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:
ACCAAir Conditioning Contractors of America
1712 New Hampshire Ave. N.W.
Washington, DC 20009
Telephone: (202) 483-9370
Fax: (202) 234-4721
ANSIAmerican 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,
Duct Design for Residential .............. ACCA Manual D
Winter and Summer Air
Conditioning and Equipment Selection
NFPANational Fire Protection Association
Batterymarch Park
P.O. Box 9101
Quincy, MA 02269-9901
Telephone: (800) 344-3555
Fax: (617) 984-7057
Manual 2100-467
Page3 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.
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.
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
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
Page9 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
Page10 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
Page11 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 tooversize 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
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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
Page12 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 aresuitable 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
240253 – 216
208220 – 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
Page13 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
Page14 of 23
C
GRY1B
Y
W1W2
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
Page15 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
Page16 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
Page17 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.
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
Page18 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.
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
Page19 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.
SymptomCause/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
SymptomCause/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
DoDon’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
Page20 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 POWERAPPLIED. 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 toFigure 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. Referto Figure 11. (Measure to unpainted motor end plate.) If any motor lead
fails this test, do not proceed to install the control module. THEMOTOR 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 CLICKWILL 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 2.3CONTROL (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 CONTROLWITH AN ECM 2.3CONTROL, 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 NOTFORCE 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.