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INSTALLATION
INSTRUCTIONS
I-TEC SERIES
PACKAGED HEAT PUMP
I30H1
I48H1
I30H1D
I48H1D
Bard Manufacturing Company, Inc.
Bryan, Ohio 43506
Since 1914 . . . Moving ahead, just as planned.
Models:
I36H1
I42H1
I60H1
I36H1D
I42H1D
I60H1D
MIS-2957 A
Manual:
Supersedes:
File:
Date:
Manual 2100-549G
Page
2100-549G
2100-549F
Vol. II Tab 14
11-05-13
1 of 59
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Summary of Contents for Bard I30H1
- Page 1 I36H1 I42H1 INSTRUCTIONS I48H1 I60H1 I30H1D I36H1D I42H1D I48H1D I60H1D MIS-2957 A Bard Manufacturing Company, Inc. Manual: 2100-549G Supersedes: 2100-549F Bryan, Ohio 43506 File: Vol. II Tab 14 Since 1914 . . . Moving ahead, just as planned. Date: 11-05-13...
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Page 2: Table Of Contents
CONTENTS Getting Other Information and Publications Service Hints .............. 31 For more information, contact these publishers: ..3 Sequence of Operation ..........32 General & ANSI Z535.5 Definitions ......4 Pressure Service Ports ..........32 Lowering Outdoor Fan Speed for Sound ....32 I-TEC General Information Defrost Cycle .............. -
Page 3: Getting Other Information And Publications
GETTING OTHER INFORMATION AND PUBLICATIONS These publications can help you install the air FOR MORE INFORMATION, CONTACT conditioner or heat pump. You can usually find these at THESE PUBLISHERS: your local library or purchase them directly from the publisher. Be sure to consult current edition of each standard. -
Page 4: General & Ansi Z535.5 Definitions
See Page 3 for information on codes and standards. The I-TEC must be installed with the Bard Size of unit for a proposed installation should be based manufactured IWS wall sleeve and ILG louver on heat loss or heat gain calculation made according to grille accessories. -
Page 5: I-Tec Model Nomenclature
I-TEC Series General Information I-TEC MODEL NOMENCLATURE CONTROLS MODEL COLOR OPTIONS SYSTEM TYPE: ELECTRIC HEAT X = 24V Terminal Block Only w/o SERIES X - Beige paint HEAT PUMP 0Z = No heat w/breaker CompleteStat 1 - White paint 04 = 4KW 1-Phase 1 = CompleteStat THO (Temp, 4 - Gray paint... -
Page 6: Table 2 Elec. Specifications
TABLE 2 ELECTRICAL SPECIFICATIONS c r i t i u c r i t i u , s t z t r c r i t i u c r i t i u s t i y t i . -
Page 7: Figure 1 Unit Dimensions
Manual 2100-549G Page 7 of 59... -
Page 8: Shipping Damage, Unit Removal From Skid
SHIPPING DAMAGE HANDLING UNIT AFTER REMOVAL FROM SKID Upon receipt of equipment, the unit should be checked If a wide and tall enough opening exists, the I-TEC can be for external signs of shipping damage. The skid must moved as a complete assembled unit. If not, it is designed remain attached until the unit is ready for installation. -
Page 9: Required Steps After Final Placement
REQUIRED STEPS AFTER FINAL PLACEMENT SECURING UNIT TO STRUCTURE The compressor is secured to the base with two (2) bolts Shipped with the I-TEC unit is a wall mounting bracket for shipping. Although the unit will perform as (screwed to shipping skid on backside of unit). This designed with the shipping bolts in place, there may be a bracket can be utilized to secure the top portion of the noticeable additional noise and vibration noted. -
Page 10: Bracket Wall Sect. View & Wood Framed Install
BRACKET WALL SECTION VIEW Optional Duct Optional Top 3" Outside Bracket " Ceiling Wall (4) optional Unit Mounting holes Optional Telescoping " 20 " 6" Trim or Wall Sleeve** Supply Duct Sleeve Mounting Hole Locations Centered on Centered Opening Outside 20"... -
Page 11: Figure 3 Center Of Gravity
FIGURE 3 CENTER OF GRAVITY CENTER OF GRAVITY "Z" "X" "Y" MIS-3269 & " " " " " " Z " " Z " 4 " 4 ½ " " 7 " 4 ¼ " ½ " " 7 " 4 "... -
Page 12: Figure 4 Req. Clearances & Rec. Access
FIGURE 4 REQUIRED CLEARANCES & RECOMMENDED ACCESS WING WALL CONSTRUCTION TOP VIEW 12" MIN. 12" MIN. CLOSET CONSTRUCTION TOP VIEW 31 3/8" 12" MIN. 12" MIN. 12" MIN. 12" MIN. RECOMMENDED SERVICE ACCESS DIMENSIONS 12" MIN. 12" MIN. FOR LEFT FOR RIGHT 48"... -
Page 13: Figure 5 Compressor Shipping Bolts
FIGURE 5 COMPRESSOR SHIPPING BOLTS COMPRESSOR SHIPPING BOLT COMPRESSOR SHIPPING BOLT FIGURE 6 REMOVAL OF AIR DUCT CRV / ERV AIR DUCT Manual 2100-549G Page 13 of 59... -
Page 14: Figure 7A Ducted Application
FIGURE 7A DUCTED APPLICATION – BASIC UNIT Manual 2100-549G Page 14 of 59... -
Page 15: Figure 7B 3" Riser Application
FIGURE 7B 3" RISER APPLICATION Manual 2100-549G Page 15 of 59... -
Page 16: Figure 7C 6" Riser Application
FIGURE 7C 6" RISER APPLICATION Manual 2100-549G Page 16 of 59... -
Page 17: Duct Work, Supply Duct Connections & Filters
DUCT WORK a floor mounted install (9'-9" with IRP3 riser & 10'-0" with IRP6 riser). The ICX10 extends 28" above the unit Any heat pump is more critical of proper operating for a total height of 10'-2" for a floor mounted install charge and an adequate duct system than a straight air (10'-5"... -
Page 18: Condensate Drain
CONDENSATE DRAIN WITH COMMERCIAL ROOM VENTILATOR 1. Open hinged front doors. There are two condensate drain connections from the 2. Disconnect unit power to eliminate shock hazard. condenser drain pan (compressor area). These are visible from the rear of the unit. Factory installed tubing 3. -
Page 19: Figures 11A & 11B Unit Mounting
FIGURE 11A UNIT MOUNTING Use (12) Field Supplied Concrete Use (12) 3/4" Long IMPORTANT! or Wood Screws to Secure Outer Self Tapping Screws REF. Sleeve to Structure. Apply Caulk bead to to Attach Inner Sleeve entire perimeter seam IMPORTANT! to Unit Back between inner and Apply liberal amount outer sleeve. - Page 20 FIGURE 11B UNIT MOUNTING INSIDE WALL (SIZE VARIES) OUTSIDE WALL (INSULATED) AREA BETWEEN WALL AND SLEEVE (INSULATED) OUTDOOR GRILLE I-TEC UNIT SLEEVE FILL INSULATION DRAIN AREA INTERIOR FLOOR INSULATED WITH 6" BATT MATERIAL MIS-2928 B Manual 2100-549G Page 20 of 59...
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Page 21: Installation Instructions
INSTALLATION INSTRUCTIONS MOUNTING THE UNIT WIRING – MAIN POWER Refer to the unit rating plate and/or Table 2 for wire sizing The wall sleeve is attached to the I-TEC unit from the information and maximum fuse or “HACR Type” circuit outside of the building. -
Page 22: Wiring-Low Volt. Wiring & Low Volt.connections
WIRING – LOW VOLTAGE WIRING “W2” terminal is first stage electric heat (if equipped). First stage electric heat can be operated simultaneously 230/208V, 1 PHASE AND 3 PHASE EQUIPMENT with the heat pump operating. DUAL PRIMARY VOLTAGE TRANSFORMERS. “A” terminal is the ventilation input. This terminal All Equipment leaves the factory wired on 240V tap. -
Page 23: Figure 13 Basic Heat Pump W/No Vent Pkg
BASIC HEAT PUMP WITH NO VENTILATION PACKAGE Completestat Model #CS9B-THO or Model #CS9BE-THO W1/E Thermostat W1/E YO/D Bard #8403-060 B/W1 Voltage Term. Strip Factory installed jumper. Remove jumper and connect to N.C fire alarm 2 Not needed below 15KW Additional wire required for dehumidification models MIS-3016... -
Page 24: Control
FIGURE 14 HEAT PUMP WITH CRV, WITHOUT CO CONTROL Completestat Model #CS9B-THO or Model #CS9BE-THO W1/E Thermostat W1/E YO/D Bard #8403-060 B/W1 Voltage Term. Strip RED/WHITE BLACK/WHITE ORANGE BROWN/WHITE CRV Wiring Harness Factory installed jumper. Remove jumper and connect Connect to "G" terminal when thermostat has "Occupancy Signal". -
Page 25: Control
FIGURE 15 HEAT PUMP WITH CRV AND CO CONTROL Completestat Model #CS9B-THO or Model #CS9BE-THO W1/E NOTE: Bard 8403-060 thermostat must be in programmed Thermostat W1/E YO/D operation mode and Bard #8403-060 in programmed fan mode for ventilation to function. -
Page 26: Control
FIGURE 16 HEAT PUMP WITH ERV, WITHOUT CO CONTROL Completestat Model #CS9B-THO or Model #CS9BE-THO W1/E NOTE: Bard 8403-060 thermostat must be in programmed Thermostat W1/E YO/D operation mode and Bard #8403-060 in programmed fan mode for ventilation to function. -
Page 27: Control
FIGURE 17 HEAT PUMP WITH ERV AND CO CONTROL (ON/OFF CYCLING) Completestat Model #CS9B-THO or Model #CS9BE-THO W1/E NOTE: Bard 8403-060 thermostat must be in programmed Thermostat W1/E YO/D operation mode and Bard #8403-060 in programmed fan mode for ventilation to function. - Page 28 FIGURE 18 HEAT PUMP WITH ERV AND CO CONTROL (FULLY MODULATING) Completestat Model #CS9B-THO or Model #CS9BE-THO W1/E NOTE: Bard 8403-060 thermostat must be in programmed Thermostat W1/E YO/D operation mode and Bard #8403-060 in programmed fan mode for ventilation to function.
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Page 29: Figure 19 Hp W/Comb. Crv & Db Econ. ("N" Vent)
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 W1/E B/W1 Voltage Term. Strip RED/WHITE BLACK/WHITE ORANGE GRAY YELLOW... -
Page 30: Start Ups
7. Never fill cylinders over 80% of total capacity. TOPPING OFF SYSTEM CHARGE 8. Store cylinders in a cool area, out of direct If a leak has occurred in the system, Bard Manufacturing sunlight. recommends reclaiming, evacuating (see criteria above), 9. -
Page 31: Description Of Standard Equipment
START UP DESCRIPTION OF STANDARD However, three phase compressors will rotate in either direction depending upon phasing of the power. Since EQUIPMENT there is a 50-50 chance of connecting power in such a Solid State Electronic Heat Pump Control way as to cause rotation in the reverse direction, verification of proper rotation must be made. -
Page 32: Sequence Of Operation
PRESSURE SERVICE PORTS SEQUENCE OF OPERATION COOLING PART LOAD – Circuit R-Y1 makes at High and low pressure service ports are installed on all thermostat pulling in compressor contactor, starting the units so that the system operating pressures can be observed. -
Page 33: Figure 20 Defrost Cycle
DEFROST CYCLE There is an initiate defrost jumper (sen jump) on the control that can be used at any outdoor ambient during The defrost cycle is controlled by temperature and time the heating cycle to simulate a 0° coil temperature. on the solid state heat pump control. -
Page 34: I-Tec Commercial Room Ventilator System
Bard The I-TEC Commercial Room Ventilator (CRV) is markets and recommends Bard Part #8403-060 designed to be used with all Bard I-TEC models. The programmable electronic thermostat. only intent of this device is to provide the required 2. -
Page 35: Figure 21 Crv Motor Speed/Cfm Configuration
FIGURE 21 CRV MOTOR SPEED/CFM CONFIGURATION VENT OPTION INTAKE/EXHAUST SPEEDS WIRE COLOR SPEED NOM. CFM BLACK BLUE MED-HI ORANGE MED-LO TO CHANGE SPEEDS, MOVE BROWN WIRE WITH WHITE TRACE. 7961-755-2 BLACK BLUE MED. HI BROWN/WHITE MED. LO ORANGE 7961-7554 Move brown/white wire to corresponding motor speed for required ventilation CFM. -
Page 36: Figure 22 Crv Speed Change Terminal Access
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 2100-549G Page 36 of 59... -
Page 37: I-Tec Comb. Crv & Economizer Vent System Description & Control Wiring
(CRV) and Dry Bulb Economizer is designed to be used The Ventilation Package is also provided with filters to with all Bard I-TEC models. This ventilation package reduce the required service needed and to further and its control provides two (2) roles: improve the I.A.Q. -
Page 38: Figure 23 Economizer Control Circuit
If outdoor temperature is above outdoor I-TEC ECON. SEQUENCE OF OPERATION thermostat setpoint If outdoor temperature is below outdoor On call from CompleteStat for first stage cooling: thermostat setpoint • “YO” thermostat signal powers relay coil “R2”. “R2” relay On call from CompleteStat for first stage cooling: then closes NO contact between “R”... -
Page 39: Figure 24 Motor Speed/Cfm Configuration
HEATING MODE OPERATION VENTILATION MODE The call for ventilation will never be disrupted with this CompleteStat should never energize “YO” terminals in conjunction with “B”, so relay “R2” will never control circuit. Anytime “A” signal from CompleteStat energize, and neither will Economizer Ventilation is present, the “VENTILATION SPEED”... -
Page 40: I-Tec Energy Recovery Ventilator System
CONTROL WIRING I-TEC ENERGY RECOVERY VENTILATOR SYSTEM The I-TEC ERV comes wired from the factory ready to operate in manual mode (ON/OFF cycling) and set to GENERAL DESCRIPTION 375 CFM of ventilation. Care must be taken when The I-TEC Energy Recovery Ventilator (ERV) was deciding how to control the operation of the ventilator. -
Page 41: Recommended Control Sequences
For example, a Flow Index of thermostat to determine occupancy in the structure. 23 would be two long blinks, followed by 3 fast blinks of Bard markets the CS2000A for this use. the “GREEN STATUS LIGHT”. 7. On exhaust Motor Control Board, observing 3. -
Page 42: Summer Cooling & Winter Heating
PERFORMANCE AND APPLICATION DATA SUMMER COOLING PERFORMANCE (INDOOR DESIGN CONDITIONS 75°DB/62°WB) WINTER HEATING PERFORMANCE LEGEND: (INDOOR DESIGN CONDITIONS 70°F DB) VLT = Ventilation Load – Total VLS = Ventilation Load – Sensible = Ventilation Load – Latent F ° HRT = Heat Recovery – Total HRS = Heat Recovery –... -
Page 43: Fig. 25A Erv Manual Mode "M" Terminal
5.15 for you to program your CO2 control output voltages in 4.58 correlation to the CO2 levels you 4.06 wish to control when Bard Part # 8403-067 CO2 Control is applied. 2.91 2.57 2.24 1.74 0.96 0.77... -
Page 44: Figure 26 Ventilation Airflow Diagram
FIGURE 26 VENTILATION AIRFLOW DIAGRAM Supply Air SUPPLY BLOWER Return Air Outdoor Air VENT INTAKE BLOWER Indoor Air VENT EXHAUST BLOWER MIS-3024 Manual 2100-549G Page 44 of 59... -
Page 45: Figure 27 Erv Control Access
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 ERV CONTROL COMPONENTS PANEL LOCATION Manual 2100-549G Page 45 of 59... -
Page 46: Figure 28 Control Board Config./Setting
Manual adjust screw. Use when operating in manual mode (“M” 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”. CONFIGURING BARD PART #8403-067 CONTROL for ERV MODULATING CONTROL BARD PART #8403-067... -
Page 47: Configuring Control For Erv Mod. Control
CONFIGURING BARD PART #8403-067 EDITING MENU PARAMETERS CONTROL for ERV MODULATING Before any adjustment can be made to the transmitter, the Menu Lockout Jumper (PJ4) must be set to the “On” CONTROL (Continued) position (See Figure below). MOUNTING MENU LOCKOUT JUMPER 1. - Page 48 MENU DESCRIPTIONS high output range Sets the CO concentration for the highest Relay on set point output (20 mA, 5 VDC or 10 VDC). When Sets the CO concentration which the optional COH is set above COL, the transmitter is direct relay is energized.
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Page 49: General Information
MAINTENANCE the desiccant will not be lost in the washing process. GENERAL INFORMATION Proper cleaning of the Bard energy recovery wheel will restore latent effectiveness to near original performance. The ability to clean exposed surfaces within air moving systems is an important design consideration for the MAINTENANCE PROCEDURES maintenance of system performance and air quality. -
Page 50: Figures (Continued) Figure 29 Hub Assembly W/Ball Bearings
3. Rinse wheel thoroughly after application of the ANNUAL MAINTENANCE cleaning solution, and allow to drain before 1. Inspect and conduct the same procedures as reinstalling. outlined under Quarterly Maintenance. 4. No re-lubrication is required to heat wheel bearings 2. To maintain peak latent (moisture) removal capac- of the drive motor, or to the intake and exhaust ity, it is recommended that the energy recovery blower motors. -
Page 51: Troubleshooting
TROUBLESHOOTING SOLID STATE HEAT PUMP CONTROL NOTE: If there was no power to 24 volt transformer, TROUBLESHOOTING PROCEDURE the compressor and outdoor fan motor will not start for 5 minutes. This is because of 1. NOTE: A thorough understanding of the defrost the compressor short cycle protection. -
Page 52: Checking Temperature Sensor
CHECKING TEMPERATURE SENSOR 4. If sensor resistance reads very low, then sensor is shorted and will not allow proper operation of the 1. Disconnect temperature sensor from board and from heat pump control. right-hand outdoor coil. 5. If sensor is out of tolerance, shorted, open, or reads 2. - Page 53 SUPPLIES BEFORE SERVICING. 1. In normal operation, this motor may rock back and c. The Bard I-TEC is equipped with a low forth on start up. Do not replace if this is the only ambient control pressure switch. This pressure symptom identified.
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Page 54: Replacing The Motor
TROUBLESHOOTING ECM ™ 142R OUTDOOR FAN MOTOR • Line power is connected as follows: NOTE: A combination of the "Yellow", "White" “Red Wire” connects to “L1” and "Orange" wires being energized (with “Black Wire” connects to “L2” 24V "R" signal) determines five (5) different “Green/Yellow Wire”... -
Page 55: Troubleshooting Indoor Ecm™ Motor
TROUBLESHOOTING INDOOR ECM ™ BLOWER MOTORS CAUTION: Symptom Cause/Procedure • Noisy blower or cabinet • Check for loose blower housing, panels, etc. Disconnect power from unit before removing or replacing • High static creating high blower speed? connectors, or servicing motor. To avoid electric shock - Check for air whistling through seams in from the motor’s capacitors, disconnect power and wait at ducts, cabinets or panels... -
Page 56: Figure 30 Control Disassembly
TROUBLESHOOTING INDOOR ECM ™ BLOWER MOTORS (Cont’d.) 7. Verify that the replacement control is correct for your Replacing ECM Control Module application. Refer to the manufacturer's authorized replacement list. To replace the control module for the GE variable-speed indoor blower USING THE WRONG CONTROL WILL RESULT IN motor you need to take the following steps: IMPROPER OR NO BLOWER OPERATION. -
Page 57: Fan Blade Setting Dimensions
TROUBLESHOOTING ECM ™ BLOWER MOTORS (Cont’d.) & l i t " , " " , " " " " , , " " " " , , " " " " , , " " " " , " 1 "... -
Page 58: Table 10A Pressures: Full Load Cooling
TABLE 10A FULL LOAD COOLING PRESSURE/TEMPERATURE F ° TABLE 10B FULL LOAD HEATING PRESSURE/TEMPERATURE F ° ° 0 ° 0 ° 0 ° 0 ° 0 Manual 2100-549G Page 58 of 59... -
Page 59: Table 11A Pressures: Part Load Cooling
TABLE 11A PART LOAD COOLING PRESSURE/TEMPERATURE F ° TABLE 11B PART LOAD HEATING PRESSURE/TEMPERATURE F ° ° 0 ° 0 ° 0 ° 0 ° 0 Manual 2100-549G Page 59 of 59...
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