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INSTALLATION INSTRUCTIONS I-TEC SERIES PACKAGED HEAT PUMP Models: I30H1-A I30H1-B I30H1-C
I36H1-A I36H1-B I36H1-C
I42H1-A I42H1-B I42H1-C
I48H1-A I48H1-B I48H1-C
I60H1-A I60H1-B I60H1-C
I30H1DA I30H1DB I30H1DC
I36H1DA I36H1DB I36H1DC
I42H1DA I42H1DB I42H1DC
I48H1DA I48H1DB I48H1DC
I60H1DA I60H1DB I60H1DC
MIS-2957 A
Bard Manufacturing Company, Inc. Bryan, Ohio 43506 www.bardhvac.com
Manual: 2100-549L Supersedes: 2100-549K Date: 2-11-15
Page
1 of 59
CONTENTS Getting Other Information and Publications For More Information, Contact These Publishers:.......... 3 General & ANSI Z535.5 Definitions........................... 4 I-TEC General Information I-TEC Model Nomenclature........................................ 5 Shipping Damage, Unit Removal From Skid................. 8 Handling Unit After Removal From Skid...................... 8 Required Steps after Final Placement......................... 9 Minimum Installation Height...................................... 9 Securing Unit to Structure & Seismic Considerations.... 9 Duct Work, Supply Duct Connections & Filters........... 17 Condensate Drain.................................................... 18 With No Vent Option and With CRV & ERV................. 18 Installation Instructions Mounting the Unit & Wiring – Main Wiring................. 21 Wiring – Low Volt. Wiring & Low Volt.Connections....... 22 Start Ups R-410A Refrigerant Required................................... 30 Topping Off System Charge...................................... 30 Safety Practices...................................................... 30 Description of Standard Equipment........................... 31 Important Installer Note........................................... 31 Phase Monitor......................................................... 31 Three Phase Scroll Compressor................................. 31 Figures Figure 1 Unit Dimensions........................................ 7 Figure 2A & 2B Unit on Lift & Unit Side..................... 8 Wall Mounting Bracket Location.................................. 9 Bracket Wall Sect. View & Wood Framed Install.......... 10 Figure 3 Center of Gravity...................................... 11 Figure 4 Req. Clearances & Rec. Access................. 12 Figure 5 Compressor Shipping Bolts....................... 13 Figure 6 Removal of Air Duct................................. 13 Figure 7A Ducted Application................................... 14 Figure 7B 3" Riser Application................................. 15 Figure 7C 6" Riser Application................................. 16 Figure 8 Supply Duct Connections.......................... 17 Figure 9 Filter Location......................................... 17 Figure 10 Drain Locations........................................ 18 Figures 11A & 11B Unit Mounting....................19 & 20 Figure 12 Component Location................................. 21 Figure 13 Basic Heat Pump w/No Vent Pkg............... 23 Figure 14 HP w/CRV, without CO2 Control.................. 24 Figure 15 HP with CRV & CO2 Control....................... 25 Figure 16 HP with ERV, w/o CO2 Control.................... 26 Figure 17 HP with ERV & CO2 Control....................... 27 Figure 18 HP w/ERV & CO2 Control (Fully Mod.)........ 28 Figure 19 HP w/Comb. CRV & DB Econ. ("N" Vent)....... 29 Figure 20 Defrost Cycle........................................... 33 Figure 21 CRV Motor Speed/CFM Configuration......... 35 Figure 22 CRV Speed Change Terminal Access.......... 36 Figure 23 Economizer Control Circuit........................ 38 Figure 24 Motor Speed / CFM Configuration.............. 39 Fig. 25A ERV Manual Mode "M" Terminal................ 43 Fig. 25B ERV Mod. Mode "P" Terminal.................... 43 Figure 26 Ventilation Airflow Diagram....................... 44 Figure 27 ERV Control Access.................................. 45 Figure 28 Control Board Config./Setting.................... 46 Manual 2100-549L Page 2 of 59
Service Hints.......................................................... 31 Sequence of Operation............................................. 32 Pressure Service Ports............................................. 32 Lowering Outdoor Fan Speed for Sound..................... 32 Defrost Cycle.......................................................... 33
I-TEC Commercial Room Ventilator System Gen. Description, Control Wiring & Rec. Seq.............. 34 Setting the Ventilation CFM Levels............................ 34 I-TEC Comb. CRV & Economizer Vent System Description & Control Wiring..................................... 37 Setting the Ventilation CFM Levels............................ 37 Economizer Seq. of Operation................................... 38 Heating & Vent Mode .............................................. 39 I-TEC Energy Recovery Ventilator System General Description & Control Wiring......................... 40 Recommended Control Sequences............................ 41 Changing Ventilation CFM Rates in Manual Mode....... 41 Changing to Fully Modulating Mode.......................... 41 Configuring Control for ERV Mod. Control................... 47 Maintenance (Gen., Frequency, Clean & Perform.)......... 49 Troubleshooting Solid State HP Control Troubleshooting Procedure......51 Checking Temperature Sensor...................................52 Troubleshooting ECM™ 142R Motor.........................53 Replacing the Motor................................................54 Troubleshooting Indoor ECM™ Motor........................55 Fan Blade Setting Dimensions..................................57 Refrigerant Charge...................................................57 Figures (continued) Figure 29 Hub Assembly w/Ball Bearings.................. 50 Figure 30 Control Disassembly................................. 56 Figure 31 Winding Test............................................ 56 Figure 32 Drip Loop................................................ 56 Figure 33 Control Connector Motor Half.................... 57 Tables Table 1 Factory Built-In Electric Heat Table............... 5 Table 1A Indoor Blower Performance.......................... 5 Table 2 Elec. Specifications..................................... 6 Center of Gravity Reference Table............................. 11 Table 3 Operating Voltage Range............................ 22 Table 4 Wall Thermostats...................................... 22 Low Voltage Connections for DDC Control.................. 22 Performance & App. Data: Summer Cooling & Winter Heating............................ 42 Table 5 Troubleshooting......................................... 51 Table 6 Temp. vs Resistance of Temp. Sensor.......... 52 Table 7 Troubleshooting ECM™ 142R.................... 54 Table 8 Cooling Mode............................................ 54 Table 9 Heat Pump Mode...................................... 54 Troubleshooting ECM™ Blower Motors...................... 57 Power Connector..................................................... 57 Table 10A Pressures: Full Load Cooling...................... 58 Table 10B Pressures: Full Load Heating...................... 58 Table 11A Pressures: Part Load Cooling ..................... 59 Table 11B Pressures: Part Load Heating..................... 59
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 .......................ACCA Manual J or Winter and Summer Manual N Air Conditioning Low Pressure, Low Velocity............. ACCA Manual D or Duct System Design Manual Q Winter and Summer Air Conditioning
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, Refrigeration, 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
Manual 2100-549L Page 3 of 59
GENERAL The equipment covered in this manual is to be installed by trained, experienced service and installation technicians.
The I-TEC must be installed with the Bard manufactured IWS wall sleeve and ILG louver grille accessories. These are sold as separate accessories. Any substitutions will void the manufacturer’s warranty.
The unit is designed for use with or without ductwork. For use without ductwork, Plenum Box IPBDF8color (8" height) or IPBDF12-color (12" height) is recommended. These instructions explain the recommended method to install the air cooled self-contained unit and the electrical connections to it. These instructions and any instructions packaged with any separate equipment required to make up the entire heating and 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.
ANSI Z535.5 Definitions: • Danger: Indicate[s] a hazardous situation which, if not avoided, will result in death or serious injury. The signal word “DANGER” is to be limited to the most extreme situations. DANGER [signs] should not be used for property damage hazards unless personal injury risk appropriate to these levels is also involved. • Warning: Indicate[s] a hazardous situation which, if not avoided, could result in death or serious injury. WARNING [signs] should not be used for property damage hazards unless personal injury risk appropriate to this level is also involved. • Caution: Indicate[s] a hazardous situation which, if not avoided, could result in minor or moderate injury. CAUTION [signs] without a safety alert symbol may be used to alert against unsafe practices that can result in property damage only. • Notice: [this header is] preferred to address practices not related to personal injury. The safety alert symbol shall not be used with this signal word. As an alternative to “NOTICE” the word “CAUTION” without the safety alert symbol may be used to indicate a message not related to personal injury.
Manual 2100-549L Page 4 of 59
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 3 for information on codes and standards. Size of unit for a proposed installation should be based on heat loss or heat gain 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.
I-TEC Series General Information I-TEC MODEL NOMENCLATURE I
36
MODEL SERIES
H
1
D
A 0Z
SYSTEM TYPE HEAT PUMP
NOMINAL CAPACITY 30 – 30,000 BTUH 36 – 36,000 42 – 42,000 48 – 48,000 60 – 60,000
R
P
SPECIAL UNITS (–) – Standard D – Dehum. VOLTS & PHASE A – 230/208, 60-1 B – 230/208, 60-3 C – 460-60-3
X
X
1– 2– 3– 4–
FILTER OPTIONS P – 2" Pleated MERV 8 M – 2" Pleated MERV 11 N – 2" Pleated MERV 13
VENTILATION OPTIONS B – Blank-Off Plate M – Multi-Speed CRV N – Comb. CRV & DB Economizer R – ERV RESERVED
2
CONTROLS X – 24V Terminal Block Only w/o
COLOR OPTIONS X – Beige paint 1 – White paint 4 – Gray paint
ELECTRIC HEAT 0Z – No heat w/breaker 04 – 4KW 1-Phase 05 – 5KW 1-Phase 06 – 6KW 3-Phase 09 – 9KW 3-Phase 10 – 10KW 1-Phase 15 – 15KW 1 & 3-Phase 18 – 18KW 3-Phase 20 – 20KW 1-Phase
REVISION
4
CompleteStat CompleteStat THO (Temp, Humidity & Occupancy) CompleteStat THO w/CO2 CompleteStat THO w/Ethernet CompleteStat THO w/CO2 & Ethernet
Note: CompleteStat must be field installed & wired. All units have 24V terminal block.
COIL TREATMENT X – Std. Hydrophilic Fin Evap. & Uncoated Alum. Cond. Coil 1 – Phenolic Coated ID Coil 2 – Phenolic Coated OD Coil 3 – Phenolic Coated ID & OD Coil
TABLE 1 FACTORY BUILT-IN ELECTRIC HEAT TABLE Models KW
I30H1-A
I30H1-B
I36H1-A I42H1-A
I30H1-C
I36H1-B I42H1-B
I36H1-C I42H1-C
BTUH
BTUH
I48H1-C I60H1-C
I60H1-A
BTUH
BTUH
BTUH
BTUH
BTUH
BTUH
BTUH
BTUH
BTUH
BTUH
BTUH
BTUH
BTUH
BTUH
BTUH
13,652 10,239 17,065 12,799
6.0
17,065 12,799 20,478 15,359 20,478
9.0 10.0
I48H1-B I60H1-B
240V-1 208V-1 240V-3 208V-3 460V-3 240V-1 208V-1 240V-3 208V-3 460V-3 240V-1 208V-1 240V-3 208V-3 460V-3 240V-1 208V-1
4.0 5.0
I48H1-A
30,717 23,038 30,717 34,130 25,598
17,065 12,799 20,478 15,359 20,478 30,717 23,038 30,717
34,130 25,598
15.0
17,065 12,799 20,478 15,359 20,478 30,717 23,038 30,717
34,130 25,598
34,130 25,598
51,195 38,396 51,195 38,396 51,195 51,195 38,396 51,195 38,396 51,195 51,195 38,396
18.0
61,434 46,076 61,434
20.0
68,260 51,195
68,260 51,195
TABLE 1A INDOOR BLOWER PERFORMANCE MODEL
Rated ESP
MAX ESP
k Continuous Airflow
Rated 2nd Stage CFM
Rated 1st Stage CFM
l 5 – 9KW CFM
m 13.5 – 18KW CFM
I30H1
.15
0.50
500
900
650
700
1400
I36H1
.15
0.50
600
1150
850
700
1400
I42H1
.20
0.50
650
1300
950
700
1400
I48H1
.20
0.50
725
1500
1050
700
1400
I60H1
.20
0.50
850
1700
1200
700
1400
Motor will deliver consistent CFM through voltage supply range with no deterioration. Continuous fan CFM is the total air being circulated during continuous fan mode. Will operate at rated Full Load Airflow when operating with Heat Pump. Will occur automatically with a call for "W3" or "Emergency Heat" signal from the thermostat (Heat Pump Operation is terminated at this condition).
Manual 2100-549L Page 5 of 59
TABLE 2 ELECTRICAL SPECIFICATIONS MODEL I30H1-A0Z A05 A10 I30H1-B0Z B06 B09 I30H1-C0Z C06 C09 I36H1-A0Z A05 A10 A15 I36H1-B0Z B06 B09 B15 I36H1-C0Z C06 C09 C15 I42H1-A0Z A05 A10 A15 I42H1-B0Z B06 B09 B15 I42H1-C0Z C06 C09 C15 I48H1-A0Z A04 A05 A10 A15 A20 I48H1-B0Z B06 B09 B15 B18 I48H1-C0Z C06 C09 C15 C18 I60H1-A0Z A05 A10 A15 A20 I60H1-B0Z B06 B09 B15 B18 I60H1-C0Z C06 C09 C15 C18
Rated No. Field Volts, Hertz Power & Phase Circuits 230/208-1 230/208-3 460-3
230/208-1
230/208-3
460-3
230/208-1
230/208-3
460-3
230/208-1
230/208-3
460-3
230/208-1
230/208-3
460-3
1 1 1 or 2 1 1 1 1 1 1 1 1 1 or 2 1 or 2 1 1 1 1 1 1 1 1 1 1 1 or 2 1 or 2 1 1 1 1 1 1 1 1 1 1 1 or 2 1 or 2 1 or 2 1 or 2 1 1 1 1 1 1 1 1 1 1 1 1 or 2 1 or 2 1 or 2 1 or 2 1 1 1 1 1 or 2 1 1 1 1 1
Single Circuit Maximum Minimum Field External Circuit Power Wire Fuse or Ckt. Ampacity Size Brkr. 8 35 22 8 50 48 4 80 74 10 25 17 8 35 35 8 45 44 14 10 9 12 20 18 10 25 22 26 40 8 52 60 6 78 80 4 84 90 4 22 30 10 40 45 8 49 50 8 51 60 6 11 15 14 20 20 12 24 25 10 28 30 10 30 45 8 56 60 6 82 90 4 82 90 4 25 35 8 43 50 8 52 60 6 52 60 6 12 15 14 21 25 10 26 30 10 28 30 10 34 50 8 54 60 6 59 70 6 85 90 3 85 90 3 110 110 2 8 35 26 8 50 44 6 60 53 6 60 53 6 60 53 12 20 12 10 30 21 10 30 26 10 30 26 10 30 26 8 60 44 4 80 70 3 100 96 3 100 96 2 120 112 8 45 31 8 60 49 6 60 58 6 60 58 6 70 63 12 20 15 10 30 25 10 30 29 10 30 29 10 30 29
Ground Wire 10 10 8 10 10 10 14 12 10 10 10 8 8 10 10 10 10 14 12 10 10 10 10 8 8 10 10 10 10 14 10 10 10 10 10 8 8 8 6 10 10 10 10 10 12 10 10 10 10 10 8 8 8 6 10 10 10 10 8 12 10 10 10 10
Dual Circuit Maximum Minimum Field Power External Fuse or Circuit Wire Size Ckt. Breaker Ampacity Ckt. A Ckt. B Ckt. A Ckt. B Ckt. A Ckt. B
Ground Wire Size Ckt. A
Ckt. B
48
30
50
30
8
10
10
10
26 26
52 52
40 40
60 60
8 8
6 6
10 10
10 10
56 56
26 52
60 60
30 60
6 6
10 6
10 10
10 10
35 35 35 59
26 52 52 52
45 45 45 60
30 60 60 60
8 8 8 6
10 6 6 6
10 10 10 10
10 10 10 10
44 44 44 60
26 52 52 52
60 60 60 60
30 60 60 60
8 8 8 6
10 6 6 6
10 10 10 10
10 10 10 10
31
54
45
60
8
6
10
10
These “Minimum Circuit Ampacity” values are to be used for sizing the field power conductors. Refer to the National Electric Code (latest revision), article 310 for power conductor sizing. Caution: When more than one field power conductor circuit is run through one conduit, the conductors must be derated. Pay special attention to note 8 of table 310 regarding Ampacity Adjustment Factors when more than three conductors are in a raceway. Maximum size of the time delay fuse or circuit breaker for protection of field wiring conductors. Based on 75°C copper wire. All wiring must conform to the National Electrical Code and all local codes. Maximum KW that can operate with heat pump on is 10KW for 1-Phase and 9KW for 3-Phase. Represents Electric Heat Only. Electrical Control Circuit will lockout Heat Pump Operation.
Manual 2100-549L Page 6 of 59
Manual 2100-549L Page 7 of 59
1
24"
Front Forklift Holes (Remove Front Trim)
13 4 "
1
5
58"
3
Side Forklift Holes (Remove Sides)
1
22 4 " Lower Section
71 4 " Upper Section
94" Total Height
15 8 "
Locking Door Latch
Electrical Disconnect
Locking Door Latch
(4) Lift-Off Hinges
High Voltage 7 Entrance 11 8 " Electric Heat Wire Channel 30" With Doors and Sides Removed
Right Side View
1
24 2 "
1
71 2 "
Outer Sleeve
Inner Sleeve
Return Air
(2) Return Openings
3
34"
8" 1
38"
Supply Air
1
38"
MIS-2917 A
(2) Opt. Unit Drain Entrances
Inner Sleeve
Outer Sleeve
Return Air
Back View
Unit Specification Sheet
(2) Unit Drains
2"
3
31 8 " Total Depth
26 4 "
3
20" x 24" Supply Frame
(2) 12" x 20" Vent Exhaust Air Filters
Low Voltage Entrance
20"
(2) Side Handles
1
11 4 "
5 47 8 " Total Width 1 46 8 " With Sides Removed
(2) Washable Vent Intake Air Filters
Control Panel
(2) 2"x24"x30" Return Air Filters
Front View
24"
28 4 "
1
34"
1
Top View
FIGURE 1 UNIT DIMENSIONS
SHIPPING DAMAGE Upon receipt of equipment, the unit should be checked for external signs of shipping damage. The skid must remain attached until the unit is ready for installation. If damage is found, the receiving party must contact the last carrier immediately, preferably in writing, requesting inspection by the carrier’s agent.
UNIT REMOVAL FROM SKID
WARNING
This unit is heavy and requires more than one person to handle during installation and removal from the skid. Extreme caution must be taken to prevent injury to personnel and damage to the unit. Use appropriate safety equipment, including gloves when handling. Failure to do so may result in serious injury.
A forklift or a lift rated for the load (Figure 2A) is required to lift the unit off from the skid. This unit is top heavy and should never be tipped while moving it. The I-TEC is designed to be lifted off the skid from the front or rear of the unit without having to remove any doors or side panels. See Figure 1 for fork openings. The shipping brackets on front and rear of the unit must be removed and discarded. The unit can now be lifted straight up and the skid can be slid out from underneath.
Tip unit from left side only. Failure to do so may result in injury due to unit topheaviness or compressor damage!
FIGURE 2A – UNIT ON LIFT
HANDLING UNIT AFTER REMOVAL FROM SKID If a wide and tall enough opening exists, the I-TEC can be moved as a complete assembled unit. If not, it is designed to break down into two sections to allow it to pass through a 36 inch wide door. 1. Depress & release both top & bottom door latches and open doors. 2. Remove the doors by lifting straight up and off from the hinge pins. 3. Remove cabinet sides by first removing the four (4) sheet metal screws from the front (leading edge) of the side panel. The panel will not fall off. Swing the panel away from the chassis 20 to 30 degrees & then pull forward from the two (2) tabs supporting the rear edge. 4. On each side of the unit is a tie plate that secures the top and bottom sections with four (4) cap bolts. Using a ½ inch wrench or socket, remove these screws from both plates and set aside. 5. If the unit is equipped with a CRV or ERV, you must unplug the wire harness on the left-hand side of the control box. 6. A forklift or a lift rated for the load is required to lift the top section off from the bottom base. Do not attempt to do this manually. Failure to do so could result in the unit tipping over & causing bodily injury and/or damage to the unit. 7. The top section can be forked from either the RH or LH side. See Figure 1 for fork openings. 8. Carefully lift the top section straight up avoiding tipping. 9. Move the top section through the doorway and place on flat surface free of debris. 10. The bottom base can now be moved through the doorway the same way. 11. Reassemble the unit by reversing this procedure.
FIGURE 2B – UNIT SIDE
ERV/CRV HARNESS CONNECTION
(4) CAP BOLTS FORK OPENING
(Visible after removing tie plate)
TIE PLATE
(Covers entire width; shortened for illustration purposes to show Fork Openings)
Manual 2100-549L Page 8 of 59
REQUIRED STEPS AFTER FINAL PLACEMENT The compressor is secured to the base with two (2) bolts for shipping. Although the unit will perform as designed with the shipping bolts in place, there may be a noticeable additional noise and vibration noted. To obtain the lowest noise and vibration levels, remove the shipping bolts after the unit is in its final operating location. To gain access to the compressor, the compressor access panel must be removed (Figure 9). Once this panel is removed, the CRV/ERV air duct must be removed. See Figure 6. The air duct is removed by pulling it straight toward you; there are no screws securing it in place. Both the top and bottom slide toward you at the same time (pull hard). Once removed, the compressor is visible as well as the tags on the shipping bolts (Figure 5). After the compressor shipping bolts have been removed, the CRV/ERV air duct can be slid back in place and the compressor access panel attached.
MINIMUM INSTALLATION HEIGHT The minimum installation height to the bottom of the roof or fixed ceiling for ducted applications is 9 ft. 7 in. This provides enough clearance to install the duct work. See Figure 7A. The IWS Series wall sleeve has a built-in vertical adjustment to fit window sill heights from 31-34 inches. If additional height is required, two riser platform accessories are available. The IRP3 increases the unit height by 3 inches (Figure 7B) and the IRP6 by 6 inches (Figure 7C). Several construction options are available for unit installation of the IZ Series. Serviceability and filter 2" 1 11/16"
access must be considered before installing. See Figure 5D for required clearances and recommended service access dimensions.
SECURING UNIT TO STRUCTURE Shipped with the I-TEC unit is a wall mounting bracket (screwed to shipping skid on backside of unit). This bracket can be utilized to secure the top portion of the unit to the wall using the appropriate field supplied hardware based upon the material you are fastening to. (There are several offset holes, sized to accept up to a 1/4" diameter fastener that will easily allow you to hit studs on a framed wall.) See BRACKET SECTION VIEW for locating this top wall bracket which will need to be applied after the unit is located in the final position. Additional/optional mounting holes for up to a 3/8" diameter fastener are also available in the backside of the unit. These can be accessed by: • removing the air filters for the uppermost set • removing the compressor section service door for the lower set Refer to WOOD FRAMED INSTALLATION for additional framing required to secure unit to wall. The additional/optional mounting holes will require a long extension to drive the fasteners.
SEISMIC CONSIDERATIONS The I-TEC product features several locations for product securement but all site conditions are different. Consult with a licensed Seismic Engineer to advise of particular needs when attaching the I-TEC unit to the structure.
43 3/8" Ø1/4"
WALL MOUNTING BRACKET LOCATION
BRACKET 3/4" 1 1/2"
7/8"
94" FROM BOTTOM OF BRACKET TO FLOOR WITHOUT RISER KIT
MIS-3029
Manual 2100-549L Page 9 of 59
RISER KIT NONE IRP-3 (3") IRP-6 (6")
DIM A 31"-34" MAX 34"-37" MAX 37"-40" MAX Optional Duct
DIM B 29 17/32" 32 17/32" 35 17/32"
DIM C 94 1/8" 97 1/8" 100 1/8"
Wall Section View BRACKET WALL SECTION VIEW Optional Top Bracket
Outside Wall
Ceiling Optional Trim or Supply Duct Box
(4) optional Unit Mounting holes
Telescoping Wall Sleeve**
7
7
20 8 "
20 8 "
Sleeve Mounting Hole Locations Centered on Opening
Outside Wall
3"
3
43 8 " 6"
Centered 20"
42-3/4" Min. 43-1/4" Max.
DIM C
48" Min. 48-1/2" Max.
Grille
3 49 8 "
Centered
1
56 2 "
20"
(4) optional Unit Mounting holes
Unit 31" Min. * 34" Max.
DIM A
*
7
20 8 "
8"
15 1 16 "
20"
Room Floor Level
CL
18 3/4
CL
7 3/8
17.5"
35"
Right Side View
DIM B
20"
7 43 8 "
Floor
11
4 16 "
8"
Front (Wall Only) View
* Higher Sill Heights Acheivable With Base Kit. ** Separate telescoping sleeves available for different wall thicknesses.
MIS-2918 D
WOOD FRAMED INSTALLATION (for Wall Attachment) 41.75 Inner wall
(4) Upper fastener holes 6.00
Unit
(4) lower fastener holes
56.50
29.56*
8.00 20.88 36.88
Floor
8.00
* Height dimension shown without riser kit. If unit uses riser kit add appropriate dimension to height. MIS-3072
Manual 2100-549L Page 10 of 59
FLOOR MOUNTING HOLE & CENTERLINES
FIGURE 3 CENTER OF GRAVITY
CENTER OF GRAVITY
"Z"
"X"
"Y"
UNIT TESTED
MIS-3269
FRONT OF UNIT DOOR TO CENTER
LEFT SIDE TO CENTER
FLOOR TO CENTER CRV & ERV
FLOOR TO CENTER NO VENT
"X" Dimension
"Y" Dimension
"Z" Dimension
"Z" Dimension
I30H1-A, -B
14"
24"
43½"
47"
I30H1-C
14"
24¼"
43½"
47"
I36H1-A, -B
14"
24"
43½"
47"
I36H1-C
14"
24¼"
43½"
47"
I42H1-A, -B
14"
24"
43½"
47"
I42H1-C
14"
24¼"
43½"
47"
I48H1-A, -B
14"
24"
43½"
47"
I48H1-C
14"
24¼"
43½"
47"
I60H1-A, -B
14"
24"
43½"
47"
I60H1-C
14"
24¼"
43½"
47"
Manual 2100-549L Page 11 of 59
FIGURE 4 REQUIRED CLEARANCES & RECOMMENDED ACCESS
WING WALL CONSTRUCTION TOP VIEW
12" MIN.
12" MIN.
IMPORTANT Unit can be located in corner with 0" clearance as long as other side is unobstructed
CLOSET CONSTRUCTION TOP VIEW
31 3/8" 12" MIN.
12" MIN. 12" MIN.
12" MIN. 48" MIN.
RECOMMENDED SERVICE ACCESS DIMENSIONS
12" MIN. FOR LEFT SIDE ACCESS
12" MIN. FOR RIGHT SIDE ACCESS
LEFT CORNER CONSTRUCTION TOP VIEW
FILTERS 24" MIN. 24" MIN. 0" REQUIRED 12" RECOMENDED
REMOVABLE SIDES 1
48" MIN. FOR FILTER ACCESS
RIGHT CORNER CONSTRUCTION TOP VIEW
0" REQUIRED 12" RECOMENDED
1 ALL FILTER AND COMPONENT ACCESS IS FROM THE FRONT. COILS CAN BE CLEANED FROM THE FRONT, BUT SIDES ARE EASILY REMOVED FOR ENHANCED ACCESS.
MIS-3273
Manual 2100-549L Page 12 of 59
FIGURE 5 COMPRESSOR SHIPPING BOLTS
COMPRESSOR SHIPPING BOLT
COMPRESSOR SHIPPING BOLT
FIGURE 6 REMOVAL OF AIR DUCT
CRV/ERV AIR DUCT
Manual 2100-549L Page 13 of 59
Manual 2100-549L Page 14 of 59
7'-9 3/4" UNIT HEIGHT
SUSPENDED CEILING
20" MINIMUM
BOTTOM OF ROOF OR FIXED CEILING
9'-7" MINIMUM CLEARANCE RECOMMENDED TO BOTTOM OF ROOF OR FIXED CEILING
FLOOR
4" MINIMUM FROM TOP OF UNIT TO DUCT BOTTOM
12" MINIMUM
MIS-2958 B
9'-2" MINIMUM REQUIRED INSTALLATION HEIGHT
TURNING VANES RECOMMENDED
FIELD SUPPLIED DUCT
FIGURE 7A DUCTED APPLICATION – BASIC UNIT
3" RISER
7'-9 3/4" UNIT HEIGHT
SUSPENDED CEILING
20" MINIMUM
BOTTOM OF ROOF OR FIXED CEILING
9'-10" MINIMUM CLEARANCE RECOMMENDED TO BOTTOM OF ROOF OR FIXED CEILING
FLOOR
4" MINIMUM FROM TOP OF UNIT TO DUCT BOTTOM
12" MINIMUM
FIELD SUPPLIED DUCT
MIS-2989 B
9'-5" MINIMUM REQUIRED INSTALLATION HEIGHT
TURNING VANES RECOMMENDED
FIGURE 7B 3" RISER APPLICATION
Manual 2100-549L Page 15 of 59
Manual 2100-549L Page 16 of 59
6" RISER
7'-9 3/4" UNIT HEIGHT
SUSPENDED CEILING
20" MINIMUM
BOTTOM OF ROOF OR FIXED CEILING
10'-1" MINIMUM CLEARANCE RECOMMENDED TO BOTTOM OF ROOF OR FIXED CEILING
FLOOR
4" MINIMUM FROM TOP OF UNIT TO DUCT BOTTOM
12" MINIMUM
TURNING VANES RECOMMENDED
MIS-2988 B
9'-8" MINIMUM REQUIRED INSTALLATION HEIGHT
FIELD SUPPLIED DUCT
FIGURE 7C 6" RISER APPLICATION
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 I-TEC series heat pump has provision to attach a supply air duct to the top of the unit. Duct connection size is 20 inches x 24 inches. The flanges are shipped flat and must be bent upward using sheet metal flanging pliers. The duct work is field supplied. See Figure 8 for suggested attachment method. Make sure to seal the slots in the bend-up flange at the time of securing your ductwork to the flange. This can be accomplished with either foil tape or caulk. Failing to do so may cause air leakage/whistling of air.
mounted install (9'-9" with IRP3 riser & 10'-0" with IRP6 riser). The ICX10 extends 28" above the unit for a total height of 10'-2" for a floor mounted install (10'5" with IRP3 riser & 10'-8" with IRP6 riser). 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 1A. 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 throw away filters (24 x 30) and two 1-inch throw away filters (12 x 20) are supplied with each unit. The 2-inch filters slide into brackets on both sides for the return air openings. The 1-inch filters are in the cabinet doors for the vent (room air) exhaust. If a CRV or ERV vent option is used, there are two (2) additional ½" (8 x 17) washable filters included with that option. See Figure 9 for specific locations. The filters are serviced from the inside of the building by opening the cabinet doors, and do not require any tools to access.
FIGURE 9 FILTER LOCATION
FIGURE 8 SUPPLY DUCT CONNECTIONS
INDOOR BLOWER ACCESS
20"
SUPPLY DUCT AND FASTENERS TO BE FIELD SUPPLIED
24"
24" X 30" X 2" FILTERS
BEND THE PROVIDED SUPPLY FRAME FLANGES UP FOR DUCT INSTALLATION
MIS-2959
COMPRESSOR ACCESS
NOTE: Unit cabinet, supply air duct and duct free plenum are approved for “0” clearance to combustible material.
ACCESS TO WASHABLE FILTERS
The IPBDF Plenum Box mounts on top of the unit and has both vertically and horizontally adjustable louvers on the front discharge grille.
VENT OPTION ACCESS
When used with a ducted supply, an ICX9 or ICX10 Cabinet Extension may be used to conceal the ductwork above the unit to the ceiling. The ICX9 extends 20" above the unit for a total height of 9'-6" for a floor
The I-TEC series heat pumps are designed for use with free return (non-ducted) and either duct free with the use of IPBDF Series Plenum Box (8" or 12") or a duct supply air system.
12" X 20" X 1" FILTERS
Manual 2100-549L Page 17 of 59
CONDENSATE DRAIN
WITH COMMERCIAL ROOM VENTILATOR
There are two condensate drain connections from the condenser drain pan (compressor area). These are visible from the rear of the unit. Factory installed tubing connects the two drains at a tee connection and then a single drain hose with a barbed hose connector carries the condensate to the draining option of your choice. Enough tubing is provided to reach all drain options and can be cut down in length.
1. Open hinged front doors. 2. Disconnect unit power to eliminate shock hazard. 3. Remove front cover/door of CRV vent package. (Can leave filter access panels in place.) 4. Unplug wires coming in on left side from upper unit section. 5. Unplug two wire harness from front (intake) blower. 6. Remove two (2) screws securing front (intake) blower and slide blower out of unit. 7. Remove four (4) screws that retain the partition behind/beneath intake blower removed in Step #6. 8. Rear drain access panels are now visible on both right-hand and left-hand sides in rear of box.
The unit is shipped from the factory with the drain line on the left-hand side as you look at the rear of the unit. The tubing can be removed from the drain connections and flipped for a right-hand drain. See Figure 10. The drain can be routed directly through the floor or through the wall. There are also two optional drain locations in the lower rear back panel. See Figure 8. The I-TEC design does not require a trap in the condensate disposal tubing. Check your local codes to see if a “P” trap is required. For a stand pipe floor drain or through the wall, there is adequate hose length to reach anything located behind the unit. The lower rear portion of the cabinet is recessed approximately 4 inches allowing room for a “P” trap to be installed with the cabinet flush with the wall. Keep in mind, the drain line must be able to be removed from the unit if necessary to remove the unit from the wall. Access plates are located on the rear of the unit for servicing the drain trap. See Figure 10. If the drain line is to be routed through an unconditioned space, it must be protected from freezing. The condensate drain line can also be routed back into the unit through either the right-hand or left-hand optional drain locations on the rear of the unit. The hole is covered by insulation on the inside of the unit and will have to be cut away. Located inside the unit, about 12 inches in from the front on both the left and right side are drain holes in the bottom of the base. These holes are covered with insulation and are not visible. They are located very close to the side panels and can be found by pressing down on the insulation. Cut insulation away to expose the hole. A drain trap can now be installed inside of the cabinet, and the drain hose routed directly through the floor. Once the I-TEC is installed, the rear drains exiting the condenser section can be easily serviced with removal of the pre-painted metal sides (lift-off doors, remove four [4] screws to remove side).
WITH ENERGY RECOVERY VENTILATOR To access the rear drain access panels of this section: 1. Open hinged front doors. 2. Disconnect unit power to eliminate shock hazard. 3. Remove front cover/door of ERV vent package. (Can leave filter access panels in place.) 4. Unplug wires coming in on left side from upper unit section. 5. Unplug heat recovery cassette on the side you wish to access, and slide cassette out the front of the unit. 6. Remove two (2) screws securing partition on outboard side of cassette and remove. 7. Rear drain access panels are now visible on both right-hand and left-hand sides in rear of box.
FIGURE 10 – DRAIN LOCATIONS
(2) Unit Drains
Drain Access Locations
8" 3
38"
If side access is not available, the drain lines and trap can be serviced by removing either one of the drain access panels on the rear of the unit (in the ventilation package area.) See Figure 10.
(2)OPTIONAL DRAIN HOLES
3
38" (2) Optional Unit Drain Entrances WALL
7 3/16" 16 1/2"
WITH NO VENT OPTION To access the drain access panels in the rear of this section, simply remove the front door/cover from the box, and the plates are located in the rear of the box. Manual 2100-549L Page 18 of 59
18 3/4"
OPTIONAL FLOOR MOUNTING HOLES
35" 3 40 4 "
MIS-2960 B
FIGURE 11A UNIT MOUNTING
Use (12) Field Supplied Concrete or Wood Screws to Secure Outer Sleeve to Structure.
IMPORTANT!
Apply Caulk bead to entire perimeter seam between inner and outer sleeve.
IMPORTANT!
Apply liberal amount of caulk to back of flange before installing. REF. A
REF. B
Use (12) 3/4" Long Self Tapping Screws to Attach Inner Sleeve to Unit Back
Use (6) 3/4" Long Self Tapping Screws to Attach Inner Sleeve to Outer Sleeve
IMPORTANT!
Use care when inserting screws to not damage gasketing material. Doing so may compromise water seal between unit and sleeve.
Pull Inner Frame Out Until Flush With Grille Mounting Angle
REF. E
REF. C REF.
Use (6) 3/4" Long Screws to Attach Exhaust Sleeve to Unit Fan Shroud
(18) 5/16" - 3/4" SELF TAPPING A AND B (6) 5/16" - 3/4" NON-TAPPING (4) 5/16" - 1/2" NON-TAPPING (4) 1-1/2" LONG SCREWS
REF. C REF. D REF. E
Use (4) 1-1/2" Long Screws to Attach Louver Grille to Outer Sleeve.
REF. D
Use (4) 1/2" Long Screws to Attach frame to Exhaust Sleeve MIS-3014 A
Manual 2100-549L Page 19 of 59
FIGURE 11B UNIT MOUNTING
Manual 2100-549L Page 20 of 59
INSTALLATION INSTRUCTIONS MOUNTING THE UNIT
WIRING – MAIN POWER
The wall sleeve is attached to the I-TEC unit from the outside of the building. See Figures 11A & 11B. Refer to wall sleeve Manual 2100-562 supplied with sleeve.
Refer to the unit rating plate and/or Table 2 for wire sizing information and maximum fuse or 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 suitable for at least 75°C”. 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.
Following are the steps for attaching the I-TEC to the wall sleeve. 1. Lift the unit into place making sure that it is aligned side to side. 2. Push the unit back until the rear panel touches the sleeve gasket. 3. This unit must be level from side to side and from front to back. If adjustments are necessary, shim up under the base rails with sheets of metal or any substance not affected by moisture. 4. Attach the sleeve to the unit using the ten (10) ¾" long self-tapping screws supplied with the sleeve. 5. The exhaust sleeve has three (3) ¾" long screw slots in each side flange. Line these up with the screw engagement holes in the fan panel. Attach using six (6) ¾" long pointed sheet metal screws supplied with the sleeve. Extend the sleeve out until it is flush with the louver grill attachment angles. 6. Lock the sleeve in place using two (2) ½" long pointed sheet metal screws on each side by shooting through the slot into a pre-punched hole. 7. A bottom trim piece is shipped loose for installation beneath the doors. Attach the trim piece to the unit with screws provided. 8. The compressor is secured to the base with two (2) bolts for shipping. Both bolts are identified with a tag. Remove shipping bolts (Figure 5).
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 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. See “START UP” section for information on three phase scroll compressor start-ups. The field wiring conduit connections are located on the top right-hand corner of the unit with a wire raceway to feed the wires down to the circuit breaker(s). See Figure 12.
FIGURE 12 COMPONENT LOCATION ELECTRIC HEAT
INDOOR BLOWER LOW VOLTAGE
WIRE RACEWAY EVAPORATOR COIL
CONTROL PANEL
REFRIGERANT PORT OUTDOOR FAN
CONDENSER COIL
COMPRESSOR
VENT OPTION
Manual 2100-549L Page 21 of 59
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 3.
TABLE 3 – OPERATING VOLTAGE RANGE TAP
RANGE
240V
253 – 216
208V
220 – 187
NOTE: The voltage should be measured at the field power connection point in the unit and while the unit is operating at full load (maximum amperage operating condition).
8403-067 (CDT-2W40-LCD-RLY)
CS9B-THO
CS9B-THOC
CS9BE-THO
CS9BE-THOC
“A” terminal is the ventilation input. This terminal energizes any factory installed ventilation option. “W3” terminal is second stage electric heat. When “W3” terminal is energized, it locks out compressor operation to limit discharge air temperature and required branch circuit ampacity. “D” terminal is the dehumidification mode (on models so equipped).
Predominant Features 3 Stage Cool; 3 Stage Heat Programmable/Non-Programmable Electronic HP or Conventional Auto or Manual changeover
Fan Only
Energize G
Cooling Part Load
Energize G, Y1
Cooling Full Load
Energize G, Y1, Y2
HP Heating Part Load
Energize G, Y1, B/W1
HP Heating Full Load
Energize G, Y1, Y2, B/W1
HP Heating Full Load + Electric Heat (up to 10KW)
Energize G, Y1, Y2, B/W1, W2
Heating with Bank #1 Electric Heat Only
Energize G, W2
Emergency Heat (Heat pump operation is negated for this condition)
Energize G, W2, W3
Ventilation
Energize A
Dehumidification * * Models w/Dehumidification Only
Energize G, D
TABLE 4 – WALL THERMOSTATS
8403-060 (1120-445)
“W2” terminal is first stage electric heat (if equipped). First stage electric heat can be operated simultaneously with the heat pump operating.
NOTE: For total and proper control using DDC, a minimum of 9 controlled outputs are needed when above 10KW Electric Heat is employed with ventilation, a total of 8 controlled outputs with below 10KW Electric Heat with Ventilation, 7 controlled outputs below 10KW Electric Heat with no ventilation, 7 controlled outputs with no Electric Heat, but with ventilation, and 6 controlled outputs with no electric heat and no ventilation. If Dehumidification Model & Vent, 10 controlled outputs are needed when above 10KW Electric Heat is employed with ventilation.
The standard unit includes a remote thermostat connection terminal strip. See Figures 13 through 19 for connection diagrams. Compatible thermostats are listed in Table 4.
Thermostat
condensate overflow trip by the electronic heat pump control. This is a 24 VAC output.
Carbon Dioxide Sensor with LCD for Sensor Readings 3 Stage Heat, 3 Stage Cool, Prog/NonProg, HP or Conv, Auto or Manual Changeover, Humidity Sensor w/ dehumidification, Motion Sensor w/ Intelligent Learning Control, BACnet-compatible 3 Stage Heat, 3 Stage Cool, Prog/NonProg, HP or Conv, Auto or Manual Changeover, Humidity Sensor w/ dehumidification, CO2 Sensor, Motion Sensor w/ Intelligent Learning Control, BACnet-compatible 3 Stage Heat, 3 Stage Cool, Prog/NonProg, HP or Conv, Auto or Manual Changeover, Humidity Sensor w/ dehumidification, Motion Sensor, Intelligent Learning Control, BACnet-compatible, Ethernet-compatible 3 Stage Heat, 3 Stage Cool, Prog/NonProg, HP or Conv, Auto or Manual Changeover, Humidity Sensor w/ dehumidification, CO2 Sensor, Motion Sensor w/ Intelligent Learning Control, BACnet-compatible, Ethernet-compatible
LOW VOLTAGE CONNECTIONS These units use a grounded 24 volt AC low voltage circuit. “G” terminal is the fan input. “Y1” terminal is the compressor part load input. “Y2” terminal is the compressor full load input. “B/W1” terminal is the reversing valve input. The reversing valve must be energized for heating mode. “R” terminal is 24 VAC hot. “C” terminal is 24 VAC grounded. “L” terminal is compressor lockout output. This terminal is activated on a high or low pressure trip and Manual 2100-549L Page 22 of 59
LOW VOLTAGE CONNECTIONS FOR DDC CONTROL
GENERAL This unit is equipped with a variable speed ECM motor. The motor is designed to maintain rated airflow up to the maximum static allowed. It is important that the blower motor plugs are not plugged in or unplugged while the power is on. Failure to remove power prior to unplugging or plugging in the motor could result in motor failure.
CAUTION
Do not plug in or unplug blower motor connectors while the power is on. Failure to do so may result in motor failure.
FIGURE 13 BASIC HEAT PUMP WITH NO VENTILATION PACKAGE
Completestat Model #CS9B-THO or Model #CS9BE-THO
SC
SC
SC
24V
COM
G
Y1
Y2
O/B
W2
L
W1/E
A
GND
D
Yellow 3
2
Blue
Orange White Red
Thermostat Bard #8403-060
R
C
G
Y1
Y2
O/B
W2
L
W1/E
A
4
YO/D
2 3
Low Voltage Term. Strip
R
RT
C
G
Y1
Y2
B/W1
W2
W3
L
A
D
6
3
4
1
1
Factory installed jumper. Remove jumper and connect to N.C fire alarm
2 Not needed below 15KW 3
Additional wire required for dehumidification models
4
Relay Provided with Completestat
MIS-3016 A
Manual 2100-549L Page 23 of 59
FIGURE 14 HEAT PUMP WITH CRV, WITHOUT CO2 CONTROL
SC
SC
SC
24V
COM
G
Completestat Model #CS9B-THO or Model #CS9BE-THO
Y1
Y2
O/B
W2
L
W1/E
A
GND
D
Yellow 3 Orange
2
Blue
White 6
Red Thermostat Bard #8403-060
R
C
G
Y1
Y2
O/B
W2
W1/E
L
A
YO/D
2
Low Voltage Term. Strip
R
RT
C
G
Y1
Y2
W2
B/W1
1
W3
L
3
A
D
6
4
3
5 4
RED/WHITE BLACK/WHITE ORANGE BROWN/WHITE
CRV Wiring Harness
1 Factory installed jumper. Remove jumper and connect to N.C fire alarm circuit if emergency shutdown required.
4
Connect to "G" terminal when thermostat has "Occupancy Signal".
2
Not needed below 15KW.
5
Install a jumper between "G" and "A" only when thermostat without "Occupancy Signal" is used.
3
Additional wire required for dehumidification models.
Manual 2100-549L Page 24 of 59
6
Relay Provided with Completestat
MIS-3017 A
FIGURE 15 HEAT PUMP WITH CRV AND CO2 CONTROL
SC
SC
SC
24V
COM
G
Completestat Model #CS9B-THO or Model #CS9BE-THO
Y1
Y2
O/B
W2
L
W1/E
A
D
GND Yellow
3
2
Blue
Orange White
7
Red Thermostat Bard #8403-060
R
C
G
Y1
Y2
O/B
W2
W1/E
L
A
YO/D
NOTE: Bard 8403-060 thermostat must be in programmed 3 operation mode and in programmed fan mode for ventilation to function.
2
Low Voltage Term. Strip
R
RT
C
G
Y1
Y2
W2
B/W1
W3
L
A
D
6
3
5
1
2
4
1
RED/WHITE BLACK/WHITE ORANGE BROWN/WHITE
5 6
CRV Wiring Harness
1
Factory installed jumper. Remove jumper and connect to N.C fire alarm circuit if emergency shutdown required.
2
Not needed below 15KW.
3
Additional wire required for dehumidification models.
4
Connect to "G" terminal when thermostat has "Occupancy Signal".
4
6 6 CO2 Control Bard #8403-067
5
Install a jumper between "G" and "A" only when thermostat without "Occupancy Signal" is used.
6
If CS9B-THOC or CS9BE-THOC is used, connect "Brown/White" directly to "A" and do not use seperate CO2 controller.
7
Relay Provided with Completestat
MIS-3018 A
Manual 2100-549L Page 25 of 59
FIGURE 16 HEAT PUMP WITH ERV, WITHOUT CO2 CONTROL
SC
SC
SC
24V
COM
G
Completestat Model #CS9B-THO or Model #CS9BE-THO
Y1
Y2
O/B
W2
L
W1/E
A
GND
D
Yellow 3
2
Blue
Orange
White Red 6 Thermostat Bard #8403-060
R
C
G
Y1
Y2
O/B
W2
W1/E
L
A
YO/D
NOTE: Bard 8403-060 thermostat must 3 be in programmed operation mode and in programmed fan mode for ventilation to function.
2
Low Voltage Term. Strip
R
RT
C
G
Y1
Y2
W2
B/W1
1
W3
L
A
D
6
4
3
5 4
RED/WHITE BLACK/WHITE ORANGE BROWN/WHITE PINK PURPLE
ERV Wiring Harness
1 Factory installed jumper. Remove jumper and connect to N.C fire alarm circuit if emergency shutdown required.
4
Connect to "G" terminal when thermostat has "Occupancy Signal".
2
Not needed below 15KW.
5
Install a jumper between "G" and "A" only when thermostat without "Occupancy Signal" is used.
3
Additional wire required for dehumidification models.
6 Relay Provided with Completestat MIS-3019 A
Manual 2100-549L Page 26 of 59
FIGURE 17 HEAT PUMP WITH ERV AND CO2 CONTROL (ON/OFF CYCLING)
Completestat Model #CS9B-THO or Model #CS9BE-THO
SC
SC
SC
24V
COM
G
Y1
Y2
O/B
W2
L
W1/E
A
D
GND Yellow
3
2
Blue
Orange White
7
Red Thermostat Bard #8403-060
R
C
G
Y1
Y2
O/B
W2
L
W1/E
A
YO/D
NOTE: Bard 8403-060 thermostat must 3 be in programmed operation mode and in programmed fan mode for ventilation to function.
2
Low Voltage Term. Strip
R
RT
C
G
Y1
Y2
W2
B/W1
W3
L
A
5
1
6
Not needed below 15KW.
3
Additional wire required for dehumidification models.
4
Connect to "G" terminal when thermostat has "Occupancy Signal".
4
5 6
ERV Wiring Harness
2
3
1
RED/WHITE BLACK/WHITE ORANGE BROWN/WHITE PINK PURPLE
Factory installed jumper. Remove jumper and connect to N.C fire alarm circuit if emergency shutdown required.
6
2
4
1
D
5
6 CO2 Control Bard #8403-067 Install a jumper between "G" and "A" only when thermostat without "Occupancy Signal" is used.
6
If CS9B-THOC or CS9BE-THOC is used, connect "Brown/White" directly to "A" and do not use seperate CO2 controller.
7
Relay Provided with Completestat MIS-3020 A
Manual 2100-549L Page 27 of 59
FIGURE 18 HEAT PUMP WITH ERV AND CO2 CONTROL (FULLY MODULATING)
Completestat Model #CS9B-THO or Model #CS9BE-THO
SC
SC
SC
24V
COM
G
Y1
Y2
O/B
W2
L
W1/E
A
D
GND Yellow
3
2
Blue
Orange White
6 Red
Thermostat Bard #8403-060
R
C
G
Y1
Y2
O/B
W2
L
W1/E
A
YO/D
NOTE: Bard 8403-060 thermostat must be in programmed 3 operation mode and in programmed fan mode for ventilation to function.
2
Low Voltage Term. Strip
R
RT
C
G
Y1
Y2
W2
B/W1
W3
L
A
D
6
3
4
5
1
2
4
1
RED/WHITE BLACK/WHITE ORANGE BROWN/WHITE PINK PURPLE
3 CO2 Control Bard #8403-067
ERV Wiring Harness
1 Factory installed jumper. Remove jumper and connect to N.C fire alarm circuit if emergency shutdown required.
4
Connect to "G" terminal when thermostat has "Occupancy Signal".
2
Not needed below 15KW.
5
Install a jumper between "G" and "A" only when thermostat without "Occupancy Signal" is used.
3
Additional wire required for dehumidification models.
6
Relay Provided with Completestat
Manual 2100-549L Page 28 of 59
MIS-3021 B
FIGURE 19 HEAT PUMP WITH COMBINATION CRV AND DB ECONOMIZER (“N” VENT CODE) Only Recommend Bard CS9B-THOC or CS9BE-THOC as Require 3 Heating/Cooling Stages
Completestat Model #CS9B-THOC or Model #CS9BE-THOC
SC
SC
SC
24V
COM
G
Y0
Y1
Y2
O/B
W2
W1/E
L
A
GND
D 3
2
Yellow
Orange
Blue
White
5 Red
Low Voltage Term. Strip
R
RT
1
C
G
6
7
8
B/W1
W2
W3
L
A
D
Y1
Y2
4
RED/WHITE BLACK/WHITE ORANGE GRAY YELLOW PURPLE BROWN/WHITE PURPLE/WHITE YELLOW/BLACK BLUE
CRV/ECON Wiring Harness 1
Factory installed jumper. Remove jumper and connect to N.C fire alarm circuit if emergency shutdown required.
4
Connect orange wire to "G" terminal
2
Not needed below 15KW.
5
Relay Provided with Completestat
3
Additional wire required for dehumidification models. MIS-3270 A
Manual 2100-549L Page 29 of 59
START UP THESE UNITS REQUIRE R-410A REFRIGERANT AND POLYOL ESTER OIL.
REMEMBER: When adding R-410A refrigerant, it must come out of the charging cylinder/tank as a liquid to avoid any fractionation, and to insure optimal system performance. Refer to instructions for the cylinder that is being utilized for proper method of liquid extraction.
GENERAL 1. Use separate service equipment to avoid cross contamination of oil and refrigerants. 2. Use recovery equipment rated for R-410A refrigerant. 3. Use manifold gauges rated for R-410A (800 psi/250 psi low).
WARNING
Failure to conform to these practices could lead to injury or death.
4. R-410A is a binary blend of HFC-32 and HFC125. 5. R-410A is nearly azeotropic - similar to R-22 and R-12. Although nearly azeotropic, charge with liquid refrigerant.
SAFETY PRACTICES
6. R-410A operates at 40-70% higher pressure than R-22, and systems designed for R-22 cannot withstand this higher pressure.
2. Use gloves and safety glasses. Polyol Ester oils can be irritating to the skin, and liquid refrigerant will freeze the skin.
7. R-410A has an ozone depletion potential of zero, but must be reclaimed due to its global warming potential.
3. Never use air and R-410A to leak check; the mixture may become flammable.
8. R-410A compressors use Polyol Ester oil. 9. Polyol Ester oil is hygroscopic; it will rapidly absorb moisture and strongly hold this moisture in the oil. 10. A liquid line dryer must be used - even a deep vacuum will not separate moisture from the oil. 11. Limit atmospheric exposure to 15 minutes. 12. If compressor removal is necessary, always plug compressor immediately after removal. Purge with small amount of nitrogen when inserting plugs.
TOPPING OFF SYSTEM CHARGE If a leak has occurred in the system, Bard Manufacturing recommends reclaiming, evacuating (see criteria above), and charging to the nameplate charge. However, if done correctly, topping off the system charge can be done without problems. With R-410A, there are no significant changes in the refrigerant composition during multiple leaks and recharges. R-410A refrigerant is close to being an azeotropic blend (it behaves like a pure compound or single component refrigerant). The remaining refrigerant charge, in the system, may be used after leaks have occurred and then “top-off” the charge by utilizing the charging charts on the inner control panel cover as a guideline.
Manual 2100-549L Page 30 of 59
1. Never mix R-410A with other refrigerants.
4. Do not inhale R-410A – the vapor attacks the nervous system, creating dizziness, loss of coordination and slurred speech. Cardiac irregularities, unconsciousness and ultimate death can result from breathing this concentration. 5. Do not burn R-410A. This decomposition produces hazardous vapors. Evacuate the area if exposed. 6. Use only cylinders rated DOT4BA/4BW 400. 7. Never fill cylinders over 80% of total capacity. 8. Store cylinders in a cool area, out of direct sunlight. 9. Never heat cylinders above 125°F. 10. Never trap liquid R-410A in manifold sets, gauge lines or cylinders. R-410A expands significantly at warmer temperatures. Once a cylinder or line is full of liquid, any further rise in temperature will cause it to burst.
DESCRIPTION OF STANDARD EQUIPMENT Solid State Electronic Heat Pump Control Provides efficient 30, 60 or 90-minute defrost cycle. A thermistor sensor and speed up terminal for service along with a 8-minute defrost override are standard on the electronic heat pump control. By default, the I-TEC are factory shipped on the 90-minute defrost cycle. High/Low Pressure Switch Provides refrigerant circuit high pressure and loss of charge protection. Includes lockout circuit built into heat pump control that is resettable from room thermostat. Five Minute Compressor Time Delay Provides short cycle protection for the compressor which extends compressor life. Built into the electronic heat pump control as standard. Condensate Overflow Senses and provides system shut down if draining issue causes water level to rise in the lower drain pan. Low Ambient Control The low ambient control permits cooling operation down to 0°F outdoor ambient.
IMPORTANT INSTALLER NOTE For improved start-up performance, wash the indoor coil with a dishwasher detergent.
PHASE MONITOR All units with three phase scroll compressors are equipped with a 3 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 the compressor contactor is allowed to 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.
THREE PHASE SCROLL COMPRESSOR START UP INFORMATION Scroll compressors, like several other types of compressors, will only compress in one rotational direction. Direction of rotation is not an issue with single phase compressors since they will always start and run in the proper direction.
However, three phase compressors will rotate in either direction depending upon phasing of the power. Since there is a 50-50 chance of connecting power in such a way as to cause rotation in the reverse direction, verification of proper rotation must be made. Verification of proper rotation direction is made by observing that suction pressure drops and discharge pressure rises when the compressor is energized. Reverse rotation also results in an elevated sound level over that with correct rotation, as well as, substantially reduced current draw compared to tabulated values. Verification of proper rotation must be made at the time the equipment is put into service. If improper rotation is corrected at this time there will be no negative impact on the durability of the compressor. However, reverse operation for even one hour may have a negative impact on the bearing due to oil pump out. All three phase scroll compressors used in the I-TEC series are wired identically internally. As a result, once the correct phasing is determined for a specific system or installation, connecting properly phased power leads to the same Fusite terminal should maintain proper rotation direction. The direction of rotation of the motor may be changed by reversing any two line connections to the unit.
SERVICE HINTS 1. Caution user to maintain clean air filters at all times and 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. Switching to heating cycle at 75°F or higher outside temperature may cause a nuisance trip of the remote reset high pressure switch. Turn thermostat off, then on to reset the high pressure switch. 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. 4. Check all power fuses or circuit breakers to be sure they are the correct rating. 5. Periodic cleaning of the outdoor coils to permit full and unrestricted airflow circulation is essential. 6. Annual maintenance is required to make sure that all of the systems are functioning properly. a. Check to make sure that the drains are not obstructed in any way. b. Remove any debris in the condenser section of the unit. c. Inspect and wash outdoor coils as necessary. 7. All motors are sealed and require no oiling.
Manual 2100-549L Page 31 of 59
SEQUENCE OF OPERATION
PRESSURE SERVICE PORTS
COOLING PART LOAD – Circuit R-Y1 makes at thermostat pulling in compressor contactor, starting the compressor and outdoor motor. The G (indoor motor) circuit is automatically completed on any call for cooling operation or can be energized by manual fan switch on subbase for constant air circulation.
High and low pressure service ports are installed on all units so that the system operating pressures can be observed. Pressure tables can be found later in the manual covering all models. It is imperative to match the correct pressure table to the unit by model number. Upper and lower service doors must be attached to obtain proper reading.
COOLING FULL LOAD – Circuit R-Y1 & Y2 makes at the thermostat energizing the 2nd stage solenoid in the compressor. The default position of the compressor staging solenoid is non-energized. The compressor will run at low capacity until this solenoid is energized. HEATING STAGE 1 – A 24V solenoid coil on reversing valve controls heating cycle operation. Two thermostat options, one allowing “Auto” changeover from cycle to cycle and the other constantly energizing solenoid coil during heating season and thus eliminating pressure equalization noise except during defrost, are to be used. On “Auto” option a circuit is completed from R-B and R-Y1 on each heating “on” cycle, energizing reversing valve solenoid and pulling in compressor contactor starting compressor and outdoor motor. R-G also make starting indoor blower motor. Heat pump heating cycle now in operation. The second option has no “Auto” changeover position, but instead energizes the reversing valve solenoid constantly whenever the system switch on subbase is placed in “Heat” position, the “B” terminal being constantly energized from R. A thermostat demand for Stage 1 heat completes R-Y1 circuit, pulling in compressor contactor starting compressor and outdoor motor. R-G also make starting indoor blower motor. HEATING STAGE 2 – Circuit R-Y1 & Y2 makes at the thermostat energizing the 2nd stage solenoid in the compressor.
Manual 2100-549L Page 32 of 59
LOWERING OUTDOOR FAN SPEED FOR SOUND Supplied in the Literature Assembly is a Fan Control Resistor Assembly that can be installed to lower the fan speed for reduced sound performance. This Resistor Assembly is to be installed in series with the Outdoor Fan Control Thermistor to change the temperature curve that the fan logic control sees. It is anticipated that you will see a 2-3% drop in system capacity and efficiency when this resistor is installed. To install the Resistor Assembly: 1. Locate Fan Control Resistor Assembly in Literature Packet hanging on right inside door of unit. 2. Throw main power disconnect to the “OFF” position to eliminate risk of injury or death due to electrical shock. 3. Remove four (4) screws that retain the control panel cover to the unit. 4. Locate Fan Logic Control Board. 5. Locate one of the red leads of the Fan Control Thermistor where it attaches to the Fan Logic Control and remove it. 6. Install resistor in-line with the thermistor lead removed in Step #5, and then connect back onto the Fan Logic Control Board.
DEFROST CYCLE The defrost cycle is controlled by temperature and time on the solid state heat pump control. See Figure 20. When the outdoor temperature is in the lower 40°F temperature range or colder, the outdoor coil temperature is 32°F or below. This coil temperature is sensed by the coil temperature sensor mounted near the bottom of the outdoor coil. Once coil temperature reaches 30°F or below, the coil temperature sensor sends a signal to the control logic of the heat pump control and the defrost timer will start accumulating run time. After 30, 60 or 90 minutes of heat pump operation at 30°F or below, the heat pump control will place the system in the defrost mode. Factory default setting is 90 minutes. During the defrost mode, the refrigerant cycle switches back to the cooling cycle, the outdoor motor stops, electric heaters are energized, and hot gas passing through the outdoor coil melts any accumulated frost. When the temperature rises to approximately 57°F, the coil temperature sensor will send a signal to the heat pump control which will return the system to heating operations automatically. If some abnormal or temporary condition such as a high wind causes the heat pump to have a prolonged defrost cycle, the heat pump control will restore the system to heating operation automatically after 8 minutes. The heat pump defrost control board has an option of 30, 60 or 90-minute setting. All models are shipped from the factory on the 90-minute pin. If special circ*mstances require a change to another time, remove the wire from the 90-minute terminal and reconnect to the desired terminal. The manufacturer’s recommendation is for 90-minute defrost cycles. Refer to Figure 20.
There is an initiate defrost jumper (sen jump) on the control that can be used at any outdoor ambient during the heating cycle to simulate a 0° coil temperature. This can be used to check defrost operation of the unit without waiting for the outdoor ambient to fall into the defrost region. By placing a jumper across the SEN JMP terminals (a ¼ inch QC terminal works best) the defrost sensor mounted on the outdoor coil is shunted out & will activate the timing circuit. This permits the defrost cycle to be checked out in warmer weather conditions without the outdoor temperature having to fall into the defrost region. In order to terminate the defrost test the SEN JMP jumper must be removed. If left in place too long, the compressor could stop due to the high pressure control opening because of high pressure condition created by operating in the cooling mode with outdoor fan off. Pressure will rise fairly fast as there is likely no actual frost on the outdoor coil in this artificial test condition. There is also a 5-minute compressor time delay function built into the HPC. This is to protect the compressor from short cycling conditions. The board’s LED will have a fast blink rate when in the compressor time delay. In some instances, it is helpful to the service technician to override or speed up this timing period, and shorting out the SPEEDUP terminals for a few seconds can do this.
FIGURE 20 DEFROST CYCLE
LOW PRESSURE BYPASS TIMER SWITCH *(FACTORY SETTING 120 SECONDS)
SW SW 1 2 TIME (SEC) OFF OFF 30 ON OFF 60 120* OFF ON ON ON 180 OFF
There is a cycle speed up jumper on the control. This can be used for testing purposes to reduce the time between defrost cycle operation without waiting for time to elapse.
ON
Use a small screwdriver or other metallic object, or another ¼ inch QC, to short between the SPEEDUP terminals to accelerate the HPC timer and initiate defrost. Be careful not to touch any other terminals with the instrument used to short the SPEEDUP terminals. It may take up to 15 seconds with the SPEEDUP terminals shorted for the speedup to be completed and the defrost cycle to start. As soon as the defrost cycle kicks in remove the shorting instrument from the SPEEDUP terminals. Otherwise the timing will remain accelerated and run through the 1-minute minimum defrost length sequence in a matter of seconds and will automatically terminate the defrost sequence.
ACCUMULATED DEFROST TIME TIMER (FACTORY SETTING 60 MIN.) (FACTORY SETTING 90 MIN.) MIS-2668 A
Manual 2100-549L Page 33 of 59
I-TEC COMMERCIAL ROOM VENTILATOR SYSTEM GENERAL DESCRIPTION The I-TEC Commercial Room Ventilator (CRV) is designed to be used with all Bard I-TEC models. The only intent of this device is to provide the required ventilation by delivering fresh air to meet I.A.Q. (Indoor Air Quality) requirements. In the installed application, this system also includes exhaust provisions which are balanced with the intake air to maintain building pressurization requirements of ASHRAE 62.1 Standard. Ventilation is accomplished with (2) blower/ motor assemblies for maximum ventilation at low sound levels. The intake and exhaust blowers are programmed independently and are balanced to maintain a slight positive pressurization in accordance to ASHRAE 62.1 Standard. The I-TEC CRV is also provided with filters to reduce the required service needed and to further improve the I.A.Q. The exhaust air blowers are protected by disposable filters, and the intake air blowers are protected by washable filters. Both are accessible without the need for tools.
CONTROL WIRING The I-TEC CRV comes wired from the factory set to 375 CFM of ventilation. Care must be taken when deciding how to control the operation of the ventilator. When designing the control circuit for the ventilator, the following requirements must be met. 1. The indoor blower must be run whenever the I-TEC CRV is run. 2. Select and configure the correct CFM ventilation level that the I-TEC CRV needs to operate and configure the system to this level following later instructions within this section. Over ventilating serves no useful purpose and significantly affects the overall efficiency of the heat pump system. System operating costs would also increase. 3. Run the I-TEC CRV only during periods when the conditioned space is occupied. Running the ventilation during unoccupied periods wastes energy, decreases the expected life of the CRV, and can result in large moisture buildup in the structure. Running the CRV when the structure is unoccupied allows moisture to build up in the structure because there is little or no cooling load. Thus, the air conditioner is not running enough to remove the excess moisture being brought in. Use a control system that in some way can control the system based upon occupancy.
Manual 2100-549L Page 34 of 59
Operating the I-TEC CRV during unoccupied periods can result in a build up of excess moisture in the structure.
RECOMMENDED CONTROL SEQUENCES Several possible scenarios are listed below: 1. Use a programmable electronic thermostat with auxiliary terminal to control the CRV based on daily programmed occupance periods. Bard markets and recommends Bard Part #8403-060 programmable electronic thermostat. 2. Use Bard CompleteStat™ that incorporates temperature, humidity and occupancy control with learning capability into a single device. No programming required. 3. Use a DDC control system to control the CRV based upon a room occupancy schedule to control the CRV. 4. Tie the operation of the CRV into the light switch. The lights in a room are usually on only when occupied. 5. Use a manual timer that the occupants turn to energize the CRV for a specific number of hours. 6. Use a programmable mechanical timer to energize the CRV and indoor blower during occupied periods of the day. NOTE: The ventilation package comes with a blower interlock function, but is disabled when it is shipped from the factory in case you do not utilize a thermostat with an occupancy output, or a occupancy sensor and must tie “A” terminal to “G” terminal to drive the ventilation package. If you do have a thermostat or control that does drive occupancy output, you will need to remove the tape from the orange wire located in the low voltage terminal box, and connect it to the “G” terminal to activate this function. (See Figures 13-19.)
SETTING THE VENTILATION CFM LEVELS The I-TEC CRV has four pre-set levels of ventilation CFM available. These are 300, 375, 450 and 525 CFM of ventilation air. The I-TEC CRV is shipped from the factory set on the 375 CFM ventilation level. To change between these four different levels of provided ventilation CFM, first refer to Figure 21 to look up the corresponding CFM needed for the intake and exhaust blowers to meet the design criteria and determine which “speed/wire color” is needed. Then, perform the following steps.
REMOVE TO DISASSEMBLE, DO NOT OVERTIGHTEN BOLTS WHEN REPLACING
IMP
level needed in accordance
Suction Discharge (Low) (High)
UNIT TIE PLATE
Front Trim Piece
7961-754-2
corresponding CFM 3 PHASE LINE MONITOR CODES HP. BOARD TROUBLESHOOTING CODES with Figure 21. DESCRIPTION Open front swinging doors of main unit (byCODE popping DESCRIPTION CODE GREEN PHASES CORRECT, Y SIGNAL SLOW BLINK NORMAL OPERATION front door latches). LIGHT PRESENT FAST BLINK COMPRESSOR TIME DELAY 1 BLINK PRESS. SWITCH 1.370 PHASES INCORRECT, REVERSE Throw main powerLOdisconnect toFAILURE the “OFF” 2 BLINKS HI PR. SW./WATER SNSR. FAIL. RED 2 UNIT SUPPLY LEADS. DO NOT position 3toBLINKS eliminate risk MODE of injury due to DEFROST ACTIVEor death LIGHT MODIFY FACTORY WIRING. DOING 4 BLINKS HI PRESS. HARD LOCKOUT SO MAY RESULT IN UNIT DAMAGE. electrical shock. 7961-754-4 7961-754-5
UNIT TIE PLATE
7961-754-10
R-410A
7961-754-5
REMOVE TO DISASSEMBLE, DO NOT OVERTIGHTEN BOLTS WHEN REPLACING
7961-754-7
7961-754-3
VENT POWER CONNECTION
UNPLUG AND REMOVE WIRE CLAMPS 7961-754 TO DISASSEMBLE UNIT 7961-754-6
8.500
FIGURE 21 CRV MOTOR SPEED/CFM CONFIGURATION COLORS: ROSE BRIGHT YELLOW DARK ORANGE WHITESPEEDS BACKGROUND VENT OPTION INTAKE/EXHAUST
WIRE COLOR SPEEDDIECUT NOM. CFM FORM: SHEET BLACK 525 HI MATERIAL: OUTDOOR VINYL, SUPPLIER MUST BE CSA BLUE 450 FOR ACCEPTABLE ADHESIVE MED-HIAPPROVED ORANGE 375 LISTING. MED-LONAMEPLATE 300 LO RED
PRINTING: BLACK
TO CHANGE SPEEDS, MOVE BROWN INDOOR/OUTDOOR END USE: WIRE WITH WHITE TRACE. 7961-755-2
HI MED. HI
BROWN/WHITE
MED. LO LO
7961-7554
Move brown/white wire to corresponding motor speed for required ventilation CFM. Factory setting is Medium Lo (375 CFM).
5.500
HAZARD OF ELECTRICAL SHOCK. HAZARD OF ELECTRICAL SHOCK. 4. CAN Locate “Brown Wire with White that has a ELECTRICAL SHOCK Trace” CAN RESULT ELECTRICAL SHOCK RESULT IN SERIOUS the endINJURY whereORitDEATH. connects to the IN SERIOUS INJURY ORblack DEATH.terminal on DISCONNECT THE REMOTE DISCONNECT THE REMOTE terminal strip (See Figure 21). ELECTRIC POWER SUPPLY OR ELECTRIC POWER SUPPLY OR SUPPLIES SERVICING. 5. SERVICING. Move “Brown Wire with BEFORE White Trace” to the SUPPLIES BEFORE
Top Wall Bracket
2.
3. Remove six (6) screws holding front CRV door in 7961-754-8
WARNING place (See Figure! 22). WARNING
MOTOR SPEEDS
1.
HAZARD OF ELECTRICAL SHOCK. ELECTRICAL SHOCK CAN RESULT IN SERIOUS INJURY OR DEATH. DISCONNECT THE REMOTE ELECTRIC POWER SUPPLY OR SUPPLIES BEFORE SERVICING.
!
EXPOSED MOVING PARTS. DISCONNECT ALL ELECTRICAL POWER BEFORE SERVICING. FAILURE TO DO SO CAN RESULT IN SEVERE INJURY OR AMPUTATION.
7961-754-2
1.370
WARNING
7961-754-2
!
7961-754-1
7961-754-1
EXPOSED MOVING PARTS. DISCONNECT ALL ELECTRICAL POWER BEFORE SERVICING. FAILURE TO DO SO CAN RESULT IN SEVERE INJURY OR AMPUTATION.
3 PHASE SCRO REQUIRE PROP TO INSTALLATIO PROPER STAR
7961-754-1
EXPOSED MOVING PARTS. DISCONNECT ALL ELECTRICAL POWER BEFORE SERVICING. FAILURE TO DO SO CAN RESULT IN SEVERE INJURY OR AMPUTATION.
BLACK BLUE ORANGE RED
MIS-3022 A
Manual 2100-549L Page 35 of 59
C
FIGURE 22 CRV SPEED CHANGE TERMINAL ACCESS
CRV INTAKE BLOWER NOTE: CRV EXHAUST BLOWER IS BEHIND INTAKE BLOWER
REMOVE (5) SCREWS FROM CRV DOOR TO ACCESS CRV COMPONENTS MIS-3023
BLOWER SPEED CONTROL LOCATION
BLOWER SPEED CONTROL
BLOWER REMOVED FOR CLARITY
Manual 2100-549L Page 36 of 59
I-TEC COMBINATION CRV AND ECONOMIZER VENTILATION SYSTEM DESCRIPTION The I-TEC combination Commercial Room Ventilator (CRV) and Dry Bulb Economizer is designed to be used with all Bard I-TEC models. This ventilation package and its control provides two (2) roles: • It will provide the required ventilation by delivering fresh air to meet I.A.Q. (Indoor Air Quality) requirements through CRV portion of the device. • It will provide up to 525 CFM of free outdoor cooling CFM when the outdoor ambient temperature is below the outdoor thermostat setpoint.
Ventilation is accomplished with (2) blower/ motor assemblies for maximum ventilation at low sound levels. The intake and exhaust blowers are programmed independently and are balanced to maintain a slight positive pressurization in accordance to ASHRAE 62.1 Standard. The Ventilation Package is also provided with filters to reduce the required service needed and to further improve the I.A.Q. The exhaust air blowers are protected by disposable filters, and the intake air blowers are protected by washable filters. Both are accessible without the need for tools.
CONTROL WIRING Refer to Low Voltage Connection (Figure 19). Reference Figure 23 for Control Sequence of Operation.
Operating the I-TEC CRV during unoccupied periods can result in a build up of excess moisture in the structure.
SETTING THE VENTILATION CFM LEVELS The I-TEC CRV has four (4) pre-set levels of ventilation CFM available. These are 300, 375, 450 and 525 CFM of ventilation air. This ventilation package is shipped from the factory set on the 375 CFM ventilation level while the Economizer portion is set on the 525 CFM ventilation level. To change between these four different levels of provided ventilation CFM, refer to Figure 24 to look up the corresponding CFM needed for the intake and exhaust blowers to meet the design criteria and determine which “speed/wire color” is needed. Perform the following steps: 1. Open front swinging doors of main unit (by popping front door latches).
Open disconnect to shut all power OFF before doing this! Failure to do so could result in injury or death due to electrical shock.
2. Throw main power disconnect to the “OFF” position to eliminate risk of injury or death due to electrical shock. 3. Remove six (6) screws holding front CRV door in place (see Figure 22). 4. For CRV blower speed, locate “Brown Wire with White Trace” that has as black terminal on the end where it connects to the terminal strip (see Figure 24). 5. Move the “Brown Wire with White Trace” to the corresponding CFM level needed in accordance with Figure 24. 6. For Economizer Blower Speed, locate “Pink Wire” that has a black terminal on the end where it connects to the terminal strip (see Figure 24). 7. Move the “Pink” to the corresponding CFM level needed in accordance with Figure 24.
Manual 2100-549L Page 37 of 59
I-TEC ECON. SEQUENCE OF OPERATION
•
If outdoor temperature is below outdoor thermostat setpoint On call from CompleteStat for first stage cooling: • “YO” thermostat signal powers vent blower motors at Economizer Speed/Airflow (black – 525 CFM) through NC contacts of Relay “R1” (“Dehum Relay”). On call from CompleteStat for first and second stage cooling: • “YO” thermostat signal powers vent blower motors at Economizer Speed/Airflow (black – 525 CFM) through NC contacts of Relay “R1” (“Dehum Relay”). • “Y1” thermostat signal powers “Y1” terminal on unit low voltage terminal strip through NC contacts of relay “R2” (“High Ambient Relay”). On call from CompleteStat for first, second and third stage cooling: • “YO” thermostat signal powers vent blower motors at Economizer Speed/Airflow (black – 525 CFM) through NC contacts of Relay “R1” (“Dehum Relay”). • “Y1” thermostat signal powers “Y1” terminal on unit low voltage terminal strip through NC contacts of relay “R2” (“High Ambient Relay”).
If outdoor temperature is above outdoor thermostat setpoint On call from CompleteStat for first stage cooling: • “YO” thermostat signal powers relay coil “R2”. “R2” relay then closes NO contact between “R” and “Y1” at low voltage terminal strip engaging stage 1 mechanical cooling. NC contacts of relay “R2” that connects thermostat “Y1” to “Y1” on low voltage terminal strip is opened to eliminate feedback. On call from CompleteStat for first and second stage cooling: • “YO” thermostat signal powers relay coil “R2”. “R2” relay then closes NO contact between “R” and “Y1” at low voltage terminal strip engaging stage 1 mechanical cooling. NC contacts of relay “R2” that connects thermostat “Y1” to “Y1” on low voltage terminal strip is opened to eliminate feedback. • “Y1” thermostat signal powers relay coil “R3” through now closed relay contacts “R2” closing contacts between “R” and “Y2” at low voltage terminal strip. • “Y2” thermostat signal will do nothing, as NC contacts of relay “R2” are now opened to eliminate any feedback to thermostat.
FIGURE 23 ECONOMIZER CONTROL CIRCUIT THERMOSTAT SIGNALS
UNIT LOW VOLTAGE TERMINAL STRIP
Y2
8
6
R2
Dehumidification Mode On call from CompleteStat for dehumidification: • “D” thermostat signal powers relay coil “R1” (Dehum. Relay). “R1” relay, then opens NC contact between “YO” and outdoor thermostat. This will then negate any ECONOMIZER SPEED SIGNAL from energizing the ventilation package. “Y1” & “Y2” thermostat signals will pass through NC contacts of Relay “R2” (“High Ambient Relay”) as relay coil “R2” will be rendered inoperable by “R1” contacts opening. Normal cooling calls can then still apply to override Dehum. call.
3
Y2
COM
8
R
COM
R3 R2 R4
NO 5 NO
G Y1 7 Y1
7
D
D
YO
6
7
R2 R2
“Y2” thermostat signal powers “Y2” terminal on unit low voltage terminal strip through NC contacts of relay “R2” (“High Ambient Relay”).
1 4
R3 R1
NC
R1
R2 COM
ECON VENT SPEED C A
A
R4 CRV VENT SPEED
R1 = DEHUM RELAY R2 = HIGH AMBIENT RELAY R3 = FULL LOAD RELAY R4 = BLOWER INTERLOCK RELAY FIELD WIRE FACTORY WIRE
Manual 2100-549L Page 38 of 59
MIS-3272
HEATING MODE OPERATION
VENTILATION MODE
CompleteStat should never energize “YO” terminals in conjunction with “B”, so relay “R2” will never energize, and neither will Economizer Ventilation Speed.
The call for ventilation will never be disrupted with this control circuit. Anytime “A” signal from CompleteStat is present, the “VENTILATION SPEED” of the vent package will be energized. “A” Signal from thermostat will also energize relay “R4” (“Blower Interlock Relay”) completing a circuit from “R” to “G” through the “NO” contacts to ensure blower operations on the ventilation call.
“Y1” and “Y2” signals will pass through NC contacts of relay “R2” contacts, and all heating operations will be normal.
FIGURE 24 MOTOR SPEED/CFM CONFIGURATION VENT OPTION INTAKE/EXHAUST SPEEDS SPEED NOM. CFM WIRE COLOR BLACK HI 525 BLUE 450 MED-HI ORANGE 375 MED-LO RED 300 LO TO CHANGE SPEEDS, MOVE BROWN WIRE WITH WHITE TRACE.
7961-755-2
PINK
HI MED. HI
BROWN/WHITE
MED. LO LO
MOTOR SPEEDS
Move pink wire to corresponding motor speed for required economizer operation CFM. Factory setting is High (525 CFM).
7961-7554
Move brown/white wire to corresponding motor speed for required ventilation CFM. Factory setting is Medium Lo (375 CFM).
BLACK BLUE ORANGE RED
MIS-3271
Manual 2100-549L Page 39 of 59
I-TEC ENERGY RECOVERY VENTILATOR SYSTEM GENERAL DESCRIPTION The I-TEC Energy Recovery Ventilator (ERV) was designed to provide energy efficient, cost effective ventilation to meet I.A.Q (Indoor Air Quality) requirements while still maintaining good indoor comfort and humidity control for a variety of applications such as schools, classrooms, lounges, conference rooms and others. It provides a constant supply of fresh air for control of airborne pollutants including CO2, smoke, radon, formaldehyde, excess moisture, virus and bacteria. The ERV incorporates patented rotary heat exchanger technology to remove both heat and moisture. The package consists of unique rotary Energy Recovery Cassettes that can be easily removed for cleaning or maintenance. It has two 15-inch diameter heat transfer wheels for efficient heat transfer. The heat transfer wheels use a permanently bonded dry dessicant coating for total heat recovery. The I-TEC ERV is also provided with filters to reduce the required service needed and to extend the life of the heat recovery wheels. The exhaust air blower is protected by disposable filters, and the intake air blower is protected by washable filters. Both are accessible without the need for tools. Ventilation is accomplished with (2) blower/motor assemblies for maximum ventilation at low sound levels. The intake and exhaust blowers can be independently adjusted to maintain desired building pressurization conditions. The rotating wheels provide the heat transfer effectively during both summer and winter conditions. Provides required ventilation to meet the requirements of ASHRAE 62.1 Standard. NOTE: During operation below 5°F outdoor temperature, freezing of moisture in the heat transfer wheel can occur. Consult the factory if this possibility exists. The I-TEC ERV can be controlled in different ways. It can be turned ON/OFF with an occupancy control, thermostat, or CO2 control. It can also be configured for fully-modulating variable speed with a CO2 control to only bring in the minimal amount of ventilation required (helping to minimize sound levels and ventilation load on the structure).
Manual 2100-549L Page 40 of 59
CONTROL WIRING The I-TEC ERV comes wired from the factory ready to operate in manual mode (ON/OFF cycling) and set to 375 CFM of ventilation. Care must be taken when deciding how to control the operation of the ventilator. When designing the control circuit for the ventilator, the following requirements must be met. 1. The indoor blower must be run whenever the I-TEC ERV is run. 2. Select and configure the correct CFM ventilation level that the I-TEC ERV needs to operate and configure the system to this level following later instructions within this section. Over ventilating serves no useful purpose and significantly affects the overall efficiency of the heat pump system. System operating costs would also increase. 3. Run the I-TEC ERV only during periods when the conditioned space is occupied. Running the ERV during unoccupied periods wastes energy, decreases the expected life of the ERV, and can result in large moisture buildup in the structure. The ERV removes 60-70% of the moisture in the incoming air, not 100% of it. Running the ERV when the structure is unoccupied allows moisture to build up in the structure because there is little or no cooling load. Thus, the air conditioner is not running enough to remove the excess moisture being brought in. Use a control system that in some way can control the system based upon occupancy.
Operating the I-TEC ERV during unoccupied periods can result in a build up of excess moisture in the structure.
RECOMMENDED CONTROL SEQUENCES
5. Locate two 0-10Vdc Motor Control Boards in control panel (see Figure 28). Several possible scenarios are listed below: 6. On intake Motor Control Board, observing “GREEN 1. Use a programmable electronic thermostat with REV. DATE DESCRIPTION ECN NO DRN CHK AP STATUS LIGHT”, turn manual adjust potentiometer auxiliary terminal to control the ERV based on “CCW” to increase “FLOW INDEX” or CW to 10629 CB SD R A 11/17/2011 REVISED 2 BLINKS CODE ON #7961-754-4 daily programmed occupance periods. Bard reduce “FLOW INDEX” to match desired setting. markets and recommends BardONPart #8403-060 B 11/19/2012 REMOVED LOCKING CAPS TEXT 7961-754-3 10849 BR SD C NOTE: After long pause, the green status light will programmable electronic thermostat. C 10/30/2013 REVISED "4" BLINKS CODE ON 7961-754-4 11096 BD SD R blink long-blinks for the “TEN COUNT” of the “FLOW 2. Install a Bard CompleteStat with occupancy sensor RATE INDEX”, then immediately followed by fast blinks which learns the room usage and automatically which indicate the second digit. For example, a Flow engages ventilation (see Figure 18). Index of 23 would be two long blinks, followed by 3 3. Use a DDC control system to control the ERV based fast blinks of the “GREEN STATUS LIGHT”. upon a room occupancy schedule to control the 7. On exhaust Motor Control Board, observing ERV. “GREEN STATUS LIGHT”, turn manual adjust 4. Tie the operation of the ERV into the light switch. potentiometer “CCW” to increase “FLOW INDEX” The lights in a room are usually on only when or CW to reduce “FLOW INDEX” to match desired occupied. setting. 5. Use a manual timer that the occupants turn to NOTE: Same “GREEN STATUS LIGHT” blink as Step #6. energize the ERV for a specific number of hours. 2.585 2.585 2.585 6. Use a programmable mechanical timer to energize CHANGING TO FULLY MODULATING the ERV and indoor blower during occupied periods MODE of the day. If you want to operate the ERV in fully variable mode (Fig. NOTE: The ventilation package comes with a blower ! but is disabled when it is shipped ! 25B) (only run at required speed to maintain ! set-point interlock function, CO2 levels), you will need to configure the ERV to the from the factory in case you do not utilize a thermostat following: with an occupancy output, or a occupancy sensor 1. Open front swinging doors of main unit (by popping and must tie “A” terminal to “G” terminal to drive the front door latches). ventilation package. If you do have a thermostat or 2. Throw main power disconnect to the “OFF” control that does drive occupancy output, you will need 2.336 position to eliminate risk of injury or death due to to remove the tape from the orange wire 7961-754-1 located in the 7961-7 7961-754-1 electrical shock. low voltage terminal box, and connect it to the “G” MOVING PARTS. EXPOSED EXPOSED MOVING terminal toEXPOSED activate this function. (See Figures 13-19.) 3. MOVING RemovePARTS. ERV Control Panel Cover by removing fourPARTS. DISCONNECT ALL ELECTRICAL DISCONNECT ALL ELECTRICAL DISCONNECT ALL ELECTRICAL (4) screws (see Figure 27). POWER BEFORE SERVICING. BEFORE SERVICING. POWER BEFORE SERVICING. CHANGING VENTILATION CFM RATESPOWER 4. Locate two 0-10Vdc Motor Control Boards in FAILURE TO DO SO CAN RESULT FAILURE TO control DO SO panel CAN RESULT IN MANUAL MODE (see Figure 28). FAILURE TO DO SO CAN RESULT IN SEVERE INJURY OR AMPUTATION. IN SEVERE INJURY OR AMPUTATION. IN SEVERE INJURY OR AMPUTATI 5. Pull jumper pins from “M” terminals, and move to “P” terminals (see Figure 28). ! ! ! 6. Connect “+” 0-10Vdc output from CO2 control to HAZARD OF ELECTRICAL SHOCK. HAZARD ELECTRICAL SHOCK HAZARD OF Terminal ELECTRICAL SHOCK. #3 (along with pink wire), and OF connect ELECTRICAL SHOCK CAN RESULT ELECTRICAL ELECTRICAL“-” SHOCK CAN RESULT to Terminal #4 (along with purple wire) ofSHOCK unit CAN RESULT 1.370 IN SERIOUS INJURY OR DEATH. IN SERIOUS INJURY OR DEATH. IN SERIOUS low INJURY OR DEATH. voltage terminal strip. DISCONNECT THE REMOTE DISCONNECT THE REMOTE DISCONNECT THE REMOTE 7. POWER Follow the directions the CO2 controlSUPPLY OR ELECTRIC POWER SUPPLY OR ELECTRIC POWER ELECTRIC SUPPLY OR supplied with to configure the control appropriately. SUPPLIES BEFORE SERVICING. SUPPLIES BEFORE SERVICING. SUPPLIES BEFORE SERVICING.
WARNING
WARNING
WARNING
WARNING
WARNING
7961-754-2
7961-754-2
WARNING
To adjust HP. the BOARD airflow TROUBLESHOOTING ventilation rate, firstCODES refer to 3 PHASE LINE MONITOR CODES Figure 25A to look up the “FLOW INDEX” needed CODE DESCRIPTION DESCRIPTION CODE NORMAL OPERATION SLOW BLINK for the intake and exhaust blowers for the CFM youGREEN PHASES CORRECT, Y SIGNAL LIGHT PRESENT BLINK COMPRESSOR TIME DELAY require. FAST Then, perform the following steps: 1 BLINK LO PRESS. SWITCH FAILURE 1.370 PHASES INCORRECT, REVERSE 1. Open front swinging of mainSNSR. unit FAIL. (by popping 2 BLINKS HI PR.doors SW./WATER RED 2 UNIT SUPPLY LEADS. DO NOT front door latches). 3 BLINKS DEFROST MODE ACTIVE LIGHT MODIFY FACTORY WIRING. DOING 4 BLINKS HI PRESS. HARDtoLOCKOUT 2. Throw main power disconnect the “OFF” SO MAY RESULT IN UNIT DAMAGE. 7961-754-4 7961-754-10 position to eliminate risk of injury or death due to 7961-754-5 7961-754-5 UNIT TIE PLATE UNIT TIE PLATE electrical shock. REMOVE TO DISASSEMBLE, DO NOT REMOVE TO DISASSEMBLE, DO NOT 3. Remove five (5) screws front ERV door inOVERTIGHTEN BOLTS WHEN REPLACING OVERTIGHTEN BOLTSholding WHEN REPLACING place (see Figure 27). 4. Remove ERV Control Panel Cover by removing four 8.500 (4) screws (see Figure 27).
Suction Discharg (Low) (High)
R-410A
7961-7
VENT POWER CONNECTIO
UNPLUG AND REMOVE WIRE CLAMPS TO DISASSEMBLE UNIT 7961
Manual 2100-549L Page 41 of 59
COLORS: ROSE
PERFORMANCE AND APPLICATION DATA SUMMER COOLING PERFORMANCE (INDOOR DESIGN CONDITIONS 75°DB/62°WB) Ambient O.D. DB/WB
VENTILATION RATE 450 CFM 65% EFFICIENCY F
VLT
VLS
VLL
HRT
HRS
75 21465 14580 6884 13952 9477 105
100
95
VENTILATION RATE 375 CFM 66% EFFICIENCY HRL
VLT
VLS
VLL
HRT
HRS
4475 17887 12150 5737 11805 8018
VENTILATION RATE 300 CFM 67% EFFICIENCY VLS
VLL
HRT
HRS
HRL
3786 14310 9720
HRL
VLT
4590
9587
6512
3075 0
70 14580 14580
9477
9477
12150 12150
8018
8018
9720
9720
6512
6512
65 14580 14580
9477
9477
12150 12150
8018
8018
9720
9720
6512
6512
80 31590 12150 19440 20533 7897 12635 26325 10125 16200 17374 6682 10692 21060 8100 12960 14110 5427
8683
75 21465 12150 9314 13952 7897
6210
9587
5427
4160
70 12352 12150
202
8029
7897
6054 17887 10125 7762 11805 6682 131
10293 10125
168
6793
6682
5123 14310 8100 111
8235
8100
135
5517
5427
90
65 12150 12150
7897
7897
10125 10125
6682
6682
8100
8100
5427
5427
60 12150 12150
7897
7897
10125 10125
6682
6682
8100
8100
5427
5427
80 31590 9720 21870 20533 6318 14215 26325 8100 18225 17374 5345 12028 21060 6480 14580 14110 4341
9768
75 21465 9720 11744 13952 6318
7634 17887 8100
9787 11805 5345
6459 14310 6480
7830
9587
4341
5246
70 12352 9720
1711 10293 8100
2193
6793
5345
1447
8235
6480
1755
5517
4341
1175
2632
8029
6318
65
9720
9720
6318
6318
8100
8100
5345
5345
6480
6480
4341
4341
60
9720
9720
6318
6318
8100
8100
5345
5345
6480
6480
4341
4341
80 31590 7290 24300 20533 4738 15794 26325 6075 20250 17374 4009 13365 21060 4860 16200 14110 3256 10854
90
75 21465 7290 14175 13952 4738
9213 17887 6075 11812 11805 4009
7796 14310 4860
9450
9587
3256
6331
70 12352 7290
3290 10293 6075
5062
8029
4738
4218
6793
4009
2784
8235
4860
3375
5517
3256
2261
65
7290
7290
4738
4738
6075
6075
4009
4009
4860
4860
3256
3256
60
7290
7290
4738
4738
6075
6075
4009
4009
4860
4860
3256
3256
80 31590 4860 26730 20533 3159 17374 26325 4050 22275 17374 2672 14701 21060 3240 17820 14110 2170 11939
85
80
75
75 21465 4860 16605 13952 3159 10793 17887 4050 13837 11805 2672
9132 14310 3240 11070 9587
2170
7416
70 12352 4860
3346
7492
8029
3159
6243
6793
2672
4120
8235
3240
4995
5517
2170
65
4860
4860
3159
3159
4050
4050
2672
2672
3240
3240
2170
2170
60
4860
4860
3159
3159
4050
4050
2672
2672
3240
3240
2170
2170
75 21465 2430 19035 13952 1579 12372 17887 2025 15862 11805 1336 10469 14310 1620 12690 9587
1085
8502
70 12352 2430
9922
1085
4432
65
4252
2430
1822
814
60
2430
2430
70 12352
65
4252
4252
60
8029
4870 10293 4050
1579
6449 10293 2025
8268
2764
1579
1184
3543
2025
1518
1579
1579
2025
2025
12352 8029
2338
1336
1002
1336
1336
6793
10293 6793
8235
1620
6615
5517
2835
1620
1215
1899
1085
1620
1620
1085
1085
8235
8235
5517
5517
2764
2764
3543
3543
2338
2338
2835
2835
1899
1899
LEGEND:
375 CFM 81% EFFICIENCY
300 CFM 82% EFFICIENCY
DB/°F
WVL
WHR
WVL
WHR
WVL
WHR
65 60 55 50 45 40 35 30 25 20 15
2430 4860 7290 9720 12150 14580 17010 19440 21870 24300 26730
1944 3888 5832 7776 9720 11664 13608 15552 17496 19440 21384
2025 4050 6075 8100 10125 12150 14175 16200 18225 20250 22275
1640 3280 4920 6561 8201 9841 11481 13122 14762 16402 18042
1620 3240 4860 6480 8100 9720 11340 12960 14580 16200 17820
1328 2656 3985 5313 6642 7970 9298 10627 11955 13284 14612
Manual 2100-549L Page 42 of 59
5457
8029 10293
VENTILATION RATE 450 CFM 80% EFFICIENCY
1336
WINTER HEATING PERFORMANCE (INDOOR DESIGN CONDITIONS 70°F DB) Ambient O.D.
6793
VLT = VLS = VLL = HRT = HRS = HRL = WVL = WHR =
Ventilation Load – Total Ventilation Load – Sensible Ventilation Load – Latent Heat Recovery – Total Heat Recovery – Sensible Heat Recovery – Latent Winter Ventilation Load Winter Heat Recovery
Note: All performance data is based on operating intake and exhaust blower on the same speed.
ERV "MANUAL MODE" JUMPERFIGURE PIN ON25A "M" Terminal
ERV "MOD
ERV “MANUAL MODE” JUMPER PIN ON “M” TERMINAL
ERV CFM 450
To adjust the airflow ventilation rate (NO CO2 FLOW INDEX (Light CONTROL/NON-MODULATING) , determine the "FLOW Blink Code) INDEX" needed for the intake and exhaust blowers for the CFM you require. 100
425
89
400
83
375
76
350
59
325
50
300
40
275
32
250
25
225
12
200
9
175
4
150
1
M" Terminal
he airflow ventilation rate (NO CO2 -MODULATING) , determine the "FLOW for the intake and exhaust blowers for the CFM you require.
-10Vdc Motor Control Boards in control panel
otor Control Board, observing "GREEN STATUS l adjust potentiometer (with a small phillips-head W" to increase "FLOW INDEX" or CW to reduce match desired setting. (NOTE: After long pause, ht will blink long-blinks for the "TEN COUNT" of NDEX", which then is immediately followed by ndicate the second digit. For example, a Flow be two long blinks, followed by 3 fast blinks of the "GREEN STATUS LIGHT".)
Motor Control Board, observing "GREEN STATUS l adjust potentiometer (with a small phillips-head W" to increase "FLOW INDEX" or CW to reduce match desired setting. (Same GREEN STATUS IGHT blink (refer to Step #5))
1.> Locate two 0-10Vdc Motor Control Boards in control panel
CFM 450 425 400
2.> On intake Motor Control Board, observing "GREEN STATUS LIGHT", turn manual adjust potentiometer (with a small phillips-head screwdriver) "CCW" to increase "FLOW INDEX" or CW to reduce "FLOW INDEX" to match desired setting. (NOTE: After long pause, the green status light will blink long-blinks for the "TEN COUNT" of the "FLOW RATE INDEX", which then is immediately followed by fast blinks which indicate the second digit. For example, a Flow Index of 23 would be two long blinks, followed by 3 fast blinks of the "GREEN STATUS LIGHT".)
3.> On exhaust Motor Control Board, observing "GREEN STATUS LIGHT", turn manual adjust potentiometer (with a small phillips-head screwdriver) "CCW" to increase "FLOW INDEX" or CW to reduce "FLOW INDEX" to match desired setting. (Same GREEN STATUS LIGHT blink (refer to Step #5))
375 350 325 300 275 250 225 200 175 150 125
FIGURE 25B ERV "MODULATING MODE" JUMPER PIN ON "P" TERMINAL ERV “MODULATING MODE” JUMPER PIN ON “P” TERMINAL CFM
Vdc Signal from CO2 Control
450
10
425
8.87
400
8.31
375
7.61
350
6.73
325
5.91
300
5.15
275
4.58
250
4.06
225
2.91
200
2.57
175
2.24
150
1.74
125
0.96
100
0.77
After determining the air volume rates needed for the intended application (Maximum & Minimum), the table immediately to the left will allow for you to program your CO2 control output voltages in correlation to the CO2 levels you wish to control when Bard Part # 8403-067 CO2 Control is applied.
Manual 2100-549L Page 43 of 59
100
Vd fr C
FIGURE 26 VENTILATION AIRFLOW DIAGRAM
Supply Air
SUPPLY BLOWER
Return Air
Outdoor Air
VENT INTAKE BLOWER
Indoor Air
VENT EXHAUST BLOWER MIS-3024
Manual 2100-549L Page 44 of 59
FIGURE 27 ERV ACCESS
ERV INTAKE BLOWER NOTE: ERV EXHAUST BLOWER IS BEHIND INTAKE BLOWER ERV CASSETTE ASSEMBLIES
MIS-3025
REMOVE (5) SCREWS FROM ERV DOOR TO ACCESS ERV COMPONENTS
ERV CONTROL PANEL LOCATION
Manual 2100-549L Page 45 of 59
Bulletin AQ-CDT
e 24 Vac side of the power transformer4. Connect the ACU+ neutral connection to the earthed lead.
Series CDT Carbon Dioxide/Temperature Transmitter
50/60Hz connection to the hot side of the 24 Vac Class II power source. With the “P” jumper out, Specifications - Installation s connection as a means to stop the ECM Motor. Most automation controllersand will Operating power the Instructions a 24 Vac on/off output, eliminating the fan relay. Automation controllers that switch neutral may FIGURE 28
CONTROL BOARD CONFIGURATION/SETTING 35/64
[13.89]
ngle-ended, so power neutral and signal common are internally connected. ECM Motor Control Cable
1-53/64 [46.43]
Control Signal
internally connected
. 271-511-RC
24Vac/dc
Universal outputs allow users to select the transmitter output to be 4 to 20 mA, 0 to 5 VDCClass or 0 to II 10Power VDC to Source work with virtually any building management controller. An optional relay with user adjustable set points can be used to control exhaust Neutral/Common Earth neutral/Common fans, open actuated windows or dampers, or signal a light or horn. at transformer
for electrical safety.
For applications that require visual indication, the Series CDT can be ordered with an integral LCD display or the Model A-449 remote LCD display that can plug into the mini-connector port on the side of the transmitter. The display can be configured to display temperature only, CO 2 only or CO2 and temperature together. Push buttons are standard on the transmitters for access to the menu structure, but the transmitter can be ordered without the buttons. To prevent tampering, the action of the buttons can be locked out using an internal jumper selection. Menu items that can be accessed include: engineering units, relay output set points, 2 configuration, transmitter output scaling, ambient barometric pressure and display field calibration of the transmitter.
Evolution Controls Inc.
CONFIGURING BARD PART #8403-067 CO CONTROL for ERV MODULATING CONTROL Single beamPART dual-wavelength sensor advantages: BARD #8403-067
• Automatically corrects for aging effects in occupied and unoccupied buildings
Carbon Dioxide and Transmitters o Perfect for hospitals and Temperature manufacturing plants that are occupied 24 hours per day accurately monitor the CO2 concentration and • Measures actual unfiltered light intensity directly temperature infrom schools, office buildings, and other indoor o Eliminates error incorrect assumptions of gas concentration in theoretical environments tomethods help achieve LEED® certification. logic assumption
SPECIFICATIONS
3-13/32 [86.52]
4x 3/16 [4.76]
Board mode pins factory shipped on “M” pin for On/Off control scheme using “A” signal on low voltage control board
1-13/32 [50.01]
SpECIfICATIONS “Red” status light (on Range: when has power) onunit model); CO2: 0 to 2000 or 0 to 5000 ppm (depending Temperature: 32 to 122°F (0 to 50°C). Accuracy: ±40 ppm + 3% of reading. “Green” Temperature Dependence: ±8 ppm / °C at 1100 ppm.signal light continuously indicates the flow index the Non-Linearity: 16 ppm. blower producing. After a mm ofisHg. pressure Dependence: 0.13% of reading per pause, the lamp will flash out Response Time: 2 minutes for 99% step change. long(0digits which will indicate Ambient Operating Temperature: 32 to 122°F to 50°C). the(non-condensing). “TENS” count, which is Ambient Operating Humidity: 10 to 95% RH followed by short power Requirements: 16 to 35 VDC / 19 toimmediately 28 VAC. flashes 1 and 99. For power Consumption: Average: 2 watts; Peak: 3.75 between watts. Sensor: Single beam, dual-wavelength NDIR. example, a flow index of 23 would Output: yield two long flashes and three Current: 4 to 20 mA (max 500 Ω); short flashes. Voltage: 0 to 5 VDC or 0 to 10 VDC (min 500 Ω); Relay: SPST NO 2A @ 30 VDC; RTD or thermistor per r-t curves (depending on model). Manual Use when operating in manual mode (“M” Weight: adjust 5.6 oz screw. (158.8 g).
life, a single-beam dual-wavelength non-dispersive infrared (NDIR) sensor is used to automatically correct the measurement in both occupied and unoccupied Common buildings against aging effects. The single-beam dual-wavelength sensor Aux r using an technology provides the highest level of accuracy Power compared to Automatic Baseline Correction Signal methodsCommon, which can unintentionally shift the calibration based on CO 2 or control cable. 24Vac/dc levels and barometric pressure Aux Common & conditions. In order to achieve a higher level of accuracy, the Series CDT includes digital barometric pressure adjustment and the Neutral/Common are ability to field-calibrate the sensor.
To Automation 21K ohm load Controller Include this Signal Common culating a 4-20 Ma Series CDT Carbon Dioxide and Temperature Transmitters accurately monitor 5 m 1% resistorthe 0-2,000 RPM RPMbuildings, Out and other CO2 concentration and temperature in schools, office = 0-10Vdc dropping indoor environments to help achieve LEED® certification. For increased sensor
1-3/16
[35.72]
4-31/64 [113.9]
c control signal tion. Connect mmon to the
1-3/16
[30.20] [30.20] Move 3x 3/8jumper pin to “P” position [9.53] to allow variable 7/8 ventilation control using 0-10 [22.35] 1-13/32 VDC CO2 controller
p.3 of 4.
jumper installed) along with the “GREEN SIGNAL LIGHT” to adjust to the required CFM of ventilation. CW rotation reduces the “FLOW INDEX”, CCW rotation increases the “FLOW INDEX”. INSTALLATION
WARNING
Disconnect power supply before installation to prevent electrical shock and equipment damage.
Make sure all connections are in accordance with the job wiring diagram and in accordance with national and local electrical codes. Use copper conductors only.
CAUTION
Use electrostatic discharge precautions (e.g., use of wrist straps) during installation and wiring to prevent equipment damage.
CAUTION
Avoid locations where severe shock or vibration, excessive moisture or corrosive fumes are present.
Range: CO2: 0 to 2000 or 0 to 5000 ppm (depending on model) CAUTION Do not exceed ratings of this device, permanent damage not covered by warranty may result. Temperature: 32 to 122°F (0 to 50°C) Accuracy: ±40 ppm + 3% of reading NOTICE Upon powering the transmitter, the firmware version will flash on the display. A warm up period of 30 minutes is required for the Temperature Dependence: ±8 ppm/°C at 1100 ppm transmitter to adjust to the current CO 2 concentration. Non-Linearity: 16 ppm Pressure Dependence: 0.13% of reading per mm of Hg NOTICE Self calibration feature of the transmitter requires exposure to normal outdoor equivalent carbon dioxide level once every thirty Response Time: 2 minutes for 99% step change days. Ambient Operating Temperature: 32 to 122°F (0 to 50°C) Ambient Operating Humidity: 10 to 95% RH (noncondensing) MOUNTING Power Requirements: 16 to 35 VDC/19 to 28 VAC 1. Push tab on bottom of cover and lift cover from Power Consumption: Average: 2 watts; Peak: 3.75 watts back plate. Sensor: Single beam, dual-wave length NDIR 2. the mounting location, away from diffusers, DWYER INSTRUMENTS, INC. phone: Select 219/879-8000 www.dwyer-inst.com Output: lights or any external influences. p.O. BOX 373 • MICHIGAN CITY, INDIANA 46361, U.S.A. fax: 219/872-9057 e-mail: [emailprotected] Current: 4 to 20 mA (max 500 Ω) 3. Mount transmitter on a vertical surface to a standard Voltage: 0 to 5 VDC or 0 to 10 VDC (min 500 Ω) electrical box using the two #6 M2C type screws Relay: SPST NO 2A @ 30 VDC provided. RTD or thermistor per r-t curves (depending on model) Weight: 5.6 oz (158.8 g) Manual 2100-549L Page 46 of 59
fIGURE 5: Active Output Diagram Use maximum 18 AWG wire for cover wiringtotobase terminals. any power. temperature are on notthe polarity 5. Reattach plate. Refer to Figure 5 for wiringThermistor and Passive RTD passive outputs outputs are located back sensitive. plate and doWiring not require Useinformation. maximum 18 AWG wire for wiring to terminals. Refer to Figure 5 for wiring any power. Passive temperature outputs are not polarity sensitive. Remote Display WIRING Thermistor and RTD Outputs information. For models without integral LCD display, Modelplate and do not r Thermistor and an RTD passive outputs areremote locateddisplay on the back Remote Displaythat are ordered The mini USB plug A-449 used toany display the Passive temperature anddisplay, carbon dioxide. Use maximum 18 AWG wire for wiring to terminals. Refer toFor Figure 5 can for wiring power. temperature outputs aredisplay not polarity sensitive. models thatbe are ordered without an integral LCD remote Model of the plugs the receptor the side of theThe housing. Afterplug a short information. A-449 can remote be useddisplay to display theinto temperature andon carbon dioxide. mini USB warm up time, the display begin to on show temperature carbon Remote Display of the remote display plugs into will the receptor the the sidecurrent of the housing. Afterand a short 4. Pull wires through sub base hole and make dioxide measurements configured by user to show only LCD temperature or Forunless models that are ordered without an integral display, remote display M warm up time, the display will begin to show thethe current temperature and carbon necessary connections. onlymeasurements carbon dioxide. A-449 can be used display the and carbon or dioxide. The mini US Before any adjustment can beuser made to the dioxide unless configured bytothe to temperature show only transmitter, temperature
EDITING MENU PARAMETERS
5. Reattach cover to base plate. PJ2
of the remote display plugs the receptor side of the housing. After a only carbonthe dioxide. Menu Lockout Jumper (PJ4)intomust be setontothethe EDITING MENU pARAMETERS warm up time, the display will begin to show the current temperature and c “On” position (See Figure below). dioxide measurements unless configured by the user to show only temperat EDITING MENU pARAMETERS Before any adjustment be made to the transmitter, the Menu Lockout Jumper onlycan carbon dioxide. (PJ4) must be set tocan the be ˝On˝ position (See Figure 6). MENU JUMPER Before any adjustment made toLOCKOUT the transmitter, the Menu Lockout Jumper
PJ2 PJ4 WIRING
PJ1
PJ5
PJ4 Use maximum 18 AWG wire for PJ2 PJ1wiring to terminals. PJ5 EDITING MENU pARAMETERS (PJ4) must be set to the ˝On˝ position (See Figure 6). Refer to Figures 13-19 for wiring information.
ENABLED DISABLED Before any adjustment can be made to the transmitter, the Menu Lockout J ENABLED DISABLED
PJ4 PJ1 PJ5 fIGURE 2: Diagram Of Circuit Board SELECTION OF VOLTAGE OUTPUTS fIGURE 2: Diagram Of Circuit Board
(PJ4) must be set to the ˝On˝ position (See Figure 6). MENU MENU Prior toand wiring, the voltage selector jumpers on MENU MENU Selection of Current Voltageverify Outputs PJ4 DISABLED PJ4 ENABLED jumpers PJ1 and PJ2 are set tojumpers voltage (See Prior toofwiring, verify the current/voltage selection (PJ1, PJ2,Figure and PJ5) Selection Current andthat Voltage Outputs PJ4 PJ4 ON OFF to the desired output type. Refer fIGURE to Figure 2jumpers locate the PJ2, selection ON OFF 2:toDiagram Of Circuit Board Priorare to set wiring, verify that the current/voltage selection (PJ1, and jumpers. PJ5) below). MENU MENU 3 for diagram of theRefer current/voltage For voltage output ON OFF fIGURE : Menu Lockout Jumper are See set toFigure the desired output type. to Figure 2selection to locate jumper. the selection jumpers. ON OFF thediagram output Selection can be current/voltage 0 to VDC, 0and to 5Voltage VDC, 2Outputs to 10For VDC or 1 output to 5 VDC. of10 Current Seeselection, Figure 3 for of the selection jumper. voltage fIGURE 6: Menu Lockout Jumper PJ4 PJ4 See Figure 4 for the output selection (PJ5).orselection ACCESSING MENU pARAMETERS the control. Then, refer to Prior wiring, verify the current/voltage jumpers (PJ1, PJ2, Finish and PJ5)installing/wiring cantype be 0ofto tovoltage 10 VDC, 0 tothat 5 VDC, 2jumper to 10 OUTPUT VDC 1 to 5 VDC. selection, the output CURRENT/VOLTAGE
and the buildingONventilation specifications OFF set to the desired output type. Refer to Figure 2 to locate the selectionFigure jumpers.20 ON OFF See Figure 4 for the typeare of voltage output selection jumper (PJ5). ACCESSING MENU pARAMETERS SELECTION JUMPER (PJ1 & PJ2) Step 1: to To decide enter structure, press fIGURE and6: Menu simultaneously for See Figure 3 for diagram of the current/voltage selection jumper. For voltage outputthe menu Lockout Jumper what the maximum ventilation rate desired VOLTAGE CURRENT 5 seconds (display will show RON parameter). selection, the output can be 0OUTPUT to 10 VDC, 0 to 5 VDC, 2 to 10 Step VDC1:orTo 1 enter to 5 VDC. the menu structure, press and simultaneously for OUTPUT is and what the minimum/maximum voltage signal is See Figure 4 for the typeVOLTAGE of voltage output selection jumper (PJ5). ACCESSING MENU pARAMETERS 5 seconds (display will show RON parameter). OUTPUT for Step 2: required Press or thosetolevels. cycle between menu items.
C V C V V V C F fIGURE 3: Current/Voltage Output FSelection
VOLTAGE OUTPUT
Jumper (pJ1 And pJ2)
1:control To enter the menu structure, press listed and Step 2: Press or Step cycle between menu items. stage Next, enter theto programming below simultaneously f Step 3: Press to edit the value for(display the displayed menu item (SET will appear 5 seconds will show RON parameter). once the system is powered-up to configure the control. on display). Step 3: Press to edit the value for the displayed menu item (SET will appear on display). Step 4: Press
Step 2: Press or to cycle between menu items. or to adjust the value of the menu item.
3: adjust Press the value to edit themenu valueitem. for the displayed menu item (SET will ap Step 4: Press or Step to of the Next, move jumper PJ5 to the V 0-10V rangeC(SeeVFigure MENU PARAMETERS Step 5: ACCESSING Press to save the changes (SET will disappear). on display). below). Step to1: Tothe enter the(SET menu F Step 5: Press save changes will structure, disappear). press
OUTPUT RANGE SELECTION JUMPER PJ5 2 to 10 V 2 to410to V20 mA 4 to 20 mA
1 to 5 V 0 to 5 V 0 to 10 V 0 to 10 mA 1 to2 5toV10 mA 0 to010to V20 mA 0 to 4: 20 Output mA fIGURE Range Selection Jumper2 to 10 mA
fIGURE 4: Output 2 to 10 V Range Selection 0 to 10 VJumper
F
F
4 to 20 mA
0 to 20 mA
fIGURE 4: Output Range Selection Jumper
F
Step 6: Repeat StepsStep 2 through 5 forsimultaneously eachorof the parameters. 4: Press to adjust of the menu item. and forthe 5 value seconds Step 6: Repeat Steps 2 through 5 for each of the parameters. (display will show RON parameter). Step 7: To exit the menu time, press and(SET will disappear). Stepat5:any Press to and savehold the changes simultaneously Step 2: Press press or 10 seconds toand cyclepushing between seconds or wait without any buttons. Step 7: To exit the menu at for any5 time, and hold
menu items. 6: Repeat Steps throughwithout 5 for each of the parameters. simultaneously forStep 5 seconds or wait 10 2seconds pushing any buttons.
Step 3: Press to edit the value for the Step 7: To exit the menu at any time, press and hold displayed menu item (SET will appear on and simultaneously for 5 seconds or wait 10 seconds without pushing any bu display). 1 to 5 V 2 to 10 Step mA 4: Press or to adjust the value of the menu item. Step 5: Press to save the changes (SET will disappear). Step 6: Repeat Steps 2 through 5 for each of the parameters. Step 7: To exit the menu at any time, press and hold and simultaneously for 5 seconds or wait 10 seconds without pushing any buttons.
Manual 2100-549L Page 47 of 59
MENU DESCRIPTIONS RON Relay on set point Sets the CO2 concentration which the optional relay is energized. Low limit: 0 PPM Factory setting: 1000 PPM High limit: 2000/5000 PPM (depending on model) ROF Relay off set point Sets the CO2 concentration which the optional relay is de-energized. Setting value lower than RON provides direct action for detecting high concentrations of CO2. Setting value higher than RON provides indirect action for detecting low concentrations of CO2. or on the LCD display will be lit to indicate when the relay is energized. Low limit: 0 PPM Factory setting: 950 PPM High limit: 2000/5000 PPM (depending on model) DSP Display configuration Determines the LCD display configuration during normal operation. The LCD display can indicate the CO2 concentration and the temperature, the CO2 concentration only or the temperature only. The factory default is to display both the temperature and the CO2 concentration. CT CO2 concentration and temperature C CO2 concentration only T Temperature only UNI Units selection Temperature and barometric pressure measurements can be displayed in US engineering units or SI engineering units. The factory default is to display US engineering units.
US units F for temperature and in Hg for barometeric pressure
SI units
C for temperature and hPa for barometric pressure
COL CO2 low output range Sets the CO2 concentration for the lowest output (4 mA or 0 VDC). Low limit: 0 PPM Factory setting: 0 PPM High limit: 2000/5000 PPM (depending on model)
Manual 2100-549L Page 48 of 59
COH CO2 high output range Sets the CO2 concentration for the highest output (20 mA, 5 VDC or 10 VDC). When COH is set above COL, the transmitter is direct acting and the output will increase with an increase in CO2 level. When COH is below COL, the transmitter is reverse acting and the output will increase with a decrease in CO2 level. Low limit: 0 PPM Factory setting: 2000/5000 PPM (depending on model) High limit: 2000/5000 PPM (depending on model) TOL Temperature low output range Sets the temperature for the lowest output (4 mA or 0 VDC). Low limit: 32.0°F/0.0°C Factory setting: 32.0°F/0.0°C High limit: 122.0°F/50.0°C TOH Temperature high output range Sets the temperature for the highest output (20 mA, 5 VDC or 10 VDC). When TOH is set above TOL, the transmitter is direct acting and the output will increase with an increase in temperature. When TOH is below TOL, the transmitter is reverse acting and the output will increase with a decrease intemperature. Low limit: 32.0°F/0.0°C Factory setting: 122.0°F/50.0°C High limit: 122.0°F/50.0°C BAR Barometric pressure Sets the typical barometric pressure for the location where the transmitter is mounted. The factory setting is for standard pressure at sea level. Adjusting the barometric pressure gives a more accurate measurement, especially at higher elevations. Low limit: 20.0 in Hg/600 hPa Factory setting: 29.9 in Hg/1013 hPa High limit: 32.0 in Hg/1100 hPa
ENERGY RECOVERY VENTILATOR MAINTENANCE GENERAL INFORMATION The ability to clean exposed surfaces within air moving systems is an important design consideration for the maintenance of system performance and air quality. The need for periodic cleaning will be a function of operating schedule, climate, and contaminants in the indoor air being exhausted and in the outdoor air being supplied to the building. All components exposed to the airstream, including energy recovery wheels, may require cleaning in most applications. Rotary counterflow heat exchanges (heat wheels) with laminar airflow are “self-cleaning” with respect to dry particles. Smaller particles pass through; larger particles land on the surface and are blown clear as the flow direction is reversed. For this reason, the primary need for cleaning is to remove films of oil-based aerosols that have condensed on energy transfer surfaces. Buildup of material over time may eventually reduce airflow. Most importantly, in the case of desiccant coated (enthalpy) wheels, such films can close off micron sized pores at the surface of the desiccant material, reducing the efficiency with which the desiccant can absorb and desorb moisture.
FREQUENCY In a reasonably clean indoor environment such as a school, office building, or home, experience shows that reductions of airflow or loss of sensible (temperature) effectiveness may not occur for ten or more years. However, experience also shows that measurable changes in latent energy (water vapor) transfer can occur in shorter periods of time in commercial, institutional and residential applications experiencing moderate occupant smoking or with cooking facilities. In applications experiencing unusually high levels of occupant smoking, such as smoking lounges, nightclubs, bars and restaurants, washing of energy transfer surfaces, as frequently as every six months, may be necessary to maintain latent transfer efficiency. Similar washing cycles may also be appropriate for industrial applications involving the ventilation of high levels of smoke or oil-based aerosols such as those found in welding or machining operations, for example. In these applications, latent efficiency losses of as much as 40% or more may develop over a period of one to three years.
CLEANABILITY AND PERFORMANCE In order to maintain energy recovery ventilation systems, energy transfer surfaces must be accessible for washing to remove oils, grease, tars and dirt that can impede performance or generate odors. Washing of the desiccant surfaces is required to remove contaminate buildups that can reduce adsorption of water molecules. The continued ability of an enthalpy wheel to transfer latent energy depends upon the
permanence of the bond between the desiccant and the energy transfer surfaces. Bard wheels feature silica gel desiccant permanently bonded to the heat exchange surface without adhesives; the desiccant will not be lost in the washing process. Proper cleaning of the Bard energy recovery wheel will restore latent effectiveness to near original performance.
MAINTENANCE PROCEDURES NOTE: Local conditions can vary and affect the required time between routine maintenance procedures, therefore all sites (or specific units at a site) may not have the same schedule to maintain acceptable performance. The following timetables are recommended and can be altered based on local experience.
QUARTERLY MAINTENANCE 1. Inspect mist eliminator/prefilter and clean if necessary. This filter is located in the fresh air intake hood on the front of the unit. This is an aluminum mesh filter and can be cleaned with water and any detergent not harmful to aluminum. 2. Inspect wall mount unit filter and clean or replace as necessary. This filter is located either in the unit, in a return air filter grille assembly, or both. If in the unit it can be accessed by removing the lower service door on the front of the unit. If in a return air filter grille, by hinging the grille open to gain access. 3. Inspect energy recovery ventilator for proper wheel rotation and dirt buildup. This can be done in conjunction with Item 2 above. Energize the energy recovery ventilator after inspecting the filter and observe for proper rotation and/or dirt buildup. 4. Recommended energy recovery wheel cleaning procedures follow Steps 5 through 8. 5. Disconnect all power to unit. Remove the lower service door of the wall mount unit to gain access to the energy recovery ventilator. 6. Remove the front access panel on the ventilator. Unplug amp connectors to cassette motors. Slide energy recovery cassette out of ventilator. 7. Use a shop vacuum with brush attachment to clean both sides of the energy recovery wheels. 8. Reverse shop vacuum to use as a blower and blow out any residual dry debris from the wheel. NOTE: Discoloration and staining of the wheel does not affect its performance. Only excessive buildup of foreign material needs to be removed. 9. If any belt chirping or squealing noise is present, apply a small amount of LPS-1 or equivalent dry film lubricant to the belt.
Manual 2100-549L Page 49 of 59
ANNUAL MAINTENANCE 1. Inspect and conduct the same procedures as outlined under Quarterly Maintenance. 2. To maintain peak latent (moisture) removal capacity, it is recommended that the energy recovery wheels be sprayed with a diluted nonacid based evaporator coil cleaner or alkaline detergent solution such as 409. NOTE: Do not use acid based cleaners, aromatic solvents, temperatures in excess of 170° F or steam. Damage to the wheel may result. Do not disassemble and immerse the entire heat wheel in a soaking solution, as bearing and other damage may result.
3. Rinse wheel thoroughly after application of the cleaning solution, and allow to drain before reinstalling. 4. No re-lubrication is required to heat wheel bearings of the drive motor, or to the intake and exhaust blower motors. 5. If any belt chirping or squealing noise is present, apply a small amount of LPS-1 or equivalent dry film lubricant to the belt.
FIGURE 29
Manual 2100-549L Page 50 of 59
TROUBLESHOOTING SOLID STATE HEAT PUMP CONTROL TROUBLESHOOTING PROCEDURE 1. NOTE: A thorough understanding of the defrost cycle sequence is essential. Review that section earlier in this manual prior to troubleshooting the control. Turn on AC power supply to unit. 2. Turn thermostat blower switch to “fan on”— the indoor blower should start. (If it doesn’t, troubleshoot indoor unit and correct problem.) 3. Turn thermostat blower to “auto” position. Indoor blower should stop. 4. Set system switch to “heat” or “cool”. Adjust thermostat to call for heat or cool. The indoor blower, compressor and outdoor fan should start.
NOTE: If there was no power to 24 volt transformer, the compressor and outdoor fan motor will not start for 5 minutes. This is because of the compressor short cycle protection.
CODES
FUNCTION
Slow Blink
Normal Operation
Fast Blink
Compressor Time Delay
1 Blink
Low Pressure Switch Failure
2 Blink
High Pressure Switch Failure or Condensate Overflow Switch Activated
3 Blink
Defrost Mode Active
4 Blink
High Pressure or Overflow Switch Lockout
TABLE 5 TROUBLESHOOTING Symptom
Description, Check & Possible Causes
What & How to Check / Repair
1. Check for LED illumination. Is there an LED illuminated on the board (flashing)?
Yes = go to Step #2; No = go to Step #3
2. Check for error codes. Is the LED flashing a Code?
Yes = go to Step #4; No = go to Step #8
3. Check for power at board. Is there 24 volts AC between R and C?
Yes = go to Step #13; No = go to Step #9
4. Check codes. What code is blinking?
Code "1", go to Step #6; Code "2", go to Steps #7A & #7B; Fast Blink, go to Step #5
5. Compressor delay active. Wait for 5 minute delay or jump board's "speed up pins".
Check for proper operation; if still needed, go back to Step #1.
6. Low pressure fault.
Check wiring circuit and unit pressures.
7A. High pressure fault.
Check wiring circuit and unit pressures.
7B. Condensate overflow fault.
Check upper indoor coil drains; check lower outdoor coil drains; check main drain line.
8. Check for Compressor input signal. Is there 24 volts AC between Y and C?
Yes = go to Step #10; No = go to Step #11
9. No power to board.
The unit either does not have unit voltage, the transformer is bad or the unit wiring is incorrect.
10. Check for Compressor output signal. Is there 24 volts AC between CC & C?
Yes = go to Step #12; No = go to Step #13
11. No "Y" compressor input signal.
Check thermostat wiring, incorrect phase of unit (see section on Phase Monitor), and finally unit wiring.
12. No "CC" compressor output signal.
Check compressor contactor for proper operation and finally check compressor.
13. Faulty board.
Replace defrost board.
Heat pump control defective
Check across fan relay on heat pump control. (Com-NC) Replace heat pump control.
Motor defective
Check for open or shorted motor winding. Replace motor.
Motor capacitor defective
Check capacitor rating. Check for open or shorted capacitor. Replace capacitor.
Heat pump control defective
Check for 24V between RV-C and B-C. 1. Check control circuit wiring. 2. Replace heat pump control
Reversing valve solenoid coil defective
Check for open or shorted coil. Replace solenoid coil.
Unit will not go into defrost (heating only)
Temperature sensor or heat pump control defective
Disconnect temperature sensor from board and jumper across "SPEEDUP" terminals and "SEN JMP" terminals. This should cause the unit to go through a defrost cycle within one minute. 1. If unit goes through defrost cycle, replace temperature sensor. 2. If unit does not go through defrost cycle, replace heat pump control.
Unit will not come out of defrost (heating only)
Temperature sensor or heat pump control defective.
Jumper across "SPEEDUP" terminal. This should cause the unit to come out of defrost within one minute. 1. If unit comes out of defrost cycle, replace temperature sensor. 2. If unit does not come out of defrost cycle, replace heat pump control.
Compressor will not start (heating or cooling)
Fan outdoor motor does not run (cooling or heating except during defrost) Reversing valve does not energize (heating only)
Manual 2100-549L Page 51 of 59
CHECKING TEMPERATURE SENSOR
3. Check resistance reading to chart of resistance use sensor ambient temperature. (Tolerance of part is ±10%.)
1. Disconnect temperature sensor from board and from right-hand outdoor coil. 2. Use an ohmmeter and measure the resistance of the sensor. Also use ohmmeter to check for short or open.
4. If sensor resistance reads very low, then sensor is shorted and will not allow proper operation of the heat pump control. 5. If sensor is out of tolerance, shorted, open, or reads very low ohms then it should be replaced.
TABLE 6 TEMPERATURE (F) VS RESISTANCE (R) OF TEMPERATURE SENSOR F
R
F
R
F
R
F
R
-25
196871
13
56985
51
19374
89
7507
-24
190099
14
55284
52
18867
90
7334
-23
183585
15
53640
53
18375
91
7165
-22
177318
16
52051
54
17989
92
7000
-21
171289
17
50514
55
17434
93
6840
-20
165487
18
49028
56
16984
94
6683
-19
159904
19
47590
57
16547
95
6531
-18
154529
20
46200
58
16122
96
6383
-17
149355
21
44855
59
15710
97
6239
-16
144374
22
43554
60
15310
98
6098
-15
139576
23
42295
61
14921
99
5961
-14
134956
24
41077
62
14544
100
5827
-13
130506
25
39898
63
14177
101
5697
-12
126219
26
38757
64
13820
102
5570
-11
122089
27
37652
65
13474
103
5446
-10
118108
28
36583
66
13137
104
5326
-9
114272
29
35548
67
12810
105
5208
-8
110575
30
34545
68
12492
106
5094
-7
107010
31
33574
69
12183
107
4982
-6
103574
32
32634
70
11883
108
4873
-5
100260
33
31723
71
11591
109
4767
-4
97064
34
30840
72
11307
110
4663
-3
93981
35
29986
73
11031
111
4562
-2
91008
36
29157
74
10762
112
4464
-1
88139
37
28355
75
10501
113
4367
85371
38
27577
76
10247
114
4274
1
82699
39
26823
77
10000
115
4182
2
80121
40
26092
78
9760
116
4093
3
77632
41
25383
79
9526
117
4006
4
75230
42
24696
80
9299
118
3921
5
72910
43
24030
81
9077
119
3838
6
70670
44
23384
82
8862
120
3757
7
68507
45
22758
83
8653
121
3678
8
66418
46
22150
84
8449
122
3601
9
64399
47
21561
85
8250
123
3526
10
62449
48
20989
86
8057
124
3452
11
60565
49
20435
87
7869
12
58745
50
19896
88
7686
Manual 2100-549L Page 52 of 59
4.250 2.585
WARNING
EXPOSED MOVING PARTS. DISCONNECT ALL ELECTRICAL POWER BEFORE SERVICING. FAILURE TO DO SO CAN RESULT IN SEVERE INJURY OR AMPUTATION.
WARNING
HAZARD OF ELECTRICAL SHOCK. ELECTRICAL SHOCK CAN RESULT IN SERIOUS INJURY OR DEATH. DISCONNECT THE REMOTE ELECTRIC POWER SUPPLY OR SUPPLIES BEFORE SERVICING.
7961-755-1
!
INTAKE VENT FILTER BEHIND THIS DOOR 7961-755-3
!
INTAKE VENT FILTER BEHIND THIS DOOR 7961-755-3
.833 TROUBLESHOOTING ECM™.833 142R OUTDOOR FAN MOTOR
Do not operate motor without fan blade attached. Such operations will cause the motor to oscillate up and down.
3.706
You must obtain the correct replacement 5.500 motor from the manufacturer that is a direct replacement for the failed motor. USING THE WRONG MOTOR VOIDS ALL WARRANTIES AND MAY PRODUCE UNEXPECTED RESULTS.
MOTOR SPEEDS
VENT OPTION INTAKE/EXHAUST SPEEDS d. If motor is not running, go to next section. 1. In normal operation, this motor may rock WIRE COLOR SPEED NOM. CFMback and forth on start up. Do not replace if this is the HI only 4. If the motor does not appear to be running at the 525 HI BLACK symptom identified. proper speed or does not shut off, refer to the next 450 MED-HI BLUE MED. HI ection for voltage1.794 checks to determine if the motor 2. If the system is operating properly, but the motor 375 MED-LO ORANGE is getting the proper input signals. appears to run slower than it should, the motor MED. LO 300optimized is good. RED High efficiencyLO systems with If the motor IS NOT receiving any communication, fan blades are engineered run BROWN slow to decrease LO troubleshoot the communication issue using the TO CHANGE SPEEDS, to MOVE noise. WIRE The Bard WITH I-TEC WHITE Series TRACE.models also adjust diagnostic table for the Fan Logic Control. fan speed based upon varied outdoor ambient 7961-755-2 7961-755-4 7961-755 a. This motor uses a 7 wire harness to control conditions to optimize sound and unit efficiency. the motor.
3. If the system is noisy, freezing up, running a high head pressure, tripping the high pressure switch or compressor overload, check the following: COLORS: a. Ensure cleanliness of condenser coil(s) and BRIGHT YELLOW MATERIAL: fan blade/shroud. DARK ORANGE WHITE BACKGROUND b. Confirm the fan blade is not bent or deformed, isn’t rubbing on the shroud, and that it is tight PRINTING: FORM: on the motor shaft. Also ensure the motor is DIECUT SHEET secure in its mounting system, and the mounting system is secure to the unit. c. The Bard I-TEC is equipped with a low ambient control pressure switch. This pressure switch completes the 24VAC Common feed to the outdoor fan motor control in cooling mode. If this switch is defective, or if the outdoor air temperature is too cold to raise the head pressure to the 325# switch closing set-point, or the system charge is too low, this could be the cause of the issue. (In heat pump {heating} mode, the low ambient fan cycling control is bypassed.)
• Line power is connected as follows: “Red Wire” connects to “L1” “Black Wire” connects to “L2” “Green/Yellow Wire”MUST connects “Ground” OUTDOOR VINYL, SUPPLIER BE to CSA END USE: INDOOR • Control power is connected as follows: APPROVED FOR ACCEPTABLE ADHESIVE “Blue Wire” connects to Fan Relay of the NAMEPLATE LISTING. Defrost Logic Control, and subsequently BLACK connects to 24VAC Common through the Fan Logic Control Board. “Yellow Wire” connects to “Y” on the Fan Logic Control Board. “White Wire” connects to “W” on the Fan Logic Control Board. “Orange Wire” connects to “O” on the Fan Logic Control Board. NOTE: A combination of the “Yellow”, “White” and “Orange” wires being energized (with 24V “R” signal) determines five (5) different speeds the fan motor will operate at. The Fan Logic Control Board uses an outdoor thermistor sensor to determine the speed the fan should operate. It also utilizes the “B” reversing valve input for heat pump mode to determine speed should operate. Manual 2100-549L Page 53 of 59
TABLE 7 TROUBLESHOOTING ECM™ 142R OUTDOOR FAN MOTOR Check between Red and Black Wires for Line Power
Check Line Power to Motor
Verify Ground by checking Green Wire to L1 and L2 Line Power Check "BR" terminal of Fan Logic Control Board
Check for 24VAC common signal to motor (against Transformer "R" Signal)
Check "Blue" Fan Lead on "Fan Relay Terminal" of "Defrost Logic Control" ** Is not energized in cooling mode until Low Ambient Fan Cycling Control is closed by 325 PSIG refrigerant pressure. ** Circuit is completed automatically when "B" is energized on the Fan Logic Control Board
Check 24VAC "hot" outputs (to "Blue" on Fan Logic Control) to motor. See the following tables based upon outdoor temperature and model of operation.
TROUBLESHOOTING FAN LOGIC CONTROL Please reference the Thermistor Temperature/ Resistance Chart in this manual (Table 6). •
GREEN STATUS LED – Blinks indicating there is a call for fan operation (simultaneous to call for compressor operation) and is normal.
•
RED STATUS LIGHT (LA) – Is illuminated when low ambient control switch is in the closed position. (NOTE: This is not required in heat pump operation as the low ambient switch is bypassed in this mode of operation.)
•
YELLOW STATUS LIGHT (B) – Is illuminated when there is a reversing valve call (for heat pump operation). (NOTE: As mentioned above, this mode
of operation negates the low ambient fan cycling control.) If the board is reading a fan temperature thermistor value of 3375Ω or less (equivalent to 125°F or an "open" sensor), the fan will operate at the highest speed setting (energizes "W" and "Y" outputs on the board). If the board is reading a fan temperature value of 118,110Ω or greater (equivalent to -10°F or a "shorted" sensor), the fan will operate at the highest speed setting (energizes "W" and "Y" outputs on the board). If the low ambient switch is open, the red light will not be illuminated and the "BR" terminal will show open. The "BR" terminal is the "24 volt common" switching output to the outdoor fan motor.
TABLE 8 COOLING MODE O.D. Temp Sensor
24VAC Signals Between
TABLE 9 HEAT PUMP MODE O.D. Temp Sensor
24VAC Signals Between
Below 55°F
Orange to Blue
Above 56°F
Orange to Blue
Between 56° - 69°F
White to Blue
Between 55° - 30°F
White to Blue
Between 70° - 85°F
Yellow to Blue
Between 29° - 14°F
Yellow to Blue
Between 86° - 112°F
Orange and White to Blue
Below 13°F
Orange and White to Blue
Above 112°F
White and Yellow to Blue
If the output signals are not matching the specified temperature range, then go to Table #6 and verify the thermistor output curve. If the motor is receiving proper communications and proper high voltage power, and is still not running, proceed with Motor Replacement. (When checking the resistance/temperature curve, don’t forget about the optional 2.2k ohm fan control resistor assembly.)
REPLACING THE MOTOR This motor is replaced in one piece. The control cannot be replaced separately from the motor. Even if the control is remotely located, the replacement part will be a new control with harness and new motor. You must have the correct replacement motor from the manufacturer that is a direct replacement for the failed motor.
Manual 2100-549L Page 54 of 59
USING THE WRONG MOTOR VOIDS ALL PRODUCT WARRANTIES AND MAY PRODUCE UNEXPECTED RESULTS. Always mount the replacement motor and control according to the manufacturers specifications using all required hardware to reduce vibration. Make sure all wires are free of the fan blade and not pinched in mountings or cabinet through points.
TROUBLESHOOTING INDOOR ECM™ BLOWER MOTORS CAUTION:
Symptom
Disconnect power from unit before removing or replacing connectors, or servicing motor. To avoid electric shock from the motor’s capacitors, disconnect power and wait at least 5 minutes before opening motor.
• Noisy blower or cabinet • Check for loose blower housing, panels, etc. • High static creating high blower speed? - Check for air whistling through seams in ducts, cabinets or panels - Check for cabinet/duct deformation
Symptom
• “Hunts” or “puffs” at • Does removing panel or filter reduce high CFM (speed) “puffing”? - Reduce restriction - Reduce max. airflow
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, but won’t start Motor oscillates up & down while being tested off of blower
• Check for loose or compliant motor mount • Make sure blower wheel is tight on shaft • Perform motor/control replacement check • It is normal for motor to oscillate with no load on shaft
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 high CFM (speed)
• Does removing panel or filter reduce “puffing”? - Reduce restriction - Reduce max airflow
• Stays at low CFM despite system call for cool or heat CFM
• Check low voltage (Thermostat) wires and connections • Verify fan is not in delay mode; wait until delay complete • “R” missing/not connected at motor • Perform motor/control replacement check
• Stays at high CFM
• “R” missing/not connected at motor • Is fan in delay mode? - wait until delay time complete • Perform motor/control replacement check
• Blower won’t shut off
• Current leakage from controls into G, Y or W? Check for Triac switched thermostat or solidstate relay
Excessive noise • Air noise
• Determine if it’s air noise, cabinet, duct or motor noise; interview customer, if necessary • High static creating high blower speed? - Is airflow set properly? - Does removing filter cause blower to slow down? Check filter - Use low-pressure drop filter - Check/correct duct restrictions
Evidence of Moisture • Motor failure or malfunction has occurred and moisture is present • Evidence of moisture present inside air mover
Do
Cause/Procedure
• Replace motor and Perform Moisture Check • Perform Moisture Check
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 2100-549L Page 55 of 59
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 unit 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 not necessary to remove the motor from the blower assembly, nor the blower assembly from the unit. Unplug the two cable connectors to the motor control assembly. There are latches on each connector. DO NOT PULL ON THE WIRES. The plugs remove easily when properly released. 4. Locate the screws that retain to the motor control bracket to the sheet metal of the unit and remove them. Remove two (2) nuts that retain the control to the bracket and then remove two (2) nuts that retain sheet metal motor control end plate. Refer to Figure 30. 5. Disconnect the three (3) wires interior of the motor control by using your thumb and forefinger squeezing the latch tab and the opposite side of the connector plug, gently pulling the connector. DO NOT PULL ON THE WIRES, GRIP THE PLUG ONLY. Refer to Figure 30. 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 31. (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. 8. Reverse the steps #5, 4, 3 to reconnect the motor control to the motor wires, securing the motor control cover plate, mounting the control to the bracket, and mounting the motor control bracket back into the unit. 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. DO NOT OVERTIGHTEN THE BOLTS. 9. Plug the 16-pin control plug into the motor. The plug is keyed. Make sure the connector is properly seated and latched. 10. 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. 11. Final installation check. Make sure the motor is installed as follows: a. Motor connectors should be oriented between the 4 o’clock and 8 o’clock positions when the control is positioned in its final location and orientation. b.Add a drip loop to the cables so that water cannot enter the motor by draining down the cables. Refer to Figure 32. 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 31 Figure 4 Winding Test
Figure 30 3 Figure Control Disassembly
Motor Connector (3-pin)
Only remove From Motor Hex Head Bolts Push until Latch Seats Over Ramp
Circuit Board
Motor
ECM 2.0 Note: Use the shorter bolts and alignment pin supplied when replacing an ECM 2.0 control.
Motor OK when R > 100k ohm
ECM 2.3/2.5
Motor Connector (3-pin) Control Connector (16-pin) Power Connector (5-pin) Hex-head Screws
Manual 2100-549L Page 56 of 59
Figure Figure32 5 Drip Loop Back of Control
Connector Orientation Between 4 and 8 o'clock
Drip Loop
TROUBLESHOOTING ECMTM BLOWER MOTORS MODE of OPERATION
OFF
Thermostat 24 VAC Inuput Signals
—
Pin #1
Continuous Blower (Ventilation Mode)
"G"
Part Load Cooling
Full Load Cooling
"G", "Y1","Y2"
"G", "Y1","Y2"
Dehum. Mode (when equipped)
"D"
Part Load Heat Pump
Full Load Heat Pump
"G", "B", "Y1"
"G", "B", "Y1", "Y2"
Heat Pump Full Load w/ 1st Bank of Elec. Heat "G", "Y1", "Y2", "B", "W1"
Heat Pump Full Load w/ 1st & 2nd Bank of Elec. Heat
Emergency Heat Mode
"G", "Y1", "Y2", "B", "W2", "W3"
"G", "W2", "W3"
24 VAC "C" (Common) Signal, Always Energized
Pin #2
X
Pin #3
24 VAC "C" (Common) Signal, Always Energized
Pin #4
Not Used
Pin #5
Not Used
Pin #6
X
Pin #7
Not Used
Pin #8
Not Used
X
X
Pin #9 Pin #10
Not Used
Pin #11
Not Used
Pin #12
24 VAC Hot "R" Signal, Always Energized
X
X
X
X
X
X
X
Pin #13
X
Pin #14 Pin #15 Pin #16
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Not Used
FIGURE 33 CONTROL CONNECTOR MOTOR HALF 9 1
POWER CONNECTOR PWB HEADER
10 11 12 13 14 15 16 2
3
4
5
6
7
PIN
8
1
*
AMP 1-350945-0 Description
2
Jumper Pin 1 to Pin 2 for 120VAC Line Input Only **
3
Chassis Ground
4
AC Line
5
AC Line
Suggested mating connector Housing — AMP 350809-1 Contact — AMP 350537-1
** WARNING – Applying 240VAC line input with PIN 1 to PIN 2 jumper in place will permanently damage unit!
MIS-2839
POWER CONNECTOR MOTOR 1 2 3 4 5 HALF
FAN BLADE SETTING DIMENSIONS The position of the fan blade should be flush with the leaving face of the orifice plate. Check to make sure the blades do not extend beyond the rear casing of the unit. Spin the blade by hand to make sure it does not hit the ring.
REFRIGERANT CHARGE This unit was charged at the factory with the quantity of refrigerant listed on the serial plate. AHRI capacity and efficiency ratings were determined by testing with this refrigerant charge quantity. The following pressure tables show nominal pressures and temperatures for the units. Since many installation specific situations can affect the pressure readings, this information should only be used by certified technicians as a guide for evaluating proper system performance. They shall not be used to adjust charge. If charge is in doubt, reclaim, evacuate and recharge the unit to the serial plate charge. Manual 2100-549L Page 57 of 59
TABLE 10A FULL LOAD COOLING PRESSURE/TEMPERATURE Model
I30H1
I36H1
I42H1
I48H1
I60H1
AIR TEMPERATURE ENTERING OUTDOOR COIL °F
Return Air Temp.
Pressure
55°
60°
65°
70°
75°
80°
85°
90°
95°
100°
105°
110°
115°
120°
125°
75° DB 62° WB
Low Side High Side
117 202
118 224
120 246
121 267
123 289
124 310
126 332
128 354
129 375
130 399
132 423
133 448
135 472
136 496
137 520
80° DB 67° WB
Low Side High Side
130 201
131 225
133 248
134 271
136 294
139 315
140 345
141 362
142 386
144 411
145 436
147 461
148 486
150 510
151 535
85° DB 72° WB
Low Side High Side
145 210
146 233
148 256
149 278
151 301
152 323
154 346
156 369
157 391
159 416
160 442
162 467
164 492
165 517
167 542
75° DB 62° WB
Low Side High Side
126 209
127 231
129 252
130 274
131 295
132 317
134 338
135 360
136 381
137 405
138 429
139 452
141 476
142 500
143 524
80° DB 67° WB
Low Side High Side
139 208
140 231
142 254
143 277
144 300
146 327
147 358
148 370
149 392
150 417
152 441
153 466
154 490
155 515
157 539
85° DB 72° WB
Low Side High Side
154 217
155 240
157 262
158 285
159 307
160 330
162 352
163 375
164 397
165 422
167 447
168 471
170 496
171 521
172 540
75° DB 62° WB
Low Side High Side
122 218
123 238
125 258
127 279
128 299
130 319
131 339
133 360
134 380
135 404
136 428
137 452
138 476
139 500
140 524
80° DB 67° WB
Low Side High Side
134 217
136 239
138 260
139 282
141 304
142 326
144 355
146 369
147 391
148 416
149 440
150 465
151 490
152 514
153 539
85° DB 72° WB
Low Side High Side
139 226
140 247
142 269
143 290
144 311
145 332
147 353
148 375
149 396
150 421
151 446
152 471
153 496
154 521
155 546
75° DB 62° WB
Low Side High Side
125 203
126 225
127 248
128 271
129 293
129 316
130 339
131 361
132 384
134 411
135 437
136 464
138 491
139 517
140 544
80° DB 67° WB
Low Side High Side
136 208
138 231
139 254
140 276
141 299
143 321
144 351
145 367
147 390
148 417
150 444
151 471
153 498
154 526
156 553
85° DB 72° WB
Low Side High Side
148 215
149 238
151 261
153 284
154 307
156 331
158 354
159 377
161 400
162 428
164 456
166 484
167 512
169 539
171 567
75° DB 62° WB
Low Side High Side
123 218
124 241
124 265
125 289
126 312
127 336
128 360
129 383
129 407
131 434
132 462
133 489
134 516
135 544
136 571
80° DB 67° WB
Low Side High Side
134 224
135 248
137 271
138 295
139 319
140 341
141 373
142 389
143 413
145 441
146 469
147 497
148 524
150 552
151 580
85° DB 72° WB
Low Side High Side
146 231
147 255
148 279
150 303
151 327
153 352
154 376
156 400
157 424
159 453
160 481
161 510
163 538
164 567
166 595
55°
60°
65°
70°
TABLE 10B FULL LOAD HEATING PRESSURE/TEMPERATURE Model
Return Air Temp.
AIR TEMPERATURE ENTERING OUTDOOR COIL °F Pressure
0°
5°
10°
15°
20°
33 247
40 257
48 267
55 277
63 287
25° 70 296
30° 78 306
35° 85 316
40° 91 317
45° 98 319
50° 107 345
116 371
125 398
134 424
143 451
I30H1
70° DB
Low Side High Side
I36H1
70° DB
Low Side High Side
30 244
38 252
45 259
52 267
59 275
67 283
74 290
81 298
89 305
97 311
105 320
112 328
120 337
127 345
135 354
I42H1
70° DB
Low Side High Side
34 255
40 263
47 271
54 278
60 286
67 294
74 301
81 309
88 314
95 319
102 325
109 331
116 337
123 343
130 349
I48H1
70° DB
Low Side High Side
33 268
40 276
47 285
54 293
60 301
67 309
74 318
81 326
89 334
97 342
106 349
114 356
122 363
130 370
138 377
I60H1
70° DB
Low Side High Side
38 290
42 294
46 297
50 300
54 303
58 306
63 310
67 313
80 335
94 357
102 366
110 375
118 384
127 393
135 402
Manual 2100-549L Page 58 of 59
TABLE 11A PART LOAD COOLING PRESSURE/TEMPERATURE Model
I30H1
I36H1
I42H1
I48H1
I60H1
AIR TEMPERATURE ENTERING OUTDOOR COIL °F
Return Air Temp.
Pressure
55°
60°
65°
70°
75°
80°
85°
90°
95°
100°
105°
110°
115°
120°
125°
75° DB 62° WB
Low Side High Side
127 184
128 206
129 227
129 249
130 270
131 292
132 313
133 334
134 356
135 380
137 403
138 427
140 451
141 475
143 498
80° DB 67° WB
Low Side High Side
141 187
141 209
142 231
143 252
143 274
144 293
144 322
145 338
146 361
147 385
149 409
151 433
152 457
154 481
156 505
85° DB 72° WB
Low Side High Side
154 194
154 216
155 237
156 259
156 280
157 302
157 323
158 344
159 366
161 390
162 415
164 439
166 464
168 488
170 512
75° DB 62° WB
Low Side High Side
131 188
133 209
134 230
136 250
137 271
139 292
140 313
142 333
143 354
144 378
145 403
146 427
148 452
149 476
150 500
80° DB 67° WB
Low Side High Side
145 191
146 212
148 233
149 254
150 275
152 295
153 323
154 338
155 359
156 384
158 409
159 433
160 458
161 483
163 508
85° DB 72° WB
Low Side High Side
158 198
159 219
161 240
162 260
163 281
164 302
166 323
167 343
168 364
169 389
171 414
172 439
173 464
175 489
176 515
75° DB 62° WB
Low Side High Side
126 192
128 212
130 233
132 253
134 274
136 294
138 315
139 335
141 356
142 379
143 402
144 426
145 449
146 472
147 496
80° DB 67° WB
Low Side High Side
140 195
141 216
143 236
145 257
146 278
148 299
150 326
151 340
153 361
154 384
155 408
156 432
157 455
158 479
159 503
85° DB 72° WB
Low Side High Side
144 202
145 223
147 243
148 264
150 284
151 304
152 325
154 345
155 366
156 390
157 414
158 438
159 462
160 486
161 510
75° DB 62° WB
Low Side High Side
129 183
130 205
131 226
132 248
133 269
133 291
134 313
135 334
136 356
137 381
139 407
140 432
142 458
143 484
144 509
80° DB 67° WB
Low Side High Side
140 187
141 209
142 230
144 252
145 274
146 295
148 324
149 339
151 361
152 387
154 413
155 439
157 465
158 491
160 517
85° DB 72° WB
Low Side High Side
154 189
155 212
157 234
158 257
160 280
161 303
162 325
164 348
165 371
167 397
168 424
170 451
172 477
173 504
175 530
75° DB 62° WB
Low Side High Side
127 196
127 218
128 240
128 261
129 283
130 305
130 326
131 348
131 370
133 396
134 422
135 448
136 474
137 500
139 526
80° DB 67° WB
Low Side High Side
137 200
138 222
139 244
140 266
142 288
142 310
143 339
144 353
146 375
147 402
148 428
150 454
151 481
152 507
154 534
85° DB 72° WB
Low Side High Side
152 203
153 226
153 249
154 271
155 294
156 317
157 340
158 363
159 385
161 412
162 440
164 467
165 494
167 521
168 548
55°
60°
65°
70°
TABLE 11B PART LOAD HEATING PRESSURE/TEMPERATURE Model
Return Air Temp.
AIR TEMPERATURE ENTERING OUTDOOR COIL °F Pressure
0°
5°
10°
15°
20°
25°
30°
35°
40°
45°
50°
I30H1
70° DB
Low Side High Side
40 239
47 249
54 258
61 268
68 278
75 288
83 297
90 307
97 311
104 315
115 328
125 341
135 353
146 366
156 378
I36H1
70° DB
Low Side High Side
36 233
44 241
51 248
58 255
65 262
73 270
80 277
87 284
96 292
104 299
114 307
123 315
133 322
142 330
152 338
I42H1
70° DB
Low Side High Side
37 242
45 250
52 258
60 265
67 273
75 281
82 288
90 296
96 303
103 309
110 316
118 323
126 331
134 338
142 345
I48H1
70° DB
Low Side High Side
35 265
43 271
51 277
59 282
67 288
75 293
83 299
92 305
98 318
105 331
115 340
124 348
134 357
143 365
153 374
I60H1
70° DB
Low Side High Side
38 263
45 272
52 281
60 291
67 300
74 309
82 318
89 327
96 336
104 345
113 356
122 366
131 377
140 387
149 398
Manual 2100-549L Page 59 of 59
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