Page 1
INSTALLATION INSTRUCTIONS
WALL MOUNTED
PACKAGE HEAT PUMPS
Standard & Dehumidication
MODELS
T24H1 T24H1D
T30H1 T30H1D
T36H1 T36H1D
T42H1 T42H1D
T48H1 T48H1D
T60H1 T60H1D
Bard Manufacturing Company, Inc.
Bryan, Ohio 43506
Since 1914...Moving ahead just as planned.
Manual: 2100-541D
Supersedes: 2100-541C
File: Volume III Tab 17
Date: 03-28-14
Manual 2100-541D
Page 1 of 28
Page 2
Contents
Getting Other Information and Publications 3
Wall Mount General Information
Wall Mount Model Nomenclature
Shipping Damage
General .................................................................4
Duct Work
Filters .................................................................5
Fresh Air Intake
Condensate Drain
Installation Instructions
Wall Mounting Information
Mounting the Unit
Placement
Clearances Required
Minimum Clearances
Wiring – Main Power
Wiring – Low Voltage Wiring
Optional Outdoor T -Stat Applications
Figures
Figure 1 Fresh Air Damper Assembly .....................5
Figure 2 Unit Dimensions .......................................7
Figure 3A Mounting Instructions T24 & 30 ...............8
Figure 3B Mounting Instructions T36, 42, 48 ............9
Figure 4 Electric Heat Clearance .........................10
Figure 5 Wall Mounting Instructions .....................11
Figure 6 Wall Mounting Instructions .....................11
Figure 7 Common Wall Mounting Installations .....12
Figure 8 Compressor Cutoff .................................14
Figure 9 Compressor Cutoff .................................14
Figure 10 Electric Heat Hold-Off Wiring .................15
Figure 11 Electric Heat Hold-Off Wiring .................15
Figure 12 Defrost Control Board ............................19
Figure 13 Fan Blade Setting ...................................22
Figure 14 Control Disassembly ..............................28
Figure 15 Winding Test ...........................................28
Figure 16 Drip Loop ................................................28
.................................................................5
.................................................................6
.....................................................4
.........................................................5
....................................................5
......................................................6
................................................6
................................................6
...............................................13
..............................4
........................................6
...................................13
......................14
Start Up
General ...............................................................16
Topping Off System Charge
Safety Practices
Important Installer Note
High & Low Pressure Switch
Three Phase Scroll Compressor
Phase Monitor
Service Hints
Sequence of Operation
Pressure Service Ports
Defrost Cycle
Troubleshooting
Solid State Heat Pump Control
Checking Temperature Sensor
Fan Blade Setting Dimensions
Removal of Fan Shroud
R-410A Refrigerant Charge
Troubleshooting ECM Motors
Troubleshooting ECM Motors
Tables
Table 1 Clearances Required ...............................6
Table 2 Min. Clearances Required ........................6
Table 3 Troubleshooting......................................20
Table Temperature F vs. Resistance ...............21
Table 4 Fan Blade Dimension .............................22
Table 5A Cooling Pressure ....................................23
Table 5B Heating Pressure ...................................23
Table 6A Electrical Specications T**H .................24
Table 6B Electrical Specications T**H Dehum. ...25
Table 7 Indoor Blower Performance ...................26
......................................................16
.........................................................17
...........................................................17
..........................................................18
....................................16
...........................................17
...................................17
.............................17
...........................................18
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................................22
..........................................22
....................................22
.................................27
.................................28
Manual 2100-541D
Page 2 of 28
Page 3
GETTING OTHER INFORMATION AND PUBLICATIONS
These publications can help you install the air
conditioner or heat pump. You can usually nd these
at your local library or purchase them directly from the
publisher. Be sure to consult current edition of each
standard.
National Electrical Code .......................ANSI/NFPA 70
Standard for the Installation ............... ANSI/NFPA 90A
of Air Conditioning and Ventilating Systems
Standard for W arm 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, Refrigeration
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 2100-541D
Page 3 of 28
Page 4
WALL MOUNT GENERAL INFORMATION
HEAT PUMP WALL MOUNT MODEL NOMENCLATURE
T 36 H 1 – A 10 X X X X X X
MODEL
NUMBER
CAPACITY |
24 - 2 Ton
30 - 2½ Ton
36 - 3 Ton
42 - 3½ Ton
48 - 4 Ton
60 - 5 Ton
For 0 KW and circuit breakers (230/208 volt) or toggle disconnect (460V) applications, insert 0Z in the KW eld of the model number. See Pages 24 & 25.
Insert “D” for dehumidication with hot gas reheat. Reference Form 7960-627 for complete details.
H - Heat Pump
SPECIALTY PRODUCTS
(Non-Standard)
VENTILATION OPTIONS
X - Barometric Fresh Air Damper (Standard)
B - Blank-off Plate
M - Motorized Fresh Air Damper
C - Commercial Ventilator - Mod. Spring Return w/Exhaust
V - Commercial Ventilator - Spring Return w/Exhaust
P - Commercial Ventilator - Power Return w/Exhaust
E - Economizer (Internal) - Fully Modulating with Exhaust
R - Energy Recovery Ventilator - Motorized with Exhaust
(See Spec. Sheet S3398)
REVISIONS
VOLTS & PHASE
A - 230/208/60/1
B - 230/208/60/3
C - 460/60/3
KW
0Z - 0KW
04 - 4KW
05 - 5KW
06 - 6KW
F8 - 8KW
S8 - 8KW
09 - 9KW
10 -10KW
15 -15KW
20 -20KW
COLOR OPTIONS
X - Beige
1 - White
4 - Buckeye Gray
5 - Desert Brown
8 - Dark Bronze
A - Aluminum
S - Stainless Steel
FILTER OPTIONS
X - 1-Inch Fiberglass (MERV 2)
M - 2-Inch Pleated (MERV 11)
H - 2-Inch Pleated (MERV 8)
P - 2-Inch Pleated (MERV 6)
E - 24V 1" Electrostatic Air Cleaner
CONTROL MODULES
(See Spec. Sheet S3436)
COIL OPTIONS
X - Standard
1 - Phenolic Coated Evaporator
2 - Phenolic Coated Condenser
3 - Phenolic Coated Evaporator
and Condenser
OUTLET OPTIONS
X - Front (Standard)
NOTE: Vent options X, B and M are without exhaust capability. May require separate eld supplied barometric relief in building.
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.
These instructions and any instructions packaged with
any separate equipment required to make up the entire
air conditioning system should be carefully read before
beginning the installation. Note particularly “Starting
Procedure” and any tags and/or labels attached to the
equipment.
While these instructions are intended as a general
GENERAL
The equipment covered in this manual is to be installed
by trained, experienced service and installation
technicians.
The refrigerant system is completely assembled and
charged. All internal wiring is complete.
The unit is designed for use with or without duct work.
Flanges are provided for attaching the supply and return
ducts.
These instructions explain the recommended method
to install the air cooled self-contained unit and the
electrical wiring connections to the unit.
recommended guide, they do not supersede any
national and/or local codes in any way. Authorities
having jurisdiction should be consulted before the
installation is made. See Page 3 for information on
codes and standards.
Size of unit for a proposed installation should be
based on heat loss/gain calculation made according
to methods of Air Conditioning Contractors of
America (ACCA). The air duct should be installed
in accordance with the Standards of the National
Fire Protection Association for the Installation of Air
Conditioning and Ventilating Systems of Other Than
Residence Type, NFPA No. 90A, and Residence Type
Warm Air Heating and Air Conditioning Systems,
NFPA No. 90B. Where local regulations are at a
variance with instructions, installer should adhere to
local codes.
Manual 2100-541D
Page 4 of 28
Page 5
DUCT WORK
FILTERS
All duct work, supply and return, must be properly sized
for the design airow requirement of the equipment.
Air Conditioning Contractors of America (ACCA) is an
excellent guide to proper sizing. All duct work or portions
thereof not in the conditioned space should be properly
insulated in order to both conserve energy and prevent
condensation or moisture damage.
Design the duct work according to methods given by the
Air Conditioning Contractors of America (ACCA). When
duct runs through unheated spaces, it should be insulated
with a minimum of one inch of insulation. Use insulation
with a vapor barrier on the outside of the insulation.
Flexible joints should be used to connect the duct work to
the equipment in order to keep the noise transmission to a
minimum.
A 1/4 inch clearance to combustible material for the rst
three feet of duct attached to the outlet air frame is required.
See Wall Mounting Instructions and Figures 3A, 3B and 4
for further details.
Ducts through the walls must be insulated and all joints
taped or sealed to prevent air or moisture entering the wall
cavity.
Some installations may not require any return air duct. A
metallic return air grille is required with installations not
requiring a return air duct. The spacing between louvers on
the grille shall not be larger than 5/8 inch.
A 1-inch throwaway lter is standard with each
unit. The lter slides into position making it easy to
service. This lter can be serviced from the outside by
removing the lter access panel. 2-inch pleated lters
are also available as optional accessories. The internal
lter brackets are adjustable to accommodate the 2-inch
lter by bending two (2) tabs down on each side of the
lter support bracket.
FRESH AIR INTAKE
All units are built with fresh air inlet slots punched in
the service door.
If the unit is equipped with a fresh air damper assembly,
the assembly is shipped already attached to the unit.
The damper blade is locked in the closed position.
To allow the damper to operate, the maximum and
minimum blade position stops must be installed. See
Figure 1.
All capacity, efciency and cost of operation
information is based upon the fresh air blank-off plate
in place and is recommended for maximum energy
efciency.
The blank-off plate is available upon request from the
factory and is installed in place of the fresh air damper
shipped with each unit.
Any grille that meets with 5/8 inch louver criteria may be
used. It is recommended that Bard Return Air Grille Kit
RG2 through RG5 or RFG2 through RFG5 be installed
when no return duct is used. Contact distributor or factory
for ordering information. If using a return air lter grille,
lters must be of sufcient size to allow a maximum
velocity of 400 fpm.
NOTE: If no return air duct is used, applicable installation
codes may limit this cabinet to installation only in a
single story structure.
FIGURE 1
FRESH AIR DAMPER
CONDENSATE DRAIN
A plastic drain hose extends from the drain pan at
the top of the unit down to the unit base. There are
openings in the unit base for the drain hose to pass
through. In the event the drain hose is connected to a
drain system of some type, it must be an open or vented
type system to assure proper drainage.
Manual 2100-541D
Page 5 of 28
Page 6
INSTALLATION INSTRUCTIONS
WALL MOUNTING INFORMATION
1. Two holes for the supply and return air openings
must be cut through the wall as shown in Figure 3.
2. On wood frame walls, the wall construction must be
strong and rigid enough to carry the weight of the
unit without transmitting any unit vibration.
3. Concrete block walls must be thoroughly inspected
to insure that they are capable of carrying the
weight of the installed unit.
MOUNTING THE UNIT
1. These units are secured by wall mounting brackets
which secure the unit to the outside wall surface at
both sides. A bottom mounting bracket, attached
to skid for shipping, is provided for ease of
installation, but is not required.
2. The unit itself is suitable for 0 inch clearance,
but the supply air duct ange and the rst 3 feet
of supply air duct require a minimum of 1/4 inch
clearance to combustible material. However, it is
generally recommended that a 1-inch clearance is
used for ease of installation and maintaining the
required clearance to combustible material. See
Figure 3 for details on opening sizes.
3. Locate and mark lag bolt locations and bottom
mounting bracket location. See Figures 3A & 3B.
4. Mount bottom mounting bracket.
5. Hook top rain ashing, attached to front - right of
supply ange for shipping, under back bend of top.
WARNING
Failure to provide the 1/4 inch clearance
between the supply duct and a combustible
surface for the rst 3 feet of duct can result in
re causing damage, injury or death.
PLACEMENT
1. On side-by-side installations, maintain a minimum
of 20 inches clearance on right side to allow access
to control panel and heat strips, and to allow proper
airow to the outdoor coil. Additional clearance
may be required to meet local or national codes.
2. Care should be taken to ensure that the recirculation
and obstruction of condenser discharge air does
not occur. Recirculation of condenser discharge
air can be from either a single unit or multiple
units. Any object such as shrubbery, a building
or a large object can cause obstructions to the
condenser discharge air. Recirculation or reduced
airow caused by obstructions will result in reduced
capacity, possible unit pressure safety lockouts and
reduced unit service life.
Units with a blow through condenser, such as the
T**H 10 EER units, it is recommended there be
a minimum distance of 15 feet between the front
of the unit and any barrier or 20 feet between the
fronts of two opposing (facing) units.
6. Position unit in opening and secure with 5/16 lag bolts;
use 7/8 inch diameter at washers on the lag bolts.
7. Secure rain ashing to wall and caulk across entire
length of top. See Figures 3A & 3B.
8. For additional mounting rigidity, the return air
and supply air frames or collars can be drilled
and screwed or welded to the structural wall itself
(depending upon wall construction). Be sure to
observe required clearance if combustible wall.
Clearances Required for Service Access
and Adequate Condenser Airow
MODELS LEFT SIDE RIGHT SIDE
T24H, T30H 15" 20"
T36H, T42H, T48H, T60H 20" 20"
Manual 2100-541D
Page 6 of 28
Minimum Clearances Required to
Combustible Materials
MODELS
T24H, T30H 1/4" 0"
T36H, T42H, T48H, T60H 1/4" 0"
SUPPL Y AIR DUCT
FIRST THREE FEET
CABINET
Page 7
Panel
Door
Vent Option
Filter Access
Ventilation
Air
Front View
5.75
F
W
G
Condenser
Air Outlet
1
1
MIS-2729 A
Electrical
Low Voltage
Entrance
High Voltage
Electrical
Entrance
4° Pitch
Rain Hood
Built In
Access
Panel
(Lockable)
Heater
Electric
Heat
C. Breaker/
Disconnect
Access Panel
Drain
Side View
HC
K
J
I
D
2.13
A
Cond.
Air
Inlet
Electrical
Entrances
Optional
Side Wall
Mounting
Brackets
(Built In)
Location
Shipping
Return Air Opening
Supply Air Opening
Top Rain
Flashing
Bottom Installation
Bracket
Back View
M
L
O
E
R
S
S
S
S
S
T
.44
N
Q
P
B
FIGURE 2
Dimensions of Basic Unit for Architectural and Installation Requirements (Nominal)
Width
Depth
Model
(W)
T24H
38.200 17.125 70.563 7.88 27.88 13.88 27.88 40.00 10.88 25.75 17.93 26.75 28.75 29.25 27.00 2.63 39.13 22.75 9.14 5.00 12.00 5.00
T30H
T36H
42.075 22.432 84.875 9.88 29.88 15.88 29.88 43.88 13.56 31.66 30.00 32.68 26.94 34.69 32.43 3.37 43.00 23.88 10.00 1.44 16.00 1.88
T42H
T48H
42.075 22.432 93.000 9.88 29.88 15.88 29.88 43.88 13.56 37.00 30.00 40.81 35.06 42.81 40.56 3.37 43.00 31.00 10.00 1.44 16.00 10.00
T60H
Height
(D)
All dimensions are in inches. Dimensional drawings are not to scale.
Supply Return
(H)
A B C B E F G I J K L M N O P Q R S T
T**H
RIGHT UNIT
Manual 2100-541D
Page 7 of 28
Page 8
D
12"
12"
12"
12"
12"
C CA
28"
1"
3"
4"
Typ.
4
1
2
"
B
E
14"
1"
3
1
8
"
4"
Typ.
5"
4
1
2
"
7
8
"
RETURN AIR
SUPPLIED
Return Opening
16 7/84 9/164 1/21030
17 5/83 13/165 1/48 1/228 1/2
EDCBA
COMBUSTIBLE MATERIALS
RECOMMENDED 1" CLEARANCE FROM
REQUIRED DIMENSIONS TO MAINTAIN
THE SIDE MOUNTING FLANGES AND UNDER
1/4" CLEARANCE ON ALL
RAIN FLASHING
COMBUSTIBLE MATERIALS
DUCT
TOP FLASHING AT TIME OF INSTALLATION.
1/4" MIN. CLEARANCE FROM
REQUIRED DIMENSIONS TO MAINTAIN
OPENING
ENTIRE LENGTH OF TOP.
MATERIALS
NOTES:
OF CAULKING ALONG
PANEL
FOAM AIR SEAL
FOUR SIDES OF SUPPLY
AIR DUCT IS REQUIRED
FROM COMBUSTABLE
WALL STRUCTURE
TOP
MIS-311 C
Wall Opening and Hole Location View Right Side View
WALL
HEATER ACCESS
SEAL WITH BEAD
IT IS RECOMMENDED THAT A BEAD OF
SILICONE CAULKING BE PLACED BEHIND
SUPPLY AIR
Supply Opening
W*R UNIT SHOWN, W*L UNIT
CONTROLS AND HEATER ACCESS
IS ON OPPOSITE (LEFT) SIDE.
FIGURE 3A
T24H1, T30H1
MOUNTING INSTRUCTIONS
Manual 2100-541D
Page 8 of 28
Page 9
D
16"
16"
16"
16"
16"
1
7
8
"
6
1
2
" 6
1
2
"
2
1
8
"
7
8
"
1"
3"
4"
Typ.
4"
Typ.
6
1
2
"
30"
E
16"
A CC
3
1
8
"
B
Wall Opening and HoleLocationView
RETURN AIR
1
REQUIRED DIMENSIONS TO MAINTAIN
1/4" MIN. CLEARANCE FROM
COMBUSTIBLE MATERIALS
REQUIRED DIMENSIONS TO MAINTAIN
29
DUCT
COMBUSTIBLE MATERIALS
A B C DE
30 1/2
10 1/2
6 1/4 11/4 29 3/4
32 12 5 1/2
2
NOTES:
WALL STRUCTURE
1
SUPPLY AIR
IT IS RECOMMENDED THAT A BEAD OF
OPENING
Right Side View
RAIN FLASHING
SILICONE CAULKING BE PLACED BEHIND
RECOMMENDED 1" CLEARANCE FROM
THE SIDE MOUNTING FLANGES AND UNDER
TOP FLASHING AT TIME OF I NSTALLATION.
TOP.
PANEL
HEATER ACCESS
FOUR SIDES OF SUPPLY
AIR DUCT IS REQUIRED
FROM COMBUSTABLE
WALL
1/4" CLEARANCE ON ALL
MATERIALS
Supply Opening
FOAM AIR SEAL
SUPPLIED
SEAL WITH BEAD
OF CAULKING ALONG
ENTIRE LENGTH OF
TOP
1
Return Opening
MIS-416 E
Dimension is 21" on 95" tall units.
2
Dimension is 10" on T48H1 & T60H1.
2
Dimension is 6" on T48H1 & T60H1.
3
3
FIGURE 3B
MOUNTING INSTRUCTIONS
T36H1, T42H1, T48H1, T60H1
Manual 2100-541D
Page 9 of 28
Page 10
FIGURE 4
ELECTRIC HEAT CLEARANCE
SIDE SECTION VIEW OF SUPPLY AIR DUCT
FOR WALL MOUNTED UNIT SHOWING 1/4 INCH
CLEARANCE TO COMBUSTIBLE SURFACES.
WARNING
A minimum of 1/4 inch clearance must be maintained between
the supply air duct and combustible materials. This is required for
the rst 3 feet of ducting.
It is important to insure that the 1/4 inch minimum spacing is
maintained at all points.
Failure to do this could result in overheating the combustible
material and may result in a re causing damage, injury or death.
Manual 2100-541D
Page 10 of 28
Page 11
FIGURE 5
DUCT
OPENING
RETURN AIR
SUPPLY AIR
WOOD FRAME WALL INSTALLATION
OPENING
WALL BEFORE
MOUNT ON UNIT
OPENING
BEFORE INSTALLATION
BOTTOM MOUNTING
CONCRETE BLOCK WALL INSTALLATION
BRACKET. MOUNT ON
OPENING
WOOD OR S TEEL SIDING
OPENING
INSTALLING UNIT.
RETURN AIR
WALL STRUCTURE
RETURN AIR
SUPPLY AIR
FACTORY SUPPLIED
RAIN FLASHING.
SUPPLY AIR
MIS-548 A
SIDE VIEW
I
A
C
K
E + 1.000
B
1.000
SUPPLY DUCT
OVER FRAME
INTERIOR FINISHED WALL
ALL AROUND DUCT
FRAMING MATERIAL
EXTERIOR FINISH WALL
OPENING
FOR ACTUAL DIMENSIONS.
2 x 4'S, 2 x 6'S &/OR
STRUCTURAL STEEL
ATTACH TO TOP
1.000" CLEARANCE
1.000" CLEARANCE
PLATE OF WALL
C
SEE UNIT DIMENSIONS, FIGURE 2,
OPENING
RETURN DUCT
2 x 6
ATTACH TO BOTTOM
OVER FRAME
PLATE OF WALL
L
THIS STRUCTURAL MEMBER
LOCATED TO MATCH STUD
SPACING FOR REST OF WALL.
A SECOND MEMBER MAY BE
REQUIRED FOR SOME WALLS.
MIS-549 B
ALL AROUND DUCT
WALL MOUNTING INSTRUCTIONS
SEE FIGURE 3 – MOUNTING INSTRUCTIONS
FIGURE 6
WALL MOUNTING INSTRUCTIONS
Manual 2100-541D
Page 11 of 28
Page 12
FIGURE 7
LOWERED
RAISED FLOOR
RAFTERS
SUPPLY AIR
CEILING SURFACE
WALL SLEEVE
RETURN AIR
CLOSET WALL
GRILLE
FLASHING
RETURN AIR
FLASHING
SUPPLY DUCT MAYBELOCATED IN AN ATTIC
OR BELOW CEILING RAFTERS AS SHOWN
SUPPLY DUCT MAY BE LOCATED IN AN ATTIC
SURFACE
RAFTERS
FINISHED CEILING
SUPPLY AIR DUCT
WALL
OPENING W/ GRILLE
SUPPLY DUCT MAYBELOCATED IN AN ATTIC
OR BELOW CEILING RAFTERS AS SHOWN
CEILING
RAIN
RETURN AIR
SLEEVE
WALL
SUPPLY AIR DUCT
RAFTERS
RAFTERS
RETURN AIR
OPENING W/ GRILLE
RAIN
FALSE WALL INSTALLATION
DUCTED SUPPLY
GRILLE
OUTSIDE
SPACE
FALSE WALL
RETURN AIR GRILLE
OUTSIDE
OR BELOW CEILING RAFTERS AS SHOWN
FINISHED CEILING S URFACE
RAIN
FLASHING
RAIN
FLASHING
RETURN AT UNITNO DUCT
WALL
SUPPLY AIR DUCT
CLOSET INSTALLATION
RETURN AIR
FINISHED
FINISHED CEILING S URFACE
MIS-550 B
FREE AIR FLOW
OUTSIDE
WALL
OUTSIDE
WALL
SUPPLY AIR DUCT
W/ GRILLE
COMMON WALL MOUNTING INSTALLATIONS
Manual 2100-541D
Page 12 of 28
Page 13
WIRING – MAIN POWER
Refer to the unit rating plate for wire sizing information
and maximum fuse or “HACR” type circuit breaker
size. Each outdoor unit is marked with a “Minimum
Circuit Ampacity”. This means that the eld wiring
used must be sized to carry that amount of current.
Depending on the installed KW of electric heat, there
may be two eld power circuits required. If this is the
case, the unit serial plate will so indicate. All models
are suitable only for connection with copper wire. Each
unit and/or wiring diagram will be marked “Use Copper
Conductors Only”. These instructions must be adhered
to. Refer to the National Electrical Code (NEC) for
complete current carrying capacity data on the various
insulation grades of wiring material. All wiring must
conform to NEC and all local codes.
The electrical data lists fuse and wire sizes (75°C
copper) for all models including the most commonly
used heater sizes. Also shown are the number of eld
power circuits required for the various models with
heaters.
The unit rating plate lists a “Maximum Time Delay
Relay Fuse” or “HACR” type circuit breaker that is to
be used with the equipment. The correct size must be
used for proper circuit protection and also to assure that
there will be no nuisance tripping due to the momentary
high starting current of the compressor motor.
WIRING – LOW VOLTAGE WIRING
230/208V, 1 phase and 3 phase equipment dual primary
voltage transformers. All equipment leaves the factory
wired on 240V tap. For 208V operation, reconnect
from 240V to 208V tap. The acceptable operating
voltage range for the 240 and 208V taps are:
TAP RANGE
240 253 – 216
208 220 – 187
NOTE: Thevoltageshouldbemeasuredattheeld
power connection point in the unit and while
the unit is operating at full load (maximum
amperage operating condition).
For wiring size and connections, refer to Wiring
Manual 2100-516.
The disconnect access door on this unit may be locked
to prevent unauthorized access to the disconnect. To
convert for the locking capability, bend the tab located
in the bottom left-hand corner of the disconnect
opening under the disconnect access panel straight
out. This tab will now line up with the slot in the door.
When shut, a padlock may be placed through the hole
in the tab preventing entry.
See “Start Up” section for important information on
three phase scroll compressor start ups.
See Tables 6A & 6B for Electrical Specications.
Manual 2100-541D
Page 13 of 28
Page 14
FIGURE 8
COMPRESSOR CUTOFF THERMOSTAT WIRING
4 – 10KW 1 PH – 6 & 9KW 3 PH
FIGURE 9
COMPRESSOR CUTOFF THERMOSTAT WIRING
15 – 20KW 1 PH AND 3 PH
OPTIONAL OUTDOOR THERMOSTAT
APPLICATIONS
Since most equipment at the time of manufacture is not
designated for any specic destination of the country
and are installed in areas not approaching the lower
outdoor temperature range, outdoor thermostats are not
factory installed as standard equipment, but are offered
as an option. There are also different applications for
applying outdoor thermostats. The set point of either
type of outdoor thermostat application is variable with
geographic region and sizing of the heating equipment
to the individual structure. Utilization of the heating
Application Data, and the heat loss calculation of the
building are useful in determining the correct set points.
NOTE: The additional LAB (low ambient bypass) relay
is required to prevent heater operation during low
temperature cooling operation.
Manual 2100-541D
Page 14 of 28
OPTIONAL COMPRESSOR CUTOFF
THERMOSTAT (See Figures 8 & 9)
Heat pump compressor operation at outdoor
temperatures below 0°F are neither desirable nor
advantageous in term of efciency. An outdoor
thermostat can be applied to take the mechanical
heating (compressor) off line, and send the
(compressor) signal to energize electric heat in its place
(to make electric heat rst stage heating). This can also
be applied to bank the quantity of available electric
heat. For example: A heat pump operates with 10KW
second stage heat – once the outdoor thermostat has
switched then operates 15KW without the compressor
as rst stage heat.
Page 15
ELECTRIC HEAT HOLD-OFF
(See Figures 10 & 11)
In other applications, it is desirable to disable the
operation of the electric heat until outdoor temperatures
have reached a certain design point. This won't allow
the electric heat to come on as second stage heating
unless the outdoor temperature is below the set point
of the outdoor thermostat. This is done to maximize
FIGURE 10
ELECTRIC HEAT HOLD-OFF WIRING
4 – 10KW 1 PH — 6 & 9KW 3 PH
efciency by utilizing the heat pump to bring the
conditioned space temperature up, rather than cycling
on the electric heat due a second stage call for heat
from the thermostat on start-up coming off a night setback condition or someone increasing the thermostat
set point. (NOTE: Some programmable thermostats
do have a built-in time delay for pulling in second stage
heat when coming off set-back conditions.)
FIGURE 11
ELECTRIC HEAT HOLD-OFF WIRING
15 – 20KW 1 PH & 3 PH
Manual 2100-541D
Page 15 of 28
Page 16
START UP
THESE UNITS REQUIRE R-410A
REFRIGERANT AND POL YOL
ESTER 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 Polyol Ester oil.
9. Polyol Ester oil is hygroscopic; it will rapidly
absorb moisture and strongly hold this moisture in
the oil.
10. A liquid line dryer must be used - even a deep
vacuum will not separate moisture from the oil.
11. Limit atmospheric exposure to 15 minutes.
12. If compressor removal is necessary, always plug
compressor immediately after removal. Purge with
small amount of nitrogen when inserting plugs.
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. If done correctly, topping off the system charge
can be done without problems.
With R-410A, there are no signicant 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 pressure 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.
WARNING
Failure to conform to these practices
could lead to damage, injury or death.
SAFETY PRACTICES:
1. Never mix R-410A with other refrigerants.
2. Use gloves and safety glasses, Polyol Ester oils can
be irritating to the skin, and liquid refrigerant will
freeze the skin.
3. Never use air and R-410A to leak check; the
mixture may become ammable.
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 ll 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 signicantly
at warmer temperatures. Once a cylinder or line is
full of liquid, any further rise in temperature will
cause it to burst.
Manual 2100-541D
Page 16 of 28
Page 17
START UP (Continued)
IMPORTANT INSTALLER NOTE
For improved start up performance wash the indoor coil
with a dish washing detergent.
HIGH & LOW PRESSURE SWITCH
All T**H wall mounted air conditioner series models
are supplied with a remote reset for the high and low
pressure switch. If tripped, this pressure switch may be
reset by turning the thermostat off then back on again.
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, verication of proper rotation must be made.
Verication 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.
PHASE MONITOR
All units with three phase scroll compressors are
equipped with a 3-phase line monitor to prevent
compressor damage due to phase reversal.
The phase monitor in this unit is equipped with two
LEDs. If the Y signal is present at the phase monitor
and phases are correct the green LED will light.
If phases are reversed, the red fault LED will be lit and
compressor operation is inhibited.
If a fault condition occurs, reverse two of the supply
leads to the unit. Do not reverse any of the unit
factory wires as damage may occur.
SERVICE HINTS
1. Caution owner/operator to maintain clean air
lters at all times. Also, not to needlessly close off
supply and return air registers. This reduces airow
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
they are the correct rating.
3. Periodic cleaning of the outdoor coil to permit full
and unrestricted airow circulation is essential.
Verication 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 ZP compressors are wired identically
internally. As a result, once the correct phasing
is determined for a specic system or installation,
connecting properly phased power leads to the same
Fusite terminal should maintain proper rotation
direction.
The direction of rotation of the compressor may be
changed by reversing any two line connections to the
unit.
Manual 2100-541D
Page 17 of 28
Page 18
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 – A 24V solenoid coil on reversing valve
controls heating cycle operation. Two thermostat options,
one allowing “Auto” changeover from cycle to cycle and
the other constantly energizing solenoid coil during heating
season, and thus eliminating pressure equalization noise
except during defrost, are to be used. On “Auto” option
a circuit is completed from R-B and R-Y on each heating
“on” cycle, energizing reversing valve solenoid and pulling
in compressor contactor starting compressor and outdoor
motor. R-G also make starting indoor blower motor. Heat
pump heating cycle now in operation. The second option
has no “Auto” changeover position, but instead energizes
the reversing valve solenoid constantly whenever the system
switch on subbase is placed in “Heat” position, the “B”
terminal being constantly energized from R. A Thermostat
demand for 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
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 the manual covering all models. It
is imperative to match the correct pressure table to the unit by
model number. See Tables 5A & 5B.
DEFROST CYCLE
The defrost cycle is controlled by temperature and time on
the solid state heat pump control.
When the outdoor temperature is in the lower 40°F
temperature range or colder, the outdoor coil temperature is
32°F or below. This coil temperature is sensed by the coil
temperature sensor mounted near the bottom of the outdoor
coil. Once coil temperature reaches 30°F or below, the
coil temperature sensor sends a signal to the control logic
of the heat pump control and the defrost timer will start
accumulating run time.
After 30, 60 or 90 minutes of heat pump operation at 30°F
or below, the heat pump control will place the system in the
defrost mode.
During the defrost mode, the refrigerant cycle switches back
to the cooling cycle, the outdoor motor stops, electric heaters
are energized, and hot gas passing through the outdoor coil
melts any accumulated frost. When the temperature rises to
approximately 57°F, the coil temperature sensor will send a
signal to the heat pump control which will return the system
to heating operations automatically.
If some abnormal or temporary condition such as a high wind
causes the heat pump to have a prolonged defrost cycle, the
heat pump control will restore the system to heating operation
automatically after 8 minutes.
The heat pump defrost control board has an option of 30, 60
or 90-minute setting. By default, this unit is shipped from
the factory with the defrost time on the 60 minute pin. If
Manual 2100-541D
Page 18 of 28
circumstances require a change to another time, remove the
wire from the 60-minute terminal and reconnect to the desired
terminal. Refer to Figure 12.
There is a cycle speed up jumper on the control. This can be
used for testing purposes to reduce the time between defrost
cycle operation without waiting for time to elapse.
Use a small screwdriver or other metallic object, or another
¼ inch QC, to short between the SPEEDUP terminals to
accelerate the HPC timer and initiate defrost.
Be careful not to touch any other terminals with the instrument
used to short the SPEEDUP terminals. It may take up to
10 seconds with the SPEEDUP terminals shorted for the
speedup to be completed and the defrost cycle to start.
As soon as the defrost cycle kicks in remove the shorting
instrument from the SPEEDUP terminals. Otherwise the
timing will remain accelerated and run through the 1-minute
minimum defrost length sequence in a matter of seconds and
will automatically terminate the defrost sequence.
There is an initiate defrost jumper (sen jump) on the control
that can be used at any outdoor ambient during the heating
cycle to simulate a 0° coil temperature.
This can be used to check defrost operation of the unit without
waiting for the outdoor ambient to fall into the defrost region.
By placing a jumper across the SEN JMP terminals (a
¼ inch QC terminal works best) the defrost sensor mounted
on the outdoor coil is shunted out & will activate the timing
circuit. This permits the defrost cycle to be checked out in
warmer weather conditions without the outdoor temperature
having to fall into the defrost region.
In order to terminate the defrost test the SEN JMP jumper
must be removed. If left in place too long, the compressor
could stop due to the high pressure control opening because
of high pressure condition created by operating in the
cooling mode with outdoor fan off. Pressure will rise fairly
fast as there is likely no actual frost on the outdoor coil in this
articial test condition.
There is also a 5-minute compressor time delay function built
into the HPC. This is to protect the compressor from short
cycling conditions. The board’s LED will have a fast blink
rate when in the compressor time delay. In some instances, it
is helpful to the service technician to override or speed up this
timing period, and shorting out the SPEEDUP terminals for a
few seconds can do this.
Low Pressure Switch Bypass Operation - The control has a
selectable (SW1) low pressure switch bypass set up to ignore
the low pressure switch input during the rst (30, 60, 120 or
180 seconds) of “Y” operation.
After this period expires, the control will then monitor the low
pressure switch input normally to make sure that the switch is
closed during “Y” operation.
High Pressure Switch Operation - The control has a built-in
lockout system that allows the unit to have the high pressure
switch trip up to two times in one hour and only encounter a
“soft” lockout. A “soft” lockout shuts the compressor off and
waits for the pressure switch to reset, which at that point then
allows the compressor to be restarted as long as the 5-minute
short cycle timer has run out. If the high pressure switch trips a
third time within one hour, the unit is in “hard” lockout indicating
something is certainly wrong and it will not restart itself.
Page 19
120*
SW1SW
2 TIME(SEC)
OFF
OFF
ON
ON
OFF
ON
OFF
ON
30
60
180
MIS-2668 A
OFF
LOW PRESSURE BYPASS TIMER SWITCH
*(FACTORY SETTING 120 SECONDS)
ACCUMULATED DEFROST TIME TIMER
(FACTORY SETTING 60 MIN.)
ON
FIGURE 12
DEFROST CONTROL BOARD
Manual 2100-541D
Page 19 of 28
Page 20
TROUBLESHOOTING
SOLID STATE HEAT PUMP CONTROL
TROUBLESHOOTING PROCEDURE
1. NOTE: A thorough understanding of the defrost
cycle sequence is essential. Review that section
NOTE: If there was no power to 24 volt transformer,
the compressor and outdoor fan motor will
not start for 5 minutes. This is because of
the compressor short cycle protection.
earlier in this manual prior to troubleshooting the
control. 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 to “auto” position. Indoor
blower should stop. NOTE: Many models have a
1-minute blower time delay on “off” command;
wait for this to time-out.
4. Set system switch to “heat” or “cool”. Adjust
thermostat to call for heat or cool. The indoor
BLINK FUNCTION
Slow Normal function (1.0 sec on/1.0 sec off)
Fast
1 Low pressure switch failure
2 High pressure switch failure/“Soft” Lockout
3 Defrost mode active
4 High pressure switch failure/“Hard” Lockout
LED BLINK CODES
Compressor Delay timer active (0.1 sec on/0.1 sec off)
blower, compressor and outdoor fan should start.
TABLE 3
TROUBLESHOOTING
Sympton Description, Check & Possible Causes What & How to Check / Repair
1. Check for LED illumination.
Is there an LED illuminated on the board (ashing)?
2. Check for error codes.
Is the LED ashing a Code?
3. Check for power at board.
Is there 24 volts AC between R and C?
4. Check codes.
What code is blinking?
5. Compressor delay active.
Compressor
will not start
(heating or
cooling)
Fan outdoor
motor does
not run
(cooling or
heating except
during defrost)
Reversing
valve does not
energize
(heating only)
Unit will not go
into defrost
(heating only)
Unit will not
come out of
defrost
(heating only)
Wait for 5 minute delay or jump board's "speed up pins".
6. Low pressure fault. Check wiring circuit and unit pressures.
7. High pressure fault. Check wiring circuit and unit pressures.
8. Check for Compressor input signal.
Is there 24 volts AC between Y and C?
9. No power to board. The unit either does not have unit voltage, the transformer is bad or the unit wiring is incorrect.
10. Check for Compressor output signal.
Is there 24 volts AC between CC & C?
11. No "Y" compressor input signal.
12. No "CC" compressor output signal. Check compressor contactor for proper operation and nally check compressor.
13. Faulty board. Replace defrost board.
Heat pump control defective
Motor defective Check for open or shorted motor winding. Replace motor.
Motor capacitor defective Check capacitor rating. Check for open or shorted capacitor. Replace capacitor.
Heat pump control defective
Reversing valve solenoid coil defective
Temperature sensor or heat pump control defective
Temperature sensor or heat pump control defective
Manual 2100-541D
Page 20 of 28
Yes = go to Step #2; No = go to Step #3
Yes = go to Step #4; No = go to Step #8
Yes = go to Step #13; No = go to Step #9
Code "1", go to Step #6; Code "2", go to Step#7; Fast Blink, go to Step #5
Check for proper operation; if still needed, go back to Step #1.
Yes = go to Step #10; No = go to Step #11
Yes = go to Step #12; No = go to Step #13
Check thermostat wiring, incorrect phase of unit (see section on Phase Monitor), and nally unit wiring.
Check across fan relay on heat pump control. (Com-NC)
Replace heat pump control.
Check for 24V between RV-C and B-C.
1. Check control circuit wiring.
2. Replace heat pump control.
Check for open or shorted coil.
Replace solenoid coil.
Disconnect temperature sensor from board and jumper across "SPEEDUP" terminals and "SEN
JMP" terminals. This should cause the unit to go through a defrost cycle within one minute.
1. If unit goes through defrost cycle, replace temperature sensor.
2. If unit does not go through defrost cycle, replace heat pump control.
Jumper across "SPEEDUP" terminal.
This should cause the unit to come out of defrost within one minute.
1. If unit comes out of defrost cycle, replace temperature sensor.
2. If unit does not come out of defrost cycle, replace heat pump control.
Page 21
CHECKING TEMPERATURE SENSOR
OUTSIDE UNIT CIRCUIT
1. Disconnect temperature sensor from board and
from outdoor coil.
2. Use an ohmmeter and measure the resistance of the
sensor. Also use ohmmeter to check for short or
open.
TEMPERATURE F VS. RESISTANCE R OF TEMPERATURE SENSOR
F R F R F R F R
-25.0 196871 13.0 56985 53.0 19374 89.0 7507
-24.0 190099 14.0 55284 52.0 18867 90.0 7334
-23.0 183585 15.0 53640 53.0 18375 91.0 7165
-22.0 177318 16.0 52051 54.0 17989 92.0 7000
-21.0 171289 17.0 50514 55.0 17434 93.0 6840
-20.0 165487 18.0 49028 56.0 16984 94.0 6683
-19.0 159904 19.0 47590 57.0 16547 95.0 6531
-18.0 154529 20.0 46200 58.0 16122 96.0 6383
-17.0 149355 21.0 44855 59.0 15710 97.0 6239
-16.0 144374 22.0 43554 60.0 15310 98.0 6098
-15.0 139576 23.0 42295 61.0 14921 99.0 5961
-14.0 134956 24.0 41077 62.0 14544 100.0 5827
-13.0 130506 25.0 39898 63.0 14177 101.0 5697
-12.0 126219 26.0 38757 64.0 13820 102.0 5570
-11.0 122089 27.0 37652 65.0 13474 103.0 5446
-10.0 118108 28.0 36583 66.0 13137
-9.0 114272 29.0 35548 67.0 12810 105.0 5208
-8.0 110575 30.0 34545 68.0 12492 106.0 5094
-7.0 107010 31.0 33574 69.0 12183 107.0 4982
-6.0 103574 32.0 32634 70.0 11883 108.0 4873
-5.0 100260 33.0 31723 71.0 11591 109.0 4767
-4.0 97064 34.0 30840 72.0 11307 110.0 4663
-3.0 93981 35.0 29986 73.0 11031 111 .0 4562
-2.0 91008 36.0 29157 74.0 10762 112.0 4464
-1.0 88139 37.0 28355 75.0 10501 113.0 4367
0.0 85371 38.0 27577 76.0 10247 114.0 4274
1.0 82699 39.0 26823 77.0 10000 115.0 4182
2.0 80121 40.0 26092 78.0 9760 116.0 4093
3.0 77632 41.0 25383 79.0 9526 117.0 4006
4.0 75230 42.0 24696 80.0 9299 118.0 3921
5.0 72910 43.0 24030 81.0 9077 119.0 3838
6.0 70670 44.0 23384 82.0 8862 120.0 3757
7.0 68507 45.0 22758
8.0 66418 46.0 22150 84.0 8449 122.0 3601
9.0 64399 47.0 21561 85.0 8250 123.0 3526
10.0 62449 48.0 20989 86.0 8057 124.0 3452
11.0 60565 49.0 20435 87.0 7869
12.0 58745 50.0 19896 88.0 7686
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.
104.0 5326
83.0 8653 121.0 3678
Manual 2100-541D
Page 21 of 28
Page 22
TROUBLESHOOTING
"A"
AIRFLOW
MIS-1724
FAN BLADE SETTING DIMENSIONS
Shown in Figure 13 is the correct fan blade setting for
proper air delivery across the outdoor coil. Refer to
Table 4 for unit specic dimension.
Any service work requiring removal or adjustment
in the fan and/or motor area will require that the
dimensions below be checked and blade adjusted in or
out on the motor shaft accordingly.
FIGURE 13
FAN BLADE SETTING
TABLE 4
FAN BLADE DIMENSION
Model Dimension A
T24H
T30H
T36H
T42H
T48H
T60H
1.25"
1.75"
REMOVAL OF FAN SHROUD
1. Disconnect all power to the unit.
2. Remove the screws holding both grilles, one on
each side of unit, and remove grilles.
3. Remove screws holding fan shroud to condenser
and bottom. Nine (9) screws.
4. Unwire condenser fan motor.
5. Slide complete motor, fan blade, and shroud
assembly out the left side of the unit.
6. Service motor/fan as needed.
7. Reverse steps to reinstall.
R-410A
REFRIGERANT CHARGE
This unit was charged at the factory with the quantity of
refrigerant listed on the serial plate. AHRI capacity and
efciency ratings were determined by testing with this
refrigerant charge quantity.
The following pressure tables show nominal pressures
for the units. Since many installation specic situations
can affect the pressure readings, this information should
only be used by certied technicians as a guide for
evaluating proper system performance. They shall not
be used to adjust charge. If charge is in doubt, reclaim,
evacuate and recharge the unit to the serial plate charge.
Manual 2100-541D
Page 22 of 28
Page 23
TABLE 5A
COOLING PRESSURE TABLE
Air Temperature Entering Outdoor Coil °F
Model
T24H
T30H
T36H
T42H
T48H
T60H
Low side pressure ± 4 PSIG
High side pressure ± 10 PSIG
Tables are based upon rated CFM (airow) across the evaporator coil. If there is any doubt as to correct operating charge being in the system, the charge
should be removed, system evacuated and recharged to serial plate charge weight.
NOTE: Pressure table based on high speed condenser fan operation. If condensing pressures appear elevated check condenser fan wiring. See
“Condenser Fan Operation”.
Return Air
Temperature
75° DB
62° WB
80° DB
67° WB
85° DB
72° WB
75° DB
62° WB
80° DB
67° WB
85° DB
72° WB
75° DB
62° WB
80° DB
67° WB
85° DB
72° WB
75° DB
62° WB
80° DB
67° WB
85° DB
72° WB
75° DB
62° WB
80° DB
67° WB
85° DB
72° WB
75° DB
62° WB
80° DB
67° WB
85° DB
72° WB
Pressure 75 80 85 90 95 100 105 110 115 120
Low Side
High Side
Low Side
High Side
Low Side
High Side
Low Side
High Side
Low Side
High Side
Low Side
High Side
Low Side
High Side
Low Side
High Side
Low Side
High Side
Low Side
High Side
Low Side
High Side
Low Side
High Side
Low Side
High Side
Low Side
High Side
Low Side
High Side
Low Side
High Side
Low Side
High Side
Low Side
High Side
131
306
140
314
145
325
127
319
136
327
141
338
133
313
142
321
147
332
131
315
140
323
145
334
133
325
142
333
147
345
129
353
138
362
143
375
133
321
142
329
147
341
129
335
138
344
143
356
135
327
144
335
149
347
132
331
141
339
146
351
136
341
145
350
150
362
130
362
139
371
144
384
135
337
144
346
149
358
131
354
140
363
145
376
137
342
146
351
151
363
134
348
143
357
148
369
137
360
147
369
152
382
132
374
141
384
146
397
137
357
146
366
151
379
133
373
142
383
147
396
138
361
148
370
153
383
136
368
145
377
150
390
139
379
149
389
154
403
133
390
142
400
147
414
138
377
148
387
153
401
135
395
144
408
149
419
139
382
149
392
154
406
137
388
147
402
152
412
141
401
151
417
156
425
134
410
144
428
148
435
140
400
150
410
155
424
137
417
146
428
151
443
141
406
151
416
156
431
139
410
149
421
154
436
142
424
152
435
157
450
136
432
145
443
150
459
142
425
152
436
157
451
137
442
147
453
152
469
143
432
153
443
158
459
142
435
152
446
157
462
144
449
154
461
159
477
137
458
146
470
151
486
143
451
153
463
158
479
139
468
149
480
154
497
145
461
155
473
160
490
144
461
154
473
159
490
145
477
155
489
160
506
137
488
147
501
152
519
145
480
155
492
160
509
140
495
150
508
155
526
147
492
157
505
162
523
146
489
156
502
161
520
147
505
157
518
162
536
139
522
149
535
154
554
147
510
157
523
162
541
141
525
151
538
156
557
149
527
159
540
165
559
149
520
159
533
165
552
148
535
158
549
164
568
140
559
150
573
155
593
TABLE 5B
HEATING PRESSURES – (ALL TEMPERATURES °F)
Model
T24H 70 deg.
T30H 70 deg.
T36H 70 deg.
T42H 70 deg.
T48H 70 deg.
T60H 70 deg.
Return Air
Temperature
Pressure
Low Side
High Side
Low Side
High Side34259
Low Side
High Side
0 5 10 15 20 25 30 35 40 45 50 55 60 65
38
26745274
47
2705027354276
53
28160289
42
50
271
283572946530572316
59
281
68
76
297
305843139232299330
80
327
64
70
287
294773028431193322
87
33894348
Low Side
High Side402944529651299573056331170319783298534093353
Low Side
High Side392604526450268
Low Side
High Side20225
31
24742267
56
27362279
69
285762938430092309
52
2856130170315
79
32786337
93
345
107
339
101
358
102
334
102
368
100
319
100
350
116
349
108
368
112
347
110
384
108
329
106
354
124
358
116
378
123
361
119
401
117
339
111
355
132
368
123
387
134
376
129
420
127
351
116
355
140
378
130
396
146
392
139
441
137
363
120
352
Manual 2100-541D
Page 23 of 28
Page 24
TABLE 6A
Electrical Specications — T**H Series
Single Circuit Multiple Circuit
No.
Field
Power
Circuits
1
1
1
1 or 2
1
1
1
1
1
1
1
1 or 2
1
1
1
1
1
1
1 or 2
1 or 2
1 or 2
1
1
1
1
1
1
1
1
1
1
1 or 2
1 or 2
1 or 2
1
1
1
1
1
1
1
1
1
1 or 2
1 or 2
1 or 2
1 or 2
1
1
1
1
1
1
1
1
1
1 or 2
1 or 2
1 or 2
1 or 3
1
1
1
1
2
1
1
1
1
1
-A04
-AS8
-B06
-B09
-C06
-C09
-A04
-AS8
-C06
-C09
-A05
-A08
-A10
-A15
-B06
-B09
-B15
-C06
-C09
-C15
-A05
-A08
-A10
-A15
-B06
-B09
-B15
-C06
-C09
-C15
-A05
-A08
-A10
-A15
-B06
-B09
-B15
-C06
-C09
-C15
-A05
-A10
-A15
-A20
-B06
-B09
-B15
-B18
-C06
-C09
-C15
-C18
Rated Volts,
HZ & Phase
230/208-60-1
230/208-60-311
460-60-3
230/208-60-1
230/208-60-311
460-60-3
230/208-60-1
230/208-60-3
460-60-3
230/208-60-1
230/208-60-3
460-60-3
230/208-60-1
230/208-60-3
460-60-3
230/208-60-1
230/208-60-3
460-60-3
MODEL
T24H1-A00, A0Z
-AF8
T24H1-B00, B0Z
T24H1-C0Z
T30H1-A00, A0Z
-AF8
T30H1-B00, B0Z
-B06
-B09
T30H1-C0Z
T36H1-A00, A0Z
T36H1-B00, B0Z
T36H1-C0Z
T42H1-A00, A0Z
T42H1-B00, B0Z
T42H1-C0Z
T48H1-A00, A0Z
T48H1-B00, B0Z
T48H1-C0Z
T60H1-A00, A0Z
T60H1-B00, B0Z
T60H1-C0Z
These “Minimum Circuit Ampacity” values are to be used for sizing the eld power conductors. Refer to the National Electrical Code (latest version), Article 310 for power conductor sizing.
Caution: When more than one eld power circuit is run through one conduit, the conductors must be derated. Pay special attention to note 8 of Table 310 regarding Ampacity Adjustment
Factors when more than three (3) conductors are in a raceway.
Maximum size of the time delay fuse or HACR type circuit breaker for protection of eld wiring conductors.
Based on 75°C copper wire. All wiring must conform to the National Electrical Code and all local codes.
Maximum KW that can operate with the heat pump on is 4KW. Full heat available during Emergency Heat Mode.
Maximum KW that can operate with the heat pump on is 10KW. Full heat available during Emergency Heat Mode.
Maximum KW that can operate with the heat pump on is 9KW. Full heat available during Emergency Heat Mode.
Maximum KW that can operate with the heat pump on is 8KW. Full heat available during Emergency Heat Mode.
IMPORTANT: While this electrical data is presented as a guide, it is important to electrically connect properly sized fuses & conductor wires in accordance w/the Nat'l. Electrical Code & all local codes.
Minimum
Circuit
Ampacity
24
45
48
65
16
34
42
9
18
23
24
45
48
66
18
36
45
10
19
24
29
55
70
81
85
21
39
48
52
12
21
26
27
31
57
73
83
86
26
44
53
53
13
22
26
27
37
63
79
89
89
27
45
54
55
15
24
28
29
44
70
96
96
113
31
49
58
58
N/A
16
25
29
29
34
Maximum
External
Fuse or
Ckt. Brkr.
35
50
50
70
20
35
45
15
20
25
35
50
50
70
25
40
45
15
20
25
40
60
70
90
90
30
45
50
60
15
25
30
30
40
60
80
90
90
35
50
60
60
15
25
30
30
50
70
90
100
100
40
50
60
60
20
25
30
30
60
80
100
100
125
45
60
60
60
N/A
20
30
30
30
35
Manual 2100-541D
Page 24 of 28
Field
Power
Wire
Size
8
8
8
6
12
8
8
14
12
10
8
8
8
4
10
8
8
14
12
10
8
6
4
4
4
10
8
6
6
14
10
10
10
8
6
4
4
3
8
8
6
6
12
10
10
10
8
6
4
3
3
8
8
6
6
12
10
10
10
8
4
3
3
2
8
8
6
6
N/A
12
10
10
10
8
Minimum
Ground
Wire
10
10
10
8 24 42 35 45 8 8 10 10
12
10
10
14
12
10
10
10
10
8 24 42 35 45 8 8 10 10
10
10
10
14
12
10
10
10
8
8
8
10
10
10
10
14
10
10
10
10
10
8
8
8
10
10
10
10
12
10
10
10
10
8
8
8
8
10
10
10
10
12
10
10
10
10
8
8
8
6
10
10
10
10
N/A 58 28 60 30 6 10 10 10
12
10
10
10
10
Circuit
Ampacity
Ckt. A Ckt. B Ckt. C Ckt. A Ckt. B Ckt. C Ckt. A Ckt. B Ckt. C Ckt. A Ckt. B Ckt. C
29
42
29
52
33
52
31
42
31
52
34
52
37
26
37
42
37
52
37
52
44
26
44
52
44
52
44
52 26
Maximum
External Fuse or
Ckt. Breaker
40
45
40
60
40
60
40
45
40
60
40
60
50
30
50
50
50
60
50
60
50
30
50
60
50
60
50
60 30
Field Power Wire
Size
8
8
8
6
8
6
8
8
8
6
8
6
8
10
8
8
8
6
8
6
8
10
8
6
8
6
8
6 10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
Ground
Wire Size
10
10
10
10
10
10
10
10
10
10
10
10
10
10 10
Page 25
TABLE 6B
Electrical Specications — T**H Series Dehumidication
Single Circuit Multiple Circuit
No.
Field
Power
Circuits
1
1
1
1 or 2
1
1
1
1
1
1 or 2
1
1
1
1
1 or 2
1 or 2
1 or 2
1
1
1
1
1
1
1
1
1
1
1 or 2
1 or 2
1 or 2
1
1
1
1
1
1
1
1
1
1 or 2
1 or 2
1 or 2
1 or 2
1
1
1
1
1
1
1
1
1
1 or 2
1 or 2
1 or 2
1 or 3
1
1
1
1
2
1
1
1
1
1
DA04
DAS8
DB06
DB09
DC06
DC09
DA04
DAS8
DC06
DC09
DA05
DA08
DA10
DA15
DB06
DB09
DB15
DC06
DC09
DC15
DA05
DA08
DA10
DA15
DB06
DB09
DB15
DC06
DC09
DC15
DA05
DA08
DA10
DA15
DB06
DB09
DB15
DC06
DC09
DC15
DA05
DA10
DA15
DA20
DB06
DB09
DB15
DB18
DC06
DC09
DC15
DC18
Rated Volts,
HZ & Phase
230/208-60-1
230/208-60-311
460-60-311
230/208-60-1
230/208-60-311
460-60-311
230/208-60-1
230/208-60-3
460-60-3
230/208-60-1
230/208-60-3
460-60-3
230/208-60-1
230/208-60-3
460-60-3
230/208-60-1
230/208-60-3
460-60-3
MODEL
T24H1DA00, DA0Z
DAF8
T24H1DB00, DB0Z
T24H1DC0Z
T30H1DA00, DA0Z
DAF8
T30H1DB00, DB0Z
DB06
DB09
T30H1DC0Z
T36H1DA00, DA0Z
T36H1DB00, DB0Z
T36H1DC0Z
T42H1DA00, DA0Z
T42H1DB00, DB0Z
T42H1DC0Z
T48H1DA00, DA0Z
T48H1DB00, DB0Z
T48H1DC0Z
T60H1DA00, DA0Z
T60H1DB00, DB0Z
T60H1DC0Z
These “Minimum Circuit Ampacity” values are to be used for sizing the eld power conductors. Refer to the National Electrical Code (latest version), Article 310 for power conductor sizing.
Caution: When more than one eld power circuit is run through one conduit, the conductors must be derated. Pay special attention to note 8 of Table 310 regarding Ampacity Adjustment
Factors when more than three (3) conductors are in a raceway.
Maximum size of the time delay fuse or HACR type circuit breaker for protection of eld wiring conductors.
Based on 75°C copper wire. All wiring must conform to the National Electrical Code and all local codes.
Maximum KW that can operate with the heat pump on is 4KW. Full heat available during Emergency Heat Mode.
Maximum KW that can operate with the heat pump on is 10KW. Full heat available during Emergency Heat Mode.
Maximum KW that can operate with the heat pump on is 9KW. Full heat available during Emergency Heat Mode.
Maximum KW that can operate with the heat pump on is 8KW. Full heat available during Emergency Heat Mode.
IMPORTANT: While this electrical data is presented as a guide, it is important to electrically connect properly sized fuses & conductor wires in accordance w/the Nat'l. Electrical Code & all local codes.
Minimum
Circuit
Ampacity
24
45
48
65
16
34
42
9
18
23
24
45
48
66
18
36
45
10
19
24
29
55
70
81
85
21
39
48
52
12
21
26
27
31
57
73
83
86
26
44
53
53
13
22
26
27
37
63
79
89
89
27
45
54
55
15
24
28
29
44
70
96
96
113
31
49
58
58
N/A
16
25
29
29
34
Maximum
External
Fuse or
Ckt. Brkr.
35
50
50
70
20
35
45
15
20
25
35
50
50
70
25
40
45
15
20
25
40
60
70
90
90
30
45
50
60
15
25
30
30
40
60
80
90
90
35
50
60
60
15
25
30
30
50
70
90
100
100
40
50
60
60
20
25
30
30
60
80
100
100
125
45
60
60
60
N/A
20
30
30
30
35
Field
Power
Wire
Size
8
8
8
6
12
8
8
14
12
10
8
8
8
4
10
8
8
14
12
10
8
6
4
4
4
10
8
6
6
14
10
10
10
8
6
4
4
3
8
8
6
6
12
10
10
10
8
6
4
3
3
8
8
6
6
12
10
10
10
8
4
3
3
2
8
8
6
6
N/A
12
10
10
10
8
Minimum
Ground
Wire
10
10
10
8 24 42 35 45 8 8 10 10
12
10
10
14
12
10
10
10
10
8 24 42 35 45 8 8 10 10
10
10
10
14
12
10
10
10
8
8
8
10
10
10
10
14
10
10
10
10
10
8
8
8
10
10
10
10
12
10
10
10
10
8
8
8
8
10
10
10
10
12
10
10
10
10
8
8
8
6
10
10
10
10
N/A 58 28 60 30 6 10 10 10
12
10
10
10
10
Circuit
Ampacity
Ckt. A Ckt. B Ckt. C Ckt. A Ckt. B Ckt. C Ckt. A Ckt. B Ckt. C Ckt. A Ckt. B Ckt. C
29
42
29
52
33
52
31
42
31
52
34
52
37
26
37
42
37
52
37
52
44
26
44
52
44
52
44
52 26
Maximum
External Fuse or
Ckt. Breaker
40
45
40
60
40
60
40
45
40
60
40
60
50
30
50
50
50
60
50
60
50
30
50
60
50
60
50
60 30
Field Power Wire
Size
8
8
8
6
8
6
8
8
8
6
8
6
8
10
8
8
8
6
8
6
8
10
8
6
8
6
8
6 10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
Manual 2100-541D
Page 25 of 28
Ground
Wire Size
10
10
10
10
10
10
10
10
10
10
10
10
10
10 10
Page 26
TABLE 7
T**H INDOOR BLOWER PERFORMANCE - CFM (0.00" — 0.50" H20)
Blower Only
Except for
CRVMP
Model
Rated
ESP
Max. ESP
Vent Options
T24H .10 .50 800 650 800 1000
T30H .10 .50 900 700 900 1000
T36H .15 .50 1100 800 1100 1100
T42H .15 .50 1250 825 1250 1250
T48H .20 .50 1550 825 1550 1550
T60H .20 .50 1650 850 1650 1650
NOTE: These units are equipped with a variable speed (ECM) indoor motor that automatically adjusts itself to maintain approximately
the same rate of indoor airow in both heating & cooling, dry & wet coil conditions and at both 230/208 or 460 volts.
Maximum ESP (inches WC) shown is with 2" thick disposable lter.
Blower only CFM is the total air being circulated during continuous fan mode. Airow remains constant.
Blower only CFM reduces during continuous fan mode. Requires wiring modication; consult Wiring Diagram and unplug and leave
disconnected the insulated male/female connector connecting together the Gray & Orange wires located near the 24V terminal block
enclosure.
CFM output on Cooling or Electric Heat.
Blower Only
for
CRVMP
Vent Options
Cooling
& Heat
Pump
Electric
Heat
Manual 2100-541D
Page 26 of 28
Page 27
TROUBLESHOOTING 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
• 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
• Motor rocks, • Check for loose or compliant motor mount
but won’t start
• Perform motor/control replacement check
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
(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
• “Hunts” or “puffs” at • Does removing panel or lter reduce
high CFM (speed) “pufng”?
- Reduce restriction
- Reduce max airow
• 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
delay complete
• “R” missing/not connected at motor
• Perform motor/control replacement check
• Stays at high CFM • “R” missing/not connected at motor
• Is fan in delay mode? - wait until delay time
complete
• Perform motor/control replacement check
• Blower won’t shut off •
Check for Triac switched thermostat or solid state relay
Excessive noise • Determine if it’s air noise, cabinet, duct or
motor noise; interview customer, if necessary
• Air noise • High static creating high blower speed?
- Is airow set properly?
- Does removing lter cause blower to slow
down? Check lter
- Use low-pressure drop lter
- Check/correct duct restrictions
• Check power at motor
• Make sure blower wheel is tight on shaft
Current leakage from controls into G, Y or W?
Symptom Cause/Procedure
• Noisy blower or cabinet • Check for loose blower housing, panels, etc.
• High static creating high blower speed?
- Check for air whistling through seams in
ducts, cabinets or panels
- Check for cabinet/duct deformation
• “Hunts” or “puffs” at • Does removing panel or lter reduce
high CFM (speed)
- Reduce restriction
- Reduce max. airow
Evidence of Moisture
• Motor failure or • Replace motor and
malfunction has occurred
and moisture is present
• Evidence of moisture
present inside air mover
“pufng”?
• Perform Moisture Check
Perform Moisture Check
Do Don’t
• Check out motor, controls, • Automatically assume the motor is bad.
wiring and connections
thoroughly before replacing
motor
• Orient connectors down so • Locate connectors above 7 and 4 o’clock
water can’t get in positions
- Install “drip loops”
• Use authorized motor and • Replace one motor or control model # with
model #’s for replacement another (unless an authorized replacement)
• Keep static pressure to a • Use high pressure drop lters some have
minimum: H20 drop!
- Recommend high • Use restricted returns
efciency, low static lters
- Recommend keeping lters
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
airow
• 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 airow (too much latent capacity)
• Check for undercharged condition
• Check and plug leaks in return ducts, cabinet
Comfort Check
• Check proper airow 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 2100-541D
Page 27 of 28
Page 28
™
MOTORS CONT’D.
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 26.
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.
TROUBLESHOOTING 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 specic 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 14. 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 forenger, 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 15. (Measure to unpainted motor end plate.) If any motor
lead fails this test, do not proceed to install the control module. THE
MOTOR IS DEFECTIVE AND MUST BE REPLACED. Installing
the new control module will cause it to fail also.
7. Verify that the replacement control is correct for your application.
Refer to the manufacturer's authorized replacement list. USING THE
WRONG CONTROL WILL RESULT IN IMPROPER OR NO
BLOWER OPERATION. Orient the control module so that the 3-wire
motor plug can be inserted into the socket in the control. Carefully insert
the plug and press it into the socket until it latches. A SLIGHT CLICK
WILL BE HEARD WHEN PROPERLY INSERTED.
the replacement control per one of the three following paragraphs, 8a, 8b or 8c.
8a. IF REPLACING AN ECM 2.0 CONTROL (control in cast
aluminum can with air vents on the back of the can) WITH AN ECM
2.3 CONTROL (control containing black potting for water protection in
black deep-drawn steel case with no vents in the bottom of the can), locate
the two through-bolts and plastic tab that are packed with the replacement
control. Insert the plastic tab into the slot at the perimeter of the open end
of the can so that the pin is located on the inside of the perimeter of the
can. Rotate the can so that the tab inserts into the tab locator 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-BOL TS 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.
Finish installing
8b. IF REPLACING AN ECM 2.3 CONTROL WITH AN ECM 2.3
CONTROL, the plastic tab and shorter through-bolts are not needed. The
control can be oriented in two positions 180° apart. MAKE SURE THE
ORIENTATION YOU SELECT FOR REPLACING THE CONTROL
ASSURES THE CONTROL'S CABLE CONNECTORS WILL
BE LOCATED DOWNWARD IN THE APPLICATION SO THAT
WATER CANNOT RUN DOWN THE CABLES AND INTO THE
CONTROL. Simply orient the new control to the motor's endshield, insert
bolts, and tighten. DO NOT OVERTIGHTEN THE BOLTS.
8c. IF REPLACING AN ECM 2.0 CONTROL WITH AN ECM 2.0
CONTROL (It is recommended that ECM 2.3 controls be used for all
replacements), the new control must be attached to the motor using through
bolts identical to those removed with the original control. DO NOT
OVERTIGHTEN THE BOLTS.
9. Reinstall the blower/motor assembly into the HVAC equipment.
Follow the manufacturer's suggested procedures.
10. Plug the 16-pin control plug into the motor. The plug is keyed.
Make sure the connector is properly seated and latched.
11. Plug the 5-pin power connector into the motor. Even though the
plug is keyed, OBSERVE THE PROPER ORIENTATION. DO NOT
FORCE THE CONNECTOR. It plugs in very easily when properly
oriented. REVERSING THIS PLUG WILL CAUSE IMMEDIATE
FAILURE OF THE CONTROL MODULE.
12.
Final installation check. Make sure the motor is installed as follows:
a. Unit is as far INTO the blower housing as possible.
b. Belly bands are not on the control module or covering vent holes.
c. Motor connectors should be oriented between the 4 o’clock and 8
o’clock positions when the blower is positioned in its nal
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 16.
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.
Back of
Control
Figure 15
Figure 25
Figure 4
Winding Test
Motor OK when
R > 100k ohm
Figure 16
Figure 26
Figure 5
Drip Loop
Connector Orientation
Between 4 and 8 o'clock
Drip Loop
Only remove
Hex Head Bolts
ECM 2.0
Note:
Use the shorter
bolts and
alignment pin
supplied when
replacing an
ECM 2.0
control.
Figure 24
Control Disassembly
Push until
Latch Seats
Over Ramp
ECM
2.3/2.5
Hex-head Screws
Figure 14
Figure 3
From Motor
Circuit
Board
Motor
Motor Connector
(3-pin)
Control Connector
(16-pin)
Power Connector
(5-pin)
Motor Connector
(3-pin)
Manual 2100-541D
Page 28 of 28
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