Bard Wall Mounted Packaged Heat Pumps Standard and Dehumidification Installation Guide
- June 7, 2024
- Bard
Table of Contents
Wall Mounted Packaged Heat Pumps Standard and Dehumidification
INSTALLATION INSTRUCTIONS
Wall Mounted Packaged Heat Pumps Standard & Dehumidification
Models:
T42H1 T42H1D T48H1 T48H1D
Bard Manufacturing Company, Inc. Bryan, Ohio 43506
www.bardhvac.com
Manual: 2100-541E
Supersedes: 2100-541D
Date:
5-14-21
Page
1 of 27
CONTENTS
Getting Other Information and Publications
3
Wall Mount General Information Wall Mount Model Nomenclature ………………………… 4 Shipping Damage …………………………………………….. 4 General ……………………………………………………….. 4 Duct Work ……………………………………………………….. 5 Filters ……………………………………………………….. 5 Fresh Air Intake………………………………………………… 5 Condensate Drain ……………………………………………. 5
Installation Instructions Wall Mounting Information …………………………………. 6 Mounting the Unit……………………………………………… 6 Placement ……………………………………………………….. 6 Clearances Required ………………………………………… 6 Minimum Clearances ………………………………………… 6 Wiring Main Power……………………………………….. 12 Wiring Low Voltage Wiring …………………………….. 12 Optional Outdoor T-Stat Applications…………………. 13
Start Up General ……………………………………………………… 15 Topping Off System
Charge……………………………… 15 Safety Practices ……………………………………………… 15 Important
Installer Note……………………………………. 16 High & Low Pressure Switch…………………………….. 16
Three Phase Scroll Compressor……………………….. 16 Phase Monitor…………………………………………………
16 Service Hints………………………………………………….. 16 Sequence of Operation …………………………………….
17 Pressure Service Ports ……………………………………. 17 Defrost Cycle
…………………………………………………. 17
Troubleshooting Solid State Heat Pump Control …………………………. 19 Checking
Temperature Sensor …………………………. 20 Fan Blade Setting Dimensions………………………….. 21
Removal of Fan Shroud …………………………………… 21 R-410A Refrigerant Charge ………………………………
21 Troubleshooting ECM Motors …………………………… 26 Troubleshooting ECM Motors
…………………………… 27
Figures Figure 1 Fresh Air Damper Assembly………………… 5 Figure 2 Unit Dimensions ………………………………… 7 Figure 3 Mounting Instructions T42, 48……………… 8 Figure 4 Electric Heat Clearance ……………………… 9 Figure 5 Wall Mounting Instructions ………………… 10 Figure 6 Wall Mounting Instructions ………………… 10 Figure 7 Common Wall Mounting Installations ….. 11 Figure 8 Compressor Cutoff …………………………… 13 Figure 9 Compressor Cutoff …………………………… 13 Figure 10 Electric Heat Hold-Off Wiring …………….. 14 Figure 11 Electric Heat Hold-Off Wiring …………….. 14 Figure 12 Defrost Control Board ………………………. 18 Figure 13 Fan Blade Setting…………………………….. 21 Figure 14 Control Disassembly ………………………… 27 Figure 15 Winding Test……………………………………. 27 Figure 16 Drip Loop………………………………………… 27
Tables Table 1 Clearances Required …………………………. 6 Table 2 Min. Clearances Required…………………… 6 Table 3 Troubleshooting……………………………….. 19 Table Temperature F vs. Resistance …………… 20 Table 4 Fan Blade Dimension……………………….. 21 Table 5A Cooling Pressure……………………………… 22 Table 5B Heating Pressure …………………………….. 22 Table 6A Electrical Specifications TH…………….. 23 Table 6B Electrical Specifications TH Dehum. … 24 Table 7 Indoor Blower Performance ………………. 25
Manual 2100-541E Page 2 of 27
GETTING OTHER INFORMATION AND PUBLICATIONS
These publications can help when installing the air conditioner or heat pump.
They can usually be found at the 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 Residential Winter and Summer Air
Conditioning
Duct Design for Residential…………… ACCA Manual D Winter and Summer Air
Conditioning and Equipment Selection
FOR MORE INFORMATION, CONTACT THESE PUBLISHERS:
ACCA
Air Conditioning Contractors of America 1712 New Hampshire Ave. N.W. 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 2100-541E
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WALL MOUNT GENERAL INFORMATION
HEAT PUMP WALL MOUNT MODEL NOMENCLATURE
T
MODEL NUMBER
42 H 1 A
REVISIONS
CAPACITY 42 – 3½ Ton 48 – 4 Ton
H – Heat Pump
VOLTS & PHASE A – 230/208/60/1 B – 230/208/60/3 C – 460/60/3
SPECIALTY PRODUCTS (Non-Standard)
10
KW 0Z – 0KW 04 – 4KW 05 – 5KW 06 – 6KW F8 – 8KW S8 – 8KW 09 – 9KW 10 -10KW 15
-15KW 20 -20KW
VENTILATION OPTIONS X – Barometric Fresh Air Damper (Standard) B – Blank-off
Plate M – Motorized Fresh Air Damper C – Commercial Ventilator – Mod. Spring
Return w/Exhaust V – Commercial Ventilator – Spring Return w/Exhaust P –
Commercial Ventilator – Power Return w/Exhaust E – Economizer (Internal) –
Fully Modulating with Exhaust R – Energy Recovery Ventilator – Motorized with
Exhaust
(See Spec. Sheet S3398)
X X X XX X
CONTROL MODULES (See Spec. Sheet S3436)
COLOR OPTIONS X – Beige 1 – White 4 – Buckeye Gray 5 – Desert Brown 8 – Dark Bronze A – Aluminum S – Stainless Steel
COIL OPTIONS X – Standard 1 – Phenolic Coated Evaporator 2 – Phenolic Coated
Condenser 3 – Phenolic Coated Evaporator
and Condenser
OUTLET OPTIONS X – Front (Standard)
FILTER OPTIONS X – 1-Inch Fiberglass (MERV 2) N – 2-Inch Pleated (MERV 13) M – 2-Inch Pleated (MERV 11) H – 2-Inch Pleated (MERV 8) P – 2-Inch Pleated (MERV 6) E – 24V 1″ Electrostatic Air Cleaner B – NPBI TECH + 2-Inch Pleated (MERV 13) A – UV-C + 2-Inch Pleated (MERV 13)
For 0 KW and circuit breakers (230/208 volt) or toggle disconnect (460V)
applications, insert 0Z in the KW field of the model number. See Pages 23 &
24. Insert “D” for dehumidification with hot gas reheat. Reference Form
7960-627 for complete details.
NOTE: Vent options X, B and M are without exhaust capability. May require
separate field supplied barometric relief in building.
SHIPPING DAMAGE
Upon receipt of equipment, the carton should be checked for external signs of
shipping damage. If damage is found, the receiving party must contact the last
carrier immediately, preferably in writing, requesting inspection by the
carrier’s agent.
GENERAL
The equipment covered in this manual is to be installed by trained,
experienced service and installation technicians.
The refrigerant system is completely assembled and charged. All internal
wiring is complete.
The unit is designed for use with or without duct work. Flanges are provided
for attaching the supply and return ducts.
These instructions explain the recommended method to install the air cooled
self-contained unit and the electrical wiring connections to the unit.
These instructions and any instructions packaged with any separate equipment
required to make up the entire air conditioning system should be carefully
read before beginning the installation. Note particularly “Starting Procedure”
and any tags and/or labels attached to the equipment.
While these instructions are intended as a general recommended guide, they do
not supersede any national and/or local codes in any way. Authorities having
jurisdiction should be consulted before the installation is made. See Page 3
for information on codes and standards.
Size of unit for a proposed installation should be based on heat loss/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 Association for the Installation of
Air Conditioning and Ventilating 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.
Manual 2100-541E Page 4 of 27
DUCT WORK
All duct work, supply and return, 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.
Design the duct work according to methods given by the Air Conditioning
Contractors of America (ACCA). 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.
A 1/4 inch clearance to combustible material for the first three feet of duct
attached to the outlet air frame is required. See Wall Mounting Instructions
and Figures 3 and 4 for further details.
Ducts through the walls must be insulated and all joints taped or sealed to
prevent air or moisture entering the wall cavity.
Some installations may not require any return air duct. A metallic return air
grille is required with installations not requiring a return air duct. The
spacing between louvers on the grille shall not be larger than 5/8 inch.
Any grille that meets with 5/8 inch louver criteria may be used. It is
recommended that Bard Return Air Grille Kit RG2 through RG5 or RFG2 through
RFG5 be installed when no return duct is used. Contact distributor or factory
for ordering information. If using a return air filter grille, filters must be
of sufficient size to allow a maximum velocity of 400 fpm.
NOTE: If no return air duct is used, applicable installation codes may limit
this cabinet to installation only in a single story structure.
FILTERS
A 1-inch throwaway filter is standard with each unit. The filter slides into
position making it easy to service. This filter can be serviced from the
outside by removing the filter access panel. 2-inch pleated filters are also
available as optional accessories. The internal filter brackets are adjustable
to accommodate the 2-inch filter by bending two (2) tabs down on each side of
the filter support bracket.
FRESH AIR INTAKE
All units are built with fresh air inlet slots punched in the service door.
If the unit is equipped with a fresh air damper assembly, the assembly is
shipped already attached to the unit. The damper blade is locked in the closed
position. To allow the damper to operate, the maximum and minimum blade
position stops must be installed. See Figure 1.
All capacity, efficiency and cost of operation information is based upon the
fresh air blank-off plate in place and is recommended for maximum energy
efficiency.
The blank-off plate is available upon request from the factory and is
installed in place of the fresh air damper shipped with each unit.
CONDENSATE DRAIN
A plastic drain hose extends from the drain pan at the top of the unit down to
the unit base. There are openings in the unit base for the drain hose to pass
through. In the event the drain hose is connected to a drain system of some
type, it must be an open or vented type system to ensure proper drainage.
FIGURE 1 FRESH AIR DAMPER
Manual 2100-541E
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INSTALLATION INSTRUCTIONS
WALL MOUNTING INFORMATION
1. Two holes for the supply and return air openings must be cut through the
wall as shown in Figure 3.
2. On wood frame walls, the wall construction must be strong and rigid enough
to carry the weight of the unit without transmitting any unit vibration.
3. Concrete block walls must be thoroughly inspected to insure that they are
capable of carrying the weight of the installed unit.
MOUNTING THE UNIT
1. These units are secured by wall mounting brackets which secure the unit to
the outside wall surface at both sides. A bottom mounting bracket, attached to
skid for shipping, is provided for ease of installation, but is not required.
2. The unit itself is suitable for 0 inch clearance, but the supply air duct
flange and the first 3 feet of supply air duct require a minimum of 1/4 inch
clearance to combustible material. However, it is generally recommended that a
1-inch clearance is used for ease of installation and maintaining the required
clearance to combustible material. See Figure 3 for details on opening sizes.
3. Locate and mark lag bolt locations and bottom mounting bracket location.
See Figure 3.
4. Mount bottom mounting bracket.
5. Hook top rain flashing, attached to front – right of supply flange for
shipping, under back bend of top.
6. Position unit in opening and secure with 5/16 lag bolts; use 7/8 inch
diameter flat washers on the lag bolts.
7. Secure rain flashing to wall and caulk across entire length of top. See
Figure 3.
8. For additional mounting rigidity, the return air and supply air frames or
collars can be drilled and screwed or welded to the structural wall itself
(depending upon wall construction). Be sure to observe required clearance if
combustible wall.
WARNING
Failure to provide the 1/4 inch clearance between the supply duct and a
combustible surface for the first 3 feet of duct can result in fire causing
damage, injury or death.
PLACEMENT
1. On side-by-side installations, maintain a minimum of 20 inches clearance
on right side to allow access to control panel and heat strips, and to allow
proper airflow to the outdoor coil. Additional clearance may be required to
meet local or national codes.
2. Care should be taken to ensure that the recirculation and obstruction of
condenser discharge air does not occur. Recirculation of condenser discharge
air can be from either a single unit or multiple units. Any object such as
shrubbery, a building or a large object can cause obstructions to the
condenser discharge air. Recirculation or reduced airflow caused by
obstructions will result in reduced capacity, possible unit pressure safety
lockouts and reduced unit service life.
Units with a blow through condenser, such as the T**H 10 EER units, it is
recommended there be a minimum distance of 15 feet between the front of the
unit and any barrier or 20 feet between the fronts of two opposing (facing)
units.
Clearances Required for Service Access and Adequate Condenser Airflow
MODELS
LEFT SIDE RIGHT SIDE
T42H, T48H
20″
20″
Minimum Clearances Required to Combustible Materials
MODELS
SUPPLY AIR DUCT FIRST THREE FEET
CABINET
T42H, T48H
1/4″
0″
Manual 2100-541E Page 6 of 27
FIGURE 2
Dimensions of Basic Unit for Architectural and Installation Requirements (Nominal)
Model
Width Depth Height (W) (D) (H)
Supply AB
Return CB
E
F
G
I
J K L M N O P QRS T
T42H 42.075 22.432 84.875 9.88 29.88 15.88 29.88 43.88 13.56 31.66 30.00 32.68 26.94 34.69 32.43 3.37 43.00 23.88 10.00 1.44 16.00 1.88
T48H 42.075 22.432 93.000 9.88 29.88 15.88 29.88 43.88 13.56 37.00 30.00 40.81 35.06 42.81 40.56 3.37 43.00 31.00 10.00 1.44 16.00 10.00
All dimensions are in inches. Dimensional drawings are not to scale.
T**H RIGHT UNIT
W
5.75 F
G
Condenser
Air Outlet
Front View
Built In Rain Hood
4° Pitch Heater Access Panel
Electric Heat
C. Breaker/ Disconnect Access Panel (Lockable)
Filter Access Panel
Vent Option Door
Ventilation Air
Low Voltage Electrical Entrance
High Voltage Electrical Entrance
D
2.13 Side Wall
A Mounting Brackets (Built In)
I Top Rain Flashing Shipping Location
Optional C H Electrical
Entrances
Cond.
K
Air
J
Inlet
L M P
Side View Drain
N
E O
.44 R
Supply Air Opening
S B
S
Return Air Opening
S
S1
1
S
T
Back View Bottom Installation
Q
Bracket
MIS-2729 A
Manual 2100-541E
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Manual 2100-541E Page 8 of 27
FIGURE 3 T42H1, T48H1 MOUNTING INSTRUCTIONS
SEAL WITH BEAD
OF CAULKING ALONG
ENTIRE LENGTH OF
A
B
C
D
E
TOP.
REQUIRED DIMENSIONS TO MAINTAIN 30 1/2 10 1/2 6 1/4 1 1/4 29 3/4
1/4″ MIN. CLEARANCE FROM
TOP
COMBUSTIBLE MATERIALS
REQUIRED DIMENSIONS TO MAINTAIN 32 12 5 1/2 2
29
RECOMMENDED 1″ CLEARANCE FROM
COMBUSTIBLE MATERIALS
WALL
D
C
A
C
Supply Opening
B
16″
HEATER ACCESS PANEL
RAIN FLASHING SUPPLIED
FOAM AIR SEAL
WALL STRUCTURE
SUPPLY AIR DUCT
1/4″ CLEARANCE ON ALL FOUR SIDES OF SUPPLY AIR DUCT IS REQUIRED FROM COMBUSTABLE MATERIALS
16″
E
16″
Return Opening
16″
1
16″
6
1 2
”
30″
1
16″
3″ 1″
4″
3
1 8
”
Typ.
7 8
”
2
1
7 8
”
4″
6
1 2
”
Typ.
6
1 2
”
1 Dimension is 21″ on 95″ tall units. 2 Dimension is 10″ on T48H1 & T60H1. 3 Dimension is 6″ on T48H1 & T60H1.
Wall Opening and Hole Location View
2
1 8
”
3
RETURN AIR OPENING
NOTES:
IT IS RECOMMENDED THAT A BEAD OF SILICONE CAULKING BE PLACED BEHIND THE SIDE
MOUNTING FLANGES AND UNDER TOP FLASHING AT TIME OF INSTALLATION.
Right Side View
MIS-416 E
FIGURE 4 ELECTRIC HEAT CLEARANCE
SIDE SECTION VIEW OF SUPPLY AIR DUCT FOR WALL MOUNTED UNIT SHOWING 1/4 INCH
CLEARANCE TO COMBUSTIBLE SURFACES.
WARNING
A minimum of 1/4 inch clearance must be maintained between the supply air duct
and combustible materials. This is required for the first 3 feet of ducting.
It is important to insure that the 1/4 inch minimum spacing is maintained at
all points. Failure to do this could result in overheating the combustible
material and may result in a fire causing damage, injury or death.
Manual 2100-541E
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FIGURE 5 WALL MOUNTING INSTRUCTIONS
SEE FIGURE 3 MOUNTING INSTRUCTIONS
FACTORY SUPPLIED RAIN FLASHING. MOUNT ON UNIT
BEFORE INSTALLATION
WALL STRUCTURE
SUPPLY AIR OPENING
SUPPLY AIR OPENING
SUPPLY AIR DUCT
RETURN AIR OPENING
RETURN AIR OPENING
RETURN AIR OPENING
CONCRETE BLOCK WALL INSTALLATION
WOOD OR STEEL SIDING
WOOD FRAME WALL INSTALLATION
BOTTOM MOUNTING BRACKET. MOUNT ON
WALL BEFORE INSTALLING UNIT.
SIDE VIEW
MIS-548 A
MIS-549 B
Manual 2100-541E Page 10 of 27
FIGURE 6 WALL MOUNTING INSTRUCTIONS
ATTACH TO TOP PLATE OF WALL
SEE UNIT DIMENSIONS, FIGURE 2, FOR ACTUAL DIMENSIONS.
E + 1.000 B
1.000″ CLEARANCE ALL AROUND DUCT
INTERIOR FINISHED WALL OVER FRAME
1.000″ CLEARANCE ALL AROUND DUCT
EXTERIOR FINISH WALL OVER FRAME
SUPPLY DUCT OPENING
RETURN DUCT OPENING
2 x 6 CL
1.000 A I C K
FRAMING MATERIAL 2 x 4’S, 2 x 6’S &/OR
STRUCTURAL STEEL
ATTACH TO BOTTOM PLATE OF WALL
THIS STRUCTURAL MEMBER LOCATED TO MATCH STUD SPACING FOR REST OF WALL. A SECOND MEMBER MAY BE REQUIRED FOR SOME WALLS.
FIGURE 7 COMMON WALL MOUNTING INSTALLATIONS
Non-Ducted Installations
Unit is sealed to wall.
Wall Mount Unit
Ceiling Supply Air Adjustable Supply Grille
Fixed Blade Return Grille
Ducted Installations
Unit is sealed to wall.
Wall Mount Unit
Ceiling
Supply Air Duct Optional Dropped Ceiling Fixed Blade Return Grille
Outside Wall Room Air
Outside Wall Supply Air Supply Air
Return Air Return Air
Room Air
Indoor Area
Indoor Area
Non-ducted installations supply conditioned air into indoor room areas without extensive duct work. The supply airstream is directed by adjusting the 4-way supply grille to reach areas being conditioned. The supply air mixes with the room air and cools or heats occupants and/or equipment in the area. Unconditioned room air is returned to the unit through the return grille. Avoid supply air leaving supply grille and re-entering the unit return grille without mixing with room air.
Ducted installations supply conditioned air into indoor room areas using solid or flexible ducts. The supply air is distributed throughout a single area or multiple areas. The supply air mixes with the room air and cools or heats occupants and/or equipment. Unconditioned room air is returned to the unit through a return grille or return duct work. Avoid using restrictive duct work to provide the best unit performance and efficiency. Review duct static pressure requirements provided in this manual.
Outdoor Wall Curb Installations
Curb is sealed to wall.
Ceiling
Supply Air
Wall Mount Unit
Adjustable Supply Grille Fixed Blade Return Grille
WAPR11 Indoor Sound Plenum Installations
Unit is sealed to wall.
Ceiling
Wall Mount Unit
Supply Air Duct Optional Dropped Ceiling
Wall Curb Outside Wall
Room Air Outside Wall
Supply Air Supply Air
Return Air
Unit is sealed to curb.
Indoor Area
Outdoor Wall curbs are installed between the wall mount unit and the outer wall surface. Wall curb use may avoid resizing supply and return openings that are currently in an existing wall. Wall curbs may also provide sound isolation and indoor area sound reduction. Various curb options are available, and it is important to select a curb that will meet the application requirements and also be the correct size for the unit. Unit duct static requirements cannot be exceeded when using a wall curb. Follow all instructions provided with the wall curb when installing the product.
WAPR11 Plenum
Return Air
Room Air Indoor Area
Indoor sound plenums are installed inside the room over the unit return air
opening. Plenum use can provide sound isolation and indoor area sound
reduction. The WAPR11 sound plenum provides a single solution for all unit
tonnage sizes. The WAPR11 may be installed horizontally or vertically in the
room. Unit duct static requirements cannot be exceeded when using a sound
plenum. Follow all instructions provided with the sound plenum when installing
the product.
MIS-550 D
Manual 2100-541E
Page
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WIRING MAIN POWER
Refer to the unit rating plate for wire sizing information and maximum fuse or
“HACR” type circuit breaker size. Each outdoor unit is marked with a “Minimum
Circuit Ampacity”. This means that the field wiring used must be sized to
carry that amount of current. Depending on the installed KW of electric heat,
there may be two field power circuits required. If this is the case, the unit
serial plate will so indicate. All models are suitable only for connection
with copper wire. Each unit and/or wiring diagram will be marked “Use Copper
Conductors Only”. These instructions must be adhered to. Refer to the National
Electrical Code (NEC) for complete current carrying capacity data on the
various insulation grades of wiring material. All wiring must conform to NEC
and all local codes.
The electrical data lists fuse and wire sizes (75°C copper) for all models
including the most commonly used heater sizes. Also shown are the number of
field power circuits required for the various models with heaters.
The unit rating plate lists a “Maximum Time Delay Relay Fuse” or “HACR” type
circuit breaker that is to be used with the equipment. The correct size must
be used for proper circuit protection and also to assure that there will be no
nuisance tripping due to the momentary high starting current of the compressor
motor.
The disconnect access door on this unit may be locked to prevent unauthorized
access to the disconnect. To convert for the locking capability, bend the tab
located in the bottom left-hand corner of the disconnect opening under the
disconnect access panel straight out. This tab will now line up with the slot
in the door. When shut, a padlock may be placed through the hole in the tab
preventing entry.
See “Start Up” section for important information on three phase scroll
compressor start ups.
See Tables 6A & 6B for Electrical Specifications.
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:
TAP 240 208
RANGE 253 216 220 187
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).
For wiring size and connections, refer to Wiring Manual 2100-516.
Manual 2100-541E Page 12 of 27
FIGURE 8 COMPRESSOR CUTOFF THERMOSTAT WIRING
4 10KW 1 PH 6 & 9KW 3 PH
FIGURE 9 COMPRESSOR CUTOFF THERMOSTAT WIRING
15 20KW 1 PH AND 3 PH
OPTIONAL OUTDOOR THERMOSTAT APPLICATIONS
Since most equipment at the time of manufacture is not designated for any
specific destination of the country and are installed in areas not approaching
the lower outdoor temperature range, outdoor thermostats are not factory
installed as standard equipment, but are offered as an option. There are also
different applications for applying outdoor thermostats. The set point of
either type of outdoor thermostat application is variable with geographic
region and sizing of the heating equipment to the individual structure.
Utilization of the heating Application Data, and the heat loss calculation of
the building are useful in determining the correct set points.
NOTE: The additional LAB (low ambient bypass) relay is required to prevent
heater operation during low temperature cooling operation.
OPTIONAL COMPRESSOR CUTOFF THERMOSTAT (See Figures 8 & 9)
Heat pump compressor operation at outdoor temperatures below 0°F are neither
desirable nor advantageous in term of efficiency. An outdoor thermostat can be
applied to take the mechanical heating (compressor) off line, and send the
(compressor) signal to energize electric heat in its place (to make electric
heat first stage heating). This can also be applied to bank the quantity of
available electric heat. For example: A heat pump operates with 10KW second
stage heat once the outdoor thermostat has switched then operates 15KW
without the compressor as first stage heat.
Manual 2100-541E
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ELECTRIC HEAT HOLD-OFF (See Figures 10 & 11)
In other applications, it is desirable to disable the operation of the
electric heat until outdoor temperatures have reached a certain design point.
This won’t allow the electric heat to come on as second stage heating unless
the outdoor temperature is below the set point of the outdoor thermostat. This
is done to maximize
efficiency by utilizing the heat pump to bring the conditioned space temperature up, rather than cycling on the electric heat due a second stage call for heat from the thermostat on start-up coming off a night setback condition or someone increasing the thermostat set point. (NOTE: Some programmable thermostats do have a built-in time delay for pulling in second stage heat when coming off set-back conditions.)
FIGURE 10 ELECTRIC HEAT HOLD-OFF WIRING
4 10KW 1 PH — 6 & 9KW 3 PH
FIGURE 11 ELECTRIC HEAT HOLD-OFF WIRING
15 20KW 1 PH & 3 PH
Manual 2100-541E Page 14 of 27
START UP
THESE UNITS REQUIRE R-410A REFRIGERANT AND POLYOL ESTER OIL.
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).
4. R-410A is a binary blend of HFC-32 and HFC-125.
5. R-410A is nearly azeotropic – similar to R-22 and R-12. Although nearly
azeotropic, charge with liquid refrigerant.
6. R-410A operates at 40-70% higher pressure than R-22, and systems designed
for R-22 cannot withstand this higher pressure.
7. R-410A has an ozone depletion potential of zero, but must be reclaimed due
to its global warming potential.
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. 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
pressure charts on the inner control panel cover as a guideline.
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.
WARNING
Failure to conform to these practices could lead to damage, injury or death.
SAFETY PRACTICES:
1. Never mix R-410A with other refrigerants. 2. Use gloves and safety
glasses, Polyol Ester oils can
be irritating to the skin, and liquid refrigerant will freeze the skin. 3.
Never use air and R-410A to leak check; the mixture may become flammable. 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.
Manual 2100-541E
Page
15 of 27
IMPORTANT INSTALLER NOTE
For improved start up performance wash the indoor coil with a dish washing
detergent.
HIGH & LOW PRESSURE SWITCH
All T**H wall mounted air conditioner series models are supplied with a remote
reset for the high and low pressure switch. If tripped, this pressure switch
may be reset by turning the thermostat off then back on again.
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 over one hour may have a negative impact on the bearing due to
oil pump out.
NOTE: If compressor is allowed to run in reverse rotation for several minutes,
the compressor’s internal protector will trip.
All three phase ZP compressors 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 compressor may be changed by reversing any
two line connections to the unit.
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.
If phases are reversed, the red fault LED will be lit and compressor operation
is inhibited.
If a fault condition occurs, reverse two of the supply leads to the unit. Do
not reverse any of the unit factory wires as damage may occur.
SERVICE HINTS
1. Caution owner/operator to maintain clean air filters at all times. Also,
not to needlessly close off supply and return air registers. This reduces
airflow through the system, which shortens equipment service life as well as
increasing operating costs.
2. Check all power fuses or circuit breakers to be sure they are the correct
rating.
3. Periodic cleaning of the outdoor coil to permit full and unrestricted
airflow circulation is essential.
Manual 2100-541E Page 16 of 27
SEQUENCE OF OPERATION
COOLING Circuit R-Y 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.
HEATING 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-Y 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 heat completes R-Y circuit, pulling
in compressor contactor starting compressor and outdoor motor. R-G also make
starting indoor blower motor.
PRESSURE SERVICE PORTS
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. See Tables 5A & 5B.
DEFROST CYCLE
The defrost cycle is controlled by temperature and time on the solid state
heat pump control. 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. 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. By default, this
unit is shipped from the factory with the defrost time on the 60 minute pin.
If
circumstances require a change to another time, remove the wire from the
60-minute terminal and reconnect to the desired terminal. Refer to Figure 12.
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. 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 10
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. 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. Low Pressure Switch Bypass Operation – The control has a
selectable (SW1) low pressure switch bypass set up to ignore the low pressure
switch input during the first (30, 60, 120 or 180 seconds) of “Y” operation.
After this period expires, the control will then monitor the low pressure
switch input normally to make sure that the switch is closed during “Y”
operation. High Pressure Switch Operation – The control has a built-in lockout
system that allows the unit to have the high pressure switch trip up to two
times in one hour and only encounter a “soft” lockout. A “soft” lockout shuts
the compressor off and waits for the pressure switch to reset, which at that
point then allows the compressor to be restarted as long as the 5-minute short
cycle timer has run out. If the high pressure switch trips a third time within
one hour, the unit is in “hard” lockout indicating something is certainly
wrong and it will not restart itself.
Manual 2100-541E
Page
17 of 27
FIGURE 12 DEFROST CONTROL BOARD
LOW PRESSURE BYPASS TIMER SWITCH *(FACTORY SETTING 120 SECONDS)
SW SW 1 2 TIME (SEC) OFF OFF 30 ON OFF 60 OFF ON 120* ON ON 180
OFF
ON
ACCUMULATED DEFROST TIME TIMER (FACTORY SETTING 60 MIN.)
MIS-2668 A
Manual 2100-541E Page 18 of 27
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.
NOTE: Many models have a 1-minute blower time delay on “off” command; wait for
this to time-out.
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.
LED BLINK CODES
BLINK FUNCTION
Slow Normal function (1.0 sec on/1.0 sec off)
Fast Compressor Delay timer active (0.1 sec on/0.1 sec off)
1
Low pressure switch failure
2
High pressure switch failure/”Soft” Lockout
3
Defrost mode active
4
High pressure switch failure/”Hard” Lockout
TABLE 3 TROUBLESHOOTING
Sympton 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 Step#7; Fast Blink, go to Step #5
Compressor will not start (heating or cooling)
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.
7. High pressure fault.
Check wiring circuit and unit pressures.
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.
Fan outdoor Heat pump control defective motor does
not run (cooling or
Motor defective
heating except during defrost) Motor capacitor defective
Check across fan relay on heat pump control. (Com-NC) Replace heat pump
control. Check for open or shorted motor winding. Replace motor.
Check capacitor rating. Check for open or shorted capacitor. Replace
capacitor.
Reversing Heat pump control defective valve does not energize (heating only) Reversing valve solenoid coil defective
Unit will not go into defrost Temperature sensor or heat pump control defective (heating only)
Unit will not come out of defrost (heating only)
Temperature sensor or heat pump control defective
Check for 24V between RV-C and B-C. 1. Check control circuit wiring. 2.
Replace heat pump control.
Check for open or shorted coil. Replace solenoid coil.
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.
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.
Manual 2100-541E
Page
19 of 27
CHECKING TEMPERATURE SENSOR OUTSIDE UNIT CIRCUIT
1. Disconnect temperature sensor from board and from outdoor coil.
2. Use an ohmmeter and measure the resistance of the sensor. Also use
ohmmeter to check for short or open.
3. Check resistance reading to chart of resistance. Use sensor ambient
temperature. (Tolerance of part is ± 10%.)
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.
TEMPERATURE F VS. RESISTANCE R OF TEMPERATURE SENSOR
F
R
F
-25.0
196871
13.0
-24.0
190099
14.0
-23.0
183585
15.0
-22.0
177318
16.0
-21.0
171289
17.0
-20.0
165487
18.0
-19.0
159904
19.0
-18.0
154529
20.0
-17.0
149355
21.0
-16.0
144374
22.0
-15.0
139576
23.0
-14.0
134956
24.0
-13.0
130506
25.0
-12.0
126219
26.0
-11.0
122089
27.0
-10.0
118108
28.0
-9.0
114272
29.0
-8.0
110575
30.0
-7.0
107010
31.0
-6.0
103574
32.0
-5.0
100260
33.0
-4.0
97064
34.0
-3.0
93981
35.0
-2.0
91008
36.0
-1.0
88139
37.0
0.0
85371
38.0
1.0
82699
39.0
2.0
80121
40.0
3.0
77632
41.0
4.0
75230
42.0
5.0
72910
43.0
6.0
70670
44.0
7.0
68507
45.0
8.0
66418
46.0
9.0
64399
47.0
10.0
62449
48.0
11.0
60565
49.0
12.0
58745
50.0
R
F
56985
53.0
55284
52.0
53640
53.0
52051
54.0
50514
55.0
49028
56.0
47590
57.0
46200
58.0
44855
59.0
43554
60.0
42295
61.0
41077
62.0
39898
63.0
38757
64.0
37652
65.0
36583
66.0
35548
67.0
34545
68.0
33574
69.0
32634
70.0
31723
71.0
30840
72.0
29986
73.0
29157
74.0
28355
75.0
27577
76.0
26823
77.0
26092
78.0
25383
79.0
24696
80.0
24030
81.0
23384
82.0
22758
83.0
22150
84.0
21561
85.0
20989
86.0
20435
87.0
19896
88.0
R 19374 18867 18375 17989 17434 16984 16547 16122 15710 15310 14921 14544
14177 13820 13474 13137 12810 12492 12183 11883 11591 11307 11031 10762 10501
10247 10000
9760 9526 9299 9077 8862 8653 8449 8250 8057 7869 7686
F 89.0 90.0 91.0 92.0 93.0 94.0 95.0 96.0 97.0 98.0 99.0 100.0 101.0 102.0 103.0 104.0 105.0 106.0 107.0 108.0 109.0 110.0 111.0 112.0 113.0 114.0 115.0 116.0 117.0 118.0 119.0 120.0 121.0 122.0 123.0 124.0
R 7507 7334 7165 7000 6840 6683 6531 6383 6239 6098 5961 5827 5697 5570 5446 5326 5208 5094 4982 4873 4767 4663 4562 4464 4367 4274 4182 4093 4006 3921 3838 3757 3678 3601 3526 3452
Manual 2100-541E Page 20 of 27
FAN BLADE SETTING DIMENSIONS
Shown in Figure 13 is the correct fan blade setting for proper air delivery
across the outdoor coil. Refer to Table 4 for unit specific dimension.
Any service work requiring removal or adjustment in the fan and/or motor area
will require that the dimensions below be checked and blade adjusted in or out
on the motor shaft accordingly.
FIGURE 13 FAN BLADE SETTING
AIRFLOW
“A”
MIS-1724
TABLE 4 FAN BLADE DIMENSION
Model
T42H T48H
Dimension A 1.75″
REMOVAL OF FAN SHROUD
1. Disconnect all power to the unit.
2. Remove the screws holding both grilles, one on each side of unit, and
remove grilles.
3. Remove screws holding fan shroud to condenser and bottom. Nine (9) screws.
4. Unwire condenser fan motor.
5. Slide complete motor, fan blade, and shroud assembly out the left side of
the unit.
6. Service motor/fan as needed.
7. Reverse steps to reinstall.
R-410A
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 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 2100-541E
Page
21 of 27
TABLE 5A COOLING PRESSURE TABLE
Air Temperature Entering Outdoor Coil °F
Model
Return Air Temperature
Pressure
75
80
85
90
95
100 105 110 115 120
T42H T48H
75° DB
Low Side 131
132
134
136
137
139
142
144
146
149
62° WB
High Side 315
331
348
368
388
410
435
461
489
520
80° DB
Low Side 140
141
143
145
147
149
152
154
156
159
67° WB
High Side 323
339
357
377
402
421
446
473
502
533
85° DB
Low Side 145
146
148
150
152
154
157
159
161
165
72° WB
High Side 334
351
369
390
412
436
462
490
520
552
75° DB
Low Side 133
136
137
139
141
142
144
145
147
148
62° WB
High Side 325
341
360
379
401
424
449
477
505
535
80° DB
Low Side 142
145
147
149
151
152
154
155
157
158
67° WB
High Side 333
350
369
389
417
435
461
489
518
549
85° DB
Low Side 147
150
152
154
156
157
159
160
162
164
72° WB
High Side 345
362
382
403
425
450
477
506
536
568
Low side pressure ± 4 PSIG High side pressure ± 10 PSIG
Tables are based upon rated CFM (airflow) across the evaporator coil. If there
is any doubt as to correct operating charge being in the system, the charge
should be removed, system evacuated and recharged to serial plate charge
weight. NOTE: Pressure table based on high speed condenser fan operation. If
condensing pressures appear elevated check condenser fan wiring. See
“Condenser Fan Operation”.
Model T42H T48H
TABLE 5B HEATING PRESSURES (ALL TEMPERATURES °F)
Return Air Temperature
Pressure
0
5 10 15 20 25 30 35 40 45 50 55 60 65
70 deg. 70 deg.
Low Side High Side
Low Side High Side
40 45 51 57 63 70 78 85 93 102 110 119 129 139 294 296 299 305 311 319 329 340
353 368 384 401 420 441
39 45 50 56 62 69 76 84 92 100 108 117 127 137 260 264 268 273 279 285 293 300
309 319 329 339 351 363
Manual 2100-541E Page 22 of 27
TABLE 6A
Electrical Specifications — T**H Series
Single Circuit
Multiple Circuit
MODEL
Rated Volts, HZ & Phase
No. Field Power Circuits
Minimum
Circuit Ampacity
T42H1-A00, A0Z
1
31
-A05
1
57
-A08 230/208-60-1 1 or 2
73
-A10
1 or 2
83
-A15
1 or 2
86
T42H1-B00, B0Z
1
26
-B06 -B09
230/208-60-3
1 1
44 53
n -B15
1
53
T42H1-C0Z
1
13
-C06 -C09
460-60-3
1 1
22 26
n -C15
1
27
T48H1-A00, A0Z
1
37
-A05
1 or 2
63
-A08 230/208-60-1 1 or 2
79
-A10
1 or 2
89
-A15
1 or 2
89
T48H1-B00, B0Z
1
27
-B06 -B09
230/208-60-3
1 1
45 54
n -B15
1
55
T48H1-C0Z
1
15
-C06 -C09
460-60-3
1 1
24 28
n -C15
1
29
Maximum External
Fuse or Ckt. Brkr.
40 60 80 90 90 35 50 60 60 15 25 30 30 50 70 90 100 100 40 50 60 60 20 25 30
30
l Field Power Wire Size
8 6 4 4 3 8 8 6 6 12 10 10 10 8 6 4 3 3 8 8 6 6 12 10 10 10
l Ground
Wire
Minimum Circuit
Ampacity
Maximum
l
External Fuse or Field Power Wire
Ckt. Breaker
Size
l Ground Wire Size
Ckt. A Ckt. B Ckt. C Ckt. A Ckt. B Ckt. C Ckt. A Ckt. B Ckt. C Ckt. A Ckt. B Ckt. C
10
10
8
31 42
40 45
8
8
10 10
8
31 52
40 60
8
6
10 10
8
34 52
40 60
8
6
10 10
10
10
10
10
12
10
10
10
10
8
37 26
50 30
8 10
10 10
8
37 42
50 50
8
8
10 10
8
37 52
50 60
8
6
10 10
8
37 52
50 60
8
6
10 10
10
10
10
10
12
10
10
10
These “Minimum Circuit Ampacity” values are to be used for sizing the field
power conductors. Refer to the National Electrical code (latest version),
Article 310 for power conductor sizing. CAUTION: When more than one field
power 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 (3) current carrying conductors are in a raceway.
Maximum size of the time delay fuse or circuit breaker for protection of field
wiring conductors. l Based on 75°copper wire. All wiring must conform to the
National Electrical Code and all local codes. Maximum KW that can operate with
the heat pump on is 10KW. Full heat available during emergency heat mode. n
Maximum KW that can operate with the heat pump on is 9KW. Full heat available
during emergency heat mode.
NOTE: The Maximum Overcurrent Protection (MOCP) value listed is the maximum
value as per UL 1995 calculations for MOCP (branch-circuit conductor sizes in
this chart are based on this MOCP). The actual factory-installed overcurrent
protective device (circuit breaker) in this model may be lower than the
maximum UL 1995 allowable MOCP value, but still above the UL 1995 minimum
calculated value or Minimum Circuit Ampacity (MCA) listed.
IMPORTANT: While this electrical data is presented as a guide, it is important
to electrically connect properly sized fuses and conductor wires in accordance
with the National Electrical Code and all local codes.
Manual 2100-541E
Page
23 of 27
TABLE 6B
Electrical Specifications — T**H Series Dehumidification
Single Circuit
Multiple Circuit
MODEL
No.
Rated Volts, Field HZ & Phase Power
Circuits
Minimum Circuit
Ampacity
T42H1DA00, DA0Z
1
31
DA05
1
57
DA08 230/208-60-1 1 or 2
73
DA10
1 or 2
83
DA15
1 or 2
86
T42H1DB00, DB0Z
1
26
DB06 DB09
230/208-60-3
1 1
44 53
n DB15
1
53
T42H1DC0Z
1
13
DC06 DC09
460-60-3
1 1
22 26
n DC15
1
27
T48H1DA00, DA0Z
1
37
DA05
1 or 2
63
DA08 230/208-60-1 1 or 2
79
DA10
1 or 2
89
DA15
1 or 2
89
T48H1DB00, DB0Z
1
27
DB06 DB09
230/208-60-3
1 1
45 54
n DB15
1
55
T48H1DC0Z
1
15
DC06 DC09
460-60-3
1 1
24 28
n DC15
1
29
Maximum External
Fuse or Ckt. Brkr.
40 60 80 90 90 35 50 60 60 15 25 30 30 50 70 90 100 100 40 50 60 60 20 25 30
30
l Field Power Wire Size
8 6 4 4 3 8 8 6 6 12 10 10 10 8 6 4 3 3 8 8 6 6 12 10 10 10
l Ground
Wire
Minimum Circuit
Ampacity
Maximum
l
External Fuse or Field Power Wire
Ckt. Breaker
Size
l Ground Wire Size
Ckt. A Ckt. B Ckt. C Ckt. A Ckt. B Ckt. C Ckt. A Ckt. B Ckt. C Ckt. A Ckt. B Ckt. C
10
10
8
31 42
40 45
88
10 10
8
31 52
40 60
86
10 10
8
34 52
40 60
86
10 10
10
10
10
10
12
10
10
10
10
8
37 26
50 30
8 10
10 10
8
37 42
50 50
88
10 10
8
37 52
50 60
86
10 10
8
37 52
50 60
86
10 10
10
10
10
10
12
10
10
10
These “Minimum Circuit Ampacity” values are to be used for sizing the field
power conductors. Refer to the National Electrical code (latest version),
Article 310 for power conductor sizing. CAUTION: When more than one field
power 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 (3) current carrying conductors are in a raceway.
Maximum size of the time delay fuse or circuit breaker for protection of field
wiring conductors. l Based on 75°copper wire. All wiring must conform to the
National Electrical Code and all local codes. Maximum KW that can operate with
the heat pump on is 10KW. Full heat available during emergency heat mode. n
Maximum KW that can operate with the heat pump on is 9KW. Full heat available
during emergency heat mode.
NOTE: The Maximum Overcurrent Protection (MOCP) value listed is the maximum
value as per UL 1995 calculations for MOCP (branch-circuit conductor sizes in
this chart are based on this MOCP). The actual factory-installed overcurrent
protective device (circuit breaker) in this model may be lower than the
maximum UL 1995 allowable MOCP value, but still above the UL 1995 minimum
calculated value or Minimum Circuit Ampacity (MCA) listed.
IMPORTANT: While this electrical data is presented as a guide, it is important
to electrically connect properly sized fuses and conductor wires in accordance
with the National Electrical Code and all local codes.
Manual 2100-541E Page 24 of 27
TABLE 7 T**H INDOOR BLOWER PERFORMANCE – CFM (0.00″ — 0.50″ H20)
Model
Rated ESP
T42H
.15
T48H
.20
Max. ESP
.50 .50
Blower Only Except for
CRVMP Vent Options
1250
1550
l Blower Only
for CRVMP Vent Options
825
825
Cooling & Heat Pump
1250
1550
Electric
Heat
1250 1550
NOTE: These units are equipped with a variable speed (ECM) indoor motor that
automatically adjusts itself to maintain approximately the same rate of indoor
airflow in both heating & cooling, dry & wet coil conditions and at both
230/208 or 460 volts.
Maximum ESP (inches WC) shown is with 2″ thick disposable filter. Blower only
CFM is the total air being circulated during continuous fan mode. Airflow
remains constant. l Blower only CFM reduces during continuous fan mode.
Requires wiring modification; consult Wiring Diagram and unplug and leave
disconnected the insulated male/female connector connecting together the Gray
& Orange wires located near the 24V terminal block
enclosure. CFM output on Cooling or Electric Heat.
Manual 2100-541E
Page
25 of 27
TROUBLESHOOTING ECMTM MOTORS
CAUTION:
Disconnect power from unit before removing or replacing connectors, or servicing motor. To avoid electric shock from the motor’s capacitors, disconnect power and wait at least 5 minutes before opening motor.
Symptom
Cause/Procedure
Mwhoetnorstraorctkins gslightly
· This is normal start-up for ECM
Motor won’t start · No movement
· Motor rocks, but won’t start Motor oscillates up & down while being tested
off of blower Motor starts, but runs erratically · Varies up and down or
intermittent
· “Hunts” or “puffs” at high CFM (speed)
· Stays at low CFM despite system call for cool or heat CFM
· Stays at high CFM
· Blower won’t shut off
Excessive noise · Air noise
· Check blower turns by hand · Check power at motor · Check low voltage (24
Vac R to C) at motor · Check low voltage connections (G, Y, W, R, C) at motor
· Check for unseated pins in connectors on
motor harness · Test with a temporary jumper between R – G · Check motor for
tight shaft · Perform motor/control replacement check · Perform Moisture Check
· 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
· Check line voltage for variation or “sag” · Check low voltage connections
(G, Y, W, R, C) at motor, unseated pins in motor harness connectors · Check
“Bk” for erratic CFM command (in variable-speed applications) · Check out
system controls, Thermostat · Perform Moisture Check
· Does removing panel or filter reduce “puffing”? – Reduce restriction –
Reduce max airflow
· 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
· “R” missing/not connected at motor · Is fan in delay mode? – wait until
delay time complete · Perform motor/control replacement check
· Current leakage from controls into G, Y or W? Check for Triac switched
thermostat or solidstate relay
· 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
Symptom
· Noisy blower or cabinet
· “Hunts” or “puffs” at high CFM (speed)
Cause/Procedure
· 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
· Does removing panel or filter reduce “puffing”? – Reduce restriction –
Reduce max. airflow
Evidence of Moisture · Motor failure or malfunction has occurred and moisture
is present
· Evidence of moisture present inside air mover
· Replace motor and Perform Moisture Check · Perform Moisture Check
Do
Don’t
· Check out motor, controls, · Automatically assume the motor is bad.
wiring and connections
thoroughly before replacing
motor
· Orient connectors down so · Locate connectors above 7 and 4 o’clock
water can’t get in
positions
– Install “drip loops”
· Use authorized motor and · Replace one motor or control model # with
model #’s for replacement another (unless an authorized replacement)
· Keep static pressure to a · Use high pressure drop filters some have ½”
minimum:
H20 drop!
– Recommend high
· Use restricted returns
efficiency, low static filters – Recommend keeping filters
clean.
– Design ductwork for min.
static, max. comfort
– Look for and recommend
ductwork improvement,
where necessary
· Size the equipment wisely
· Check orientation before inserting motor connectors
· Oversize system, then compensate with low airflow
· Plug in power connector backwards · 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 2100-541E Page 26 of 27
TROUBLESHOOTING ECMTM MOTORS CONT’D.
Replacing ECM Control Module
To replace the control module for the GE variable-speed indoor blower motor
you need to take the following steps:
1. You MUST have the correct replacement module. The controls are factory
programmed for specific operating modes. Even though they look alike,
different modules may have completely different functionality.
USING THE WRONG CONTROL MODULE VOIDS ALL PRODUCT WARRANTIES AND MAY PRODUCE
UNEXPECTED RESULTS.
2. Begin by removing AC power from the furnace or air handler being serviced.
DO NOT WORK ON THE MOTOR WITH AC POWER APPLIED. To avoid electric shock from
the motor’s capacitors, disconnect power and wait at least 5 minutes before
opening motor.
3. It is usually not necessary to remove the motor from the blower assembly.
However, it is recommended that the whole blower assembly, with the motor, be
removed from the furnace/air handler. (Follow the manufacturer’s procedures).
Unplug the two cable connectors to the motor. There are latches on each
connector. DO NOT PULL ON THE WIRES. The plugs remove easily when properly
released.
4. Locate the two standard ¼” hex head bolts at the rear of the control
housing (at the back end of the control opposite the shaft end). Refer to
Figure 14. Remove these two bolts from the motor and control assembly while
holding the motor in a way that will prevent the motor or control from falling
when the bolts are removed. If an ECM2.0 control is being replaced (recognized
by an aluminum casting rather that a deep-drawn black steel can housing the
electronics), remove only the hex-head bolts. DO NOT REMOVE THE TORX-HEAD
SCREWS.
5. The control module is now free of mechanical attachment to the motor
endshield but is still connected by a plug and three wires inside the control.
Carefully rotate the control to gain access to the plug at the control end of
the wires. With thumb and forefinger, reach the latch holding the plug to the
control and release it by squeezing the latch tab and the opposite side of the
connector plug and gently pulling the plug out of the connector socket in the
control. DO NOT PULL ON THE WIRES. GRIP THE PLUG ONLY.
6. The control module is now completely detached from the motor. Verify with
a standard ohmmeter that the resistance from each motor lead (in the motor
plug just removed) to the motor shell is >100K ohms. Refer to Figure 15.
(Measure to unpainted motor end plate.) If any motor lead fails this test, do
not proceed to install the control module. THE MOTOR IS DEFECTIVE AND MUST BE
REPLACED. Installing the new control module will cause it to fail also.
7. Verify that the replacement control is correct for your application. Refer
to the manufacturer’s authorized replacement list. USING THE WRONG CONTROL
WILL RESULT IN IMPROPER OR NO BLOWER OPERATION. Orient the control module so
that the 3-wire motor plug can be inserted into the socket in the control.
Carefully insert the plug and press it into the socket until it latches. A
SLIGHT CLICK WILL BE HEARD WHEN PROPERLY INSERTED. Finish installing the
replacement control per one of the three following paragraphs, 8a, 8b or 8c.
8a. IF REPLACING AN ECM 2.0 CONTROL (control in cast aluminum can with air
vents on the back of the can) WITH AN ECM 2.3 CONTROL (control containing
black potting for water protection in black deep-drawn steel case with no
vents in the bottom of the can), locate the two through-bolts and plastic tab
that are packed with the replacement control. Insert the plastic tab into the
slot at the perimeter of the open end of the can so that the pin is located on
the inside of the perimeter of the can. Rotate the can so that the tab inserts
into the tab locator hole in the endshield of the motor. Using the two
through-bolts provided with the replacement control, reattach the can to the
motor.
THE TWO THROUGH-BOLTS PROVIDED WITH THE REPLACEMENT ECM 2.3 CONTROL ARE
SHORTER THAN THE BOLTS ORIGINALLY REMOVED FROM THE ECM 2.0 CONTROLAND MUST BE
USED IF SECURE ATTACHMENT OF THE CONTROL TO THE MOTOR IS TO BE ACHIEVED. DO
NOT OVERTIGHTEN THE BOLTS.
8b. IF REPLACING AN ECM 2.3 CONTROL WITH AN ECM 2.3 CONTROL, the plastic tab
and shorter through-bolts are not needed. The control can be oriented in two
positions 180° apart. MAKE SURE THE ORIENTATION YOU SELECT FOR REPLACING THE
CONTROL ASSURES THE CONTROL’S CABLE CONNECTORS WILL BE LOCATED DOWNWARD IN THE
APPLICATION SO THAT WATER CANNOT RUN DOWN THE CABLES AND INTO THE CONTROL.
Simply orient the new control to the motor’s endshield, insert bolts, and
tighten. DO NOT OVERTIGHTEN THE BOLTS.
8c. IF REPLACING AN ECM 2.0 CONTROL WITH AN ECM 2.0 CONTROL (It is recommended
that ECM 2.3 controls be used for all replacements), the new control must be
attached to the motor using through bolts identical to those removed with the
original control. DO NOT OVERTIGHTEN THE BOLTS.
9. Reinstall the blower/motor assembly into the HVAC equipment. Follow the
manufacturer’s suggested procedures.
10. Plug the 16-pin control plug into the motor. The plug is keyed. Make sure
the connector is properly seated and latched.
11. Plug the 5-pin power connector into the motor. Even though the plug is
keyed, OBSERVE THE PROPER ORIENTATION. DO NOT FORCE THE CONNECTOR. It plugs in
very easily when properly oriented. REVERSING THIS PLUG WILL CAUSE IMMEDIATE
FAILURE OF THE CONTROL MODULE.
12. Final installation check. Make sure the motor is installed as follows: a.
Unit is as far INTO the blower housing as possible. b. Belly bands are not on
the control module or covering vent holes. c. Motor connectors should be
oriented between the 4 o’clock and 8 o’clock positions when the blower is
positioned in its final location and orientation. d. Add a drip loop to the
cables so that water cannot enter the motor by draining down the cables. Refer
to Figure 16.
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.
FFigiguurree23144 Control Disassembly
Only remove
From Motor
Hex Head Bolts Push until
Latch Seats Over Ramp
Circuit
Board
FFiigguurree 4125 Winding Test
Motor Connector (3-pin)
ECM 2.0
Motor
Note: Use the shorter bolts and alignment pin supplied when replacing an ECM
2.0 control.
ECM 2.3/2.5
Motor Connector (3-pin)
Control Connector (16-pin) Power Connector (5-pin)
Hex-head Screws
Motor OK when R > 100k ohm
FFigiguurree1256 Drip Loop
Back of Control
Connector Orientation Between 4 and 8 o’clock
Drip Loop
Manual 2100-541E
Page
27 of 27