[...]

  • Page 46

    Manual 2100-532B Page 46 of 46 THE FOL LOWIN G INFORMA TION IS NEED ED TO CHECK PERFORMANCE OF UNIT FLUID SIDE DATA C oolin g ** Heating 9. Enter ing fluid te mperat ure F 10. Leavi ng fluid temper ature F 11. Entering fl uid press ure PSIG 12. Leaving fluid press ur e PSIG 13. Pressur e drop t hrough coil PSIG 14. Gallons per mi nute thr ough the [...]