Bard PA13481-B, PA13481-A, PA13421-A, PA13601-B, PA13601-A User Manual

...
INSTALLATION INSTRUCTIONS
SINGLE PACKAGE
AIR CONDITIONERS
MODELS
PA13241-A PA13301-A PA13361-A PA13361-B PA13421-A PA13421-B PA13481-A PA13481-B PA13601-A PA13601-B
Bard Manufacturing Company Bryan, Ohio 43506
Since 1914 . . . Moving ahead just as planned
Manual : 2100-467 Supersedes: NEW File: Volume II Tab 10 Date: 03-03-06
© Copyright 2006
Manual 2100-467 Page 1 of 23
CONTENTS
Getting Other Informations and Publications ........ 3
General Instructions
Important ................................................................ 4
Shipping Damage .................................................... 4
General ................................................................ 4
Field Installed Heater Packages (Optional) ............. 4
Installation
Location ................................................................ 9
Slab Mounting .......................................................... 9
Typical Installations ......................................... 9 & 12
Condensate Drain Trap ......................................... 12
Air Filters .............................................................. 12
Wiring – Main Power ............................................. 13
Wiring – 24V Low Voltage Control Circuit ............. 13
Transformer Taps ................................................... 13
Thermostats ........................................................... 13
Figures
Figure 1 Unit Dimensions ...................................... 8
Figure 2 Slab Mounting at Ground Level ............ 10
Figure 3 Airflow and Service Access
Clearances ............................................ 10
Figure 4 Elevated Mounting Platform ...................11
Figure 5 Condensate Drain Trap ......................... 12
Figure 6 Low Voltage Wiring ............................... 14
Figure 7 Low Ambient Control Wiring ................. 17
Figure 8 Fan Blade Setting ................................. 18
Figure 9 Brazing Diagram ................................... 19
Figure 10 Control Disassembly ............................. 21
Figure 11 Winding Test ......................................... 21
Figure 12 Drip Loop .............................................. 21
Start Up and Operation
General .............................................................. 15
Topping Off System Charge ................................... 15
Safety Practices..................................................... 15
Start Up Notes ....................................................... 15
Three Phase Scroll Compressor Start Up
Information ............................................................. 16
Sequence of Operation .......................................... 16
Indoor Blower Motor .............................................. 16
Compressor Control Module .......................... 16 & 17
Adjustments ........................................................... 17
Low Ambient Control ............................................. 17
Service and Troubleshooting
Service Hints ......................................................... 18
Pressure Service Ports .......................................... 18
Refrigerant Charge ................................................ 18
Fan Blade Settings ................................................ 18
Suction and Discharge Tube Brazing .................... 19
Troubleshooting ECM Blower Motors ............. 20-21
Pressure Tables ............................................. 22 & 23
Tables
Table 1 Rated CFM & ESP .................................. 4
Table 2 Electrical Specifications .......................... 5
Table 3 Opt. Field Installed Heater Packages ..... 6
Table 4 Opt. Field Installed Elec. Heater ............. 7
Table 5 Filter Requirements & Sizes ................. 12
Table 6 Thermostat Wire Size ........................... 13
Table 7 Wall Thermostat and Subbase
Combinations ........................................ 13
Table 8 Refrigerant Charge ............................... 18
Table 9 Fan Blade Setting Dimensions.............. 18
Table 10 Indoor Blower Performance .................. 18
Table 11 Pressure Table ...................................... 22
Table 12 Pressure Table ...................................... 23
Manual 2100-467 Page 2 of 23
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
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
Duct Design for Residential .............. ACCA Manual D
Winter and Summer Air Conditioning and Equipment Selection
NFPA National Fire Protection Association
Batterymarch Park P.O. Box 9101 Quincy, MA 02269-9901 Telephone: (800) 344-3555 Fax: (617) 984-7057
Manual 2100-467 Page 3 of 23
GENERAL INSTRUCTIONS
IMPORTANT
The equipment covered in this manual is to be installed by trained, experienced service and installation technicians. All duct work, supply and return ducts, must be properly sized for the design air flow requirement of the equipment. 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.
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 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 system should be carefully read before beginning the installation. Note particularly “Starting Procedure” and any tags and/or labels attached to the equipment.
FIELD INSTALLED HEATER PACKAGES (OPTIONAL)
These packaged air conditioners are manufactured without supplementary electric heaters. Supplementary heaters are available for simple, fast field installation.
A separate power circuit is required for the supplementary heaters.
IMPORTANT: Refer to Table 1 when designing duct work for maximum available static pressure with heater installed.
Refer to data shown in Table 3 and 4 for proper application information on all available heater combinations and what units they can be used with. It also shows the applicable circuit ampacities, fuse size, and wire size for each heater combination.
TABLE 1
RATED CFM AND EXTERNAL STATIC
PRESSURE (ESP)
ledoM
.oN
14231AP 10331AP0001 16331AP 12431AP 18431AP 10631AP
detaR
MFC
008
0011 0041 0551 0561
dednemmoceR
egnaRwolfriA
etoN etoN etoN etoN etoN etoN
detaR
PSE
81.005.0
32.005.0
32.005.0
32.005.0
82.005.0
82.005.0
PSE
.xaM
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.
Manual 2100-467 Page 4 of 23
NOTE: ECM motors provide rated CFM up to 0.50 ESP
TABLE 2
ELECTRICAL SPECIFICATIONS
1-06-802/0321-06-802/0321-06-802/0323-06-802/0321-06-802/0323-06-802/0321-06-802/0323-06-802/0321-06-802/0323-06-802/032
resnednoCdnarotoMnaF
yticapmAtiucriCmuminiM51814271133243428362
egnaRegatloVgnitarepO352-791352-791352-791352-781352-791352-781352-791352-781352-791352-781
AtiucriCzH06
gnitaRcirtcelE
ledoMA-14231APA-10331APA-16331APB-16331APA-12431APB-12431APA-18431APB-18431APA-10631APB-10631AP
*
eziSeriWdnuorG21018210101801801
eziSeriWdleiF21018210101801801
CSCB9115101125122416261
802/032spmAtinulatoT8.11/8.018.41/3.314.81/4.613.31/0.711.81/2.614.51/1.417.42/0.320.81/9.619.82/3.529.91/7.71
AtiucriCrosserpmoC
**.xaMesuFyaleD02525303050455040604
epyTrosserpmoC.piceR.piceR.piceR.piceRllorcSllorcSllorcSllorcSllorcSllorcS
spmAdaoLdetaR5.8/5.711/5.941/219.8/6.77.31/8.116.9/3.87.81/7121/9.019.22/3.919.31/7.11
spmArotoRkcoL84/8475/7547/4757/57511/511511/511711/7111.38/1.38431/431011/011
stloV802/032802/032802/032802/032802/032802/032802/032802/032802/032802/032
MPR/PHrotoMnaF528-6/1528-6/1528-6/1528-6/1528-4/1528-4/1528-4/1528-4/1528-4/1528-4/1
spmArotoMnaF1.11.11.11.15.15.15.15.15.15.1
MFC/.aiDnaF0072/"420062/"420062/"42/"420043/"420043/"420043/"420043/"420043/"420043/"42
*MPR/PHrotoMrewolBSV-3/1SV-2/1SV-2/1SV-2/1SV-2/1SV-2/1SV-4/3SV-4/3SV-4/3SV-4/3
rotaropavEdnarotoM
spmArotoMrewolB2.27.23.33.33.43.45.45.47.47.4
PSE&gnilooCMFC 32./004132./004182./005182./005182./007182./0071
)sdnuop(thgieWgnippihS003003053053
).zo014-R(egrahC5758021021061061061061061061
* VS = Variable Speed Programmable Motor
Manual 2100-467 Page 5 of 23
XX
TABLE 3
OPTIONAL FIELD INSTALLED HEATER PACKAGES
ONLY TO BE USED WITH THE MODELS INDICATED
Manual 2100-467 Page 6 of 23
esahPA-14231APA-10331APA-16331APB-16331APA-12431APB-12431APA-18431APB-18431APA-10631APB-10631AP
&stloV
egakcaPretaeH
50A-313PHE1-802/042 XXX
ledoM
51A-313PHE1-802/042XX
90B-313PHE3-802/042X
0
1A-313PHE1-802/042 XXX
51B-313PHE3-802/042X
0
51A-315PHE1-802/042XXX
90B-315PHE3-802/042 XXX
50A-315PHE1-802/042X
1A-315PHE1-802/042XXX
51B-315PHE3-802/042 XXX
eziSeriW
dnuorG
2
rewoP
gniriW
dleiF
2
revO.xaM
noitcetorP
BtiucriC
tnerruC
1
yticapmA
tiucriC
.niM
3
dleiF.oN
stiucriC
lanretnI
rekaerB
tiucriC
retaeH
64 /3505/068/601
132/6252/0301/0101
132/6252/0301/0101
06/03
/9707/084/48
06/03
93 /6404/058/801
142/8252/0301/0101
enoN
93 /6404/058/801
142/8252/0301/0101
enoN
V802/042
spmA
.rtH
TABLE 4
yticapaC&WK.rtH
stloV802@
yticapaC&WK.rtH
OPTIONAL FIELD INSTALLED ELECTRIC HEATER TABLE
stloV042@
00 1,7157.3008,211.81/8.02
00 1,7157.3008,211.81/8.02
WKHUTBWKHUTB
stloVtinU
sesahP
01A-313PHE1-802/04201001,4305.7000,622.63/6.141
.oNledoM
egakcaP
retaeH
50A-313PHE1-802/0425
51A-313PHE1-802/04251002,1552.11004,831.45/5.26186/9707/084/48
01A-315PHE1-802/04201001,4305.7000,622.63/6.14164/3505/068/601
50A-315PHE1-802/0425
90B-313PHE3-802/0429007,0357.6000,327.81/7.12
51A-315PHE1-802/04251002,1552.11004,831.45/5.26186
conductor wires in accordance with the National Electrical Code and all existing local codes.
90B-315PHE3-802/0429007,0357.6000,327.81/7.12
51B-313PHE3-802/04251002,1552.11004,832.13/2.631
51B-315PHE3-802/04251002,1552.11004,832.13/2.631
conform to the National Electric Code and all local codes.
1 Maximum size of the time delay fuse or HACR circuit breaker for protection of field wiring devices.
2 Based on wire suitable for 75°C. Other wiring materials must be rated for marked “Minimum Circuit Ampacity” or greater. Based on 75°C copper wire. All wiring must
conductor sizing.
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
IMPORTANT: While this electrical data is presented as a guide, it is important to electrically connect properly sized fuses and
Manual 2100-467 Page 7 of 23
FIGURE 1
Unit General Dimensions
DIMENSIONS OF UNITS
Compressor access door
Control panel door
High voltage knockout
W
D
Low voltage knockout
Heater package knockout
Heater package access panel
Drain access
L
A
E
B
C
Supply opening
Return opening
F
Condenser fan
H
Condenser air intake grille
Blower motor
access door
47 11/16"
G
Condenser air
intake grille
Unit Dimension Chart
Unit
PA/PH1324,1330,1336 5.875 32.875 13.875 32.875 26.25 53.25 38.125 23.25 1.125 1.375 35.625 PA/PH1342,1348,1360 9.875 37.875 15.875 37.875 33.25 55.25 42.375 30.25 1.5 2.375 38.125
Manual 2100-467 Page 8 of 23
Supply Size Return Size Unit Overall Dimensions
A C B C H (height) L (length) W (widt h) D E F G
MIS-2142
INSTALLATION
LOCATION
GENERAL
The unit must be located outside, or in a well ventilated area. It must not be in the space being heated or cooled. A sound absorbing material should be considered if the unit is to be installed in such a position or location that might cause transmission of sound or vibration to the living area or adjacent buildings.
SLAB MOUNTING
A minimum of 24 inches should be provided between the coil inlet and any building surfaces. Provide a minimum of three feet clearance on the service access side of the unit. See Figure 2.
TYPICAL INSTALLATIONS
1.
ROOF MOUNTED
sturdy base on the roof of the building. Return air to the unit is brought through a single return grille (grilles with built-in filters are best since they enable easy access for filter changing). Return air ducts are attached to the lower section of the front panel. Supply air is brought from the unit to attic duct work or to a furred down hall. Supply air duct is attached to the top of the front panel.
– The unit is mounted on a
In roof top installation, as in all installations, the air conditioner must be level from side to side. However, the unit should have a pitch along the length to assure complete external drainage of precipitation and of defrost condensate.
2.
CRAWL SPACE
space must be well insulated and provided with a vapor barrier. In addition, the crawl space must be thoroughly ventilated and provided with a good vapor barrier as a ground cover. It is most desirable to install the unit will be outdoors rather than inside the crawl space, so that it will be readily accessible for service.
3.
SLAB MOUNTED AT GROUND LEVEL
type installation is ideal for homes with a slab floor construction where a roof mounted unit is not desired. The supply and return duct work can be run through a furred closet space.
4.
THROUGH THE WALL
requires a suitable framework to be fabricated capable of withstanding the unit weight. Normally the unit will be insulated so as to minimize supply and return duct work.
– Duct work installed in crawl
– This type installation
– This
CAUTION: All outdoor duct work must be
thoroughly insulated and weatherproofed. All attic duct work must be thoroughly insulated. Two inch thick insulation with suitable vapor barrier is recommended for both outdoor and attic runs.
Manual 2100-467 Page 9 of 23
FIGURE 2
SLAB MOUNTING AT GROUND LEVEL
1 inch clearance
between duct and
any combustible
material if distance
between outside
wall and unit is less
than 3 feet (needed
on electric heat
units only).
Supply Duct
Return Duct
Building
AIRFLOW AND SERVICE ACCESS CLEARANCES
The distance between outside wall and unit varies with installation requirements.
FIGURE 3
Air Outlet
Side
View
Package Unit
Mounting Slab
1/4 inch per foot slope away from building
Ground Level
Building
Heater Package
Access
Heater Package
Blower
and
Blower Motor
Supply and Return Ducts
Blower Service
Access
Nearest Structure
Control Panel
Access
Control Panel
24" min.
Nearest Structure
36" min.
Air Inlet
Compressor
Access
Comp-
ressor
Top
View
24" min.
Nearest Structure
Air Inlet
Condenser fan
and motor access
from top.
Leave 60" min.
above fan.
MIS-2143
Manual 2100-467 Page 10 of 23
FIGURE 4
48" min.
32°F or lower climate
12" min. if in
on surface of platform
Both legs must rest
48" min.
32°F or lower climate
12" min. if in
on surface of platform
Both legs must rest
Metal frame
MIS-2144
Platform can be as
shown or solid
Poured concrete, brick, or block
ELEVATED MOUNTING PLATFORM
*
* AS REQUIRED
*
Manual 2100-467 Page 11 of 23
5.
OTHER INSTALLATIONS
– Many other installations are possible with the packaged air conditioner. No matter what the installation, always consider the following facts:
A. Insure that the discharge air is not obstructed in
any way so as to cause operation difficulties.
B. The indoor coil drain pan is equipped with a
coupling that must be piped through a condensate drain trap to a suitable drain.
C. Always mount the unit is such a position that it
may be easily reached for servicing and maintenance.
D. Insure that the unit is clear so that proper air
flow over the outdoor coil will be maintained.
If this unit is operated in cooling below a 55° outdoor ambient temperature, the installation of low ambient controls (CMA-28) to unit is required.
Prior thought should be given to return air location and placement of the air filter(s). The air filter(s) must be of adequate size and readily accessible to the operator of the equipment. Filters must be adequate in size and properly maintained for proper operation. If this is not done, excessive energy use, poor performance, and multiple service problems will result. It is impossible to oversize air filters. Generous sizing will result in cleaner air and coils as well as lower operating costs and extend the time between required changes. Table 5 shows minimum filter areas and recommended filter sizes. Actual filter sizes can vary with the installation due to single or multiple returns utilizing a filter/grille arrangement or being placed immediately ahead of the indoor coil face in the return air duct.
TABLE 5
FILTER REQUIREMENTS & SIZES
CONDENSATE DRAIN TRAP
It is very important to provide a trap in the condensate drain line to allow a positive liquid seal in the line and assure correct drainage from the coil condensate pan.
Install condensate drain trap shown in Figure 8. Use drain connection size or larger. Do not operate unit without trap. Unit must be level or slightly inclined toward drain. With a trap installed on a unit located in an unconditioned area, water in the trap may freeze. It is recommended that the trap material be of a type that will allow for expansion of water when it freezes.
AIR FILTERS
Air filters for the return air side of the system are not provided as part of these models, and must be field supplied and installed as part of the final installation.
CONDENSATE DRAIN TRAP
NOTE: If roof hood accessory is to be used,
FIGURE 5
.oNledoMaerAretliFmuminiM
4231AP 0331AP 6331AP
2431AP 8431AP 0631AP
sehcnIerauqS264
)teeFerauqS12.3(
sehcnIerauqS806
)teeFerauqS26.4(
eziS
information on air filters may be found under that heading in this manual. Air filters are supplied as part of that package.
dednemmoceR
1x8/5-03x51
1x02x61)2(
Manual 2100-467 Page 12 of 23
MIS-136
AVremrofsnarTALFeguaGeriW
mumixaM
ecnatsiD
teeFnI
553.2
02 81 61 41 21
54 06
001 061 052
WIRING – MAIN POWER
Refer to the unit rating plate for wire sizing information and maximum fuse 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. If field installed heaters are added to the basic unit, a second separate power supply circuit will be required. The heater rating plate located adjacent to the basic unit rating plate will show the appropriate circuit ampacity fuse size, etc. (Also see “Electrical Specifications” on pages 5 & 7.) All models are suitable for connection with copper wire only. These instructions must be adhered to. Refer to the National Electrical Code for complete current carrying capacity data on the various insulation grades of wiring material.
The electrical specifications list fuse and wire sizes (75°F copper) for all models including the most commonly used heater sizes.
The unit rating plate lists a “Maximum Time Delay 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.
WIRING – 24V LOW VOLTAGE CONTROL CIRCUIT
Five (5) wires should be run from thermostat subbase to the 24V terminal board in the unit. A five conductor, 18 gauge copper, color-coded thermostat cable is recommended. The connection points are shown in Figure 6.
TABLE 6
THERMOSTAT WIRE SIZE
TRANSFORMER TAPS
230/208V, 1 phase and 3 phase equipment employ 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).
THERMOSTATS
See specific wiring information for the different models, heater KWs, and voltages on unit and heating wiring diagrams.
IMPORTANT NOTE: Only the thermostat and subbase combinations as shown above will work with this equipment.
TABLE 7
WALL THERMOSTAT AND SUBBASE COMBINATIONS
tatsomrehTesabbuSserutaeFtnanimoderP
940-3048 083-39F1
240-3048
0701G1158T
840-3048
3131C0048T
The thermostat and subbase MUST be matched, and correct operation can be assured only by proper selection and application of these parts.
,loocegats2,taehegats2
elbammargorPcinortcelE
,loocegats1,taehegats2
otua-no:naFotuA-looc-ffo-taeH:metsyS
elbammargorP-noNcinortcelE
,loocegats1,taehegats1
otua-no:naFlooc-ffo-taeH:metsyS
elbammargorP-noNcinortcelE
Manual 2100-467 Page 13 of 23
IF93-380
OR
LOW VOLTAGE WIRING
GR
Y1C
FIGURE 6
BY2
W1
W2
Thermostat Subbase
W3
A1
E2
P
L
DE
T8511G1070
C
OR
T8400C1313
G
G
R
R
Y
Y
B
W1
W
W2
E
L
Unit 24V Terminal
Block
Manual 2100-467 Page 14 of 23
C
GR Y1B
Y
W1 W2
W3
REMOVE JUMPER FOR 2 STAGE ELECTRIC HEAT ON UNITS WITH 15 OR MORE KW
DH
D1
E
L
Unit Control Panel
MIS-2149
START UP
These units require R-410A refrigerant and polyolester oil.
GENERAL:
1. Use separate service equipment to avoid cross contamination of oil and refrigerants.
2. Use recovery equipment rated for R-410A refrigerant.
3. Use manifold gauges rated for R-410A (800 psi/250 psi low).
4. R-410A is a binary blend of HFC-32 and HFC-125.
5. R-410A is nearly azeotropic - similar to R-22 and R-12. Although nearly azeotropic, charge with liquid refrigerant.
6. R-410A operates at 40-70% higher pressure than R-22, and systems designed for R-22 cannot withstand this higher pressure.
7. R-410A has an ozone depletion potential of zero, but must be reclaimed due to its global warming potential.
8. R-410A compressors use polyolester oil.
9. Polyolester oil is hygroscopic; it will rapidly absorb moisture and strongly hold this moisture in the oil.
10. A liquid line dryer must be used - even a deep vacuum will not separate moisture from the oil.
11. Limit atmospheric exposure to 15 minutes.
12. If compressor removal is necessary, always plug compressor immediately after removal. Purge with small amount of nitrogen when inserting plugs.
SAFETY PRACTICES:
1. Never mix R-410A with other refrigerants.
2. Use gloves and safety glasses, polyolester 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.
START UP NOTES
For improved start up performance, wash the indoor coil with dishwasher detergent.
TOPPING OFF SYSTEM CHARGE
If a leak has occurred in the system, Bard Manufacturing recommends reclaiming, evacuating (see criteria above), and charging to the nameplate charge. Topping off the system charge can be done without problems.
With R-410A, there are no significant changes in the refrigerant composition during multiple leaks and recharges. R-410A refrigerant is close to being an azeotropic blend (it behaves like a pure compound or single component refrigerant). The remaining refrigerant charge, in the system, may be used after leaks have occurred and then “top-off” the charge by utilizing the charging charts on the inner control panel cover as a guideline.
REMEMBER: When adding R-410A refrigerant, it must come out of the charging cylinder/tank as a liquid to avoid any fractionation, and to insure optimal system performance. Refer to instructions for the cylinder that is being utilized for proper method of liquid extraction.
Manual 2100-467 Page 15 of 23
START UP AND OPERATION
THREE PHASE SCROLL COMPRESSOR START UP INFORMATION
(PA1336, 42, 48 and 60 Models)
Scroll compressors, like several other types of compressors, will only compress in one rotational direction. Direction of rotation is not an issue with single phase compressors since they will always start and run in the proper direction.
However, three phase compressors will rotate in either direction depending upon phasing of the power. Since there is a 50-50 chance of connecting power in such a way as to cause rotation in the reverse direction, verification of proper rotation must be made. Verification of proper rotation direction is made by observing that suction pressure drops and discharge pressure rises when the compressor is energized. Reverse rotation also results in an elevated sound level over that with correct rotation, as well as, substantially reduced current draw compared to tabulated values.
Verification of proper rotation must be made at the time the equipment is put into service. If improper
rotation is corrected at this time there will be no negative impact on the durability of the compressor. However, reverse operation for over one hour may have a negative impact on the bearing due to oil pump out.
NOTE: If compressor is allowed to run in reverse
rotation for several minutes the compressor’s internal protector will trip.
All three phase scroll 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 terminals should maintain proper rotation direction.
The direction of rotation of the motor may be changed by reversing any two line connections to the unit.
position and the blower is already in operation, then the motor will ramp up to the required speed for cooling.
HEATING (1st Stage)
the room thermostat (circuit R-W1 makes), the blower will energize (circuit R-G is automatic when R-W1 makes). This will place the system into heating operation to maintain the thermostat set temperature. Note that if the “Fan” switch on the room thermostat is in the “On” position and the blower is already in operation, then the motor will ramp up to the required speed for heating.
HEATING (2nd Stage)
Stage electric heaters will not maintain the set room temperature, then the thermostat will call for additional heat to help maintain the set temperature. On a call for second stage heating from the room thermostat (circuit R-W2 makes), additional electric heaters will be energized if installed.
– On a call for heating from
– If the operation of the 1st
INDOOR BLOWER MOTOR
Some models feature a variable speed (ECM) motor providing high efficiency, low sound levels and soft start capabilities. The motor is self adjusting to provide the proper air flow rate at duct static pressures up to
0.50" WC without user adjustment or wiring changes.
On command from the wall thermostat the motor will start slowly and ramp up to full speed over a period of 10- 15 seconds.
When the thermostat is satisfied the blower will operate for approximately 1 minute, and then slow down and stop.
COMPRESSOR CONTROL MODULE
The compressor control is an anti-short cycle/lockout timer with high and low pressure switch monitoring and alarm output.
SEQUENCE OF OPERATION
BLOWER ONLY
room thermostat is placed in the “On” position (circuit R-G makes), the blower will energize and run until the “Fan” switch is placed back into the “Auto” position. This will allow for constant air circulation at a lower airflow during times when the unit is not in operation for cooling or heating.
COOLING
thermostat (circuit R-Y makes), the blower will energize (circuit R-G is automatic when R-Y makes) as well as the compressor, and outdoor fan motor. Note that if the “Fan” switch on the room thermostat is in the “On”
Manual 2100-467 Page 16 of 23
– When the “Fan” switch on the
– On a call for cooling from the room
ADJUSTABLE DELAY-ON-MAKE AND BREAK TIMER
On a call for compressor operation the delay-on-make period begins which will be 10% of the delay-on-break setting. When the delay-on-make is complete and the high pressure switch (and low pressure switch if employed) is closed, the compressor contactor is energized. Upon shutdown the delay-on-break timer starts and prevents restart until the delay-on-break and delay-on-make periods have expired.
HIGH PRESSURE SWITCH AND LOCKOUT SEQUENCE (Standard Feature)
If the high pressure switch opens, the compressor contactor will de-energize immediately. The lockout timer will go into a soft lockout and stay in soft lockout until the high pressure switch closes and the delay-on­make time has expired. If the high pressure switch opens again in this same operating cycle the unit will go into manual lockout condition and the alarm circuit will energize. Recycling the wall thermostat resets the manual lockout.
LOW PRESSURE SWITCH, BYPASS, AND LOCKOUT SEQUENCE (Standard Feature)
If the low pressure switch opens for more that 120 seconds, the compressor contactor will de-energize and go into a soft lockout. Regardless the state of the low pressure switch, the contactor will reenergize after the delay-on-make time delay has expired. If the low pressure switch remains open or opens again for longer than 120 seconds the unit will go into manual lockout condition and the alarm circuit will energize. Recycling the wall thermostat resets the manual lockout.
LOW AMBIENT CONTROL
Optional Low Ambient Control
An optional low ambient control is available for both factory and field installed options. The low ambient control is to be applied to the PA13 Series models when operation below 55°outdoor conditions are anticipated. Without this device, the evaporating pressure would fall off, and the indoor coil would ice over.
The fan cycling control cycles the fan motor on, once the liquid refrigerant pressure reaches 350 psig, and off, once it has dropped to 225 psig. It will continue to cycle between these parameters depending on outdoor temperatures and the load/stage of the system.
This cycling maintains a minimum liquid pressure affecting the minimum suction pressure. This effect insures an evaporating temperature that is slightly above the point of ice formation on the evaporator.
This field installed option is Bard Part #CMA-28. See Figure 7.
ALARM OUTPUT
Alarm terminal is output connection for applications where alarm signal is desired. This terminal is powered whenever compressor is locked out due to HPC or LPC sequences as described.
NOTE: Both high and low pressure switch controls are
inherently automatic reset devices. The high pressure switch and low pressure switch cut out and cut in settings are fixed by specific air conditioner or heat pump unit model. The lockout features, both soft and manual, are a function of the Compressor Control Module.
ADJUSTMENTS
ADJUSTABLE DELAY-ON-MAKE AND DELAY-ON-BREAK TIMER
The potentiometer is used to select Delay-on-Break time from 30 seconds to 5 minutes. Delay-on-Make (DOM) timing on power-up and after power interruptions is equal to 2 minutes plus 10% of Delay-on-Break (DOB) setting:
0.5 minute (30 seconds) DOB = 123 second DOM
1.0 minute (60 seconds) DOB = 126 second DOM
2.0 minute (120 seconds) DOB = 132 second DOM
3.0 minute (160 seconds) DOB = 138 second DOM
4.0 minute (240 seconds) DOB = 144 second DOM
5.0 minute (300 seconds) DOB = 150 second DOM
FIGURE 7
LOW AMBIENT CONTROL WIRING
Manual 2100-467 Page 17 of 23
SERVICE AND TROUBLESHOOTING
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 air flow through the system which shortens equipment service life as well as increasing operating costs.
2. Check all power fuses or circuit breakers to be sure that they are the correct rating.
3. Periodic cleaning of the outdoor coil to permit full and unrestricted airflow circulation is essential.
PRESSURE SERVICE PORTS
High and low pressure service ports are installed on all units so that the system operating pressures can be observed. Pressure tables can be found later in this manual covering all models on cooling cycle. It is imperative to match the correct pressure table to the unit by model number.
REFRIGERANT CHARGE
The correct system R-410A charge is shown on the unit rating plate.
TABLE 8
REFRIGERANT CHARGE
ledoM
4231AP00879-6948-38 0331AP000159-4938-28 6331AP001189-7968-58 2431AP004199-8968-58 8431AP055199-8968-58 0631AP0561201-10198-88
The above liquid line temperatures are based upon 80°F dry bulb/67° wet bulb (50% RH) temperatures and rated airflow across the evaporator during cooling cycle.
detaR wolfriA
Manual 2100-467 Page 18 of 23
DO°59
erutarepmeT
DO°28
erutarepmeT
1 Motor will deliver consistent CFM through voltage supply range with no deterioration
(197-253V for all 230/208V models).
2 Continuous CFM is the total air being circulated during continuous (manual fan) mode. 3 Will occur automatically with a call for "Y" for cooling mode operation. 4 Will occur automatically with a call for "W1" for heating mode operation.
FAN BLADE SETTINGS
Shown in Figure 8 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 8
FAN BLADE SETTING
"B"
“A”
TABLE 9
FAN BLADE SETTING DIMENSIONS
ledoM"A"noisnemiD
4231AP 0331AP 6331AP 2431AP 8431AP 0631AP
"¼3
TABLE 10
INDOOR BLOWER PERFORMANCE
2
ledoM
4231AP01.005.0006008008 0331AP51.005.005700010001 6331AP51.005.052800110011 2431AP02.005.052900410041 8431AP02.005.0520105510551 0631AP02.005.0051105610561
detaR
PSE
XAM PSE
suounitnoC
wolfriA
3
detaR
MFC
MD-1417BC
1
gnilooC
4
detaR
gnitaeH
MFC
SUCTION AND DISCHARGE TUBE BRAZING
Compliant Scroll compressors have copper plated steel suction and discharge tubes. These tubes are far more rugged and less prone to leaks than copper tubes used on other compressors. Due to different thermal properties of steel and copper, brazing procedures may have to be changed from those commonly used.
To disconnect: heat joint Areas 2 and 3 slowly and uniformly until braze material softens and the tube can be pulled out of suction fitting. (See Figure 9.)
To connect:
– Recommended brazing materials: silfos with
minimum 5% silver or silver braze material with flux.
BRAZING DIAGRAM
– Reinsert tube into fitting.
– Heat tube uniformly in Area 1 moving slowly to
Area 2. When joint reaches brazing temperature, apply brazing material. (See Figure 9)
– Heat joint uniformly around the circumference
to flow braze material completely around the joint.
– Slowly move torch into Area 3 to draw braze
material into joint. (See Figure 9.)
Do not overheat joint.
FIGURE 9
MIS-1179
Manual 2100-467 Page 19 of 23
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
• Motor rocks, • Check for loose or compliant motor mount but won’t start
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
• “Hunts” or “puffs” at • Does removing panel or filter reduce
high CFM (speed) “puffing”?
• 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
• Stays at high CFM • “R” missing/not connected at motor
• Blower won’t shut off
• Check power at motor
• Check low voltage (24 Vac R to C) at motor
• Check low voltage connections (G, Y, W, R, C) at motor
• Check for unseated pins in connectors on motor harness
• Test with a temporary jumper between R - G
• Check motor for tight shaft
• Perform motor/control replacement check
Perform Moisture Check
• Make sure blower wheel is tight on shaft
• Perform motor/control replacement check
(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
- Reduce restriction
- Reduce max airflow
delay complete
• “R” missing/not connected at motor
• Perform motor/control replacement check
• Is fan in delay mode? - wait until delay time complete
• Perform motor/control replacement check
Current leakage from controls into G, Y or W? Check for Triac switched thermostat or solid­ state relay
Symptom Cause/Procedure
• Noisy blower or cabinet Check for loose blower housing, panels, etc.
• “Hunts” or “puffs” at Does removing panel or filter reduce high CFM (speed)
Evidence of Moisture
• Motor failure or • Replace motor and malfunction has occurred and moisture is present
• Evidence of moisture Perform Moisture Check
present inside air mover
• High static creating high blower speed?
- Check for air whistling through seams in ducts, cabinets or panels
- Check for cabinet/duct deformation
“puffing”?
- Reduce restriction
- Reduce max. airflow
Perform Moisture Check
Do Don’t
• Check out motor, controls, Automatically assume the motor is bad.
wiring and connections thoroughly before replacing motor
• Orient connectors down so • Locate connectors above 7 and 4 o’clock
water can’t get in positions
- Install “drip loops”
• Use authorized motor and • Replace one motor or control model # with
model #’s for replacement another (unless an authorized replacement)
• Keep static pressure to a • Use high pressure drop filters some have
minimum: H20 drop!
- Recommend high • Use restricted returns
efficiency, low static filters
- Recommend keeping filters
clean.
- Design ductwork for min.
static, max. comfort
- Look for and recommend
ductwork improvement, where necessary
• Size the equipment wisely • Oversize system, then compensate with low
airflow
• 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 airflow (too much latent capacity)
• Check for undercharged condition
• Check and plug leaks in return ducts, cabinet
Comfort Check
• Check proper airflow settings
• Low static pressure for lowest noise
• Set low continuous-fan CFM
• Use humidistat and 2-speed cooling units
• Use zoning controls designed for ECM that regulate CFM
• Thermostat in bad location?
Excessive noise • Determine if it’s air noise, cabinet, duct or
• Air noise • High static creating high blower speed?
motor noise; interview customer, if necessary
- Is airflow set properly?
- Does removing filter cause blower to slow down? Check filter
- Use low-pressure drop filter
- Check/correct duct restrictions
Manual 2100-467 Page 20 of 23
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 specific operating modes. Even though they look alike, different modules may have completely different functionality.
USING THE WRONG CONTROL MODULE VOIDS ALL PRODUCT WARRANTIES AND MAY PRODUCE UNEXPECTED RESULTS.
2. Begin by removing AC power from the furnace or air handler being serviced. DO NOT WORK ON THE MOTOR WITH AC POWER APPLIED. To avoid electric shock from the motor’s capacitors, disconnect power and wait at least 5 minutes before opening motor.
3. It is usually not necessary to remove the motor from the blower assembly. However, it is recommended that the whole blower assembly, with the motor, be removed from the furnace/air handler. (Follow the manufacturer’s procedures). Unplug the two cable connectors to the motor. There are latches on each connector. DO NOT PULL ON THE WIRES. The plugs remove easily when properly released.
4. Locate the two standard housing (at the back end of the control opposite the shaft end). Refer to Figure 10. Remove these two bolts from the motor and control assembly while holding the motor in a way that will prevent the motor or control from falling when the bolts are removed. If an ECM2.0 control is being replaced (recognized by an aluminum casting rather that a deep-drawn black steel can housing the electronics), remove only the hex-head bolts.
DO NOT REMOVE THE TORX-HEAD SCREWS.
5. The control module is now free of mechanical attachment to the motor endshield but is still connected by a plug and three wires inside the control. Carefully rotate the control to gain access to the plug at the control end of the wires. With thumb and forefinger, reach the latch holding the plug to the control and release it by squeezing the latch tab and the opposite side of the connector plug and gently pulling the plug out of the connector socket in the control. DO NOT PULL ON THE
WIRES. GRIP THE PLUG ONLY.
6. The control module is now completely detached from the motor. Verify with a standard ohmmeter that the resistance from each motor lead (in the motor plug just removed) to the motor shell is >100K ohms. Refer to Figure 11. (Measure to unpainted motor end plate.) If any motor lead fails this test, do not proceed to install the control module. THE MOTOR IS DEFECTIVE AND MUST BE REPLACED. Installing the new control module will cause it to fail also.
7. Verify that the replacement control is correct for your application. Refer to the manufacturer's authorized replacement list. USING THE
WRONG CONTROL WILL RESULT IN IMPROPER OR NO BLOWER OPERATION. Orient the control module so that the 3-wire
motor plug can be inserted into the socket in the control. Carefully insert the plug and press it into the socket until it latches. A SLIGHT CLICK WILL BE HEARD WHEN PROPERLY INSERTED. the replacement control per one of the three following paragraphs, 8a, 8b or 8c.
8a. IF REPLACING AN ECM 2.0 CONTROL (control in cast aluminum can with air vents on the back of the can) WITH AN ECM 2.3 CONTROL (control containing black potting for water protection in black deep-drawn steel case with no vents in the bottom of the can), locate the two through-bolts and plastic tab that are packed with the replacement control. Insert the plastic tab into the slot at the perimeter of the open end of the can so that the pin is located on the inside of the perimeter of the can. Rotate the can so that the tab inserts into the tab locater hole in the endshield of the motor. Using the two through-bolts provided with the replacement control, reattach the can to the motor.
THE TWO THROUGH-BOLTS PROVIDED WITH THE REPLACEMENT ECM 2.3 CONTROL ARE SHORTER THAN THE BOLTS ORIGINALLY REMOVED FROM THE ECM 2.0 CONTROL AND MUST BE USED IF SECURE ATTACHMENT OF THE CONTROL TO THE MOTOR IS TO BE ACHIEVED.
DO NOT OVERTIGHTEN THE BOLTS.
¼" hex head bolts at the rear of the control
Finish installing
8b. IF REPLACING AN ECM 2.3 CONTROL WITH AN ECM 2.3 CONTROL, the plastic tab and shorter through-bolts are not needed. The control can be oriented in two positions 180° apart. MAKE SURE
THE ORIENTATION YOU SELECT FOR REPLACING THE CONTROL ASSURES THE CONTROL'S CABLE CONNECTORS WILL BE LOCATED DOWNWARD IN THE APPLICATION SO THAT WATER CANNOT RUN DOWN THE CABLES AND INTO THE CONTROL. Simply orient the new control to the motor's
endshield, insert bolts, and tighten. DO NOT OVERTIGHTEN THE BOLTS.
8c. IF REPLACING AN ECM 2.0 CONTROL WITH AN ECM 2.0 CONTROL (It is recommended that ECM 2.3 controls be used for all
replacements), the new control must be attached to the motor using through-bolts identical to those removed with the original control. DO
NOT OVERTIGHTEN THE BOLTS.
9. Reinstall the blower/motor assembly into the HVAC equipment.
Follow the manufacturer's suggested procedures.
10. Plug the 16-pin control plug into the motor. The plug is keyed.
Make sure the connector is properly seated and latched.
11. Plug the 5-pin power connector into the motor. Even though the plug is keyed, OBSERVE THE PROPER ORIENTATION. DO NOT FORCE THE CONNECTOR. It plugs in very easily when properly oriented. REVERSING THIS PLUG WILL CAUSE IMMEDIATE
FAILURE OF THE CONTROL MODULE.
12.
Final installation check. Make sure the motor is installed as
follows:
a. Unit is as far INTO the blower housing as possible. b.Belly bands are not on the control module or covering vent holes. c. Motor connectors should be oriented between the 4 o’clock and 8
o’clock positions when the blower is positioned in its final location and orientation.
d.Add a drip loop to the cables so that water cannot enter the motor
by draining down the cables. Refer to Figure 12.
The installation is now complete. Reapply the AC power to the HVAC equipment and verify that the new motor control module is working properly. Follow the manufacturer's procedures for disposition of the old control module.
Only remove
Hex Head Bolts
ECM 2.0
Note: Use the shorter bolts and alignment pin supplied when replacing an ECM 2.0 control.
Figure 10
Control Disassembly
Push until Latch Seats Over Ramp
ECM
2.3/2.5
Hex-head Screws
Figure 3
From Moto r
Circuit Board
Motor
Motor Connector (3-pin)
Control Co nnector
(16-pin) Power Connector (5-pin)
Motor Connector (3-pin)
Back of Control
Figure 11
Figure 4
Winding Test
Motor OK when R > 100k ohm
Figure 5
Figure 12
Drip Loop
Connector Orientation
Between 4 and 8 o'clock
Drip Loop
Manual 2100-467 Page 21 of 23
151
741
255
835
175
961
751
261
965
555
341
471
655
985
461
351
095
075
TABLE 11
PRESSURE TABLE
541
015
441
284
241
454
141
824
931
Air Temperature Entering Outdoor Coil Degree F
304
731
873
631
553
331
233
031
013
821
982
551
325
661
451
494
361
251
664
151
261
934
061
941
314
851
741
883
651
541
463
351
241
043
941
931
813
741
731
692
725
641
115
894
341
074
284
141
444
454
831
814
724
731
493
204
531
073
773
331
743
253
131
423
923
031
303
603
145
941
761
171
951
045
115
651
351
284
151
554
841
924
641
404
441
973
241
653
041
233
113
931
241
955
041
861
925
931
461
994
731
174
261
631
951
444
431
751
814
131
551
293
921
351
863
151
521
443
221
941
223
145
361
251
725
051
994
941
374
741
844
541
224
341
893
041
373
831
053
431
823
131
603
065
161
035
215
061
205
584
851
574
954
651
844
334
451
224
804
151
693
383
841
273
953
441
843
633
141
523
413
Manual 2100-467 Page 22 of 23
erusser5050505005001511°02521
erutarepmeT
riAnruteR
ledoM
COOLING
521
962
131
221
052
ediShgiH
ediSwoL
ediSwoL
08 ° BD
57 ° BD
26 ° BW
4231AP
682
672
141
721
562
652
ediShgiH
ediShgiH
BW°76
ediSwoL
ediSwoL
57 ° BD
58 ° BD
27 ° BW
382
362
ediShgiH
26 ° BW
092
641
631
072
ediShgiH
ediSwoL
ediSwoL
58 ° BD
08 ° BD
76 ° BW
0331AP
003
972
ediShgiH
27 ° BW
682
421
562
611
ediShgiH
ediSwoL
ediSwoL
08 ° BD
57 ° BD
26 ° BW
6331AP
392
272
ediShgiH
76 ° BW
303
331
282
ediShgiH
ediSwoL
+5 PSIG
+2 PSIG
58 ° BD
27 ° BW
HIGH SIDE PRESSURE
LOW SIDE PRESSURE
831
821
021
741
731
821
441
431
(Continued on Page 23 in Table 12)
TABLE 12
PRESSURE TABLE
erusser5050505005001511°02521
ediShgiH
ediSwoL
ediSwoL
ediShgiH
ediShgiH
ediSwoL
ediSwoL
ediSwoL
ediSwoL
ediSwoL
ediSwoL
ediSwoL
ediShgiH
ediShgiH
ediShgiH
ediShgiH
ediShgiH
ediShgiH
erutarepmeT
riAnruteR
57 ° BD
26 ° BW
ledoM
COOLING Air Temperature Entering Outdoor Coil Degree F
+5 PSIG
BW°76
58 ° BD
08 ° BD
57 ° BD
58 ° BD
08 ° BD
08 ° BD
2431AP
57 ° BD
58 ° BD
27 ° BW
26 ° BW
8431AP
76 ° BW
27 ° BW
26 ° BW
76 ° BW
0631AP
+2 PSIG
27 ° BW
HIGH SIDE PRESSURE
LOW SIDE PRESSURE
Manual 2100-467 Page 23 of 23
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