Bard CH5S1, CH4S1, CH3S1 User Manual 2
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
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