INSTALLATION INSTRUCTIONS
WALL MOUNTED
PACKAGED HEAT PUMP
Models:
C24H1-A
C24H1-B
C30H1-A
C30H1-B
C30H1-C
C36H1-A
C36H1-B
C36H1-C
C42H1-A
C42H1-B
C42H1-C
C48H1-A
C48H1-B
C48H1-C
C60H1-A
C60H1-B
C60H1-C
Bard Manufacturing Company, Inc.
Bryan, Ohio 43506
www.bardhvac.com
Manual: 2100-586D
Supersedes: 2100-5486C
Date: 7-28-15
Page 1 of 25
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 ............................................... 13
Wiring – Low Voltage Wiring ................................... 13
Optional Outdoor T-Stat Applications ...................... 13
Figures
Figure 1 Fresh Air Damper Assembly ..................... 5
Figure 2 Unit Dimensions ....................................... 7
Figure 3A Mounting Instructions C24H, C30H ..........8
Figure 3B Mounting Instructions C36, 42, 48, 60H ... 9
Figure 4 Electric Heat Clearance ......................... 10
Figure 5 Wall Mounting Instructions ..................... 11
Figure 6 Wall Mounting Instructions ..................... 11
Figure 7 Common Wall Mounting Installations ..... 12
Figure 8 Defrost Control Board ............................ 17
Figure 9 Fan Blade Setting ................................... 20
Figure 10 Control Disassembly .............................. 25
Figure 11 Winding Test ........................................... 25
Figure 12 Drip Loop ................................................ 25
Start Up
General ............................................................... 14
Topping Off System Charge .................................... 14
Safety Practices ...................................................... 14
Important Installer Note ........................................... 15
High & Low Pressure Switch ................................... 15
Three Phase Scroll Compressor ............................. 15
Phase Monitor ......................................................... 15
Service Hints ........................................................... 15
Sequence of Operation ........................................... 16
Pressure Service Ports ........................................... 16
Defrost Cycle .......................................................... 16
Troubleshooting
Solid State Heat Pump Control ............................... 18
Checking Temperature Sensor ............................... 19
Fan Blade Setting Dimensions ................................ 20
Removal of Fan Shroud .......................................... 20
R-410A Refrigerant Charge ....................................20
Troubleshooting GE ECM Motors ........................... 24
Troubleshooting GE ECM Motors ........................... 25
Tables
Table 1 Clearances Required ............................... 6
Table 2 Min. Clearances Required ........................ 6
Table 3 Troubleshooting......................................18
Table Temperature F vs. Resistance ............... 19
Table 4 Fan Blade Dimension ............................. 20
Table 5A Cooling Pressure .................................... 21
Table 5B Heating Pressure ................................... 21
Table 6 Electrical Specications C**H ................ 22
Table 7 Indoor Blower Performance ................... 23
Manual 2100-586D
Page 2 of 25
GETTING OTHER INFORMATION AND PUBLICATIONS
These publications can help you install the air
conditioner or heat pump. You can usually nd 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
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 2100-586D
Page 3 of 25
WALL MOUNT GENERAL INFORMATION
HEAT PUMP WALL MOUNT MODEL NOMENCLATURE
C 36 H 1 – A 05 V P X X X X
MODEL
NUMBER
CAPACITY |
24 - 2 Ton
30 - 2½ Ton
36 - 3 Ton
42 - 3½ Ton
48 - 4 Ton
60 - 5 Ton
Note All 230/208V units with or without electric heat have circuit breaker. 0C is for 460V circuit breaker & 0KW. No 460V electric heat options w/circuit
breaker available.
H - Heat Pump
VENTILATION OPTIONS
B - Blank-off Plate
V - Commercial Ventilator - Mod. Spring Return w/Exhaust
S - Economizer (Internal) - Fully Modulating with Exhaust
R - Energy Recovery Ventilator - Motorized with Exhaust
(See Spec. Sheet S3459)
460V -0Z and all 460V KW options are with Rotary Disconnect.
REVISIONS
VOLTS & PHASE
A - 230/208/60/1
B - 230/208/60/3
C - 460/60/3
KW
0C - 0KW
0Z - 0KW
04 - 4KW
05 - 5KW
06 - 6KW
F8 - 8KW
S8 - 8KW
09 - 9KW
10 -10KW
15 -15KW
20 -20KW
CONTROL MODULES
(See Spec. Sheet S3459)
COLOR OPTIONS
X - Beige
1 - White
4 - Buckeye Gray
5 - Desert Brown
8 - Dark Bronze
S - Stainless Steel
FILTER OPTIONS
X - 1-Inch Fiberglass (MERV 2)
M - 2-Inch Pleated (MERV 11)
P - 2-Inch Pleated (MERV 8)
See available heater options by unit model number.
COIL OPTIONS
X - Standard Hydrophilic Fin
Indoor Coil & Uncoated
Aluminum Outdoor Coil
1 - Phenolic Coated Indoor Coil
2 - Phenolic Coated Outdoor Coil
3 - Phenolic Coated ID & OD Coil
SUPPLY AIR OUTLET
X - Front (Standard)
WARNING
Falling or tipping the unit could cause injury or death!
Use two (2) people or a machine to move the unit.
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 2100-586D
Page 4 of 25
DUCT WORK
All duct work, supply and return, must be properly sized
for the design airow 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 rst
three feet of duct attached to the outlet air frame is required.
See Wall Mounting Instructions and Figures 3A, 3B 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.
FILTERS
A 1-inch throwaway lter is standard with each
unit. The lter slides into position making it easy to
service. This lter can be serviced from the outside by
removing the lter access panel. 2-inch pleated lters
are also available as optional accessories. The internal
lter brackets are adjustable to accommodate the 2-inch
lter by bending two (2) tabs down on each side of the
lter 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, efciency and cost of operation
information is based upon the fresh air blank-off plate
in place and is recommended for maximum energy
efciency.
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.
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 lter grille,
lters must be of sufcient 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.
FIGURE 1
FRESH AIR DAMPER
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 assure proper drainage.
Manual 2100-586D
Page 5 of 25
INSTALLATION INSTRUCTIONS
WARNING
Failure to bolt the unit to the wall could result
in the unit falling, causing injury or death!
Follow all mounting 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 ensure 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 ange and the rst 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 Figures 3A & 3B.
4. Mount bottom mounting bracket.
5. Hook top rain ashing, attached to front - right of
supply ange for shipping, under back bend of top.
6. Position unit in opening and secure with 5/16 lag bolts;
use 7/8 inch diameter at washers on the lag bolts.
7. Secure rain ashing to wall and caulk across entire
length of top. See Figures 3A & 3B.
WARNING
Failure to provide the 1/4 inch clearance
between the supply duct and a combustible
surface for the rst 3 feet of duct can result in
re causing damage, injury or death.
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.
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
airow 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
airow caused by obstructions will result in reduced
capacity, possible unit pressure safety lockouts and
reduced unit service life.
Units with a draw through condenser, such as
the C**H 11 EER, it is recommended there be a
minimum distance of 15 feet between the front of
the unit and any barrier to airow.
REQUIRED STEPS AFTER FINAL
PLACEMENT (C48H & C60H UNITS
ONLY)
The compressor is secured to the unit base for shipping.
Although unit will perform as designed with the
compressor secured in place, there may be noticeable
additional noise and vibration. To obtain the lowest
noise and vibration levels, remove the compressor
Clearances Required for Service Access
and Adequate Condenser Airow
MODELS LEFT SIDE RIGHT SIDE
C24H, C30H 36" 36"
C36H, C42H, C48H, C60H 36" 36"
Manual 2100-586D
Page 6 of 25
Minimum Clearances Required to
Combustible Materials
MODELS
C24H, C30H 1/4" 0"
C36H, C42H, C48H, C60H 1/4" 0"
SUPPLY AIR DUCT
FIRST THREE FEET
CABINET
3"
8620-160 Drain Fitting Supplied with unit,
field installed.
Panel
Air Inlet
Door
Vent Option
Condenser
Filter Access
Ventilation
Air
Front View
F
W
5.75
G
Panel
indoor coil
Electric
Cond.
Access
Heater
4° Pitch
Rain Hood
Side View
Heat
Built In
Air
Disconnect
(Lockable)
Access Panel
Drain for
Outlet
C. Breaker/
ERV and
ECONWMS
only hood
Low Voltage
Electrical
Entrance
High Voltage
Electrical
Entrance
D
2.13
A
C H
K
J
I
Supply Air Opening
Return Air Opening
Top Rain
Flashing
Shipping
Location
Back View
Electrical
Entrances
Optional
Side Wall
Mounting
Brackets
(Built In)
T
S
S
M
.44
L
Q
P
S
N
O
E
R
S
S
B
Bottom Installation
Bracket - optional use
for direct mount, not
used when unit
installed with curb
shipping brackets after the unit is in its nal operating
location.
Remove the side grille to gain access to the compressor
shipping brackets. The brackets are located on the
compressor double isolation base at the front and rear
of the compressor. The brackets are secured to the unit
base with two (2) screws, and secured to the isolation
plate with a 1/4" nut. Remove and dispose of the two
(2) screws and brackets. Re-install the 1/4" nut once
bracket is removed.
FIGURE 2
Dimensions of Basic Unit for Architectural & Installation Requirements (Nominal)
WIDTH
DEPTH
MODEL
C24H1
C30H1
C36H1
C42H1
C48H1
C60H1
(W)
38.200 17.125 70.563 7.88 27.88 13.88 27.88 40.00 10.88 25.75 17.93 26.75 28.75 29.25 27.00 2.63 39.13 22.75 9.14 5.00 12.00 5.00
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
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
HEIGHT
(D)
All dimensions are in inches. Dimensional drawings are not to scale.
SUPPLY RETURN
(H)
A B C B E F G I J K L M N O P Q R S T
C**H
RIGHT UNIT
Manual 2100-586D
Page 7 of 25
D
12"
12"
12"
12"
12"
C CA
28"
1"
3"
4"
Typ.
4
1
2
"
B
E
14"
1"
3
1
8
"
4"
Typ.
5"
4
1
2
"
7
8
"
RETURN AIR
SUPPLIED
Return Opening
16 7/84 9/164 1/21030
17 5/83 13/165 1/48 1/228 1/2
EDCBA
COMBUSTIBLE MATERIALS
RECOMMENDED 1" CLEARANCE FROM
REQUIRED DIMENSIONS TO MAINTAIN
THE SIDE MOUNTING FLANGES AND UNDER
1/4" CLEARANCE ON ALL
RAIN FLASHING
COMBUSTIBLE MATERIALS
DUCT
TOP FLASHING AT TIME OF INSTALLATION.
1/4" MIN. CLEARANCE FROM
REQUIRED DIMENSIONS TO MAINTAIN
OPENING
ENTIRE LENGTH OF TOP.
MATERIALS
NOTES:
OF CAULKING ALONG
PANEL
FOAM AIR SEAL
FOUR SIDES OF SUPPLY
AIR DUCT IS REQUIRED
FROM COMBUSTABLE
WALL STRUCTURE
TOP
MIS-311 C
Wall Opening and Hole Location View Right Side View
WALL
HEATER ACCESS
SEAL WITH BEAD
IT IS RECOMMENDED THAT A BEAD OF
SILICONE CAULKING BE PLACED BEHIND
SUPPLY AIR
Supply Opening
W*R UNIT SHOWN, W*L UNIT
CONTROLS AND HEATER ACCESS
IS ON OPPOSITE (LEFT) SIDE.
FIGURE 3A
C24H, C30H
MOUNTING INSTRUCTIONS
Manual 2100-586D
Page 8 of 25
D
16"
16"
16"
16"
16"
1
7
8
"
6
1
2
" 6
1
2
"
2
1
8
"
7
8
"
1"
3"
4"
Typ.
4"
Typ.
6
1
2
"
30"
E
16"
A CC
3
1
8
"
B
Wall Opening and Hole Location View
RETURN AIR
1
REQUIRED DIMENSIONS TO MAINTAIN
1/4" MIN. CLEARANCE FROM
COMBUSTIBLE MATERIALS
REQUIRED DIMENSIONS TO MAINTAIN
29
DUCT
COMBUSTIBLE MATERIALS
A B C DE
30 1/2
10 1/2
6 1/4 1 1/4 29 3/4
32 12 5 1/2
2
NOTES:
WALL STRUCTURE
1
SUPPLY AIR
IT IS RECOMMENDED THAT A BEAD OF
OPENING
Right Side View
RAIN FLASHING
SILICONE CAULKING BE PLACED BEHIND
RECOMMENDED 1" CLEARANCE FROM
THE SIDE MOUNTING FLANGES AND UNDER
TOP FLASHING AT TIME OF INSTALLATION.
TOP.
PANEL
HEATER ACCESS
FOUR SIDES OF SUPPLY
AIR DUCT IS REQUIRED
FROM COMBUSTABLE
WALL
1/4" CLEARANCE ON ALL
MATERIALS
Supply Opening
FOAM AIR SEAL
SUPPLIED
SEAL WITH BEAD
OF CAULKING ALONG
ENTIRE LENGTH OF
TOP
1
Return Opening
MIS-416 E
Dimension is 21" on 95" tall units.
2
Dimension is 10" on T48H1 & T60H1.
2
Dimension is 6" on T48H1 & T60H1.
3
3
FIGURE 3B
C36H, C42H, C48H, C60H
MOUNTING INSTRUCTIONS
k
Dimension is 10" on T48S1 & T60S1.
k Dimension is 6" on T48S1 & T60S1.
Manual 2100-586D
Page 9 of 25
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 rst 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 re causing damage, injury or death.
Manual 2100-586D
Page 10 of 25
FIGURE 5
DUCT
OPENING
RETURN AIR
SUPPLY AIR
WOOD FRAME WALL INSTALLATION
OPENING
WALL BEFORE
MOUNT ON UNIT
OPENING
BEFORE INSTALLATION
BOTTOM MOUNTING
CONCRETE BLOCK WALL INSTALLATION
BRACKET. MOUNT ON
OPENING
WOOD OR STEEL SIDING
OPENING
INSTALLING UNIT.
RETURN AIR
WALL STRUCTURE
RETURN AIR
SUPPLY AIR
FACTORY SUPPLIED
RAIN FLASHING.
SUPPLY AIR
MIS-548 A
SIDE VIEW
I
A
C
K
E + 1.000
B
1.000
SUPPLY DUCT
OVER FRAME
INTERIOR FINISHED WALL
ALL AROUND DUCT
FRAMING MATERIAL
EXTERIOR FINISH WALL
OPENING
FOR ACTUAL DIMENSIONS.
2 x 4'S, 2 x 6'S &/OR
STRUCTURAL STEEL
ATTACH TO TOP
1.000" CLEARANCE
1.000" CLEARANCE
PLATE OF WALL
C
SEE UNIT DIMENSIONS, FIGURE 2,
OPENING
RETURN DUCT
2 x 6
ATTACH TO BOTTOM
OVER FRAME
PLATE OF WALL
L
THIS STRUCTURAL MEMBER
LOCATED TO MATCH STUD
SPACING FOR REST OF WALL.
A SECOND MEMBER MAY BE
REQUIRED FOR SOME WALLS.
MIS-549 B
ALL AROUND DUCT
WALL MOUNTING INSTRUCTIONS
SEE FIGURE 3 – MOUNTING INSTRUCTIONS
FIGURE 6
WALL MOUNTING INSTRUCTIONS
Manual 2100-586D
Page 11 of 25
FIGURE 7
LOWERED
RAISED FLOOR
RAFTERS
SUPPLY AIR
CEILING SURFACE
WALL SLEEVE
RETURN AIR
CLOSET WALL
GRILLE
FLASHING
RETURN AIR
FLASHING
SUPPLY DUCT MAYBE LOCATED IN AN ATTIC
OR BELOW CEILING RAFTERS AS SHOWN
SUPPLY DUCT MAY BE LOCATED IN AN ATTIC
SURFACE
RAFTERS
FINISHED CEILING
SUPPLY AIR DUCT
WALL
OPENING W/ GRILLE
SUPPLY DUCT MAYBE LOCATED IN AN ATTIC
OR BELOW CEILING RAFTERS AS SHOWN
CEILING
RAIN
RETURN AIR
SLEEVE
WALL
SUPPLY AIR DUCT
RAFTERS
RAFTERS
RETURN AIR
OPENING W/ GRILLE
RAIN
FALSE WALL INSTALLATION
DUCTED SUPPLY
GRILLE
OUTSIDE
SPACE
FALSE WALL
RETURN AIR GRILLE
OUTSIDE
OR BELOW CEILING RAFTERS AS SHOWN
FINISHED CEILING SURFACE
RAIN
FLASHING
RAIN
FLASHING
RETURN AT UNITNO DUCT
WALL
SUPPLY AIR DUCT
CLOSET INSTALLATION
RETURN AIR
FINISHED
FINISHED CEILING SURFACE
MIS-550 B
FREE AIR FLOW
OUTSIDE
WALL
OUTSIDE
WALL
SUPPLY AIR DUCT
W/ GRILLE
COMMON WALL MOUNTING INSTALLATIONS
Manual 2100-586D
Page 12 of 25
WIRING – MAIN POWER
WIRING – LOW VOLTAGE WIRING
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 eld wiring
used must be sized to carry that amount of current.
Depending on the installed KW of electric heat, there
may be two eld 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 eld
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.
230/208V, 1 phase and 3 phase units are equipped with
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 RANGE
240 253 – 216
208 220 – 187
NOTE: Thevoltageshouldbemeasuredattheeld
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 2100-554.
OPTIONAL OUTDOOR THERMOSTAT
APPLICATIONS
Since most equipment at the time of manufacture is not
designated for any specic 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. See Specication Sheet for outdoor
thermostat options. They may vary according to the
thermostat used to control the unit. 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.
See Table 6 for Electrical Specications.
Manual 2100-586D
Page 13 of 25
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 signicant 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 ammable.
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 ll 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 signicantly
at warmer temperatures. Once a cylinder or line is
full of liquid, any further rise in temperature will
cause it to burst.
Manual 2100-586D
Page 14 of 25
START UP (Continued)
IMPORTANT INSTALLER NOTE
For improved start up performance wash the indoor coil
with a dish washing detergent.
HIGH & LOW PRESSURE SWITCH
All C**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, verication of proper rotation must be made.
Verication 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.
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
lters at all times. Also, not to needlessly close off
supply and return air registers. This reduces airow
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 airow circulation is essential.
Verication 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 specic 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.
CAUTION
Remove service panels carefully. Falling
panels could cause lacerations.
Manual 2100-586D
Page 15 of 25
SEQUENCE OF OPERATION
COOLING STAGE 1 – 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.
COOLING STAGE 2 – Circuit R-Y1 makes at the thermostat
energizing the 2nd stage solenoid in the compressor. Default
position is not energized. 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-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 Stage 1 heat completes R-Y
circuit, pulling in compressor contactor starting compressor and
outdoor motor. R-G also make starting indoor blower motor.
HEATING STAGE 2 – Circuit R-Y2 makes at the thermostat
energizing the 2nd stage solenoid in the compressor.
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.
Manual 2100-586D
Page 16 of 25
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 8.
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 articial 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 rst (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.
120*
SW1SW
2 TIME (SEC)
OFF
OFF
ON
ON
OFF
ON
OFF
ON
30
60
180
MIS-2668 A
OFF
LOW PRESSURE BYPASS TIMER SWITCH
*(FACTORY SETTING 120 SECONDS)
ACCUMULATED DEFROST TIME TIMER
(FACTORY SETTING 60 MIN.)
ON
FIGURE 8
DEFROST CONTROL BOARD
Manual 2100-586D
Page 17 of 25
TROUBLESHOOTING
SOLID STATE HEAT PUMP CONTROL
TROUBLESHOOTING PROCEDURE
1. NOTE: A thorough understanding of the defrost
cycle sequence is essential. Review that section
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.
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.
BLINK FUNCTION
Slow Normal function (1.0 sec on/1.0 sec off)
Fast ASCD (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
LED BLINK CODES
TABLE 3 TROUBLESHOOTING
Symptom Description, Check & Possible Causes What & How to Check / Repair
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)
Unit will not go
into defrost
(heating only)
Unit will not come
out of defrost
(heating only)
1. Check for LED illumination.
Is there an LED illuminated on the board (ashing)?
2. Check for error codes.
Is the LED ashing a Code?
3. Check for power at board.
Is there 24 volts AC between R and C?
4. Check codes.
What code is blinking?
5. Compressor delay active.
Wait for 5 minute delay or jump board's "speed up pins".
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?
9. No power to board.
10. Check for Compressor output signal.
Is there 24 volts AC between CC & C?
11. No "Y" compressor input signal.
12. No "CC" compressor output signal. Check compressor contactor for proper operation and nally check compressor.
13. Faulty board. Replace defrost board.
Heat pump control defective
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
Reversing valve solenoid coil defective
Temperature sensor or heat pump control defective
Temperature sensor or heat pump control defective
Yes = go to Step #2; No = go to Step #
Yes = go to Step #4; No = go to Step #8
Yes = go to Step #13; No = go to Step #9
Code "1", go to Step #6; Code "2", go to Step#7; Fast Blink, go to Step #5
Check for proper operation; if still needed, go back to Step #1.
Yes = go to Step #10; No = go to Step #11
The unit either does not have unit voltage, the transformer is bad or the unit
wiring is incorrect.
Yes = go to Step #12; No = go to Step #13
Check thermostat wiring, incorrect phase of unit (see section on Phase Monitor),
and nally unit wiring.
Check across fan relay on heat pump control. (Com-NC)
Replace heat pump control.
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 2100-586D
Page 18 of 25
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.
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 11 0 4663
-3 93981 35 29986 73 11031 111 4562
-2 91008 36 29157 74 10762 11 2 4464
-1 88139 37 28355 75 10501 11 3 4367
0 85371 38 27577 76 10247 11 4 4274
1 82699 39 26823 77 10000 11 5 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
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.
Manual 2100-586D
Page 19 of 25
TROUBLESHOOTING
"A"
S**H AIRFLOW
W**H AIRFLOW
MIS-2725 A
FAN BLADE SETTING DIMENSIONS
Shown in Figure 9 is the correct fan blade setting for
proper air delivery across the outdoor coil. Refer to
Table 4 for unit specic 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 9
FAN BLADE SETTING
C**H
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
efciency ratings were determined by testing with this
refrigerant charge quantity.
The following pressure tables show nominal pressures
for the units. Since many installation specic situations
can affect the pressure readings, this information should
only be used by certied 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 2100-586D
Page 20 of 25
TABLE 4
FAN BLADE DIMENSION
MODEL Dimension A
C24H
C30H
C36H
C42H
C48H
C60H
1.00"
TABLE 5A
COOLING PRESSURE TABLE
COOLING AIR TEMPERATURE ENTERING OUTDOOR COIL °F
MODEL
C24H
C30H
C36H
C42H
C48H
C60H
Low side pressure ± 4 PSIG
High side pressure ± 10 PSIG
Tables are based upon rated CFM (airow) 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”.
RETURN AIR
TEMPERATURE
75° DB
62° WB
80° DB
67° WB
85° DB
72° WB
75° DB
62° WB
80° DB
67° WB
85° DB
72° WB
75° DB
62° WB
80° DB
67° WB
85° DB
72° WB
75° DB
62° WB
80° DB
67° WB
85° DB
72° WB
75° DB
62° WB
80° DB
67° WB
85° DB
72° WB
75° DB
62° WB
80° DB
67° WB
85° DB
72° WB
PRESSURE 75°F 80°F 85°F 90°F 95°F 100°F 105°F 110°F 115°F 120°F
LOW SIDE
HIGH SIDE
LOW SIDE
HIGH SIDE
LOW SIDE
HIGH SIDE
LOW SIDE
HIGH SIDE
LOW SIDE
HIGH SIDE
LOW SIDE
HIGH SIDE
LOW SIDE
HIGH SIDE
LOW SIDE
HIGH SIDE
LOW SIDE
HIGH SIDE
LOW SIDE
HIGH SIDE
LOW SIDE
HIGH SIDE
LOW SIDE
HIGH SIDE
LOW SIDE
HIGH SIDE
LOW SIDE
HIGH SIDE
LOW SIDE
HIGH SIDE
LOW SIDE
HIGH SIDE
LOW SIDE
HIGH SIDE
LOW SIDE
HIGH SIDE
134
288
143
295
148
305
129
303
138
311
143
322
134
305
143
313
148
324
133
302
142
310
147
321
137
315
147
323
152
334
135
290
145
297
150
307
137
309
146
317
151
328
131
328
140
336
145
348
135
326
144
334
149
346
133
321
142
329
147
341
137
336
147
345
152
357
136
313
146
321
151
332
138
331
148
339
153
351
133
353
142
362
147
375
137
348
146
357
151
369
133
341
142
350
147
362
138
360
148
369
153
382
137
337
147
346
152
358
141
353
151
362
156
375
135
378
144
388
149
402
137
372
147
382
152
395
134
365
143
374
148
387
139
385
149
395
154
409
137
362
147
371
152
384
144
377
154
387
159
401
136
405
145
415
150
430
139
399
149
409
154
423
136
391
145
401
150
415
141
412
151
423
156
438
139
387
149
397
154
411
146
402
156
412
161
426
137
431
147
442
152
457
140
427
150
438
155
453
137
418
146
429
151
444
142
442
152
453
157
469
140
412
150
423
155
438
148
427
158
438
164
453
138
457
148
469
153
485
141
458
151
470
156
486
138
449
148
460
153
476
143
473
153
485
158
502
143
438
153
449
158
465
151
454
161
466
167
482
139
485
149
497
154
514
143
490
153
503
158
521
141
481
151
493
156
510
145
506
155
519
160
537
146
464
156
476
161
493
152
482
163
494
169
511
141
513
151
526
156
544
145
526
155
539
160
558
143
516
153
529
158
548
147
541
157
555
162
574
149
490
159
503
165
521
154
510
165
523
171
541
142
541
152
555
157
574
146
563
156
577
161
597
146
553
156
567
161
587
148
578
158
593
164
614
152
518
163
531
169
550
HEATING PRESSURES – (ALL TEMPERATURES °F)
HEATING AIR TEMPERATURE ENTERING OUTDOOR COIL °F
MODEL
C24H 70° DB
C30H 70° DB
C36H 70° DB
C42H 70° DB
C48H 70° DB
C60H 70° DB
RETURN AIR
TEMPERATURE
PRESSURE 0°F 5°F 10°F 15°F 20°F 25°F 30°F 35°F 40°F 45°F 50°F 55°F 60°F 65°F
LOW SIDE
HIGH SIDE25233342424225150260582696627874287812968830595314
LOW SIDE
HIGH SIDE34261392674527451281572896429771307783178632794338
LOW SIDE
HIGH SIDE36244422514825954267612756828375291832999030799316
LOW SIDE
HIGH SIDE37270422744727952285592936530173311813228933498347
LOW SIDE
HIGH SIDE24240342514326152271602806828975297833058931296318
LOW SIDE
HIGH SIDE312304024548259562716428372293803028831095317
TABLE 5B
102
323
102
109
331
110
363
116
333
118
377
108
330
116
331
115
339
119
376
125
341
128
394
113
336
123
333
322
102
350
107
324
108
361
102
325
109
327
Manual 2100-586D
Page 21 of 25
121
348
128
390
135
350
140
411
118
341
130
334
TABLE 6
Electrical Specications — C**H Series
Model
Volts &
Phase
Rated
C24H1-A0Z
C24H1-B0Z
C30H1-A0Z
C30H1-B0Z
C30H1-C0Z
C36H1-A0Z
C36H1-B0Z
C36H1-C0Z
C42H1-A0Z
C42H1-B0Z
C42H1-C0Z
C48H1-A0Z
C48H1-B0Z
C48H1-C0Z
C60H1-A0Z
C60H1-B0Z
C60H1-C0Z
These “Minimum Circuit Ampacity” values are to be used for sizing the eld power conductors. Refer to the National Electrical Code (latest version), Article 310 for power conductor sizing.
Caution: When more than one eld 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) conductors are in a raceway.
k Maximum size of the time delay fuse or HACR type circuit breaker for protection of eld 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 the heat pump on is 4KW. Full heat available during Emergency Heat Mode.
Maximum KW that can operate with the heat pump on is 10KW. Full heat available during Emergency Heat Mode.
Maximum KW that can operate with the heat pump on is 9KW. Full heat available during Emergency Heat Mode.
Maximum KW that can operate with the heat pump on is 8KW. Full heat available during Emergency Heat Mode.
IMPORTANT: While this electrical data is presented as a guide, it is important to electrically connect properly sized fuses & conductor wires in accordance with the National Electrical Code & all
local codes.
NOTE A: -C Models have Rotary Disconnect. C0C 460V circuit breaker only available for 0KW. All electrical ratings are the same.
230/208-
-A04 1 42 50 8 10
-AS8
-AF8
-AS8
-AF8
-A15
-B15
-C15
-A15
-B15
-C15
-A15
-A20
-B15
-B18
-C15
-A15
-A20
-B15
-B18
-C15
60-1
230/208-
-B06
60-3
-B09
230/208-
-A04 1 44 50 8 10
60-1
230/208-
-B06 1 36 40 8 10
60-3
-B09 1 45 45 8 10
460-60-3
-C06 1 19 20 12 12
-C09 1 24 25 10 10
230/208-
-A05 1 53 60 6 10
60-1
-A10 1 or 2 79 80 4 8 27 52 40 60 8 6 10 10
230/208-
-B06 1 41 45 8 10
60-3
-B09 1 50 50 8 10
-C06 1 21 25 10 10
460-60-3
-C09 1 26 30 10 10
230/208-
-A05 1 57 60 6 10
60-1
-A10 1 or 2 83 90 4 8 31 52 40 60 8 6 10 10
230/208-
-B06 1 45 50 8 10
60-3
-B09 1 54 60 6 10
-C06 1 22 25 10 10
460-60-3
-C09 1 26 30 10 10
-A04 1 57 60 6 10
230/208-
-A05 1 62 70 6 8 37 26 50
-A10 1 or 2 88 90 3 8 37 52 50 60 8 6 10 10
60-1
-B06 1 45 50 8 10
230/208-
-B09 1 54 60 6 10
60-3
-C06 1 22 25 10 10
460-60-3
-C09 1 27 30 10 10
-A05 1 or 2 71 80 4 8 45 26 50 30 8 10 10 10
230/208-
-A10 1 or 2 97 100 3 8 45 52 50 60 8 6 10 10
60-1
-B06 1 50 60 8 10
230/208-
-B09 1 59 60 6 10
60-3
-C06 1 26 30 10 10
460-60-3
-C09 1 31 35 8 10
No.
Field
Power
Circuits
Minimum
Circuit
Ampacity
1 22 30 10 10
1 48 50 8 10
1 or 2
1
1
1
1 23 30 10 10
1 49 50 8 10
1 or 2 65 70 6 8 23 42 30 45 10 8 10 10
1 18 25 10 10
1 10 15 14 14
1 27 40 8 10
1 or 2 85 90 4 8 33 52 40 60 8 6 10 10
1 23 30 10 10
1 52 60 6 10
1 12 15 14 14
1 27 30 10 10
1 31 40 8 10
1 or 2 86 90 3 8 34 52 40 60 8 6 10 10
1 27 35 8 10
1 54 60 6 10
1 13 15 14 14
1 27 30 10 10
1 37 50 8 10
1 or 2 88 90 3 8 37 52 50 60 8 6 10 10
1 or 3 113 125 2 6 37 52 26 50 60 30 8 6 10 10 10 10
1 27 40 8 10
1 54 60 6 10
2 N/A N/A N/A N/A 54 28 60 30 6 10 10 10
1 13 20 12 12
1 27 30 10 10
1 45 60 8 10
1 or 2 97 100 3 8 45 52 50 60 8 6 10 10
1 or 3 113 125 2 6 45 52 26 50 60 30 8 6 10 10 10 10
1 32 45 8 10
1 59 60 6 10
2 N/A N/A N/A N/A 59 28 60 30 6 10 10 10
1 17 20 12 12
1 31 35 8 10
Manual 2100-586D
Page 22 of 25
Single Circuit Multiple Circuit
63 70 6 8 22 42 30 45 10 8 10 10
15 20 12 12
33 35 8 10
42 45 8 10
Max.
k
External
Fuse or
Ckt. Brkr.
Field
Power
Wire
Size
Ground
Minimum Circuit
Wire
Ampacity
Ckt. A Ckt. B Ckt. C Ckt. A Ckt. B Ckt. C Ckt. A Ckt. B Ckt. C Ckt. A Ckt. B Ckt. C
k Max. Circuit
Exterior Fuse
or Ckt. Brkr.
30 8 10 10 10
Field Power
Wire Size
Ground Wire
TABLE 7
C**H INDOOR BLOWER PERFORMANCE - CFM (0.00" — 0.50" H20)
Model
C24H .10 .50 550 550 740 900
C30H .10 .50 650 650 900 900
C36H .15 .50 800 800 1100 1100
C42H .15 .50 800 900 1250 1250
C48H .20 .50 825 1000 1550 1550
C60H .20 .50 850 1300 1650 1650
NOTE: These units are equipped with a variable speed (ECM) indoor motor that automatically adjusts itself to maintain approximately
the same rate of indoor airow 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 lter.
k Blower only CFM is the total air being circulated during continuous fan mode. Airow remains constant.
Blower only CFM reduces during continuous fan mode. Requires wiring modication; consult Installation Instructions & Wiring Diagram.
CFM output on Cooling or Electric Heat.
Rated
ESP
MAX
ESP
k
Blower
Only
Cooling
& Heat Pump
Stage 1
Cooling
& Heat Pump
Stage 2
Electric
Heat
Manual 2100-586D
Page 23 of 25
TROUBLESHOOTING GE ECM
™
MOTORS
CAUTION:
Disconnect power from unit before removing or replacing
connectors, or servicing motor. To avoid electric shock from
the motor’s capacitors, disconnect power and wait at least 5
minutes before opening motor.
Symptom Cause/Procedure
Motor rocks slightly • This is normal start-up for ECM
when starting
Motor won’t start • Check blower turns by hand
• No movement
• Check low voltage (24 Vac R to C) at motor
• Check low voltage connections
(G, Y, W, R, C) at motor
• Check for unseated pins in connectors on
motor harness
• Test with a temporary jumper between R - G
• Check motor for tight shaft
• Perform motor/control replacement check
• Perform Moisture Check
• Motor rocks, • Check for loose or compliant motor mount
but won’t start
• Perform motor/control replacement check
Motor oscillates up • It is normal for motor to oscillate with no
load & down while being on shaft
tested off of blower
Motor starts, but
runs erratically
• Varies up and down • Check line voltage for variation or “sag”
or intermittent • Check low voltage connections
(G, Y, W, R, C) at motor, unseated pins in
motor harness connectors
• Check “Bk” for erratic CFM command (in
variable-speed applications)
• Check out system controls, Thermostat
• Perform Moisture Check
• “Hunts” or “puffs” at • Does removing panel or lter reduce
high CFM (speed) “pufng”?
- Reduce restriction
- Reduce max airow
• Stays at low CFM • Check low voltage (Thermostat) wires and
despite system call connections
for cool or heat CFM • Verify fan is not in delay mode; wait until
delay complete
• “R” missing/not connected at motor
• Perform motor/control replacement check
• Stays at high CFM • “R” missing/not connected at motor
• Is fan in delay mode? - wait until delay time
complete
• Perform motor/control replacement check
• Blower won’t shut off •
Check for Triac switched thermostat or solid state relay
Excessive noise • Determine if it’s air noise, cabinet, duct or
motor noise; interview customer, if necessary
• Air noise • High static creating high blower speed?
- Is airow set properly?
- Does removing lter cause blower to slow
down? Check lter
- Use low-pressure drop lter
- Check/correct duct restrictions
• Check power at motor
• Make sure blower wheel is tight on shaft
Current leakage from controls into G, Y or W?
Symptom Cause/Procedure
• Noisy blower or cabinet • Check for loose blower housing, panels, etc.
• High static creating high blower speed?
- Check for air whistling through seams in
ducts, cabinets or panels
- Check for cabinet/duct deformation
• “Hunts” or “puffs” at • Does removing panel or lter reduce
high CFM (speed)
- Reduce restriction
- Reduce max. airow
Evidence of Moisture
• Motor failure or • Replace motor and
malfunction has occurred
and moisture is present
• Evidence of moisture
present inside air mover
“pufng”?
• 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 lters some have
minimum: H20 drop!
- Recommend high • Use restricted returns
efciency, low static lters
- Recommend keeping lters
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
airow
• Check orientation before • Plug in power connector backwards
inserting motor connectors • Force plugs
½"
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 airow (too much latent capacity)
• Check for undercharged condition
• Check and plug leaks in return ducts, cabinet
Comfort Check
• Check proper airow 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 2100-586D
Page 24 of 25
TROUBLESHOOTING GE ECM
™
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 specic 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
housing (at the back end of the control opposite the shaft end). Refer to
Figure 10. 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 forenger, 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 11. (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.
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
CONTROL AND MUST BE USED IF SECURE ATTACHMENT OF
THE CONTROL TO THE MOTOR IS TO BE ACHIEVED.
DO NOT OVERTIGHTEN THE BOLTS.
¼" hex head bolts at the rear of the control
Finish installing
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.
Final installation check. Make sure the motor is installed as follows:
12.
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 nal
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 12.
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 10 Figure 11
Only remove
Hex Head Bolts
ECM 2.0
Note:
Use the shorter
bolts and
alignment pin
supplied when
replacing an
ECM 2.0
control.
Control Disassembly
Push until
Latch Seats
Over Ramp
ECM
2.3/2.5
Hex-head Screws
Figure 3
From Motor
Circuit
Board
Motor
Motor Connector
(3-pin)
Control Connector
(16-pin)
Power Connector
(5-pin)
Motor Connector
(3-pin)
Back of
Control
Figure 4
Winding Test
Motor OK when
R > 100k ohm
Figure 12
Figure 5
Drip Loop
Connector Orientation
Between 4 and 8 o'clock
Drip Loop
Manual 2100-586D
Page 25 of 25
Loading...