Bard PH11242, PH12241, PH11361, PH1236, PH11422 Installation Instructions Manual

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Page 1

INSTALLATION INSTRUCTIONS

SINGLE PACKAGE

HEAT PUMPS

Models:

PH11242 PH12241 PH11301 PH1230 PH11361 PH1236 PH11422 PH1242 PH10481 PH12481 PH1060

Bard Manufacturing Company, Inc. Bryan, Ohio 43506

Since 1914 . . . Moving ahead, just as planned.

Manual : 2100-354F Supersedes: 2100-354E File: Volume II Tab 11 Date: 12-20-06

Manual 2100-354F Page 1 of 32

Page 2

CONTENTS

Getting Other Informations and Publications

General Instructions

Important ................................................................ 3

Shipping Damage .................................................... 4

General ................................................................ 4

Field-Installed Heater Packages (Optional) ............. 4

Installation

Location ............................................................... 11

Typical Installations ....................................... 11 & 16

Condensate Drain Trap ......................................... 16

Air Filters .............................................................. 16

Wiring – Main Power ............................................. 17

Wiring – 24V Low Voltage Control Circuit ............. 17

Thermostats ........................................................... 18

Thermostat Indicator Lamps .................................. 19

Emergency Heat Position ...................................... 19

Transformer Taps ................................................... 19

Compressor Cutoff Thermostat and Outdoor

Thermostat Wiring ................................................. 19

Figures

Figure 1 Unit Dimensional Drawing ..................... 10

Figure 2 Slab Mounting at Ground Level ............ 12

Figure 3 Airflow and Service Access

Clearances ............................................ 12

Figure 4 Roof Top Application ............................. 13

Figure 5 Elevated Mounting Platforms ................ 13

Figure 6 Prefabricated Rood Curb

Specifications ........................................ 14

Figure 7 Field Fabricated Curbing ....................... 15

Figure 8 Condensate Drain Trap ......................... 16

Figure 9 Low Voltage Wiring ............................... 17

Figure 10 Unit 24V Terminal Board (5–10 KW)..... 19

Figure 11 Unit 24V Terminal Board (15–20 KW) ... 20

Figure 12 Heat Pump Control Board ..................... 22

Figure 13 Fan Blade Setting ................................. 25

Figure 14 Brazing Diagram ................................... 26

Start Up and Operation

Three Phase Scroll Compressor Start Up

Information ............................................................. 21

Sequence of Operation .......................................... 21

Defrost Cycle ......................................................... 22

Troubleshooting

Solid State Heat Pump Control

Troubleshooting Procedure ................................... 23

Troubleshooting Guide .......................................... 23

Checking Temperature Sensor Check Out ............ 24

Temperature vs. Resistance of

Temperature Sensor Chart .................................... 24

Service

Service Hints ......................................................... 25

Pressure Service Ports .......................................... 25

Refrigerant Charge ................................................ 25

Fan Blade Settings ................................................ 25

Suction and Discharge Tube Brazing .................... 26

Troubleshooting GE ECM™ Blower Motors ... 27 & 28

Pressure Tables ................................................ 29-32

Tables

Table 1 Rated CFM and ESP .............................. 4

Table 2 Electrical Data ......................................... 5

Table 2A Electrical Data ......................................... 6

Table 2B Electrical Data ......................................... 7

Table 3 Optional Field Installed Heater

Packages ................................................ 8

Table 4 Electric Heater Table ............................... 9

Table 5 Dimensions of Unit................................ 10

Table 6 Roof Curb Dimensions .......................... 14

Table 7 Dimension “X” for Field Fab Curbing .... 15

Table 8 Filters Required & Size ......................... 16

Table 9 Heat Pump Thermostats ....................... 18

Table 10 Thermostat Wire Size ........................... 18

Table 11 Compressor Cutoff Thermostat

Wiring (5 - 10 KW) ............................... 20

Table 12 Compressor Cutoff Thermostat

Wiring (15 - 20 KW) ............................. 20

Table 13 Refrigerant Charge ............................... 25

Table 14 Fan Blade Setting Dimensions .............. 25

Table 15 Indoor Blower Performance .................. 26

Table 16 Pressure Table - Cooling ....................... 29

Table 17 Pressure Table - Heating ...................... 29

Table 18 Pressure Table - Cooling ....................... 30

Table 19 Pressure Table - Heating ...................... 30

Table 20 Pressure Table - Cooling ....................... 31

Table 21 Pressure Table - Heating ...................... 31

Table 22 Pressure Table - Cooling ....................... 32

Table 23 Pressure Table - Heating ...................... 32

Manual 2100-354F Page 2 of 32

Page 3

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 2100-354F Page 3 of 32

Page 4

GENERAL INSTRUCTIONS

IMPORTANT

The equipment covered in this manual is to be installed by trained, experienced service and installation technicians. 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 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 and any instructions packaged with any separate equipment required to make up the entire heat pump 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.

FIELD INSTALLED HEATER PACKAGES (OPTIONAL)

These packaged heat pumps 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 electrical data shown in Tables 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.

These instructions explain the recommended method to install the air cooled self-contained unit and the electrical wiring connections to the unit.

RATED CFM AND EXTERNAL STATIC PRESSURE (ESP)

ledoM

24211HP008088-08602.005.0

14221HP008

10311HP00010011-57703.004.0

0321HP0001

16311HP00010121-57702.004.0

6321HP0001

22411HP00410451-062102.053.0

2421HP0041

18401HP05510071-004104.005.0 18421HP0551

0601HP00710781-035102.005.0

detaR

MFC

NOTE: Motor will adjust to deliver rated airflow.

TABLE 1

1etoN

dednemmoceR

egnaRwolfriA

detaR

PSE

01.005.0

51.005.0

02.005.0

mumixaM

PSE

Manual 2100-354F Page 4 of 32

Page 5

TABLE 2

ELECTRICAL DATA

ledoM24211HP10311HP16311HPB-16311HPC-16311HP22411HP

gnitaRcirtcelE

AtkC-zH06

1-06-802/0321-06-802/0321-06-802/0323-06-802/0323-06-0641-06-802/032

egnaRegatoVgnitarepO352-791352-791352-791352-781605-414352-791

yticapmAtiucriCmuminiM711252812123

CSCB115.3181116

*eziSeriWdleiF0101801418

eziSeriWdnuorG010101014101

**.xaM-esuFyaleD520304525105

802-302-spmAtinUlatoT9.41/9.312.71/7.517.02/9.818.31/2.319.62.42/8.22

AtiucriC-rosserpmoC

epyTrosserpmoCllorcSllorcSllorcSllorcSllorcSllorcS

stloV802/032802/032802/032802/032064802/032

spmAdaoLdetaR11/0131/5.115.61/7.416.9/0.97.45.81/1.71

spmArotoRkcoL45/455.27/5.2788/8877/7793401/401

resnednoCdnarotoMnaF

MPR/PH-rotoMnaF0901-5/15701-5/15701-5/15701-5/15701-5/1528-3/1

spmArotoMnaF2.16.16.16.18.05.2

MFC/aiDnaF0561/"020002/"020002/"020002/"020002/"020592/"42

rotaropavEdnarotoM

MPR/PH-rotoMrewolB5701-3/15701-3/15701-3/15701-3/15701-3/15701-2/1

spmA-rotoMrewolB1.26.26.26.24.17.3

PSE&gnilooCMFC02.0@00803.0@001102.0@001102.0@001102.0@001102.0@0041

).zo22-R(egrahC8839686868121

)sdnuop(thgieWgnippihS563563563563563534

5.81

* 75 degree C copper wire

** Maximum time delay fuse of HACR type circuit breaker

Manual 2100-354F Page 5 of 32

Page 6

TABLE 2A

ELECTRICAL DATA

ledoM18401HPB-18401HPC-18401HP0601HPB-0601HPC-0601HP

gnitaRcirtcelE

AtkC-zH06

1-06-802/0323-06-802/0323-06-0641-06-802/0323-06-802/0323-06-064

egnaRegatoVgnitarepO352-791352-781605-414352-791352-781605-414

yticapmAtiucriCmuminiM435221349241

CSCB5.127.411.792819

*eziSeriWdleiF8

8218821

eziSeriWdnuorG010101010121

**.xaM-esuFyaleD055351065402

802-302-spmAtinUlatoT2.12/2.527.91/3.819

5.23/3.038.22/3.1211

AtiucriC-rosserpmoC

epyTrosserpmoCllorcSllorcSllorcSllorcSllorcSllorcS

stloV802/032802/032064802/032802/032064

spmAdaoLdetaR5.12/5.910.41/6.212.68.62/6.421.71/6.512.8

spmArotoRkcoL731/73119/1905841/841731/73126

resnednoCdnarotoMnaF

MPR/PH-rotoMnaF058-3/1058-3/1058-3/1058-3/1058-3/1058-3/1

spmArotoMnaF5.25.22.15.25.22.1

MFC/aiDnaF0003/"420003/"420003/"420003/"420003/"420003/"42

rotaropavEdnarotoM

MPR/PH-rotoMrewolB5701-2/15701-2/15701-2/15701-2/15701-2/15701-2/1

spmA-rotoMrewolB7.37.38.17.37.38.1

PSE&gnilooCMFC0551

04.00551

04.00071

02.00071

02.0

).zo22-R(egrahC521521521761761761

)sdnuop(thgieWgnippihS054054054054054054

* 75 degree C copper wire

** Maximum time delay fuse of HACR type circuit breaker

Manual 2100-354F Page 6 of 32

Page 7

TABLE 2B

ELECTRICAL DATA

ledoM14221HP0321HP6321HPB-6321HP2421HP18421HPB-18421HP

gnitaRcirtcelE

AtkC-zH06

egnaRegatoVgnitarepO352-791352-791352-791352-781352-791352-791352-781

yticapmAtiucriCmuminiM7112629103334.52

CSCB5.015.315.619.01815.027.41

*eziSeriWdleiF21010121018

eziSeriWdnuorG01010101010101

**.xaM-esuFyaleD52030452540553

802-302-spmAtinUlatoT9.31/9.211.71/6.512.12/4.916.51/7.415.42/5.325.72/5.523.02/0.91

AtiucriC-rosserpmoC

epyTrosserpmoCllorcSllorcSllorcSllorcSllorcSllorcSllorcS

stloV802/032802/032802/032802/032802/032802/032802/032

spmAdaoLdetaR5.01/5.90.31/5.115.61/7.419.01/017.71/7.615.02/5.813.31/0.21

spmArotoRkcoL45/455.27/5.2788/8877/77401/401731/73119/19

resnednoCdnarotoMnaF

MPR/PH-rotoMnaF0901-5/15701-5/15701-5/15701-5/1528-3/1528-3/1528-3/1

spmArotoMnaF2.14.14.14.15.25.25.2

MFC/aiDnaF0561/"020002/"020002/"020002/"020003/"420003/"420003/"42

rotaropavEdnarotoM

MPR/PH-rotoMrewolBelbairaV3/1elbairaV2/1elbairaV2/1elbairaV2/1elbairaV4/3elbairaV4/3elbairaV4/3

spmA-rotoMrewolB1.27.23.33.33.45.45.4

PSE&gnilooCMFC01.0@00851.0@000151.0@000151.0@000102.0@004102.0@055102.0@0551

).zo22-R(egrahC1999121121331321321

)sdnuop(thgieWgnippihS023533543543024044044

1-06-802/0321-06-802/0321-06-802/0323-06-802/0321-06-802/0321-06-802/0323-06-802/032

* 75 degree C copper wire

** Maximum time delay fuse of HACR type circuit breaker

Manual 2100-354F Page 7 of 32

Page 8

tfelneebsah

nmulocsihT

yllanoitnetni

knalb

TABLE 3

AN SAA ANAN

AN ASA ANS3

OPTIONAL FIELD INSTALLED HEATER PACKAGES

ANSAN SAA ANAN

ONLY TO BE USED WITH THE HEAT PUMP MODELS INDICATED

dnastloV

esahP24211HP14221HP10311HP0321HP16311HPB-16311HPC-16311HP6321HPB-6321HP

50A-CP3HE1-802/042ANSANSANANANSAN

01A-CP3HE1-802/042ANSANANANANANANAN

80A-BP3HE1-802/042SANSAN SAA ANAN

50A-BP3HE1-802/042S

01A-BP3HE1-802/042ANANS1 SS1 A 1 A 1 SAN

egakcaP

ledoM

retaeH

51A-BP3HE1-802/042ANANS

51A-CP3HE1-802/042ANANANS2 ANANANS2 AN

90B-BP3HE3-802/042ANANA1 ANA1 S 1 A 1 ANS

90C-BP3HE3-084ANANA1 ANA1 A 1 S 1 ANAN

51B-BP3HE3-802/042ANANA

51C-BP3HE3-084ANANAAN AAS ANAN

Max. KW that can operate with Heat Pump on.

Max. KW that can operate with Heat Pump on is 10 KW. 15 KW will operate during

emergency heat.

Max. KW that can operate with Heat Pump on is 9KW. 15 KW will operate during

emergency heat

ASA ANS3 AS A

S2 SAAS2 ANSAA

SSSAAS ANSAA

dnastloV

esahP22411HP2421HP18401HPB-18401HPC-18401HP18421HPB-18421HP0601HPB-0601HPC-0601HP

90C-CP5HE3-084ANANA1 A 1 S 1 ANANA1 A 1 S 1

90B-BP5HE3-802/042ANANA1 S 1 A 1 ANSA1 S 1 A 1

51B-BP5HE3-802/042ANAN

81B-BP5HE3-802/042ANAN ASA ANANASA

50A-BP5HE1-802/042

egakcaP

ledoM

retaeH

02A-BP5HE1-802/042ANAN SAA ANANSAA

01A-BP5HE1-802/042S1 SS1 A 1 A 1 SANS1 A 1 A 1

51A-BP5HE1-802/042S

81C-CP5HE3-084ANAN AAS ANANAAS

Manual 2100-354F Page 8 of 32

S=Standard application – heater voltage and phase same as basic unit.

A=Alternate application – heater voltage and phase different from basic unit.

NA=Not approved.

Page 9

eziSeriW

dnuorG

rewoP

gniriW

noitcetorP

tnerruC

010101801

01/01

8/6

52/03

05/0607/08

04/54

dleiF

revO.xaM

BtiucriC

yticapmA

tiucriC

.niM

.oN

retaeH

32/62

stiucriC

dleiF

1111111

lanretnI

esuF

64/35

63/24

01/01

8/6

4/4

52/03

05/06

86/97

32/62

84/35

06/03

4/4

07/08

86/97

01/01

8/6

4/4

52/03

05/06

07/08

32/62

86/97

64/35

111

06/03

01/01

3/2

001/011

52/03

19/401

42/82

010101

01/01

8/8

04/05

93/64

8/8

52/03

04/05

42/82

93/64

111

8/6

05/

74/55

111

06/06

1.81/8.02

retaeH

spmA

008,21

TABLE 4

V802/042

&WKretaeH

stloV802

@yticapaC

57.3

OPTIONAL FIELD INSTALLED ELECTRIC HEATER TABLE

&WKretaeH

stloV042

@yticapaC

001,71

1.45/5.26

1.81/8.02

1.45/5.26

8.82/3.33

2.63/6.14

005,02

000,62

2.63/6.14

008,21

004,83

000,62

1.81/8.02

008,21

004,83

1.27/2.38

1.45/5.26

2.63/6.14

000,62

004,83

00 2,15

00.6

05.7

52.11

57.3

05.7

52.11

57.3

05.7

52.11

00.51

003,72

001,71

002,15

001,43

001,4

001,71

002,15

002,86

002,15

001,43

WKHUTBWKHUTB

5 1-802/042

sesahP&

stloVtinU

51501

8 1-802/042

1-802/042

5 1-80

1-802/042

2/042

.gkPretaeH

50A-BP3HE

80A-BP3HE

.oNledoM

80A-CP3HE

01A-CP3HE

01A-BP3HE

51A-BP3HE

51A-CP3HE

50A-BP5HE

02A-BP5HE

01A-BP5HE

51A-BP5HE

2.13/2.63

7.81/7.12

000,32

004,83

2.13/2.63

7.81/7.12

5.73/4.34

8.01

0.81

8.01

0.81

7.12

000,32

004,83

002,82

001,64

002,82

000,74

4,65

52.11

57.6

007,03

002,15

9 3-802/042

3-802/042

90B-BP3HE

51B-BP3HE

05.31

52.11

57.3

007,03

002,15

004,16

9 3-802/042

3-802/042

90B-BP5HE

51B-BP5HE

81B-BP5HE

77.31

62.8

007,03

002,15

3-084

90C-BP3HE

51C-BP3HE

77.31

35.61

62.8

007,03

002,15

004,16

3-084

90C-BP5HE

51C-BP5HE

81C-BP5HE

Time delay fuses of HACR type circuit breakers must be used for 60 and smaller sizes. Standard fuses or circuit breakers are suitable for sizes 70 and

larger. 480V circuit breakers are not HACR type.

Based on wire suitable for 75 degree C. Other wiring materials must be rated for marked Minimum Circuit Ampacity or greater.3Based upon Table 250-95 of N.E.C. 1993. See electric data for basic heat pump for Circuit A wiring specification requirements.

accordance with the national Electrical Code and all existing local codes.

NOTE: While this electrical data is presented as a guide, it is important to electrically connect properly sized fuses and conductor wires in

Manual 2100-354F Page 9 of 32

Page 10

FIGURE 1

UNIT DIMENSIONAL DRAWING

TABLE 5

DIMENSIONS OF UNIT

)sehcnI(gninepOtcuD

ledoM

.oN

ABCJKLMDEFG

4211HP 4221HP 0311HP 0321HP 6311HP 6321HP

2411HP 2421HP 8411HP 8421HP 0601HP

4/1-4261/3-848/1-838/1-628/1-261/961/933633418/7

4/1-130524623

)sehcnI(snoisnemiDtenibaClanimoN

4/3-261/9-7830183618/3-1

egrahcsiDriAnruteR

Manual 2100-354F Page 10 of 32

Page 11

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

In areas where winter temperatures DO NOT go below 32°F for periods over twelve hours, the unit may be slab mounted at grade level. When installing unit at grade level, install on a concrete slab at least four inches above finished grade level. Slab should have a slope tolerance away from the building structure of at lease ¼ inch per foot, while being level from side to side. This will prevent ice buildup under the unit during defrost cycles. Place slab in a location where runoff water from higher ground will not collect around unit. See Figure 2.

A minimum of 18 inches should be provided between the coil inlet and any building surfaces. Provide at least four feet between coil outlet and any building wall, fences or other vertical structures. Provide a minimum of three feet clearance on the service access side of the unit. See Figure 3.

ROOF MOUNTING

When a unit is installed in areas where low ambient temperatures or strong winter winds exist, it should be placed so prevailing winter winds are not in direct line with the heat pump coil. If this is not possible, a wind barrier should be constructed. Place barrier 24 inches from the coil inlet side of the unit and in the direction of prevailing winds. Size barrier at least the same height and width as the unit. This may be necessary on ground level installations, also. See Figure 4.

TYPICAL INSTALLATIONS

ROOF MOUNTED

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.

CAUTION: All outdoor duct work must be thoroughly

insulated and weatherproofed. All attic duct work must be thoroughly insulated. 2-inch thick insulation with suitable vapor barrier is recommended for both outdoor and attic runs.

In roof top installation, as in all installations, the heat pump 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. See Figures 6 and 7, and Tables 6 and 7.

CRAWL SPACE

2. 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 outdoors rather than inside the crawl space, so that it will be readily accessible for service. In addition, it is necessary to dispose of the condensate from the outdoor coil on the heating cycle, and this is virtually impossible with the unit installed inside the crawl space.

SLAB MOUNTED AT GROUND LEVEL

3. 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.

– The unit is mounted on a sturdy

– Duct work installed in crawl

– This

WINTER INSTALLATION BELOW 32°F

In areas where winter conditions go below 32°F for extended periods, the unit must be elevated above the mounting surface to prevent snowfall or defrost ice accumulation from interfering with the operation of the unit. A minimum of twelve inches elevation is recommended, while greater elevation may be required for areas of high snow accumulation. Poured concrete, steel framework, brick, cement block, etc., can be utilized to construct a suitable raised mounting platform. See Figure 5.

THROUGH THE WALL

4. 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.

– This type installation

Manual 2100-354F Page 11 of 32

Page 12

FIGURE 2

SLAB MOUNTING AT GROUND LEVEL

(Above 32°F Outside Temperature)

FIGURE 3

AIRFLOW AND SERVICE ACCESS CLEARANCES

Manual 2100-354F Page 12 of 32

Page 13

FIGURE 4

ROOF TOP APPLICATION

(May also be required for ground level installations)

FIGURE 5

ELEVATED MOUNTING PLATFORMS

Manual 2100-354F Page 13 of 32

Page 14

sliateDbruCfooR

FIGURE 6

TABLE 6

ROOF CURB DIMENSIONS

PREFABRICATED ROOF CURB SPECIFICATIONS

ONE PIECE CONSTRUCTION – READY TO INSTALL

fooR

HEAVY GAUGE GALVANIZED WITH WOOD NAILING STRIP, WELDED/LEAKPROOF

fooR

ABCDEFGH I JKL

ledoM

bruC

ledoM

dooH

ledoMtinU

63-EHR300-2409573.0852.0452.73573.83573.532452.42521.91881.8457.41521.8352.83

*4221HP

*0321HP

*4211HP

*6321HP

*0311HP

*6311HP

06-EHR400-2409573.28521.44521.14573.83573.534452.13521.910557.412452.83

*0601HP

*2421HP

*8401HP

*8421HP

*2411HP

Revision Level

Manual 2100-354F Page 14 of 32

Page 15

FIGURE 7

FIELD FABRICATED CURBING

TABLE 7

DIMENSION “X” FOR FIELD

FABRICATED CURBING

ledoMtinU

4211HP

4221HP 0311HP 0321HP 6311HP 6321HP

2411HP 2421HP 8401HP 8421HP 0601HP

dooHfooR

ledoM

63-EHR14

06EHR8/7-44

noisnemiD

Manual 2100-354F Page 15 of 32

Page 16

OTHER INSTALLATIONS

– Many other installations are possible with the packaged heat pump. 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 in such a position that it

may be easily reached for servicing and maintenance.

D. Insure that the unit is clear so that proper airflow

over the outdoor coil will be maintained.

If this unit is operated in cooling below a 65° outdoor ambient temperature, the installation of low ambient controls (CMA-6) to unit is required.

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 the various types of applications for these models, and must be field supplied and installed as part of the final installation.

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 8 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 8

FILTERS REQUIRED AND SIZE

.oNledoMaerAretliFmuminiM

4211HP 4221HP 0311HP 0321HP 6311HP 6321HP

2411HP 2421HP 8401HP 8421HP 0601HP

sehcnIerauqS264

)teeFerauqS12.3(

sehcnIerauqS806

)teeFerauqS26.4(

eziS

dednemmoceR

1x8/5-03x51

1x02x61)2(

Manual 2100-354F Page 16 of 32

NOTE: If roof hood accessory is to be used, information

on air filters may be found under that heading in this manual. Air filters are supplied as part of that package.

FIGURE 8

CONDENSATE DRAIN TRAP

Page 17

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 Data” on pages 3, 4 and 5.) 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.

LOW VOLTAGE WIRING

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

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 9.

FIGURE 9

Manual 2100-354F Page 17 of 32

Page 18

THERMOSTATS

See specific wiring information for the different models, heater KWs, and voltages.

TABLE 9

HEAT PUMP THERMOSTATS

tatsomrehTserutaeFtnanimoderP

940-3048

)083-39F1(

850-3048

)1511D0225HT(

IMPORTANT NOTE: Only the thermostats shown above are recommended for use with this equipment.

taeHegats2;looCegats2

cinortcelEelbammargorP

revoegnahclaunaMrootuA

taeHegats2;looCegats2

elbammargorP-noNcinortcelE

revoegnahclaunaMrootuA

Manual 2100-354F Page 18 of 32

TABLE 10

THERMOSTAT WIRE SIZE

remrofsnarT

553.202

ALF

eriW

eguaG

54 81 61 41 21

htgneLmumixaM

teeFnI

001 061 052

Page 19

THERMOSTAT INDICATOR LAMPS

The red lamp marked “EM. HT.” comes on and stays on whenever the system switch is placed in Em. Ht. position. The green lamp marked “Check” will come on if there is any problem that prevents the compressor from running when it is supposed to be.

EMERGENCY HEAT POSITION

The operator of the equipment must manually place the system switch in this position. This is done when there is a known problem with the outdoor section, or when the green “Check” lamp comes on indicating a problem.

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).

COMPRESSOR CUTOFF THERMOSTAT and OUTDOOR THERMOSTAT WIRING

Heat pump compressor operation at outdoor temperatures below 0°F are neither desirable not advantageous in terms of efficiency. Since most equipment at time of manufacture is not designated for any specific destination of the country and most of the equipment is installed in areas not approaching the lower outdoor temperature range, the compressor cutoffs are not factory installed.

Outdoor thermostats are available to hold off various banks of electric heat until needed as determined by outdoor temperature. The set point of either type of thermostat is variable with geographic region and sizing of the heating equipment to the structure. Utilization of the Heating Application Data and the heat loss calculation of the building are useful in determining the correct set points. Refer to Installation Instructions of CMH-14 Outdoor Thermostat Kit for more information.

FIGURE 10

UNIT 24V TERMINAL BOARD (5 THROUGH 10 KW)

Manual 2100-354F Page 19 of 32

Page 20

COMPRESSOR CUTOFF THERMOSTAT WIRING (5 through 10 KW) (FIGURE 10)

COMPRESSOR CUTOFF THERMOSTAT WIRING (15 through 20 KW) (FIGURE 11)

TABLE 11

5 through 10 KW

ledoMWKstloVesahP

24211HP8,5,00321 14221HP01,5,00321 10311HP8,5,00321

0321HP01,5,00321

16311HP8,5,00321

6321HP01,5,00321

22411HP01,5,00321

2421HP01,5,00321

18401HP01,5,00321

C-,B-18401hP9,0064/0323

18421HP01,5,00321

B-18421HP9,00323

0601HP01,5,00321

C-,B-0601HP9,0064/0323

TABLE 12

15 through 20 KW

ledoMWKstloVesahP

24211HP510321

14221HP510321

10311HP510321

0321HP510321

16311HP510321

6321HP510321

22411HP02,510321

2421HP510321

18401HP02,510321

C-,B-18401HP81,51064/0323

18421HP510321

B-18421HP510321

0601HP02,510321

C-,B-0601HP81,51064/0323

FIGURE 11

UNIT 24V TERMINAL BOARD (15 through 20 KW)

Manual 2100-354F Page 20 of 32

Page 21

START UP AND OPERATION

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. 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.

SEQUENCE OF OPERATION

COOLING

compressor contactor starting the compressor and outdoor motor. The G (indoor motor) circuit is automatically completed on any call for cooling operation, or can be energized by manual fan switch on subbase for constant air circulation.

HEATING

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 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 heat completes R-Y circuit, pulling in compressor contactor starting compressor and outdoor motor. R-G also make starting indoor blower motor.

– Circuit R-Y makes at thermostat pulling in

– A 24V solenoid coil on reversing valve

All three phase ZR*3 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.

Manual 2100-354F Page 21 of 32

Page 22

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 sensor mounted near the bottom of the outdoor coil. Once coil temperature reaches 30°F or below, the coil sends a signal to the control logic of the heat pump control and the defrost timer will start.

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 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.

After 30 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 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.

There are three settings on the heat pump control – 30, 60 and 90 minutes. Models are shipped wired on the 60-minute setting for greatest operating economy. If special circumstances require a change to another time, remove wire connected to terminal 60 and reconnect to desired terminal. Refer to Figure 12. The manufacturer’s recommendation is for 60-minute defrost cycles.

FIGURE 12

HEAT PUMP CONTROL BOARD

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 maximum 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 coils 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 in 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 the 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 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 2100-354F Page 22 of 32

MIS-1191

Page 23

TROUBLESHOOTING

SOLID STATE HEAT PUMP CONTROL TROUBLESHOOTING PROCEDURE

1. Turn on AC power supply to unit.

2. Turn thermostat blower switch to fan on. The indoor blower should start. (If it doesn’t, troubleshoot indoor unit and correct problem.)

3. Turn thermostat blower switch to Auto position. Indoor blower should stop.

TROUBLESHOOTING

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tonlliwrosserpmoC

rognitaehnitrats

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evitcefed

.evitcefed

gniriWtiucriClortnoCnoCotRmorfV42rofkcehC

gniriWtiucriClortnoCnoCotYmorfV42rofkcehC

gniriWtiucriClortnoCCCotCmorfV42rofkcehC

tuokcolrosserpmoCtuokcolrosserpmoC -hgihehtkcehcl,ortnocpmuptaehehtfo1LtatneserptonsiV42fI

lortnocpmuptaeH

evitcefedrotoMdetrohsroneporofkcehC

roticapacrotoM

.roticapac

lortnocpmuptaeH

dionelosevlovgnisreveR

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lortnocpmuptaeH

lortnocpmuptaeh

.lioc

.C-Bdna

rorosneserutarepmeT

.etunim

rorosneserutarepmeT

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 is 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.

dnaremrofsnartotdraobmorfgniriwkcehc,RtatneserptonsiV42fI

lortnocpmuptaeheht

.remrofsnartecalperdnaesuacenimreted,tuptuoV42

pirtslanimretegatlovwol

.petstxenoteunitnoc,tneserp

lortnocpmuptaehno

.yaledemitetunim-5edirrevootsdnoces01rof

lortnocpmuptaehevitcefeD ,lortnocpmuptaehehtno1LotCdna,YotCmorftneserpsiV42fI

.lortnocpmuptaehehtecalperCCta

.rotomecalpeR

.gnidniwrotom

.gnitarroticapackcehC

detrohsroneporofkcehC

noyalernafssorcakcehC

)CN-moC(.lortnocpmuptaeh

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C-VRneewtebV42rofkcehC

erutarepmettcennocsiD

dnadraobmorfrosnes

pudeepsssorcarepmuj

pmujnesdnaslanimret

esuacdluohssihT.slanimret

ahguorhtogottinueht

enonihtiwelcyctsorfed

pudeepsssorcarepmuJ

esuacdluohssihT.slanimret

.etunimenonihtiw

.lortnoc

tsorfedfotuoemocottinueht

.roticapacecalpeR

.lortnocpmuptaehecalpeR

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.gniriwtiucriclortnockcehC.1

lortnocpmuptaehecalpeR.2

ecalper,elcyctsorfedfotuosemoctinufI.1

.rosneserutarepmet

,elcyctsorfedfotuoemoctonseodtinufI.2

.lortnocpmuptaehecalper

onsahremrofsnartfI.egatlovtuptuodnatupniremrofsnartkcehc

roodtuo,gniriwtatsomrehtdnatatsomrehtkcehc,tneserptonsiV42fI

siV42fI.)deppiuqefi(rotinomesahp)deppiuqefi(tatsomreht

siV42fI.rotcatnocrosserpmocecalperro/&kcehc,tneserpsiV42fI

rosserpmocfI.sdnoces01roflanimretpudeepsehtpmuj,tneserpton

.lortnocpmuptaehehtno1LotCmorfV42rofkcehctratstonseod

lladna)deppiuqefi(yalerssapyberusserp-woldnahctiwserusserp

.tiucricdesolcasitiucricytefasehT.slanimretdnagniriwdetaicossa

eht,nepoerayalerssapyberusserpwolrohctiwserusserphgihehtfI

.tnenopmocevitcefedecalpeR.rosserpmocehttuokcollliwlortnoc

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tneserpsiV42ondnaderipxeroneddirrevoneebsahyaledemiteht

.rosneserutarepmetecalper,elcyctsorfedhguorhtseogtinufI.1

pmuptaehecalper,elcyctsorfedhguorhtogtonseodtinufI.2

Manual 2100-354F Page 23 of 32

Page 24

CHECKING TEMPERATURE SENSOR CHECK OUT

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.

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.

TEMPERATURE F VS RESISTANCE R OF TEMPERATURE SENSOR

FR FR FR FR

0.52-

0.42-

0.32-

0.22-

0.12-

0.02-

0.91-

0.81-

0.71-

0.61-

0.51-

0.41-

0.31-

0.21-

0.11-

0.01-

0.9-

0.8-

0.7-

0.6-

0.5-

0.4-

0.3-

0.2-

0.1-

0.0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

0.01

0.11

0.21

178691 990091 585381 813771 982171 784561 409951 925451 553941 473441 675931 659431 605031 912621 980221 801811 272411 575011 010701 475301 062001 46079

18939 80019 93188

17358 99628

12108 23677 03257 01927 07607 70586 81466 99346 94426 56506 54785

0.31

0.41

0.51

0.61

0.71

0.81

0.91

0.02

0.12

0.22

0.32

0.42

0.52

0.62

0.72

0.82

0.92

0.03

0.13

0.23

0.33

0.43

0.53

0.63

0.73

0.83

0.93

0.04

0.14

0.24

0.34

0.44

0.54

0.64

0.74

0.84

0.94

0.05

58965 48255 04635

15025 41505 82094 09574 00264 55844 45534 59224 77014 89893 75783 25673 38563 84553 54543 47533 43623 32713 04803 68992 75192 55382 77572 32862 29062 38352 69642 03042 48332 85722 05122

16512 98902 53402 69891

0.35

0.25

0.35

0.45

0.55

0.65

0.75

0.85

0.95

0.06

0.16

0.26

0.36

0.46

0.56

0.66

0.76

0.86

0.96

0.07

0.17

0.27

0.37

0.47

0.57

0.67

0.77

0.87

0.97

0.08

0.18

0.28

0.38

0.48

0.58

0.68

0.78

0.88

47391 76881 57381 98971 43471 48961 74561 22161 01751 01351

12941 44541 77141 02831 47431 73131 01821 29421 38121 38811

19511 70311

13011 26701

10501 74201 00001 0679 6259 9929 7709 2688 3568 9448 0528 7508 9687 6867

0.98

0.09

0.19

0.29

0.39

0.49

0.59

0.69

0.79

0.89

0.99

0.001

0.101

0.201

0.301

0.401

0.501

0.601

0.701

0.801

0.901

0.011

0.111

0.211

0.311

0.411

0.511

0.611

0.711

0.811

0.911

0.021

0.121

0.221

0.321

0.421

7057 4337 5617 0007 0486 3866

1356 3836 9326 8906

1695 7285 7965 0755 6445 6235 8025 4905 2894 3784 7674 3664 2654 4644 7634 4724 2814 3904 6004

1293 8383 7573 8763

1063 6253 2543

Manual 2100-354F Page 24 of 32

Page 25

SERVICE HINTS

ledoM

detaR wolfriA

DO°59

erutarepmeT

DO°28

erutarepmeT

24211HP00875-6576-56

14221HP00866-4696-76 0311HP000185-6506-85 0321HP000185-6506-85 6311HP001125-0545-25 6321HP001125-0545-25 2411HP004165-4595-75 2421HP004165-4595-75 8401HP055175-5506-85 8421HP055175-5595-75 0601HP007145-2595-75

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 manual reset 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 that they are the correct rating.

SERVICE

TABLE 13

REFRIGERANT CHARGE

5. 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 in Tables 16 through 23 in this 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.

REFRIGERANT CHARGE

The correct system R-22 charge is shown on the unit rating plate. Optimum unit performance will occur with a refrigerant charge resulting in a suction line temperature (6" from compressor) as shown in Table 13.

The above suction line temperatures are based upon 80°F dry bulb/67°F wet bulb (50% RH) temperature and rated airflow across the evaporator during cooling cycle.

FAN BLADE SETTINGS

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 in Table 14 be checked and blade adjusted in or out on the motor shaft accordingly.

FIGURE 13

FAN BLADE SETTING

TABLE 14

FAN BLADE SETTING

DIMENSIONS

ledoM

4211HP 4221HP

0311HP 0321HP 6311HP 6321HP

22411HP 2421HP 8401HP 8421HP 0601HP

Manual 2100-354F Page 25 of 32

"A"

"00.1

"57.

"57.1

noisnemiD

Page 26

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 14.)

•

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 14.)

– 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 14.)

– Do not overheat joint.

FIGURE 14

/ niPSE/

0.0/519009/02310521/02310521/05615261/05910291/05810581

1.0/068538/08215711/08215711/00515251/06810381/00810871

2.0/518008/03210011/03210011/53410041/08710571/52710071

3.0/587057/08110001/08110001/04310131/08610661/06615261

4.0/057017/0311059/0311059/03210121/08510551/08510451

5.0/047007/0701098/0701098/02110001/00510841AN

Manual 2100-354F Page 26 of 32

4211HP

lioCteW/yrD

TABLE 15

INDOOR BLOWER PERFORMANCE

0311HP

lioCteW/yrD

6311HP

lioCteW/yrD

2411HP

lioCteW/yrD

8401HP

lioCteW/yrD

0601HP

lioCteW/yrD

Page 27

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

• 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

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

Check

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

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

½"

• “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 •

Excessive noise • Determine if it’s air noise, cabinet, duct or

• Air noise • High static creating high blower speed?

- 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

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

• Size the equipment wisely • Oversize system, then compensate with low airflow

• Check orientation before • Plug in power connector backwards

inserting motor connectors • Force plugs

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?

Manual 2100-354F Page 27 of 32

Page 28

TROUBLESHOOTING GE ECM

™

MOTORS CONT’D.

Replacing ECM Control Module

To replace the control module for the GE variable-speed indoor blower motor you need to take the following steps:

1. You MUST have the correct replacement module. The controls are factory programmed for 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 ¼" hex head bolts at the rear of the control housing (at the back end of the control opposite the shaft end). Refer to Figure 15. 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 16. (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. Finish installing 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.

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 17.

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.

Figure 15 Figure 16

Only remove Hex Head Bolts

ECM 2.0

Note: Use the shorter bolts and alignment pin supplied when replacing an ECM 2.0 control.

Control Disassembly

Push until

Latch Seats

Over Ramp

ECM

2.3/2.5

Hex-head Screws

Figure 3

From Motor

Circuit Board

Motor

Motor Connector (3-pin)

Control Connector

(16-pin) Power Connector (5-pin)

Motor Connector (3-pin)

Back of Control

Figure 4

Winding Test

R > 100k ohm

Figure 5

Figure 17

Drip Loop

Connector Orientation Between 4 and 8 o'clock

Drip Loop

Motor OK when

Manual 2100-354F Page 28 of 32

Page 29

PRESSURE TABLES

TABLE 16

COOLING

Air Temperature Entering Outdoor Coil Degrees F

riAnruteR

ledoM

4211HP

0311HP

6311HP

BD.ged57

BW.ged26

BD.ged08

BW.ged76

BD.ged58

BW.ged27

BD.ged57

BW.ged26

BD.ged08

BW.ged76

BD.ged58

BW.ged27

BD.ged57

BW.ged26

BD.ged08

BW.ged76

BD.ged58

BW.ged27

erutarepmeTerusserP

5708580959001501011511

ediSwoL

ediShgiH ediSwoL

ediShgiH

191

902

722

542

362

691

512

332

252

072

302

222

242

162

082

802

622

542

462

382

132

232

252

172

092

022

042

062

082

003

902

722

542

262

082

512

332

152

072

782

222

042

952

872

792

182

58 882

992

203 78

903

39 023

67 892

503 88

613

992

713

553

703

523

443

813

833

753

123

043

853

823

843

763

043

063

083

513

333

323 98

533

453

153

143

953

29 273

TABLE 17

HEATING

nruteR

riA

ledoM

4211HPged07

0311HPged07

6311HPged07

Low side pressure ± 2 PSIG High side pressure ± 5 PSIG

Tables are based upon rated CFM (airflow across the evaporator coil and should be found under section titled “Refrigerant Charge” elsewhere in manual. 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 instructions.

.pmeTerusserP0501517102520353045474055506

ediSwoL

ediShgiH

392

391

ediSwoL

ediShgiH

ediSwoL

ediShgiH

971

771

512

991

002

702

671

771

881

081

Air Temperature Entering Outdoor Coil Degrees F

012

412

122

922

632

342

871

081

481

981

871

671

971

691

502

681

791

052

352

512

912

112

812

752

462

622

932

922

152

Manual 2100-354F Page 29 of 32

07 272

38 452

78 772

Page 30

PRESSURE TABLES

TABLE 18

COOLING

Air Temperature Entering Outdoor Coil Degrees F

riAnruteR

ledoM

2411HP

8401HP

0601HP

erutarepmeTerusserP5708580959001501011511

BD.ged57

BW.ged26

BD.ged08

BW.ged76

BD.ged58

BW.ged27

BD.ged57

BW.ged26

BD.ged08

BW.ged76

BD.ged58

BW.ged27

BD.ged57

BW.ged26

BD.ged08

BW.ged76

BD.ged58

BW.ged27

ediSwoL

ediShgiH

291

012

722

442

162

972

692

413

ediShgiH

791

512

332

052

862

682

403

223

ediShgiH

402

322

142

952

772

ediShgiH

112

622

342

852

672

612

232

942

562

382

422

042

852

472

292

991

612

532

452

272

402

222

142

062

972

112

032

942

962

982

692

513

333

392

013

923

003

813

733

113

923

943

192

903

823

892

713

633

803

823

843

38 233

98 043

69 253

743 78

653 49

863 47

543 97

453 58

663

TABLE 19

HEATING

nruteR

riA

ledoM

2411HPged07

8401HPged07

0601HPged07

Low side pressure ± 2 PSIG High side pressure ± 5 PSIG

.pmeTerusserP0501517102520353045474055506

ediSwoL

ediShgiH

651

161

561

ediSwoL

ediShgiH

061

ediSwoL

ediShgiH

651

461

861

461

271

961

171

271

471

081

381

Air Temperature Entering Outdoor Coil Degrees F

371

771

181

681

391

671

081

481

781

591

302

881

491

112

912

991

302

102

402

622

032

85 702

06 802

55 432

412

122

412

122

342

052

Manual 2100-354F Page 30 of 32

Page 31

COOLING

PRESSURE TABLES

TABLE 20

Air Temperature Entering Outdoor Coil Degrees F

riAnruteR

ledoM

4221HP

0321HP

6321HP

erutarepmeTerusserP5708580959001501011511

BD.ged57

BW.ged26

BD.ged08

BW.ged76

BD.ged58

BW.ged27

BD.ged57

BW.ged26

BD.ged08

BW.ged76

BD.ged58

BW.ged27

BD.ged57

BW.ged26

BD.ged08

BW.ged76

BD.ged58

BW.ged27

ediSwoL

ediShgiH

191

502

912

432

691

012

522

042

302

712

332

842

802

222

732

452

312

822

342

062

022

632

252

962

112

522

242

852

612

132

842

562

422

932

752

472

152

762

582

303

752

472

292

113

662

482

203

223

072

882

703

623

772

592

513

433

782

503

623

643

672

492

413

333

382

203

223

243

392

313

333

453

38 323

133

29 343

48 643

09 553

39 763

28 553

88 463

773

TABLE 21

HEATING

Air Temperature Entering Outdoor Coil Degrees F

nruteR

riA

ledoM

4221HPged07

0321HPged07

6321HPged07

Low side pressure ± 2 PSIG High side pressure ± 5 PSIG

.pmeTerusserP05015171025203530454740555

ediSwoL

ediShgiH

471

281

091

891

102

502

312

122

ediSwoL

ediShgiH

761

071

471

871

971

281

ediSwoL

ediShgiH

491

591

791

102

202

502

781

291

112

812

922

732

791

302

622

532

542

842

012

312

642

052

352

162

712

422

752

072

Manual 2100-354F Page 31 of 32

Page 32

COOLING

PRESSURE TABLES

TABLE 22

Air Temperature Entering Outdoor Coil Degrees F

riAnruteR

ledoM

2421HP

8421HP

erutarepmeTerusserP5708580959001501011511

BD.ged57

BW.ged26

BD.ged08

BW.ged76

BD.ged58

BW.ged27

BD.ged57

BW.ged26

BD.ged08

BW.ged76

BD.ged58

BW.ged27

ediSwoL

ediShgiH

691

112

522

142

752

472

ediShgiH

102

612

132

742

462

802

422

932

652

372

302

152

032

542

162

082

802 08

512

922

122

632

152

862

782

442

062

772

792

192

803

182

892

613

192

803

723

892

913

603

723

713

833

28 623

88 433

643 48

043 09

943 39

163

TABLE 23

HEATING

Air Temperature Entering Outdoor Coil Degrees F

nruteR

riA

ledoM

2421HPged07

8421HPged07

Low side pressure ± 2 PSIG High side pressure ± 5 PSIG

.pmeTerusserP05015171025203530454740555

ediSwoL

ediShgiH

061

461

861

371

471

771

281

781

ediSwoL

ediShgiH

561

661

861

071

171

371

771

281

291

891

781

491

402

602

012

102

402

902

612

322

712

722

Manual 2100-354F Page 32 of 32