INSTALLATION INSTRUCTIONS
WALL MOUNTED
PACKAGE HEAT PUMPS
Models:
CH3S1
CH4S1
CH5S1
This is an R-410a
high PRessuRe
RefRigeRanT sysTem
Bard Manufacturing Company, Inc.
Bryan, Ohio 43506
Since 1914...Moving ahead just as planned.
Note
Manual : 2100-455M
Supersedes: 2100-455L
File: Volume III Tab 17
Date: 02-06-12
Manual 2100-455M
Page 1 of 27
CONTENTS
Getting Other Information and Publications
For More Information ................................................3
Wall Mount General
Heat Pump Wall Mount Model Nomenclature .........4
Shipping Damage ...................................................8
General ................................................................8
Duct Work ...............................................................8
Filters ................................................................8
Condensate Drain – Evaporator .............................8
Wall Mounting Information ......................................8
Installation Instructions
Optional Top Outlet Flange .....................................9
Mounting the Unit ....................................................9
Wiring – Main Power .............................................15
Wiring – Low Voltage Wiring .................................15
Low Voltage Connections .....................................16
Start Up
Application ............................................................16
Safety Practices ....................................................17
Important Installer Note .........................................17
Pressure Service Ports .........................................17
High & Low Pressure Switch .................................17
Three Phase Scroll Compressor Start Up .............17
Phase Monitor .......................................................18
Service Hints .........................................................18
Sequence of Operation .........................................18
Compressor Current & Pressure
Control Module ......................................................18
Defrost Cycle ........................................................19
Troubleshooting GE ECM™ Motors .............27 & 28
Troubleshooting
Solid State Heat Pump Control
Troubleshooting Procedure ...................................21
Checking Temperature Sensor
Outside Unit Circuit ...............................................22
Temperature vs. Resistance of Temperature ........22
Compressor Solenoid ...........................................23
Fan Blade Setting Dimensions ..............................23
Removal of Fan Shroud ........................................23
Refrigerant Charge R-410A ..................................23
Pressure Tables ...........................................25 & 26
Figures
Figure 1 Unit Dimensions CH3S1 ........................5
Figure 2 Unit Dimensions CH4S1 & CH5S1 ........6
Figure 3 Optional Top Outlet Flange ....................9
Figure 4 Mounting Instructions CH3S1 ..............10
Figure 5
Figure 6 Electric Heat Clearance .......................12
Figure 7 Wall Mounting Instructions ...................13
Figure 8 Wall Mounting Instructions ...................13
Figure 9
Figure 10
Figure 11 Unit 24V Terminal Board ......................15
Figure 12 Defrost Control Board .................19 & 20
Figure 13 Fan Blade Setting ................................23
Figure 14 Control Disassembly ............................28
Figure 15 Winding T est ........................................ 28
Figure 16 Drip Loop .............................................28
Mounting Instructions CH4S1/CH5S1
Common Wall Mounting Installations
Common Wall Mounting Installations
....14
....15
...11
Tables
Table 1 Electric Heat Table ..................................4
Table 2 Electrical Specications ..........................7
Table 3 Thermostat Wire Size ...........................15
Table 4 Troubleshooting ....................................21
Table 5 Fan Blade Dimensions ..........................23
Table 6 Indoor Blower Performance ..................24
Table 7 Maximum ESP of Operation .................24
Table 8 Pressure Table - High Cooling ..............25
Table 9 Pressure Table - Low Cooling ...............25
Table 10 Pressure Table - High Heating ..............26
Table 11 Pressure Table - Low Heating ...............26
Manual 2100-455M
Page 2 of 27
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, Refrigerating,
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 2100-455M
Page 3 of 28
Wall mOunt General InFOrmatIOn
heat PumP Wall mOunt mODel nOmenclature
mODel number
caPacItY
3S - 3 ton
4S - 4 ton
5S - 5 ton
VOlts & Phase
A - 230/208/60/1
B - 230/208/60/3
C - 460/60/3
ch 4s 1 – a 05 b P X X X X
KW
reVIsIOns
VentIlatIOn OPtIOns
B - Blank-off Plate
R - Energy Recovery
V - Commercial Ventilator Motorized with Exhaust
FIlter OPtIOns
P - 2-Inch Pleated
cOlOr OPtIOns
X - Beige (Standard)
4 - Buckeye Gray
5 - Desert Brown
8 - Dark Bronze
cOntrOl mODules
cOIl OPtIOns
X - Standard
Outlet OPtIOns
X - Front (Standard)
T - T op Outlet
table 1
electrIc heat table
ch
models
240-1 208-1 240-3 208-3 460-3 240-1 208-1 240-3 208-3 460-3
KW
a btu a btu a btu a btu a btu a btu a btu a btu a btu a btu
4 16.7 13650 14.4 10240
5 20.8 17065 18.1 12800 20.8 17065 18.1 12800
6 14.4 20500 12.5 15360 7.2 20480 14.4 20500 12.5 15360 7.2 20480
9 21.7 30600 18.7 23030 10.8 30700 21.7 30600 18.7 23030 10.8 30700
10 41.6 34130 36.2 25600 41.6 34130 36.2 25600
15 62.5 51200 54.1 38400 36.2 51200 31.2 38400 18 51200 62.5 51200 54.1 38400 36.2 51200 31.2 38400 18 51200
18 43.3 61400 37.5 46050 21.6 61400
20 83.2 68250 72.1 51200
3s1-a ch3s1-b ch3s1-c
ch4s1-a
ch5s1-a
Manual 2100-455M
Page 4 of 28
ch4s1-a
ch5s1-a
ch4s1-a
ch5s1-a
16"
16"
16"
16"
16"
31 5/8"
32 3/4"
84 11/16"
43 7/8"
42 3/16"
13 3/8"
48 1/16"
5 13/16"
"
31"
6 7/8"
39 7/8"
9 13/16"
15 7/8"
29 7/8"
6 1/8"
1 3/8"
43"
6 9/16"
7/8"
2 1/4"
8 9/16"
Left Side View
(12) Wall
Right Side View Back View
Entrances
Top Rain
Outlet
Grille
Cond.
"CH3S1" Unit Dimensions
Grille
Outlet
Opt. High Voltage
Cond.
Inlet
Supply
Grille
Flashing
Opening
Opening
Slope Top
Cond.
Return
Optional Top Outlet
Blower Access
Door
Filter Access
Door
Vent Option
Access Door
Heater Access
Door
Control Panel
Access Door
Door
C. Breaker
Low Voltage
Entrance
Entrance
High Voltage
Top View
MIS-2146
Mounting Holes
Access Door
Evap. Drain
Hose
Front View
Drain for optional
drain pan
FIGure 1
unIt DImensIOns
Manual 2100-455M
Page 5 of 28
42 3/4"
39 7/8"
1 3/8"
6 7/8"
Right Side View
Front View
MIS-2020 A
Left Side View
"CH4S1 and CH5S1" Unit Dimensions
Back View
Door
Filter Access
Supply
Opening
Mounting
(12) Wall
Return
Opening
Top Rain
Flashing
Evap. Drain
Hose
Holes
Opt. High
Voltage
Entrances
16"
6 9/16"
48 1/16"
9 13/16"
15 7/8"
29 7/8"
6 1/8"
43"
16"
16"
16"
7/8"
16"
2 1/4"8 9/16"
Cond.
Grille
Outlet
Entrance
Entrance
Low Voltage
Heater Access
Door
Control Panel
Door
C. Breaker
Access Door
High Voltage
Access Door
22 3/16"
31"
Blower Access
Door
Inlet Grille
Condenser
Vent Option
Access Door
94 11/16"
43 7/8"
42 3/16"
13 3/8"
41 5/8"
5 13/16"
Drain for optional
drain pan
Grille
Cond.
Outlet
Slope Top
Optional Top Outlet
Top View
FIGure 2
unIt DImensIOns
Manual 2100-455M
Page 6 of 28
model
CH3S1-A0Z
A05
A10
A15
CH3S1-B0Z
B06
B09
B15
CH3S1-C0Z
C06
C09
C15
CH4S1-A0Z
A04
A05
A10
A15
A20
CH4S1-B0Z
B06
B09
B15
B18
CH4S1-C0Z
C06
C09
C15
C18
CH5S1-A0Z
A04
A05
A10
A15
A20
CH5S1-B0Z
B06
B09
B15
B18
CH5S1-C0Z
C06
C09
C15
C18
rated
Volts &
Phase
230/208-1
230/208-1
230/208-1
230/208-1
230/208-3
230/208-3
230/208-3
230/208-3
460-3
460-3
460-3
460-3
230/208-1
230/208-1
230/208-1
230/208-1
230/208-1
230/208-1
230/208-3
230/208-3
230/208-3
230/208-3
230/208-3
460-3
460-3
460-3
460-3
460-3
230/208-1
230/208-1
230/208-1
230/208-1
230/208-1
230/208-1
230/208-3
230/208-3
230/208-3
230/208-3
230/208-3
460-3
460-3
460-3
460-3
460-3
no.
Field
Power
ciruits
1
1
1 or 2
1 or 2
1
1
1
1
1
1
1
1
1
1
1 or 2
1 or 2
1 or 2
1 or 3
1
1
1
1
2
1
1
1
1
1
1
1 or 2
1 or 2
1 or 2
1 or 2
1 or 3
1
1
2
2
2
1
1
1
1
1
table 2
electrIcal sPecIFIcatIOns
sInGle cIrcuIt Dual cIrcuIt
minimum
ircuit
c
a
mpacity
29
55
81
85
23
41
50
51
11
20
24
25
37
57
63
89
89
3
11
27
45
54
54
NA
14
23
28
28
31
44
65
70
96
96
11
4
36
54
NA
NA
NA
19
28
32
32
33
m
aximum
xternal
e
Fuse or
c
ircuit
b
reaker
45
60
90
90
30
45
50
60
15
20
25
30
50
60
70
90
90
125
35
50
60
60
NA
20
25
30
30
35
60
70
80
110
110
125
50
60
NA
NA
NA
25
35
35
35
35
Field
Power
W
ire
ize
s
8
6
4
4
10
8
8
8
14
12
10
10
8
6
6
3
3
2
8
8
6
6
NA
12
10
10
10
8
6
6
4
3
3
2
8
6
NA
NA
NA
10
8
8
8
8
Ground
ire
W
s
ize
10
10
8
8
10
10
10
10
14
12
10
10
10
10
8
8
8
6
10
10
10
10
NA
12
10
10
10
10
10
8
8
6
6
6
10
10
NA
NA
NA
10
10
10
10
10
inimum
m
c
ircuit
mpacity
a
c
c
kt.
a
---
--29
33
---
---
---
---
---
---
---
---
---
--37
37
37
37
---
---
---
--35
---
---
---
---
---
--44
44
44
44
44
---
--36
36
37
---
---
---
---
---
c
kt.
kt.
b
c
---
---
---
---
52
---
52
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
26
---
52
---
52
---
52
26
---
---
---
---
---
---
---
---
28
---
---
---
---
---
---
---
---
---
---
---
---
---
21
---
26
---
52
---
52
---
52
26
---
---
---
---
28
---
28
---
28
---
---
---
---
---
---
---
---
---
---
---
maximum
e
xternal Fuse or
ircuit breaker
c
c
c
kt.
kt.
a
b
---
---
---
---
45
60
45
60
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
50
30
50
60
50
60
50
60
---
---
---
---
---
---
---
---
50
30
---
---
---
---
---
---
---
---
---
---
---
---
60
25
60
30
60
60
60
60
60
60
---
---
---
---
50
30
50
30
50
30
---
---
---
---
---
---
---
---
---
---
c
c
kt.
c
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
--30
---
---
---
---
---
---
---
---
---
---
---
---
---
---
--30
---
---
---
---
---
---
---
---
---
---
Field Power
Wire size
c
kt.
kt.
a
b
---
---
---
---
10
6
8
6
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
8
10
8
6
8
6
6
6
---
---
---
---
---
---
---
---
8
10
---
---
---
---
---
---
---
---
---
---
---
---
8
10
8
10
8
6
8
6
8
6
---
---
---
---
8
10
8
10
8
10
---
---
---
---
---
---
---
---
---
---
c
kt.
c
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
--10
---
---
---
---
---
---
---
---
---
---
---
---
---
---
--10
---
---
---
---
---
---
---
---
---
---
Ground
ire size
W
c
c
kt.
a
---
--10
10
---
---
---
---
---
---
---
---
---
--10
10
10
10
---
---
---
--10
---
---
---
---
---
--10
10
10
10
10
---
--10
10
10
---
---
---
---
---
c
kt.
kt.
b
c
---
---
---
---
10
---
10
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
10
---
10
---
10
---
10
10
---
---
---
---
---
---
---
---
10
---
---
---
---
---
---
---
---
---
---
---
---
---
10
---
10
---
10
---
10
---
10
10
---
---
---
---
10
---
10
---
10
---
---
---
---
---
---
---
---
---
---
---
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 NEC and all local codes.
These “Minimum Circuit Ampacity” values are to be used for sizing the eld power conductors. Refer to the National Electric Code
(latest revision), Article 310 for power conductor sizing.
CAUTION:Whenmorethanoneeldpowerconductorcircuitisrunthroughoneconduit,theconductorsmustbederated.Payspecial
attentiontonote8oftable310regardingAmpacityAdjustmentFactorswhenmorethan3conductorsareinaraceway.
Manual 2100-455M
Page 7 of 28
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/heat gain calculation made according
to methods of Air Conditioning Contractors of
America (ACCA). The air duct should be installed
in accordance with the Standards of the National
Fire Protection 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.
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.
These units are suitable for 0 inch clearance to
combustible material. See Wall Mounting Instructions
and Figures 4, 5, 6, 7 & 8 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.
NOTE: If no return air duct is used, applicable
installation codes may limit this cabinet to
installation only in a single story structure.
Any grille that meets with 5/8 inch louver criteria
may be used. It is recommended that Bard Return Air
Grille Kit RG3 through RG5 or RFG3 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.
FIlters
A 2-inch pleated lter is supplied 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 door.
cOnDensate DraIn – eVaPOratOr
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.
Wall mOuntInG InFOrmatIOn
Duct WOrK
Any heat pump is more critical of proper operating
charge and an adequate duct system than a straight
air conditioning unit. All duct work, 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.
Manual 2100-455M
Page 8 of 28
1. Two holes for the supply and return air openings
must be cut through the wall as shown in Figure 4.
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.
Insulation
MIS-2306
Top
Insert top outlet flange
from inside unit and compress
insulation
Insert top outlet flange
from inside unit and compress
insulation
Fasten flanges to
top using (8) screws
InstallatIOn InstructIOns
OPtIOnal tOP Outlet FlanGe
Top outlet ange is screwed to the back of the unit
upon delivery. Flange must be installed on to the top of
the unit before mounting. See Figure 3 for details.
mOuntInG the unIt
1. These units are secured by wall mounting brackets
which secure the unit to the outside wall surface at
both sides.
2. The unit itself is suitable for 0 inch clearance. If
a combustible wall use a minimum of 30" x 10"
supply opening dimensions for sizing. However, it
is generally recommended that a 1-inch clearance
be used for ease of installation. The supply air
opening would then be 32" x 12". See Figures 4
and 5 for details.
3. Hook top rain ashing under back bend of top. Top
rain ashing is shipped with unit attached to back of
unit on the right side.
FIGure 3
OPtIOnal tOP Outlet FlanGe InstallatIOns
4. Position unit in opening and secure with 5/16 lag
bolts; use 3/4 inch diameter at washers on the lag
bolts.
5. Secure rain ashing to wall and caulk across entire
length of top. See Figure 4.
6. 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.
7. 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.
Manual 2100-455M
Page 9 of 28
7
0" min.
0" min.
"6
8
1
3
8
"
Top
Rain Flashing (supplied)
flanges
Apply a bead of caulk
along entire length of top
and behind side mounting
Foam
"CH3S1" Wall Mounting Instructions
A B C D E
REQUIRED DIM. TO MAINTAIN 0"
MIN. CLEARANCE FROM
COMBUSTIBLE MATERIALS
30 10 6 1/2 1 6
REQUIRED DIM. TO MAINTAIN
OPTIONAL 1" CLEARANCE FROM
COMBUSTIBLE MATERIALS
32 12 5 1/2 2 5
Return Air
Panel
Wall Section
Opening
Supply Duct
Access
Heater
Optional
Top Outlet
MIS-2209 A
Return Opening
Holes, 12 places
Unit Mounting
Wall
* NOT USED ON TOP OUTLET UNITS
16"
C
E
C
30"
16"
16"
16"
43"
16"
16"
16"
A
16"
16"
16"
D
16"
B
D
Supply Opening *
FIGure 4
mOuntInG InstructIOns
Manual 2100-455M
Page 10 of 28
1 3/8"
0" min.
0" min.
6 7/8"
Return Opening
Holes, 12 places
Unit Mounting
Wall
* NOT USED ON TOP
OUTLET UNITS
C
16"
D
B
16"
16"
16"
E
16"
30"
C
16"
16"
16"
A
16"
16"
43"
D
16"
Supply Opening *
"CH4S1 and CH5S1" Wall Mounting Instructions
MIS-2021 B
flanges
Foam
Rain Flashing (supplied)
Apply a bead of caulk
along entire length of top
and behind side mounting
Top
Top Outlet
Optional
Return Air
Opening
Wall Section
Supply Duct
Heater
Access
Panel
A B C D E
REQUIRED DIMS. TO MAINTAIN 0"
MIN. CLEARANCE FROM
COMBUSTIBLE MATERIALS
30 10 6 1/2 1 6
REQUIRED DIMS. TO MAINTAIN
OPTIONAL 1" CLEARANCE FROM
COMBUSTIBLE MATERIALS
32 12 5 1/2 2 5
FIGure 5
mOuntInG InstructIOns
Manual 2100-455M
Page 11 of 28
FIGure 6
RECOMMENDED
1" OPTIONAL CLEARANCE
Duct
Outside Sheeting
Unit
Inside Sheeting
Wall Frame
Supply Air
Typical Building
Supply Air Duct
Flange of Wall
MIS-2210
Side section view of supply air
duct for wall mounted unit showing
0" clearance to combustible surfaces.
electrIc heat clearance
Note: This unit is approved for 0" clearance, but the optional 1" clearance is recommended. See Figures 4 & 5.
Manual 2100-455M
Page 12 of 28
FIGure 7
flashing. Attach to
"CH" Unit
structural steel
steel siding wall
Exterior wood or
when framing wall to support unit.
Follow all local building codes
opening
Interior finished wall
Supply opening
Return
2x4's, 2x6's, and/or
Framing material:
unit before installing.
Factory supplied rain
!
MIS-2024 A
1" clearance
51 1/4"
1" clearance
9 13/16"
6 1/8"
15 7/8"
29 7/8"
3" MIN. TO OVER HANG OR EAVES
MIS-2025 A
C
L
be required for some
Supply Opening
walls.
unit.
Return Opening
These structural
members must be
able to support the
entire weight of the
Locate stud to match
spacing for rest of wall.
A second member may
!
Follow all local building codes
when framing wall to support unit.
44 7/8"
Wall mOuntInG InstructIOns
FIGure 8
Wall mOuntInG InstructIOns
Manual 2100-455M
Page 13 of 28
Isolation Curb
WM1CF5-X
Supply Air
Return Air
Silencer
WAPR11-X
RETURN AIR
Free Blow
Supply Plenum
WAFB51-X
Outside Wall
Unit (outside)
Note: duct maybe in attic or
below rafters as shown.
Note: direction of return
Rafters
Supply Air
Return Air
Outside Wall
Unit (outside)
Rafters
Supply Air
Return Air
Unit (outside)
Finished Ceiling
Finished Ceiling
Finished Ceiling
Supply Air
Rafters
Outside Wall
False Wall Installation
False Wall
Return Air
Return Air
for lowest sound level as shown.
Grille
Grille
below rafters as shown.
Note: duct maybe in attic or
grille louvers is pointed down
Grille
Duct
Free Air Flow - No Duct
Ducted Supply - Return At Unit
Duct
MIS-2027
Wall Sleeve
Free Air Flow - No Duct
Low Sound With Acoustical Plenums
And Isolation Curbs
cOmmOn Wall mOuntInG InstallatIOns
FIGure 9
Manual 2100-455M
Page 14 of 28
#8403-052, 8403-053, 8403-055
Y
DH
THERMOSTAT
BARD PART #8403-060
G
L
Y1
W1/E
R
O/B W2
A
AUX
UNIT LOW VOLTAGE
TERMINAL BLOCK
THERMOSTAT BARD PART
B L
E
W3
W2
W1
Y1
Y2
D/YO
R
G
C
O1
W1
B
Y2Y1
RhRcGC
C
Factory Jumper
1
GND
MIS-2026 C
ID
GND
OD
OPTIONAL
8403-061
OUTDOOR
SENSOR
OPTIONAL
8403-062
INDOOR
SENSOR
Outside Wall
Closet Wall
Closet Wall
Grille
Return Air
Return Air
Supply Air
Duct
Finished Ceiling
Raised Closet Floor
Rafters
Wall Sleeve
Closet Installation
Unit (outside)
Note: duct maybe in attic or
below rafters as shown.
MIS-2240
Grille
FIGure 10
cOmmOn Wall mOuntInG InstallatIOns
WIRING – LOW VOLTAGE WIRING
230 / 208V, 1 phase and 3 phase equipment have 24V
transformers with dual primary voltage. 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: 460V units require no action. The voltage
shouldbemeasuredattheeldpower
connectionpointintheunitandwhiletheunitis
operating at full load (maximum amperage
operating condition).
FIGure 11
unIt 24V thermOstat cOnnectIOns
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 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.
Only needed if dehumidication is used.
Eleven (11) wires should be run from thermostat
subbase to the 24V terminal board in the unit. An
eleven conductor, 18 gauge copper color-coded
thermostat cable is recommended. The connection
points are shown in Figure 11. An additional wire is
needed if dehumidication is used.
ImPOrtant
Only the thermostat combinations as shown
above will work with this equipment.
table 3
thermOstat WIre sIZe
transformer
Va
65 2.3
Fla Wire Gauge
20 gauge 45
18 gauge 60
16 gauge 100
14 gauge 160
12 gauge 250
Manual 2100-455M
Page 15 of 28
maximum
Distance
In Feet
lOW VOltaGe cOnnectIOns
These units use a grounded 24 volt AC low voltage
circuit and require at least a 2 stage heating and a 2
stage cooling thermostat.
“G” terminal is the fan input.
“Y” terminal is the compressor Stage 1 input.
“Y1” terminal is the compressor Stage 2 input.
“B” terminal is the reversing valve input. The
reversing valve must be energized for heating mode.
“R” terminal is 24 VAC hot.
“C” terminal is 24 VAC grounded.
“L” terminal is compressor lockout output. This
terminal is activated on a high or low pressure trip by
the electronic heat pump control. This is a 24 VAC
output.
“W2” terminal is second stage heat (if equipped).
“O1” terminal is the ventilation input. This terminal
energizes any factory or eld installed ventilation
option.
“DH” terminal is the dehumidierinput. This terminal
energizes the factory or eld installed dehumidier
option.
“E” terminal is the emergency heat input. This
terminal energizes the emergency heat relay if
equipped.
NOTE: For total and proper control using DDC, a
minimum of 8 controlled outputs are required
(6ifnoventilationordehumidieroption
is installed). For proper system operation
underEmergencyHeatconditionswhere
the compressor needs to be deactivated,
the B-W2-E outputs need to be energized.
Removing the Y (compressor) signal alone
turns the compressor off, but does not activate
the additional circuitry embedded in the heat
pump for proper and complete operation.
start uP
These units require R-410A refrigerant & Polyol Ester oil.
aPPlIcatIOn:
1. Use separate service and manufacturing 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 -
MAxIMuM.
12. If compressor removal is necessary, always plug
compressor immediately after removal. Purge
with small amount of nitrogen when inserting plugs.
lOW VOltaGe cOnnectIOns
FOr DDc cOntrOl
Fan Only Energize G
Cooling Mode 1st Stage Energize Y, G
Cooling Mode 2nd Stage Energize Y, Y1, G
Heat Pump Heating 1st Stage Energize Y, G, B
Heat Pump Heating 2nd Stage Energize Y, Y1, G, B
3rd Stage Heating Energize G, W2, Y, B, Y1
w/Heat Pump (if employed)
Ventilation Energize G, O1
Dehumidier Energize DH
Emergency Heat Energize B, W2, E, G
Manual 2100-455M
Page 16 of 28
start uP cOnt’D.
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.
ImPOrtant Installer nOte
For improved start-up performance, wash the indoor coil
with a dish washing detergent.
Pressure serVIce POrts
R-410A requires high pressure hose connections
and gauges. 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 on both cooling
and heating cycles. It is imperative to match the correct
pressure table to the unit by model number.
hIGh & lOW Pressure sWItch
All models are supplied with a remote reset high and low
pressure switch. If tripped, this pressure switch may be
reset by turning the thermostat off then back on again.
High/Low Pressure control provides protection for the
compressor. In the event system pressures go above 575
PSI or below 32 PSI, in either cooling or heating mode,
the compressor will be stopped. This high pressure switch
is located on the discharge line and is matched with Bard
Part #8406-113. This will activate the “L” terminal of
the low voltage terminal strip. This terminal can be used
for remote indication of a pressure lockout. The lockout
circuit will hold compressor off line. When the system
problem is corrected, the unit operation can be restored
by turning the main power supply off and then back on, or
reset the room thermostat. The low pressure control has a
bypass circuit built into the Defrost Control Board.
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. All three
phase units incorporate a phase monitor to ensure proper
eld wiring. See the “Phase Monitor” section later in
this manual.
Verication of proper rotation must be made any time a
compressor is changed or rewired. 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: Ifcompressorisallowedtoruninreverse
rotation for several minutes, the compressor’s
internalprotectorwilltrip.
All three phase ZR3 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.
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 rotations, as well as substantially reduced
current draw compared to tabulate values.
The direction of rotation of the compressor may be
changed by reversing any two line connections to the unit.
Manual 2100-455M
Page 17 of 28
Phase mOnItOr
All units with three phase 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, shut off main power and
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. Switching to heating cycle at 75°F or higher outside
temperature may cause a nuisance trip of the remote
reset high pressure switch. Turn thermostat off then
on to reset the high pressure switch.
3. The heat pump wall thermostats perform multiple
functions. Be sure that all function switches are
correctly set for the desired operating mode before
trying to diagnose any reported service problems.
4. Check all power fuses or circuit breakers to be sure
they are the correct rating.
5. Periodic cleaning of the outdoor coil to permit full
and unrestricted airow circulation is essential.
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.
cOmPressOr current & Pressure
cOntrOl mODule
The compressor control module monitors compressor
current and pressure and prevents internal overload
trips due to low voltage or extremely high ambient
temperatures by de-energizing the full capacity
compressor solenoid. The control monitors current
to the compressor and discharge pressure. If current
is sensed that is in excess of 93% of the compressor
maximum continuous current rating or pressure is
sensed greater than 540 PSI (located on liquid line and
is marked with Bard Part #8406-111), the compressor
control module de-energizes the second stage solenoid
in the compressor for a time as determined by the time
potentiometer on the compressor control module. This
will drop the current draw and pressure and allow the
compressor to run at 75 percent of capacity rather than
not at all. Once the time period has elapsed the full
capacity compressor solenoid will re-energize and try
again to run at full capacity. If the pressure or current
is exceeded again, the coil will again de-energize. This
sequence will repeat until the ambient temperature drops
or the line voltage increases enough that the trip values
are not exceeded.
The relay on the compressor control module is a single
pole double throw relay. The full capacity compressor
solenoid connects to the common terminal of the relay.
Once current is sensed by the compressor control
module, the relay closes and the second stage cooling
call (if present) is sent to the full capacity compressor
solenoid. This sequence prevents damage to the full
capacity compressor solenoid by ensuring that the
solenoid is not energized when the compressor is
not running. A brief time delay in this sequence also
prevents locked rotor amperage during start-up from
tripping the device and engaging the time delay period.
Manual 2100-455M
Page 18 of 28
DeFrOst cYcle
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
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.
FIGure 12 — DeFrOst cOntrOl bOarD
Manual 2100-455M
Page 19 of 28
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.
Manual 2100-455M
Page 20 of 28
trOubleshOOtInG
sOlID state heat PumP cOntrOl
trOubleshOOtInG PrOceDure
1. NotE: A thorough understanding of the defrost
cyclesequenceisessential.Reviewthatsection
NOTE:Iftherewasnopowerto24volttransformer,
thecompressorandoutdoorfanmotorwill
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-minuteblowertimedelayon“off”command;
waitforthistotime-out.
4. Set system switch to “heat” or “cool”. Adjust
thermostat to call for heat or cool. The indoor
LED BLINK CoDES
BLINK FuNCtIoN
Slow Normal function (1.0 sec on/1.0 sec off)
Fast ASCD 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
blower, compressor and outdoor fan should start.
table 4
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) Heat pump control defective
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.
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 #3
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 2100-455M
Page 21 of 28
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
F r F r F r F r
-25 196871 13 56985 51 19374 89 7507
-24 190099 14 55284 52 18867 90 7334
-23 183585 15 53640 53 18375 91 7165
-22 177318 16 52051 54 17989 92 7000
-21 171289 17 50514 55 17434 93 6840
-20 165487 18 49028 56 16984 94 6683
-19 159904 19 47590 57 16547 95 6531
-18 154529 20 46200 58 16122 96 6383
-17 149355 21 44855 59 15710 97 6239
-16 144374 22 43554 60 15310 98 6098
-15 139576 23 42295 61 14921 99 5961
-14 134956 24 41077 62 14544 100 5827
-13 130506 25 39898 63 14177 101 5697
-12 126219 26 38757 64 13820 102 5570
-11 122089 27 37652 65 13474 103 5446
-10 118108 28 36583 66 13137 104 5326
-9 114272 29 35548 67 12810 105 5208
-8 110575 30 34545 68 12492 106 5094
-7 107010 31 33574 69 12183 107 4982
-6 103574 32 32634 70 11883 108 4873
-5 100260 33 31723 71 11591 109 4767
-4 97064 34 30840 72 11307 110 4663
-3 93981 35 29986 73 11031 111 4562
-2 91008 36 29157 74 10762 112 4464
-1 88139 37 28355 75 10501 113 4367
0 85371 38 27577 76 10247 114 4274
1 82699 39 26823 77 10000 115 4182
2 80121 40 26092 78 9760 116 4093
3 77632 41 25383 79 9526 117 4006
4 75230 42 24696 80 9299 118 3921
5 72910 43 24030 81 9077 119 3838
6 70670 44 23384 82 8862 120 3757
7 68507 45 22758 83 8653 121 3678
8 66418 46 22150 84 8449 122 3601
9 64399 47 21561 85 8250 123 3526
10 62449 48 20989 86 8057 124 3452
11 60565 49 20435 87 7869
12 58745 50 19896 88 7686
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 2100-455M
Page 22 of 28
cOmPressOr sOlenOID
A nominal 24-volt direct current coil activates the
internal compressor solenoid. The input control
circuit voltage must be 18 to 28 volt ac. The coil
power requirement is 20 VA. The external electrical
connection is made with a molded plug assembly (PN
029-0311-00). This plug contains a full wave rectier
to supply direct current to the unloader coil.
Compressor Solenoid test Procedure – If it is
suspected that the unloader is not working, the
following methods may be used to verify operation.
1. Operate the system and measure compressor
amperage. Cycle the compressor solenoid on
and off at ten-second intervals. The compressor
amperage should go up or down at least 25 percent.
2. If step one does not give the expected results, shut
unit off. Apply 18 to 28 volt ac to the solenoid
molded plug leads and listen for a click as the
solenoid pulls in. Remove power and listen for
another click as the solenoid returns to its original
position.
3. If clicks can’t be heard, shut off power and remove
the control circuit molded plug from the compressor
and measure the solenoid coil resistance. The
resistance should be 32 to 60 ohms depending on
compressor temperature.
4. Next, check the molded plug.
Voltage check: Apply control voltage to the plug wires
(18 to 28 volt ac). The measured dc voltage at the
female connectors in the plug should be around 15 to
27 vdc.
Resistance check: Measure the resistance from the end
of one molded plug lead to either of the two female
connectors in the plug. One of the connectors should
read close to zero ohms, while the other should read
innity. Repeat with other wire. The same female
connector as before should read zero, while the other
connector again reads innity. Reverse polarity on the
ohmmeter leads and repeat. The female connector that
read innity previously should now read close to zero
ohms.
Replace plug if either of these test methods does not
show the desired results.
Fan blaDe settInG DImensIOns
Shown in Figure 13 are the correct fan blade setting
dimensions for proper air delivery across the outdoor
coil.
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
table 5
Fan blaDe DImensIOn
model Dimension a
All 1.0"
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 2100-455M
Page 23 of 28
table 6
InDOOr blOWer PerFOrmance
model
CH3S1 .15 0.5 1100 800 500 1100
CH4S1 .2 0.5 1500 1100 500 1700
CH5S1 .2 0.5 1700 1300 500 1700
NOTE: Theseunitsareequippedwithavariablespeed(ECM)indoormotorthatautomaticallyadjustsitselftomaintain
Maximum ESP (inches WC) shown is with 2" thick disposable lter.
Rated CFM for 2nd Stage Operation – required for maximum performance rating.
1st Stage – the CFM output on 1st Stage Heating or Cooling.
Blower only CFM is the total air being circulated during continuous fan mode.
rated
esP
approximatelythesamerateofindoorairowinbothheatingandcooling,dryandwetcoilconditionsandatboth
230/208or460volts.
max
esP
2nd stage cooling
2nd stage heating
1st stage cooling
1st stage heating
blower Only
or Vent mode
electric heat
table 7
maXImum esP OF OPeratIOn
All
high speed
.5
Manual 2100-455M
Page 24 of 28
table 8
Pressure table
hIGh caPacItY cOOlInG aIr temPerature enterInG OutDOOr cOIl DeGree F
mODel
CH3S1
CH4S1
CH5S1
low side pressure ± 2 PSIG
High side pressure ± 5 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 instruction.
return aIr
temPerature
75° DB lOW SIDE 134 134 134 135 137 138 140 143 146
62° WB HIGH SIDE 298 318 339 363 388 415 445 476 510
80° DB lOW SIDE 143 143 143 144 152 148 150 153 156
67° WB HIGH SIDE 306 326 348 372 402 426 456 488 523
85° DB lOW SIDE 148 148 148 149 151 153 155 158 161
72° WB HIGH SIDE 317 337 360 385 412 441 472 505 541
75° DB lOW SIDE 131 133 135 137 138 139 139 140 140
62° WB HIGH SIDE 308 332 356 380 406 431 456 483 509
80° DB lOW SIDE 140 142 144 146 147 149 149 150 150
67° WB HIGH SIDE 316 340 365 390 416 442 468 495 522
85° DB lOW SIDE 145 147 149 151 153 154 154 155 155
72° WB HIGH SIDE 327 352 378 404 431 457 484 512 540
75° DB lOW SIDE 130 131 131 132 134 135 137 138 140
62° WB HIGH SIDE 336 359 381 406 430 455 482 510 538
80° DB lOW SIDE 139 140 140 141 143 144 146 148 150
67° WB HIGH SIDE 345 368 391 416 441 467 494 523 552
85° DB lOW SIDE 144 145 145 146 148 149 151 153 155
72° WB HIGH SIDE 357 381 405 431 456 483 511 541 571
Pressure 75°F 80°F 85°F 90°F 95°F 100°F 105°F 110°F 115°F
table 9
Pressure table
lOW caPacItY cOOlInG aIr temPerature enterInG OutDOOr cOIl DeGree F
mODel
CH3S1
CH4S1
CH5S1
low side pressure ± 2 PSIG
High side pressure ± 5 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 instruction.
return aIr
temPerature
75° DB lOW SIDE 139 140 141 142 143 145 147 149 151
62° WB HIGH SIDE 259 284 308 333 359 385 410 438 464
80° DB lOW SIDE 149 150 151 152 157 155 157 159 161
67° WB HIGH SIDE 266 291 316 342 370 395 421 449 476
85° DB lOW SIDE 154 155 156 157 158 160 162 165 167
72° WB HIGH SIDE 275 301 327 354 381 409 436 465 493
75° DB lOW SIDE 137 137 139 140 141 143 144 146 147
62° WB HIGH SIDE 281 301 323 345 370 394 419 447 475
80° DB lOW SIDE 146 147 149 150 151 153 154 156 157
67° WB HIGH SIDE 288 309 331 354 379 404 430 458 487
85° DB lOW SIDE 151 152 154 155 156 158 159 161 162
72° WB HIGH SIDE 298 320 343 366 392 418 445 474 504
75° DB lOW SIDE 136 137 139 141 142 143 144 145 145
62° WB HIGH SIDE 293 316 340 364 389 413 439 464 489
80° DB lOW SIDE 145 147 149 151 150 153 154 155 155
67° WB HIGH SIDE 300 324 349 373 391 424 450 476 502
85° DB lOW SIDE 150 152 154 156 157 158 159 160 160
72° WB HIGH SIDE 311 335 361 386 413 439 466 493 520
Pressure 75°F 80°F 85°F 90°F 95°F 100°F 105°F 110°F 115°F
Manual 2100-455M
Page 25 of 28
139
475
160
463
129
478
146
412
170
411
148
465
table 10
Pressure table
127
116
105
95
86
78
71
64
59
54
50
46
44
442
413
387
364
346
330
318
309
304
303
300
295
290
141
123
108
94
83
74
66
61
57
56
56
55
54
431
402
376
353
334
317
304
294
288
284
283
281
280
119
108
99
90
82
75
68
63
57
53
49
46
44
452
427
404
383
364
346
330
316
304
293
284
277
272
table 11
Pressure table
134
122
111
101
91
83
75
68
62
57
53
49
46
389
369
350
334
320
308
298
291
286
283
283
280
275
149
130
113
99
87
77
70
64
62
61
63
65
60
388
367
348
331
316
303
293
284
278
273
271
271
270
133
119
106
95
85
77
70
64
60
58
56
56
58
434
406
381
358
338
321
306
294
285
279
275
274
275
lOW SIDE
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
RETURN AIR
TEMPERATURE
MODEl
hIGh caPacItY heatInG AIR TEMPERATURE ENTERING OUTDOOR COIl DEGREE F
Manual 2100-455M
Page 26 of 28
lOW SIDE
HIGH SIDE
CH3S 70°
lOW SIDE
HIGH SIDE
CH4S 70°
HIGH SIDE
CH5S 70°
High side pressure ± 5 PSIG
Tables are based upon rated CFM (airow) across the evaporator coil. If there is any doubt as to correct operating charge
low side pressure ± 2 PSIG
being in the system, the charge should be removed, system evacuated and recharged to serial plate instruction.
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
RETURN AIR
TEMPERATURE
MODEl
lOW caPacItY heatInG AIR TEMPERATURE ENTERING OUTDOOR COIl DEGREE F
lOW SIDE
HIGH SIDE
CH3S 70°
lOW SIDE
HIGH SIDE
CH4S 70°
lOW SIDE
HIGH SIDE
CH5S 70°
low side pressure ± 2 PSIG
High side pressure ± 5 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 instruction.
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 2100-455M
Page 27 of 28
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 unit being serviced. Do Not
woRK oN tHE MotoR wItH AC PowER APPLIED. To avoid
electric shock from the motor’s capacitors, disconnect power and wait at
least 5 minutes before opening motor.
3. It is not necessary to remove the motor from the blower assembly, nor
the blower assembly from the unit. Unplug the two cable connectors to the
motor control assembly. There are latches on each connector. Do Not
PuLL oN tHE wIRES. The plugs remove easily when properly released.
4. Locate the screws that retain to t
metal of the unit and remove them. Remove two (2) nuts that retain
the control to the bracket and then remove two (2) nuts that retain sheet
metal motor control end plate. Refer to Figure 14.
Disconnect the three (3) wires interior of the motor control by using
5.
your thumb and forenger squeezing the latch tab and the opposite side
of the connector plug, gently pulling the connector. Do Not PuLL oN
tHE wIRES, gRIP tHE PLug oNLy. Refer to Figure 14.
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.
he motor control bracket to the sheet
7. Verify that the replacement control is correct for your application.
Refer to the manufacturer’s authorized replacement list. uSINg tHE
wRoNg CoNtRoL wILL RESuLt IN IMPRoPER oR No
BLowER oPERAtIoN. Orient the control module so that the 3-wire
motor plug can be inserted into the socket in the control. Carefully insert
the plug and press it into the socket until it latches. A SLIgHt CLICK
wILL BE HEARD wHEN PRoPERLy INSERtED.
8. Reverse the steps #5, 4, 3 to reconnect the motor control to the
motor wires, securing the motor control cover plate, mounting the
control to the bracket, and mounting the motor control bracket back
into the unit. MAKE SuRE tHE oRIENtAtIoN you SELECt
FoR REPLACINg tHE CoNtRoL ASSuRES tHE CoNtRoL'S
CABLE CoNNECtoRS wILL BE LoCAtED DowNwARD
IN tHE APPLICAtIoN So tHAt wAtER CANNot RuN
DowN tHE CABLES AND INto tHE CoNtRoL. DO nOt
OvErtigHtEn tHE BOLtS.
9. Plug the 16-pin control plug into the motor. The plug is keyed.
Make sure the connector is properly seated and latched.
10. Plug the 5-pin power connector into the motor. Even though the
plug is keyed, oBSERvE tHE PRoPER oRIENtAtIoN. Do Not
FoRCE tHE CoNNECtoR. It plugs in very easily when properly
oriented. REvERSINg tHIS PLug wILL CAuSE IMMEDIAtE
FAILuRE oF tHE CoNtRoL MoDuLE.
Final installation check. Make sure the motor is installed as follows:
11.
a. Motor connectors should be oriented between the 4 o’clock
and 8 o’clock positions when the control is positioned in its
nal location and orientation.
b. Add a drip loop to the cables so that water cannot enter the
motor by draining down the cables. Refer to Figure 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.
Note:
Use the shorter
bolts and
alignment pin
supplied when
replacing an
ECM 2.0
control.
Manual 2100-455M
Page 28 of 28
Only remove
Hex Head Bolts
ECM 2.0
ECM
Figure 14
Figure 3
Control Disassembly
Push until
Latch Seats
Over Ramp
2.3/2.5
Hex-head Screws
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 15
Figure 4
Winding Test
Motor OK when
R > 100k ohm
Figure 16
Figure 5
Drip Loop
Connector Orientation
Between 4 and 8 o'clock
Drip Loop
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