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 : 2100-455A Supersedes: 2100-455 File: Volume III Tab 17 Date: 08-18-06
© Copyright 2004
Manual 2100-455A Page 1 of 25
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
Installation Instructions
Wall Mounting Information .................................... 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 & 18
Phase Monitor..................................................... 18
Service Hints ....................................................... 18
Sequence of Operation ....................................... 18
Compressor Current & Pressure
Control Module ................................................... 18
Defrost Cycle ...................................................... 19
Troubleshooting
Solid State Heat Pump Control
Troubleshooting Procedure................................. 20
Checking Temperature Sensor
Outside Unit Circuit ............................................. 21
Temperature vs. Resistance of Temperature ...... 21
Compressor Solenoid ......................................... 22
Fan Blade Setting Dimensions ........................... 22
Removal of Fan Shroud ...................................... 22
Refrigerant Charge R-410A ................................ 22
Pressure Tables ............................................. 24-25
Figures
Figure 1 Unit Dimensions CH3S1 ...................... 5
Figure 2 Unit Dimensions CH4S1 & CH5S1 ...... 6
Figure 3 Mounting Instructions CH3S1 ............ 10
Figure 4
Figure 5 Electric Heat Clearance ..................... 12
Figure 6 Wall Mounting Instructions ................. 13
Figure 7 Wall Mounting Instructions ................. 13
Figure 8 Common Wall Mounting Installations . 14 Figure 9 Common Wall Mounting Installations . 15
Figure 10 Unit 24V Terminal Board .................... 15
Figure 11 Low Pressure Control Bypass Timer . 17
Figure 12 Defrost Control Board ........................ 19
Figure 13 Fan Blade Setting .............................. 22
Manual 2100-455A Page 2 of 25
Mounting Instructions CH4S1/CH5S1 .
11
Tables
Table 1 Electric Heat Table ................................ 4
Table 2 Electrical Specifications ........................ 7
Table 3 Thermostat Wire Size ......................... 15
Table 4 Wall Thermostat .................................. 16
Table 5 Troubleshooting .................................. 20
Table 6 Fan Blade Dimensions........................ 22
Table 7 Refrigerant Charge ............................. 23
Table 8 Indoor Blower Performance ................ 23
Table 9 Maximum ESP of Operation ............... 23
Table 10 Pressure Table - High Cooling ............ 24
Table 11 Pressure Table - Low Cooling ............. 24
Table 12 Pressure Table - High Heating ............ 25
Table 13 Pressure Table - Low Heating ............. 25
Getting Other Information and Publications
These publications can help you install the air conditioner or heat pump. You can usually find 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 2100-455A Page 3 of 25
WALL MOUNT GENERAL INFORMATION
HEAT PUMP WALL MOUNT MODEL NOMENCLATURE
CH 4S 1 – A 05 B P X X X X
MODEL NUMBER
KW
CAPACITY
3S - 3 ton 4S - 4 ton 5S - 5 ton
REVISIONS
VOLTS & PHASE
A - 230/208/60/1 B - 230/208/60/3 C - 460/60/3
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 - Top Outlet
sledoM
1-0421-8023-0423-8023-0641-0421-8023-0423-8023-064
WKA 4 5 6 9
01 51 81
02
UTBAUTBAUTBAUTBAUTBAUTBAUTBAUTBAUTBAUTB
8.02560711.81008218.02560711.8100821
6.14031432.63006526.14031432.6300652
5.26002151.45004832.63002152.13004830.81002155.26002151.45004832.63002152.13004830.8100215
Manual 2100-455A Page 4 of 25
ELECTRIC HEAT TABLE
A-1S3HCB-1S3HCC-1S3HC
4.41005025.21063512.7084024.41005025.21063512.708402
7.12006037.81030328.01007037.12006037.81030328.0100703
TABLE 1
A-1S4HC A-1S5HC
7.61056314.4104201
2.38052861.2700215
B-1S4HC B-1S5HC
3.34004165.73050646.1200416
C-1S4HC C-1S5HC
43"
29 7/8"
9 13/16"
Supply
Opening
6 1/8"
48 1/16"
15 7/8"
Return
Opening
Flashing
Top Rain
2 1/4"
8 9/16"
(12) Wall
Entrances
Opt. High Voltage
Mounting Holes
MIS-2146
FIGURE 1
UNIT DIMENSIONS
6 7/8"
39 7/8"
Optional Top Outlet
7/8"
6 9/16"
"CH3S1" Unit Dimensions
" 31"
43 7/8"
Heater Access
42 3/16"
Top View
16"
Door
16"
84 11/16"
16"
Door
C. Breaker
Control Panel
5 13/16"
Entrance
Access Door
Low Voltage
13 3/8"
16"
32 3/4"
Outlet
Cond.
Entrance
High Voltage
Cond.
Grille
31 5/8"
Inlet
Grille
16"
Access Door
Right Side View Back View
Drain for optional
drain pan
Front View
1 3/8"
Slope Top
Door
Blower Access
Door
Vent Option
Filter Access
Access Door
Grille
Outlet
Cond.
Manual 2100-455A Page 5 of 25
Hose
Evap. Drain
Left Side View
6 1/8"
9 13/16"
48 1/16"
15 7/8"
Top Rain
Flashing
2 1/4"8 9/16"
Opt. High
Voltage
Entrances
MIS-2020 A
"CH4S1 and CH5S1" Unit Dimensions
FIGURE 2
UNIT DIMENSIONS
6 7/8"
43"
29 7/8"
6 9/16"
7/8"
31"
Supply
Opening
16"
Door
Heater Access
Return
Opening
16"
Control Panel
94 11/16"
Door
16"
C. Breaker
5 13/16"
Low Voltage
Access Door
13 3/8"
16"
Entrance
High Voltage
16"
42 3/4"
Cond.
Outlet
Entrance
41 5/8"
Grille
Holes
(12) Wall
Mounting
Access Door
Back View
22 3/16"
Right Side View
39 7/8"
Manual 2100-455A Page 6 of 25
Optional Top Outlet
1 3/8"
43 7/8"
Top View
Slope Top
42 3/16"
Door
Door
Filter Access
Blower Access
Vent Option
Access Door
Inlet Grille
Condenser
Grille
Cond.
Outlet
Drain for optional
drain pan
Front View
Hose
Evap. Drain
Left Side View
TABLE 2
ELECTRICAL SPECIFICATIONS
TIUCRICELGNIS TIUCRICLAUD
detaR
ledoM
Z0A-1S3HC
50A 01A 51A
Z0B-1S3HC
60B 90B 51B
Z0C-1S3HC
60C 90C 51C
Z0A-1S4HC 40A 50A 01A 51A 02A
Z0B-1S4HC 60B 90B 51B 81B
Z0C-1S4HC 60C 90C 51C 81C
Z0A-1S5HC 40A 50A 01A 51A 02A
Z0B-1S5HC 60B 90B 51B 81B
Z0C-1S5HC 60C 90C 51C 81C
1 Maximum size of the time delay fuse or HACR type circuit breaker for protection of field wiring conductors. 2 Based on 75°C copper wire. All wiring must conform to NEC and all local codes. 3 These “Minimum Circuit Ampacity” values are to be used for sizing the field power conductors. Refer to the National Electric Code
(latest revision), Article 310 for power conductor sizing.
CAUTION: When more than one field power conductor 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 3 conductors are in a raceway.
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Manual 2100-455A Page 7 of 25
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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 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 3, 4, 5, 6 & 7 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 RG2 through RG5 or RFG2 through RFG5 be installed when no return duct is used. Contact distributor or factory for ordering information. If using a return air filter grille, filters must be of sufficient size to allow a maximum velocity of 400 fpm.
FILTERS
A 2-inch pleated filter is supplied with each unit. The filter slides into position making it easy to service. This filter can be serviced from the outside by removing the filter access 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.
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 airflow requirement of the equipment. Air Conditioning Contractors of America (ACCA) is an excellent guide to proper sizing. All duct work or portions thereof not in the conditioned space should be properly insulated in order to both conserve energy and prevent condensation or moisture damage.
Manual 2100-455A Page 8 of 25
INSTALLATION INSTRUCTIONS
WALL MOUNTING INFORMATION
1. Two holes for the supply and return air openings must be cut through the wall as shown in Figure 3.
2. On wood frame walls, the wall construction must be strong and rigid enough to carry the weight of the unit without transmitting any unit vibration.
3. Concrete block walls must be thoroughly inspected to insure that they are capable of carrying the weight of the installed unit.
MOUNTING THE UNIT
1. These units are secured by wall mounting brackets which secure the unit to the outside wall surface at both sides. A bottom mounting bracket is provided for ease of installation, but is not required.
2. The unit itself is suitable for 0 inch clearance. If a combustible wall use a minimum of 30" x 10" dimensions for sizing. However, it is generally recommended that a 1-inch clearance is used for ease of installation. The supply air opening would then be 32" x 12". See Figures 3 and 4 for details.
3. Locate and mark lag bolt locations and bottom mounting bracket location. See Figure 3.
4. Mount bottom mounting bracket.
5. Hook top rain flashing under back bend of top. Top rain flashing is shipped with unit attached to back of unit on the right side.
6. Position unit in opening and secure with 5/16 lag bolts; use 3/4 inch diameter flat washers on the lag bolts.
7. Secure rain flashing to wall and caulk across entire length of top. See Figure 3.
8. For additional mounting rigidity, the return air and supply air frames or collars can be drilled and screwed or welded to the structural wall itself (depending upon wall construction). Be sure to observe required clearance if combustible wall.
9. On side-by-side installations, maintain a minimum of 20 inches clearance on right side to allow access to control panel and heat strips, and to allow proper airflow to the outdoor coil. Additional clearance may be required to meet local or national codes.
Manual 2100-455A Page 9 of 25
Foam
flanges
Top
0" min.
"
3
8
1
Supply Duct
"6
7
8
0" min.
Opening
Return Air
MIS-2209
Wall Section
Apply a bead of caulk
Rain Flashing (supplied)
along entire length of top
and behind side mounting
FIGURE 3
MOUNTING INSTRUCTIONS
ABCDE
30 10 6 1/2 1 6
32 12 5 1/2 2 5
43"
C
A
C
Optional
Top Outlet
D
Panel
Heater
Access
B
16"
Supply Opening
16"
16"
30"
Return Opening
16"
Unit Mounting
Holes, 12 places
16"
(Install before unit)
Bottom Wall Bracket
16"
Wall
"
8
5
6
"CH3S1" Wall Mounting Instructions
Manual 2100-455A Page 10 of 25
MIN. CLEARANCE FROM
COMBUSTIBLE MATERIALS
REQUIRED DIM. TO MAINTAIN 0"
COMBUSTIBLE MATERIALS
REQUIRED DIM. TO MAINTAIN
OPTIONAL 1" CLEARANCE FROM
16"
D
16"
16"
16"
16"
3E8
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MOUNTING INSTRUCTIONS
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Manual 2100-455A Page 11 of 25
FIGURE 5
ELECTRIC HEAT CLEARANCE
Typical Building
Outside Sheeting
Unit
Supply Air Duct
Flange of Wall
Wall Frame
Inside Sheeting
Supply Air Duct
1" OPTIONAL CLEARANCE
RECOMMENDED
Side section view of supply air
duct for wall mounted unit showing
0" clearance to combustible surfaces.
MIS-2210
Note: This unit is approved for 0" clearance, but the optional 1" clearance is recommended. See Figures 3 & 4.
Manual 2100-455A Page 12 of 25
FIGURE 6
1" clearance
1" clearance
9 13/16"
6 1/8"
15 7/8"
29 7/8"
51 1/4"
44 7/8"
Supply Opening
Return Opening
These structural members must be able to support the entire weight of the unit.
Locate stud to match spacing for rest of wall. A second member may be required for some walls.
!
Follow all local building codes when framing wall to support unit.
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MIS-2025
WALL MOUNTING INSTRUCTIONS
Exterior wood or
steel siding wall
Factory supplied rain
flashing. Attach to
unit before installing.
"CH" Unit
Interior finished wall
Supply opening
Bottom mounting
bracket. Mount on wall
before installing unit.
Follow all local building codes
!
when framing wall to support unit.
Framing material: 2x4's, 2x6's, and/or structural steel
Return opening
MIS-2024
WALL MOUNTING INSTRUCTIONS
FIGURE 7
Manual 2100-455A Page 13 of 25
Free Air Flow - No Duct
Unit (outside)
COMMON WALL MOUNTING INSTALLATIONS
Grille
Supply Air
Return Air
Grille
Outside Wall
Rafters
Finished Ceiling
FIGURE 8
Free Air Flow - No Duct
Low Sound With Acoustical Plenums
And Isolation Curbs
Isolation Curb WM1CF5-X
Supply Air
Free Blow Supply Plenum WAFB51-X
Return Air Silencer WAPR11-X
Unit (outside)
False Wall Installation
Note: duct maybe in attic or below rafters as shown.
Rafters
Supply Air
Finished Ceiling
Wall Sleeve
Return Air
Outside Wall
False Wall
Duct
RETURN AIR
Ducted Supply - Return At Unit
Note: duct maybe in attic or below rafters as shown.
Unit (outside)
Supply Air
Note: direction of return grille louvers is pointed down for lowest sound level as shown.
Outside Wall
Rafters
Return Air
Duct
Finished Ceiling
Manual 2100-455A Page 14 of 25
Return Air
Grille
MIS-2027
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FIGURE 9
COMMON WALL MOUNTING INSTALLATIONS
Closet Installation
Note: duct maybe in attic or below rafters as shown.
Supply Air
Rafters
Finished Ceiling
Wall Sleeve
Duct
Grille
Unit (outside)
WIRING – LOW VOLTAGE WIRING
230 / 208V, 1 phase and 3 phase equipment dual primary voltage transformers. All equipment leaves the factory wired on 240V tap. For 208V operation, reconnect from 240V to 208V tap. The acceptable operating voltage range for the 240 and 208V taps are:
TAP RANGE
240 253 – 216 208 220 – 187
NOTE: The voltage should be measured at the field
power connection point in the unit and while the unit is operating at full load (maximum amperage operating condition).
WIRING – MAIN POWER
Refer to the unit rating plate for wire sizing information and maximum fuse or “HACR” type circuit breaker size. Each outdoor unit is marked with a “Minimum Circuit Ampacity”. This means that the field wiring used must be sized to carry that amount of current. Depending on the installed KW of electric heat, there may be two field power circuits required. If this is the case, the unit serial plate will so indicate. All models are suitable only for connection with copper wire. Each unit and/or wiring diagram will be marked “Use Copper Conductors Only”. These instructions must be adhered to. Refer to the National Electrical Code (NEC) for complete current carrying capacity data on the various insulation grades of wiring material. All wiring must conform to NEC and all local codes.
The electrical data lists fuse and wire sizes (75° C copper) for all models including the most commonly used heater sizes. Also shown are the number of field power circuits required for the various models with heaters.
The unit rating plate lists a “Maximum Time Delay Relay Fuse” or “HACR” type circuit breaker that is to be used with the equipment. The correct size must be used for proper circuit protection and also to assure that there will be no nuisance tripping due to the momentary high starting current of the compressor motor.
The disconnect access door on this unit may be locked to prevent unauthorized access to the disconnect. To convert for the locking capability, bend the tab located in the bottom left hand corner of the disconnect opening under the disconnect access panel straight out. This tab will now line up with the slot in the door. When shut, a padlock may be placed through the hole in the tab preventing entry.
See “Start Up” section for important information on three phase scroll compressor start ups.
Outside Wall
Return Air
Closet Wall
Raised Closet Floor
Return Air
Closet Wall
Grille
MIS-2240
FIGURE 10
UNIT 24V TERMINAL BOARD
T7652H1000 THERMOSTAT
BARD PART #8403-052
G
C
Rc
Rh
Y1
G
C
C
G
Y1
R
R
Y
Factory Jumper
B
Y2
Y2
Y1
W1
1F93-380 THERMOSTAT
B
B
W1
W1
W2
W2 E
W3
L
BARD PART #8403-049
L
E
UNIT LOW VOLTAGE
TERMINAL BLOCK
DH
A1
W3/A1
O1
MIS-2026 A
Nine (9) wires should be run from thermostat subbase to the 24V terminal board in the unit. A nine conductor, 18 gauge copper color-coded thermostat cable is recommended. The connection points are shown in Figure 10.
IMPORTANT
Only the thermostat combinations as shown above will work with this equipment.
TABLE 3
THERMOSTAT WIRE SIZE
Manual 2100-455A Page 15 of 25
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.
The “R” terminal is the hot terminal and the “C” terminal is grounded.
“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.
TABLE 4
WALL THERMOSTAT
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“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 installed ventilation 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
total of 7 controlled outputs are required (6 if no ventilation system is installed). For proper system operation under Emergency Heat conditions where 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.
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
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.
Heat Pump Heating 2nd Stage Energize Y, Y1, G, B
3rd Stage Heating w/Heat Pump (if employed)
Ventilation Energize G, O1
Emergency Heat Energize B, W2, E, G
Manual 2100-455A Page 16 of 25
Energize G, W2, Y, B, Y1
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 flammable.
4. Do not inhale R-410A – the vapor attacks the nervous system, creating dizziness, loss of coordination and slurred speech. Cardiac irregularities, unconsciousness and ultimate death can result from breathing this concentration.
5. Do not burn R-410A. This decomposition produces hazardous vapors. Evacuate the area if exposed.
6. Use only cylinders rated DOT4BA/4BW 400.
7. Never fill cylinders over 80% of total capacity.
8. Store cylinders in a cool area, out of direct sunlight.
9. Never heat cylinders above 125°F.
10. Never trap liquid R-410A in manifold sets, gauge lines or cylinders. R-410A expands significantly at warmer temperatures. Once a cylinder or line is full of liquid, any further rise in temperature will cause it to burst.
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 540 PSI or below 35 PSI, in either cooling or heating mode, the compressor will be stopped. 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 to eliminate nuisance lockout on cold start up.
The bypass timer should be set to 200 seconds, and this is to assure there is no nuisance tripping of the low­pressure control during startup in heating mode under cold weather conditions. See Figure 10:
FIGURE 11
LOW PRESSURE CONTROL BYPASS TIMER
THREE PHASE SCROLL COMPRESSOR START UP INFORMATION
Scroll compressors, like several other types of compressors, will only compress in one rotational direction. Direction of rotation is not an issue with single phase compressors since they will always start and run in the proper direction.
However, three phase compressors will rotate in either direction depending upon phasing of the power. Since there is a 50-50 chance of connecting power in such a way as to cause rotation in the reverse direction, verification of proper rotation must be made. All three phase units incorporate a phase monitor to ensure proper field wiring. See the “Phase Monitor” section later in this manual.
Verification 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: If compressor is allowed to run in reverse
rotation for several minutes, the compressor’s internal protector will trip.
All three phase ZR3 compressors are wired identically internally. As a result, once the correct phasing is determined for a specific system or installation, connecting properly phased power leads to the same Fusite terminal should maintain proper rotation direction.
Manual 2100-455A Page 17 of 25
Verification of proper rotation direction is made by observing that suction pressure drops and discharge pressure rises when the compressor is energized. Reverse rotation also results in an elevated sound level over that with correct 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.
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, reverse two of the supply leads to the unit. Do not reverse any of the unit factory wires as damage may occur.
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-W1 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.
SERVICE HINTS
1. Caution homeowner to maintain clean air filters at all times. Also, not to needlessly close off supply and return air registers. This reduces airflow through the system, which shortens equipment service life as well as increasing operating costs.
2. 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 airflow 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 of 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.
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 525 PSI, the compressor control module de­energizes 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 2100-455A Page 18 of 25
DEFROST CYCLE
The defrost cycle is controlled by temperature and time on the solid state heat pump control. See Figure 12.
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.
After 60 minutes 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 10 minutes.
The heat pump defrost control board has an option of 30, 60 or 90-minute setting. All models are shipped from the factory on the 60-minute pin. If special circumstances require a change to another time, remove the wire from the 60-minute terminal and reconnect to the desired terminal. The manufacturer's recommendation is for 60-minute defrost cycles. Refer to Figure 12.
FIGURE 12
DEFROST CONTROL BOARD
There is a cycle speed up jumper on the control. This can be used to reduce the time between defrost cycle operation without waiting for time to elapse.
Use a small screwdriver or other metallic object, or another 1/4 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 1/4 inch QC terminal works best) the defrost sensor mounted on the outdoor coil is shunted out and will activate the timing circuit. This permits the defrost cycle to be checked out in warmer weather conditions without the outdoor temperature having to fall into the defrost region.
In order to terminate the defrost test the SEN JMP jumper must be removed. If left in place too long the compressor could stop due to the high pressure control opening because of high pressure condition created by
operating in the cooling mode with outdoor fan off. Pressure will rise fairly fast as there is likely no actual frost on the outdoor coil in this artificial test condition.
There is also a 5-minute compressor time delay function built into the HPC. This is to protect the compressor from short cycling conditions. 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.
Manual 2100-455A Page 19 of 25
TROUBLESHOOTING
SOLID STATE HEAT PUMP CONTROL TROUBLESHOOTING PROCEDURE
1. Turn on AC power supply to indoor and outdoor units.
2. Turn thermostat blower switch to fan on. The indoor blower should start. (If it doesn’t, troubleshoot indoor unit and correct problem.)
TROUBLESHOOTING
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4. Set system switch to heat or cool. Adjust thermostat to call for heat or cool. The indoor blower, compressor, and outdoor fan should start.
NOTE: If there was no power to 24 volt transformer,
the compressor and outdoor fan motor will not start for 5 minutes. This is because of the compressor short cycle protection.
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Manual 2100-455A Page 20 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
F R F R F R
-25.0
-24.0
-23.0
-22.0
-21.0
-20.0
-19.0
-18.0
-17.0
-16.0
-15.0
-14.0
-13.0
-12.0
-11.0
-10.0
-9.0
-8.0
-7.0
-6.0
-5.0
-4.0
-3.0
-2.0
-1.0
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1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
11.0
12.0
13.0
14.0
15.0
16.0
17.0
18.0
19.0
20.0
21.0
22.0
23.0
24.0
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27.0
28.0
29.0
30.0
31.0
32.0
33.0
34.0
35.0
36.0
37.0
38.0
39.0
40.0
41.0
42.0
43.0
44.0
45.0
46.0
47.0
48.0
49.0
50.0
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52.0
53.0
54.0
55.0
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57.0
58.0
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61.0
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63.0
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65.0
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67.0
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70.0
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72.0
73.0
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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.
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77.0
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83.0
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87.0
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94.0
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97.0
98.0
99.0
100.0
101.0
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104.0
105.0
106.0
107.0
108.0
109.0
110.0
111.0
112.0
113.0
114.0
115.0
116.0
117.0
118.0
119.0
120.0
121.0
122.0
123.0
124.0
10501 10247 10000
9760 9526 9299 9077 8862 8653 8449 8250 8057 7869 7686 7507 7334 7165 7000 6840 6683 6531 6383 6239 6098 5961 5827 5697
0
5570 5446 5326 5208 5094 4982 4873 4767 4663 4562 4464 4367 4274 4182 4093 4006 3921 3838 3757 3678 3601 3526 3452
Manual 2100-455A Page 21 of 25
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 rectifier 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 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 infinity. Repeat with other wire. The same female connector as before should read zero, while the other connector again reads infinity. Reverse polarity on the ohmmeter leads and repeat. The female connector that read infinity previously should now read close to zero ohms.
Replace plug if either of these test methods does not show the desired results.
dc voltage at the female
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 6
FAN BLADE DIMENSION
ledoMAnoisnemiD
LLA0.1
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
The correct system R-410A charge is shown on the unit rating plate. Optimum unit performance will occur with a refrigerant charge shown on the unit serial plate.
If correct charge is in doubt, recover the refrigerant and recharge per the charge on the unit rating plate. See Table 7 for proper subcooling levels for evaluation of proper charge.
Manual 2100-455A Page 22 of 25
TABLE 7
1
REFRIGERANT CHARGE - SUBCOOLING LEVEL
GNILOOCGNITAEH
detaR
ledoM
wolfriA
DO59
erutarepmeT
DO08
erutarepmeT
DO74
erutarepmeT
DO53
erutarepmeT
1S3HC001102-6191-5123-8203-62 1S4HC005122-8112-7142-0291-51 1S5HC007103-6242-0253-1313-72
1 Expected subcooling levels during high capacity Stage 2 operation. Above subcooling levels are provided to troubleshoot low
charge or overcharged conditions. If charge is in doubt, evacuate and recharge the unit to the refrigerant charge listed on the serial plate.
TABLE 8
INDOOR BLOWER PERFORMANCE
1
ledoM
detaR
PSE
xaM PSE
2
gnilooCegatSdn2
gnitaeHegatSdn2
3
gnilooCegatSts1 gnitaeHegatSts1
1S3HC51.5.00110080080011 1S4HC2.5.005100110580071 1S5HC2.5.007100310580071
NOTE: These units are equipped with a variable speed (ECM) indoor motor that automatically adjusts itself to maintain
1 Maximum ESP (inches WC) shown is with 2" thick disposable filter.
2 Rated CFM for 2nd Stage Operation – required for maximum performance rating.
3 1st Stage – the CFM output on 1st Stage Heating or Cooling.
4 Blower only CFM is the total air being circulated during continuous fan mode.
approximately the same rate of indoor airflow in both heating and cooling, dry and wet coil conditions and at both 230/ 208 or 460 volts.
4
ylnOrewolB
edoMtneVro
taeHcirtcelE
TABLE 9
MAXIMUM ESP OF OPERATION
deepShgiH
LLA5.
Manual 2100-455A Page 23 of 25
TABLE 10
PRESSURE TABLE
GNILOOCYTICAPACHGIH
LEDOM
1S3HC
1S4HC
1S5HC
RIANRUTER
ERUTAREPMET
BD°57
BW°26
BD°08
BW°76
BD°58
BW°27
BD°57
BW°26
BD°08
BW°76
BD°58
BW°27
BD°57
BW°26
BD°08
BW°76
BD°58
BW°27
ERUSSERP 57oF 08oF 58oF 09oF 59oF 001oF 501oF 011oF 511oF
EDISWOL
431
431
431
531
731
831
041
EDISHGIH
892
813
933
363
883
514
EDISWOL
341
341
341
441
641
EDISHGIH
603
623
843
273
EDISWOL
841
841
841
EDISHGIH
713
733
EDISWOL
131
EDISHGIH EDISWOL
EDISHGIH EDISWOL
EDISHGIH EDISWOL
EDISHGIH EDISWOL
EDISHGIH EDISWOL
EDISHGIH
331
803
233
041
241
613
043
541
741
723
253
031
633
543
753
131
953
931
041 863
441
541 183
941
063
583
531
731
653
083
441
641
563
093
941
151
873
404
131
231
183
604
041
141
193
614
541
641
504
134
841
893
624
151
351
214
144
831
931
604
134
841
941
614
244
351
451
134
754
431
531
034
554
341
441
144
764
841
941
654
384
341
544
674
051
351
654
884
551
851
274
505
931
041
654
384
941
051
864
594
451
551
484
215
731
831
284
015
641
841
494
325
151
351
115
145
641 015
651 325
161 145
041 905
051 225
551 045
041 835
051 255
551
175
Low side pressure ± 2 PSIG High side pressure ± 5 PSIG Tables are based upon rated CFM (airflow) across the evaporator coil. If there is any doubt as to correct operating charge
being in the system, the charge should be removed, system evacuated and recharged to serial plate instruction.
TABLE 11
PRESSURE TABLE
GNILOOCYTICAPACWOL
LEDOM
1S3HC
1S4HC
1S5HC
RIANRUTER
ERUTAREPMET
BD°57 BW°26
BD°08 BW°76
BD°58 BW°27
BD°57 BW°26
BD°08 BW°76
BD°58 BW°27
BD°57 BW°26
BD°08 BW°76
BD°58 BW°27
ERUSSERP 57oF 08oF 58oF 09oF 59oF 001oF 501oF 011oF 511oF
EDISWOL
931
041
141
241
341
541
EDISHGIH
952
482
803
333
953
EDISWOL
941
051
151
251
EDISHGIH
662
192
613
EDISWOL
451
551
EDISHGIH
572
EDISWOL
731
EDISHGIH
182
EDISWOL
641
EDISHGIH
882
EDISWOL
151
EDISHGIH
892
EDISWOL
631
EDISHGIH
392
EDISWOL
541
EDISHGIH
003
EDISWOL
051
EDISHGIH
113
651
103
723
731
931
103
323
741
941
903
133
251
451
023
343
731
931
613
043
741
941
423
943
251
451
533
163
351
243
863
751
851
453
183
041
141
543
073
051
151
453
973
551
651
663
293
141
241
463
983
151
251
373
993
651
751
683
314
741
583
014
551
751
593
124
061
261
904
634
341
441
493
914
351
451
404
034
851
951
814
544
341
441
314
934
351
451
424
054
851
951
934
664
FEERGEDLIOCROODTUOGNIRETNEERUTAREPMETRIA
941
151
834
464
951
161
944
674
561
761
564
394
641
741
744
574
651
751
854
784
161
261
474
405
541
541
464
984
551
551
674
205
061
061
394
025
Low side pressure ± 2 PSIG High side pressure ± 5 PSIG Tables are based upon rated CFM (airflow) across the evaporator coil. If there is any doubt as to correct operating charge
being in the system, the charge should be removed, system evacuated and recharged to serial plate instruction.
Manual 2100-455A Page 24 of 25
F
931
o
574
921
061
874
364
F
641
214
o
841
071
114
564
F 56
o
F 06
o
FEERGEDLIOCROODTUOGNIRETNEERUTAREPMETRIA
F 55
o
F 05
o
F 54
o
F 04
o
F 53
o
F 03
o
F 52
o
F 02
o
TABLE 12
F 51
o
PRESSURE TABLE
141
721
611
501
59
68
87
17
46
95
45
134
911
244
321
314
801
783
463
49
643
38
033
47
813
66
903
16
403
75
303
65
254
801
724
204
673
404
99
383
353
09
463
433
28
643
713
57
033
403
86
613
492
36
403
882
75
392
482
35
F 56
431
983
o
F 06
221
963
o
FEERGEDLIOCROODTUOGNIRETNEERUTAREPMETRIA
F 55
111
053
o
F 05
101
433
o
F 54
023
19
o
F 04
803
o
38
F 53
892
o
57
F 03
192
o
86
F 52
682
o
26
F 02
382
o
75
331
941
883
434
031
911
763
604
183
601
843
311
133
853
59
99
833
613
58
78
123
303
77
77
603
392
07
07
492
482
46
46
582
872
06
26
972
372
16
85
TABLE 13
003
05
65
482
382
94
PRESSURE TABLE
F 51
o
35
172
382
36
572
65
182
592
F 01
o
F 5
o
ERUSSERP 0
ERUTAREPMET
RIANRUTER
55
64
092
45
44
EDISHGIH
EDISWOL
EDISWOL
GNITAEHYTICAPACHGIH
LEDOM
S3H07
772
64
272
082
44
EDISHGIH
EDISHGIH
EDISWOL
F 01
94
o
F 5
64
o
ERUSSERP 0
EDISWOL
ERUTAREPMET
RIANRUTER
GNITAEHYTICAPACWOL
S5H07
S4HC °07
Low side pressure ± 2 PSIG
High side pressure ± 5 PSIG
Tables are based upon rated CFM (airflow) across the evaporator coil. If there is any doubt as to correct operating charge
being in the system, the charge should be removed, system evacuated and recharged to serial plate instruction.
LEDOM
172
082
56
572
06
EDISHGIH
EDISWOL
S3H07
472
65
572
072
85
EDISHGIH
EDISHGIH
EDISWOL
S5H07
S4HC °07
Low side pressure ± 2 PSIG
High side pressure ± 5 PSIG
Tables are based upon rated CFM (airflow) across the evaporator coil. If there is any doubt as to correct operating charge
being in the system, the charge should be removed, system evacuated and recharged to serial plate instruction.
Manual 2100-455A Page 25 of 25
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