Bard T24H1, T30H1, T24H1D, T30H1D, T36H1 Installation Instructions Manual

INSTALLATION INSTRUCTIONS

WALL MOUNTED

PACKAGE HEAT PUMPS

Standard & Dehumidification

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: 2100-541C
Supersedes: 2100-541B
File: Volume III Tab 17
Date: 02-17-12

Manual 2100-541C
Page 1 of 28

Contents

Getting Other Information and Publications 3

Wall Mount General Information

Wall Mount Model Nomenclature ............................ 4

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

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

Duct Work ................................................................ 5

Filters ................................................................ 5

Fresh Air Intake ....................................................... 5

Condensate Drain .................................................... 5

Installation Instructions

Wall Mounting Information ....................................... 6

Mounting the Unit .................................................... 6

Placement ................................................................ 6

Clearances Required ............................................... 6

Minimum Clearances ............................................... 6

Wiring – Main Power ............................................. 13

Wiring – Low Voltage Wiring ................................. 13

Optional Outdoor T-Stat Applications ..................... 14

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

Start Up

General .............................................................. 16

Topping Off System Charge ................................... 16

Safety Practices ..................................................... 16

Important Installer Note ......................................... 17

High & Low Pressure Switch ................................. 17

Three Phase Scroll Compressor............................ 17

Phase Monitor ....................................................... 17

Service Hints ......................................................... 17

Sequence of Operation .......................................... 18

Pressure Service Ports .......................................... 18

Defrost Cycle ......................................................... 18

Troubleshooting

Solid State Heat Pump Control .............................. 20

Checking Temperature Sensor .............................. 21

Fan Blade Setting Dimensions .............................. 22

Removal of Fan Shroud ......................................... 22

R-410A Refrigerant Charge ................................... 22

Troubleshooting GE ECM Motors .......................... 27

Troubleshooting GE ECM Motors .......................... 28

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 Specifications T**H ................ 24

Table 6B Electrical Specifications T**H Dehum. .. 25

Table 7 Indoor Blower Performance .................. 26

Manual 2100-541C
Page 2 of 28

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: [phone]
Fax: [phone]

ANSI American National Standards Institute

11 West Street, 13th Floor
New York, NY 10036
Telephone: [phone]
Fax: [phone]

ASHRAE American Society of Heating, Refrigeration

and Air Conditioning Engineers, Inc.

1791 Tullie Circle, N.E.
Atlanta, GA 30329-2305
Telephone: [phone]
Fax: [phone]

NFPA National Fire Protection Association

Batterymarch Park
P.O. Box 9101
Quincy, MA 02269-9901
Telephone: [phone]
Fax: [phone]

Manufactured under the following

U.S. Patent numbers:
5,485,878; 5,301,744

Manual 2100-541C
Page 3 of 28

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

1 For 0 KW and circuit breakers (230/208 volt) or toggle disconnect (460V) applications, insert 0Z in the KW field of the model number. See Pages 24 & 25.
2 Insert “D” for dehumidification 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

2

KW1

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

OUTLET OPTIONS

X - Front (Standard)

CONTROL MODULES

(See Spec. Sheet S3436)

COIL OPTIONS

X - Standard
1 - Phenolic Coated Evaporator
2 - Phenolic Coated Condenser
3 - Phenolic Coated Evaporator

and Condenser

NOTE: Vent options X, B and M are without exhaust capability. May require separate field 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 2100-541C
Page 4 of 28

DUCT WORK

All duct work, supply and return, must be properly sized
for the design airflow requirement of the equipment. Air
Conditioning Contractors of America (ACCA) is an
excellent guide to proper sizing. All duct work or portions
thereof not in the conditioned space should be properly
insulated in order to both conserve energy and prevent
condensation or moisture damage.

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 first
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.

Any grille that meets with 5/8 inch louver criteria may be
used. It is recommended that Bard Return Air Grille Kit
RG2 through RG5 or RFG2 through RFG5 be installed
when no return duct is used. Contact distributor or factory
for ordering information. If using a return air filter grille,
filters must be of sufficient size to allow a maximum
velocity of 400 fpm.

NOTE: If no return air duct is used, applicable installation

codes may limit this cabinet to installation only in a
single story structure.

FILTERS

A 1-inch throwaway filter is standard with each unit.
The filter slides into position making it easy to service.
This filter can be serviced from the outside by removing
the filter access panel. 2-inch pleated filters are also
available as optional accessories. The internal filter
brackets are adjustable to accommodate the 2-inch filter
by bending two (2) tabs down on each side of the filter
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, efficiency and cost of operation
information is based upon the fresh air blank-off plate in
place and is recommended for maximum energy
efficiency.

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.

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.

FIGURE 1

FRESH AIR DAMPER

Manual 2100-541C
Page 5 of 28

s

C
a

M

E

T
T

T

T
T

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.

WARNING

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 flange and the first 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 flashing, attached to front - right of
supply flange for shipping, under back bend of top.

Failure to provide the 1/4 inch clearance
between the supply duct and a combustible
surface for the first 3 feet of duct can result in
fire 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
airflow 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 airflow 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 flat washers on the lag bolts.

7. Secure rain flashing 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.

SLEDO

H03T,H42

H06T,H84T,H24T,H63

Manual 2100-541C
Page 6 of 28

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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

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FIGURE 2

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All dimensions are in inches. Dimensional drawings are not to scale.

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Manual 2100-541C
Page 7 of 28

1/4" CLEARANCE ON ALL

FOUR SIDES OF SUPPLY

MIS-311 C

MATERIALS

AIR DUCT IS REQUIRED

FROM COMBUSTABLE

FOAM AIR SEAL

RAIN FLASHING

SUPPLIED

FIGURE 3A

T24H1, T30H1

SEAL WITH BEAD

OF CAULKING ALONG

ENTIRE LENGTH OF TOP.

MOUNTING INSTRUCTIONS

EDCBA

TOP

17 5/83 13/165 1/48 1/228 1/2

WALL STRUCTURE

WALL

SUPPLY AIR

DUCT

PANEL

HEATER ACCESS

RETURN AIR

OPENING

NOTES:

IT IS RECOMMENDED THAT A BEAD OF

SILICONE CAULKING BE PLACED BEHIND

THE SIDE MOUNTING FLANGES AND UNDER

TOP FLASHING AT TIME OF INSTALLATION.

W*R UNIT SHOWN, W*L UNIT

CONTROLS AND HEATER ACCESS

IS ON OPPOSITE (LEFT) SIDE.

16 7/84 9/164 1/21030

B

E

14"

1"

"

1

2

"

1

8

3

4"

Typ.

4

COMBUSTIBLE MATERIALS

1/4" MIN. CLEARANCE FROM

REQUIRED DIMENSIONS TO MAINTAIN

COMBUSTIBLE MATERIALS

RECOMMENDED 1" CLEARANCE FROM

REQUIRED DIMENSIONS TO MAINTAIN

Manual 2100-541C
Page 8 of 28

28"

Supply Opening

Return Opening

C CA

D

12"

12"

12"

12"

1"

4"

3"

"

7

8

12"

Typ.

"

1

2

4

Wall Opening and Hole Location View Right Side View

5"

RAIN FLASHING

SUPPLIED

FOAM AIR SEAL

FOUR SIDES OF SUPPLY

AIR DUCT IS REQUIRED

1/4" CLEARANCE ON ALL

WALL STRUCTURE

FROM COMBUSTABLE

MATERIALS

PANEL

SUPPLY AIR

DUCT

RETURN AIR

OPENING

NOTES:

THE SIDE MOUNTING FLANGES AND UNDER

TOP FLASHING AT TIME OF INSTALLATION.

IT IS RECOMMENDED THAT A BEAD OF

SILICONE CAULKING BE PLA CE D BEHI ND

MIS-416 E

Right Side View

TOP.

FIGURE 3B

TOP

SEAL WITH BEAD

ENTIRE LENGTH OF

OF CAULKING ALONG

MOUNTING INSTRUCTIONS

T36H1, T42H1, T48H1, T60H1

6 1/4 1 1/4 29 3/4

10 1/2

ABCDE

30 1/2

29

2

32 12 5 1/2

WALL

HEATER ACCESS

A CC

Typ.

3

"

1

8

2

"

1

2

"

7

B

E

16"

8

"

8

1

3

4"

30"

3"

1"

4"

Typ.

"

2

6

1

16"

" 6

1

2

6

Dimension is 21" on 95" tall units.

Dimension is 10" on T48H1 & T60H1.

Dimension is 6" on T48H1 & T60H1.

2

3

1

"

7

8

1

2

Wall Opening and Hole Location View

16"

Return Opening

1

1

16"

Supply Opening

D

16"

16"

REQUIRED DIMENSIONS TO MAINTAIN

1/4" MIN. CLEARANCE FROM

COMBUSTIBLE MATERIALS

RECOMMENDED 1" CLEARANCE FROM

REQUIRED DIMENSIONS TO MAINTAI N

COMBUSTIBLE MATERIALS

Manual 2100-541C
Page 9 of 28

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 first 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 fire causing damage, injury or death.

Manual 2100-541C
Page 10 of 28

FIGURE 5

WALL MOUNTING INSTRUCTIONS

SEE FIGURE 3 – MOUNTING INSTRUCTIONS

SUPPLY AIR

OPENING

RETURN AIR

OPENING

CONCRETE BLOCK WA LL I NST A L LA T I O N

SUPPLY AIR

OPENING

RETURN AIR

OPENING

WOOD OR STEEL SIDING

WOOD FRAME WALL INSTALLATION

FACTORY SUPPLIED

RAIN FLASHING.
MOUNT ON UNIT

BEFORE INSTALLATION

BOTTOM MOUNTING

BRACKET. MOUNT ON

WALL BEFORE

INSTALLING UNIT.

SIDE VIEW

WALL STRUCTURE

SUPPLY AIR

DUCT

RETURN AIR

OPENING

MIS-548 A

MIS-549 B

WALL MOUNTING INSTRUCTIONS

FRAMING MATERIAL

2 x 4'S, 2 x 6'S &/OR

STRUCTURAL STEEL

FIGURE 6

ATTACH TO TOP
PLATE OF WALL

1.000" CLEARANCE

ALL AROUND DUCT

INTERIOR FINISHED WALL
OVER FRAME

1.000" CLEARANCE
ALL AROUND DUCT

EXTERIOR FINISH WALL
OVER FRAME

ATTACH TO BOTTOM

PLATE OF WALL

SEE UNIT DIMENSIONS, FIGURE 2,
FOR ACTUAL DIMENSIONS.

E + 1.000

B

SUPPLY DUCT

OPENING

RETURN DUCT

OPENING

C

2 x 6

L

THIS STRUCTURAL MEMBER
LOCATED TO MATCH STUD
SPACING FOR REST OF WALL.
A SECOND MEMBER MAY BE
REQUIRED FOR SOME WALLS.

1.000

A

I

C

K

Manual 2100-541C
Page 11 of 28

FIGURE 7

COMMON WALL MOUNTING INSTALLATIONS

SUPPLY DUCT MAY BE LOCATED IN AN ATTIC

OR BELOW CEILING RAFTERS AS SHOWN

RAIN

FLASHING

OUTSIDE

WALL

RAIN

FLASHING

RAFTERS

FINISHED CEILING SURFACE

SUPPLY AIR DUCT
W/ GRILLE

RETURN AIR
OPENING W/ GRILLE

FREE AIR FLOW

SUPPLY DUCT MAYBE LOCATED IN AN ATTIC

OR BELOW CEILING RAFTERS AS SHOWN

RAFTERS

RAIN

FLASHING

OUTSIDE

WALL

RAIN

FLASHING

RAFTERS

SUPPLY AIR DUCT

FINISHED CEILING SURFACE

RETURN AIR
OPENING W/ GRILLE

DUCTED SUPPLY

RETURN AT UNIT NO DUCT

SUPPLY DUCT MAYBE LOCATED IN AN ATTIC

OR BELOW CEILING RAFTERS AS SHOWN

RAFTERS

SUPPLY AIR DUCT

FINISHED
CEILING SURFACE

WALL SLEEVE
FALSE WALL

OUTSIDE

WALL

RETURN AIR GRILLE

FALSE WALL INSTALLATION

Manual 2100-541C
Page 12 of 28

RETURN AIR

SPACE

OUTSIDE

WALL

SUPPLY AIR DUCT

LOWERED
CEILING

CLOSET WALL

WALL

SLEEVE

RAISED FLOOR

RETURN AIR

SUPPLY AIR

GRILLE

FINISHED CEILING

CLOSET INSTALLATION

SURFACE

RETURN AIR
GRILLE

MIS-550 B

WIRING – MAIN POWER

Refer to the unit rating plate for wire sizing information
and maximum fuse or “HACR” type circuit breaker
size. Each outdoor unit is marked with a “Minimum
Circuit Ampacity”. This means that the field wiring
used must be sized to carry that amount of current.
Depending on the installed KW of electric heat, there
may be two field power circuits required. If this is the
case, the unit serial plate will so indicate. All models
are suitable only for connection with copper wire. Each
unit and/or wiring diagram will be marked “Use Copper
Conductors Only”. These instructions must be adhered
to. Refer to the National Electrical Code (NEC) for
complete current carrying capacity data on the various
insulation grades of wiring material. All wiring must
conform to NEC and all local codes.

The electrical data lists fuse and wire sizes (75°C
copper) for all models including the most commonly
used heater sizes. Also shown are the number of field
power circuits required for the various models with
heaters.

The unit rating plate lists a “Maximum Time Delay
Relay Fuse” or “HACR” type circuit breaker that is to
be used with the equipment. The correct size must be
used for proper circuit protection and also to assure that
there will be no nuisance tripping due to the momentary
high starting current of the compressor motor.

WIRING – LOW VOLTAGE WIRING

230/208V, 1 phase and 3 phase equipment dual primary
voltage transformers. All equipment leaves the factory
wired on 240V tap. For 208V operation, reconnect from
240V to 208V tap. The acceptable operating voltage
range for the 240 and 208V taps are:

TAP RANGE

240 253 – 216
208 220 – 187

NOTE: The voltage should be measured at the field power

connection point in the unit and while the unit is
operating at full load (maximum amperage
operating condition).

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 Specifications.

Manual 2100-541C
Page 13 of 28

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 specific 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 2100-541C
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 efficiency. 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 first 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 first
stage heat.

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

ELECTRIC HEAT HOLD-OFF WIRING

4 – 10KW 1 PH — 6 & 9KW 3 PH

efficiency 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 set-back
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 10

FIGURE 11

ELECTRIC HEAT HOLD-OFF WIRING

15 – 20KW 1 PH & 3 PH

Manual 2100-541C
Page 15 of 28

START UP

THESE UNITS REQUIRE R-410A
REFRIGERANT AND POLYOL
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 significant changes in the
refrigerant composition during multiple leaks and
recharges. R-410A refrigerant is close to being an
azeotropic blend (it behaves like a pure compound or
single component refrigerant). The remaining
refrigerant charge, in the system, may be used after
leaks have occurred and then “top-off” the charge by
utilizing the 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 flammable.

4. Do not inhale R-410A – the vapor attacks the
nervous system, creating dizziness, loss of
coordination and slurred speech. Cardiac
irregularities, unconsciousness and ultimate death
can result from breathing this concentration.

5. Do not burn R-410A. This decomposition
produces hazardous vapors. Evacuate the area if
exposed.

6. Use only cylinders rated DOT4BA/4BW 400.

7. Never fill cylinders over 80% of total capacity.

8. Store cylinders in a cool area, out of direct
sunlight.

9. Never heat cylinders above 125°F.

10. Never trap liquid R-410A in manifold sets, gauge
lines or cylinders. R-410A expands significantly
at warmer temperatures. Once a cylinder or line is
full of liquid, any further rise in temperature will
cause it to burst.

Manual 2100-541C
Page 16 of 28

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,
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.

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 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. 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 airflow circulation is essential.

Verification of proper rotation must be made at the
time the equipment is put into service. If improper
rotation is corrected at this time, there will be no
negative impact on the durability of the compressor.
However, reverse operation for over one hour may have
a negative impact on the bearing due to oil pump out.

NOTE: If compressor is allowed to run in reverse rotation

for several minutes, the compressor’s internal
protector will trip.

All three phase ZP compressors are wired identically
internally. As a result, once the correct phasing is
determined for a specific system or installation,
connecting properly phased power leads to the same
Fusite terminal should maintain proper rotation
direction.

The direction of rotation of the compressor may be
changed by reversing any two line connections to the
unit.

Manual 2100-541C
Page 17 of 28

SEQUENCE OF OPERATION

COOLING – Circuit R-Y makes at thermostat pulling in
compressor contactor, starting the compressor and outdoor
motor. The G (indoor motor) circuit is automatically completed
on any call for cooling operation or can be energized by manual
fan switch on subbase 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.

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 2100-541C
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 artificial test condition.
There is also a 5-minute compressor time delay function built
into the HPC. This is to protect the compressor from short
cycling conditions. 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 first (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.

FIGURE 12

DEFROST CONTROL BOARD

LOW PRESSURE BYPASS TIMER SWITCH
*(FACTORY SETTING 120 SECONDS)

SW1SW

OFF

OFF

OFF

ON

ON

ON
ON

OFF

OFF

ON

2 TIME (SEC)

30
60

120*

180

ACCUMULATED DEFROST TIME TIMER
(FACTORY SETTING 60 MIN.)

MIS-2668 A

Manual 2100-541C
Page 19 of 28

TROUBLESHOOTING

SOLID STATE HEAT PUMP CONTROL
TROUBLESHOOTING PROCEDURE

1. NOTE: A thorough understanding of the defrost
cycle sequence is essential. Review that section
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
blower, compressor and outdoor fan should start.

TROUBLESHOOTING

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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.

LED BLINK CODES

BLINK FUNCTION

Slow Normal function (1.0 sec on/1.0 sec off)
Fast ASCD timer active (0.1 sec on/0.1 sec off)
1 Low pressure switch failure
2 High pressure switch failure/“Soft” Lockout
3 Defrost mode active
4 High pressure switch failure/“Hard” Lockout

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Manual 2100-541C
Page 20 of 28

CHECKING TEMPERATURE SENSOR

7
4
5
0
0
3

1
3
9
8

1
7
7
0
6
6
8
4
2
3
7
3
2
4
7
4
2
3
6

1
8
7
8

1
6
2

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.

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

Manual 2100-541C
Page 21 of 28

057
337
617
007
486
866

356
836
326
906

695
285
965
755
445
235
025
905
894
784
674
664
654
644
634
724
814
904
004

293
383
573
763

063
253
543

TROUBLESHOOTING

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 specific 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

AIRFLOW

"A"

MIS-1724

TABLE 4

FAN BLADE DIMENSION

ledoM

42T

H

03T

H

63T

H

24T

H

84T

H

06T

H

AnoisnemiD

"52.1

"57.1

REMOVAL OF FAN SHROUD

1. Disconnect all power to the unit.

2. Remove the screws holding both grilles, one on each
side of unit, and remove grilles.

3. Remove screws holding fan shroud to condenser and
bottom. Nine (9) screws.

4. Unwire condenser fan motor.

5. Slide complete motor, fan blade, and shroud
assembly out the left side of the unit.

6. Service motor/fan as needed.

7. Reverse steps to reinstall.

R-410A

REFRIGERANT CHARGE

This unit was charged at the factory with the quantity of
refrigerant listed on the serial plate. AHRI capacity and
efficiency ratings were determined by testing with this
refrigerant charge quantity.

The following pressure tables show nominal pressures
for the units. Since many installation specific situations
can affect the pressure readings, this information should
only be used by certified 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 2100-541C
Page 22 of 28

ledoM

1
1

1

0
8

0
6

6
2

9

1

7
3

0
2

H42T

H03T

H63T

H24T

H84T

H06T

Low side pressure ± 4 PSIG
High side pressure ± 10 PSIG

Tables are based upon rated CFM (airflow) across the evaporator coil. If there is any doubt as to correct operating charge being in the system, the charge
should be removed, system evacuated and recharged to serial plate charge weight.

riAnruteR

erutarepmeTerusserP5708580959001501011511021

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

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

NOTE: Pressure table based on high speed condenser fan operation. If condensing pressures appear elevated check condenser fan wiring.
See “Condenser Fan Operation”.

HEATING PRESSURES – (ALL TEMPERATURES °F)

ledoM

H42T.ged07

H03T.ged07

H63T.ged07

H24T.ged07

H84T.ged07

H06T.ged07

riAnruteR

erutarepmeTerusserP05015102520353045405550656

TABLE 5A

COOLING PRESSURE TABLE

ediSwoL
ediShgiH

ediSwoL
ediShgiH

ediSwoL
ediShgiH

ediSwoL
ediShgiH

ediSwoL
ediShgiH

ediSwoL
ediShgiH

ediSwoL
ediShgiH

ediSwoL
ediShgiH

ediSwoL
ediShgiH

ediSwoL
ediShgiH

ediSwoL
ediShgiH

ediSwoL
ediShgiH

ediSwoL
ediShgiH

ediSwoL
ediShgiH

ediSwoL

ediShgiH

ediSwoL

ediShgiH

ediSwoL

ediShgiH

ediSwoL

ediShgiH

131

331

603
041

413
541

523
721

913
631

723

141

833
331

313
241

123

741
233

131

513
041

323
541

433
331

523
241

333
741

543
921

353
831

263
341

573

531

123

733

241

441

923

643

741

941

143

853

921

131

533

453

831

041

443

363

341

541

653

673

531

731

723

243

441

641

533

153

941

151

743

363

231

431

133

843

141

341

933

753

641

841

153

963

631

731

143

063

541

741

053

963

051

251

263

283

031

231

263

473

931

441
483

141

173

483
641

793

TABLE 5B

ediSwoL

83

54

35

ediShgiH

762

472

ediSwoL

43

ediShgiH
ediSwoL

ediShgiH
ediSwoL

ediShgiH
ediSwoL

ediShgiH
ediSwoL

ediShgiH

24

952

172

74

05

072

372

04

54

492

692

93

54

062

462

02

13

522

742

06

182

982

05

75

382

492

45

95

672

182

15

75

992

503

05

65

862

372

24

25

762

582

Air Temperature Entering Outdoor Coil °F

731

831

041

241

341

541

753

773

004

524

641

841

051

663

783

151

351

973

104

331

531

373

593

241

441

383

804

741

941

693

914

831

931

163

283

841

941

073

293

351

451

383

604

631

731

863

883

541

741

773

204

051

251

093

214

931

141

973

104

941

151

983

714

451

651

304

524

331

431

093

014

241

441

004

824

741

841

414

534

86

67

48

792

503

56

27

503

613

46

07

782

492

36

07

113

913

26

96

972

582

16

07

103

513

29

313

223

08

78

723

833

77

48

203

113

87

58

923

043

67

48

392

003

97

68

723

733

251

014

634

551

751

424
731

731

714

244

641

741

824

354

151

251

344

964

141

341

604

234

151

351

614

344

651

851

134

954

931

241

014

534

941

251

124

644

451

751

634

264

241

441

424

944

251

451

534
751

951

054

774

631

731

234

854

541

641

344

074

051
954

684

99
033

49
843

39
223

39
353

29
903

39
543

154

351
364

851

154

974
931

864
941

084
451

794
541

164

551
374

061
094

441

164

451
374

951
094

541
774

551

164

984
061

605
731

884
741

105

151

251
915

701

611

933

101

853
201

433
201

863
001

913
001

053

421

943

853

801

611

863

873

211

321

743

163

011

911

483

104

801

711

923

933

601

111

453

553

Manual 2100-541C
Page 23 of 28

741

084

015

551

751

294

325

061

261

45

905

41

041

525

594

51

051

835

805
551

651

625

755

741

941

294

725

751

951

505

045

261

561

325

955

641

941

984

025

651

951

205

335

161

561

025

255

741

841

505

535

751

851

815

945

261

461

635

865

931

041

225

955

941

051

535

375

451

551

455

395

231

41

863

73

321

31

783

93

431

41

673

93

921

31

024

44

721

31

153

63

611

21

553

53

TABLE 6A

Electrical Specifications — T**H Series

tiucriCelgniS tiucriCelpitluM

detaR

sledoM

Z0A,00A-1H42T

40A-15405801

4

8SA-

7

8FA-

Z0B,00B-1H42T
60B- 1 43 53 8 01
90B- 1 24 54 8 01
Z0C-1H42T
60C-181022121
90C-132520101

Z0A,00A-1H03T
40A- 1 54 05 8 01

4

8SA-

7

8FA-

Z0B,00B-1H03T
60B-16304801
90B-15454801
Z0C-1H03T
60C- 1 91 02 21 21
90C- 1 42 52 01 01

Z0A,00A-1H63T
50A-15506601
80A-2ro107074892240454880101
01A-2ro118094892250406860101

5

51A-

Z0B,00B-1H63T
60B- 1 93 54 8 01
90B- 1 84 05 6 01

6

51B­Z0C-1H63T
60C-112520101
90C-162030101

6

51C-

Z0A,00A-1H24T
50A- 1 75 06 6 01
80A- 2ro1 37 08 4 8 13 24 04 54 8 8 01 01
01A- 2ro1 38 09 4 8 13 25 04 06 8 6 01 01

5

51A-

Z0B,00B-1H24T
60B-14405801
90B-13506601

6

51B­Z0C-1H24T
60C- 1 22 52 01 01
90C- 1 62 03 01 01

6

51C-

Z0A,00A-1H84T
50A-2ro1360768736205038010101
80A-2ro197094873240505880101
01A-2ro1980013873250506860101

5

51A-

Z0B,00B-1H84T
60B- 1 54 05 8 01
90B- 1 45 06 6 01

6

51B­Z0C-1H84T
60C-142520101
90C-182030101

6

51C-

Z0A,00A-1H06T
50A- 2ro1 07 08 4 8 44 62 05 03 8 01 01 01
01A- 2ro1 69 001 3 8 44 25 05 06 8 6 01 01

5

51A-

5

02A-

Z0B,00B-1H06T
60B-19406801
90B-18506601

6

51B-

6

81B­Z0C-1H06T
60C- 1 52 03 01 01
90C- 1 92 03 01 01

6

51C-

6

81C-

fo.oN

ZH,stloV

esahPdna

14253801

1-06-802/032

18405801

1 61 02 21 21

3-06-802/032

19 514141

3-06-064

1 42 53 8 01

1-06-802/032

1 84 05 8 01

181520101

3-06-802/032

1 01 51 41 41

3-06-064

19204801

1-06-802/032

1 12 03 01 01

3-06-802/032

1 25 06 6 01
121514141

3-06-064

172030101
1 13 04 8 01

1-06-802/032

16253801

3-06-802/032

13506601
1 31 51 21 21

3-06-064

1 72 03 01 01
17305801

1-06-802/032

1 72 04 8 01

3-06-802/032

1 55 06 6 01
151022121

3-06-064

192030101
1 44 06 8 01

1-06-802/032

11354801

3-06-802/032

18506601

2A/NA/NA/NA/N858206036010101

1 61 02 21 21

3-06-064

1 92 03 01 01
1 43 53 8 01

muminiM

dleiF

tiucriC

rewoP

2ro156076842245354880101

2ro1 66 07 4 8 42 24 53 54 8 8 01 01

2ro158094833250406860101

2ro1 68 09 3 8 43 25 04 06 8 6 01 01

2ro1980013873250506860101

2ro1 69 001 3 8 44 25 05 06 8 6 01 01
3ro1 311 521 2 6 44 25 62 05 06 03 8 6 01 01 01 01

yticapmA

stiucriC

1

rekaerB 2

mumixaM

dleiF

esuFlanretxE

tiucriCro

3

dnuorG

rewoP

eziSeriW

eziSeriW

3

tiucriC.niM

yticapmA 1

A.tkC B.tkC C.tkC A.tkC B.tkC C.tkC A.tkC B.tkC C.tkC A.tkC B.tkC C.tkC

tiucriC.xaM

roesuFroiretxE

.rkB.trC 2

eziSeriW 3

rewoPdleiF

dnuorG
eziSeriW 3

1 These “Minimum Circuit Ampacity” values are to be used for sizing the field power conductors. Refer to the National Electrical Code (latest version), Article

310 for power conductor sizing.
Caution: When more than one field 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.

2 Maximum size of the time delay fuse or HACR type circuit breaker for protection of field wiring conductors.
3 Based on 75°C copper wire. All wiring must conform to the National Electrical Code and all local codes.
4 Maximum KW that can operate with the heat pump on is 4KW. Full heat available during Emergency Heat Mode.
5 Maximum KW that can operate with the heat pump on is 10KW. Full heat available during Emergency Heat Mode.
6 Maximum KW that can operate with the heat pump on is 9KW. Full heat available during Emergency Heat Mode.
7 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.

Manual 2100-541C
Page 24 of 28

TABLE 6B

Electrical Specifications — T**H Series Dehumidification

tiucriCelgniS tiucriCelpitluM

detaR

sledoM

Z0A,00AD1H42T

40AD15405801

4

8SAD

7

8FAD

Z0B,00BD1H42T
60BD 1 43 53 8 01
90BD 1 24 54 8 01
Z0CD1H42T
60CD181022121
90CD132520101

Z0A,00AD1H03T

D40A 1 54 05 8 01

4

8SAD

7

8FAD

Z0B,00BD1H03T

D60B16304801

90BD15454801
Z0CD1H03T
60CD 1 91 02 21 21
90CD 1 42 52 01 01

Z0A,00AD1H63T
50AD15506601
80AD2ro107074892240454880101
01AD2ro118094892250406860101

5

51AD

Z0B,00BD1H63T
60BD 1 93 54 8 01
90BD 1 84 05 6 01

6

51BD
Z0CD1H63T
60CD112520101
90CD162030101

6

51CD

Z0A,00AD1H24T
50AD 1 75 06 6 01
80AD 2ro1 37 08 4 8 13 24 04 54 8 8 01 01
01AD 2ro1 38 09 4 8 13 25 04 06 8 6 01 01

5

51AD

Z0B,00BD1H24T
60BD14405801
90BD13506601

6

51BD
Z0CD1H24T
60CD 1 22 52 01 01
90CD 1 62 03 01 01

6

51CD

Z0A,00AD1H84T
50AD2ro1360768736205038010101
80AD2ro197094873240505880101
01AD2ro1980013873250506860101

5

51AD

Z0B,00BD1H84T
60BD 1 54 05 8 01
90BD 1 45 06 6 01

6

51BD
Z0CD1H84T
60CD142520101
90CD182030101

6

51CD

Z0A,00AD1H06T
50AD 2ro1 07 08 4 8 44 62 05 03 8 01 01 01
01AD 2ro1 69 001 3 8 44 25 05 06 8 6 01 01

5

51AD

5

02AD

Z0B,00BD1H06T
60BD19406801
90BD18506601

6

51BD

6

81BD
Z0CD1H06T
60CD 1 52 03 01 01
90CD 1 92 03 01 01

6

51CD

6

81CD

fo.oN

ZH,stloV

dleiF

esahPdna

14253801

1-06-802/032

18405801

1 61 02 21 21

3-06-802/032

19 514141

3-06-064

1 42 53 8 01

1-06-802/032

1 84 05 8 01

181520101

3-06-802/032

1 01 51 41 41

3-06-064

19204801

1-06-802/032

1 12 03 01 01

3-06-802/032

1 25 06 6 01
121514141

3-06-064

172030101
1 13 04 8 01

1-06-802/032

16253801

3-06-802/032

13506601
1 31 51 21 21

3-06-064

1 72 03 01 01
17305801

1-06-802/032

1 72 04 8 01

3-06-802/032

1 55 06 6 01
151022121

3-06-064

192030101
1 44 06 8 01

1-06-802/032

11354801

3-06-802/032

18506601
2A/NA/NA/NA/N858206036010101
1 61 02 21 21

3-06-064

1 92 03 01 01
1 43 53 8 01

muminiM
tiucriC

rewoP

stiucriC

1

2ro156076842245354880101

2ro1 66 07 4 8 42 24 53 54 8 8 01 01

2ro158094833250406860101

2ro1 68 09 3 8 43 25 04 06 8 6 01 01

2ro1980013873250506860101

2ro1 69 001 3 8 44 25 05 06 8 6 01 01
3ro1 311 521 2 6 44 25 62 05 06 03 8 6 01 01 01 01

mumixaM

dleiF

dnuorG

rewoP

eziSeriW

eziSeriW

3

rekaerB 2

esuFlanretxE

tiucriCro

3

yticapmA

tiucriC.niM

yticapmA 1

A.tkC B.tkC C.tkC A.tkC B.tkC C.tkC A.tkC B.tkC C.tkC A.tkC B.tkC C.tkC

tiucriC.xaM

roesuFroiretxE

.rkB.trC 2

eziSeriW 3

rewoPdleiF

dnuorG

eziSeriW 3

1 These “Minimum Circuit Ampacity” values are to be used for sizing the field power conductors. Refer to the National Electrical Code (latest version), Article

310 for power conductor sizing.
Caution: When more than one field 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.

2 Maximum size of the time delay fuse or HACR type circuit breaker for protection of field wiring conductors.
3 Based on 75°C copper wire. All wiring must conform to the National Electrical Code and all local codes.
4 Maximum KW that can operate with the heat pump on is 4KW. Full heat available during Emergency Heat Mode.
5 Maximum KW that can operate with the heat pump on is 10KW. Full heat available during Emergency Heat Mode.
6 Maximum KW that can operate with the heat pump on is 9KW. Full heat available during Emergency Heat Mode.
7 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.

Manual 2100-541C
Page 25 of 28

TABLE 7

t

T**H INDOOR BLOWER PERFORMANCE - CFM (0.00" — 0.50" H20) 1

22222

ledoM

detaR

PSE

11111

PSExaM

ylnOrewolB

roftpecxE

PMVRC

snoitpOtneV

33333

ylnOrewolB

rof

PMVRC

&pmuPtaeH

44444

gnilooC

44444

aeHcirtcelE

snoitpOtneV

H42T01.05.0080560080001
H03T01.05.0090070090001
H63T51.05.001100800110011
H24T51.05.052152805210521
H84T02.05.055152805510551
H06T02.05.056105805610561

NOTE: These units are equipped with a variable speed (ECM) indoor motor that automatically adjusts itself to maintain approximately
the same rate of indoor airflow in both heating & cooling, dry & wet coil conditions and at both 230/208 or 460 volts.

1 Maximum ESP (inches WC) shown is with 2" thick disposable filter.
2 Blower only CFM is the total air being circulated during continuous fan mode. Airflow remains constant.
3 Blower only CFM reduces during continuous fan mode. Requires wiring modification; consult Installation Instructions & Wiring Diagram.
4 CFM output on Cooling or Electric Heat.

Manual 2100-541C
Page 26 of 28

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 2100-541C
Page 27 of 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
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 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 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.

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
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-BOLTS PROVIDED WITH THE
REPLACEMENT ECM 2.3 CONTROL ARE SHORTER THAN
THE BOLTS ORIGINALLY REMOVED FROM THE ECM 2.0
CONTROL AND MUST BE USED IF SECURE ATTACHMENT
OF THE CONTROL TO THE MOTOR IS TO BE ACHIEVED.

DO NOT OVERTIGHTEN THE BOLTS.

¼" hex head bolts at the rear of the control

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 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 4

Winding Test

Motor OK when
R > 100k ohm

Figure 16

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 14

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)

Manual 2100-541C
Page 28 of 28