Bard HA 4S3, HA 5S3, HL 4S2, HL 5S2 wall mounted packaged air conditioner Installation instructions
Below you will find brief information for wall mounted packaged air conditioner HA 4S3, wall mounted packaged air conditioner HA 5S3, wall mounted packaged air conditioner HL 4S2. The unit is designed for use with or without duct work. Flanges are provided for attaching the supply and return ducts. Ducts through the walls must be insulated and all joints taped or sealed to prevent air or moisture entering the wall cavity. This unit features a 2-inch pleated filter that is easy to service. It also includes a compressor control module that features anti-short cycle/lockout timer with high and low pressure switch monitoring and alarm relay output.
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WALL MOUNTED PACKAGED AIR CONDITIONER INSTALLATION INSTRUCTIONS Models: HA4S3 HA5S3 HL4S2 HL5S2 NOTE THIS IS AN R-410A HIGH PRESSURE REFRIGERANT SYSTEM 0,6 Bard Manufacturing Company, Inc. Bryan, Ohio 43506 Since 1914...Moving ahead just as planned. Manual : Supersedes: File: Date: 2100-573 NEW Volume III Tab 16 05-29-12 Manual Page 2100-573 1 of 23 CONTENTS Getting Other Information and Publications For more information contact these publishers ........ 3 Wall Mount General Information Air Conditioner Wall Mount Model Nomenclature .... Shipping Damage .................................................... General ............................................................... Duct Work ............................................................... Filters ............................................................... Condensate Drain .................................................... 4 7 7 7 7 7 Installation Instructions Wall Mounting Information ....................................... 8 Mounting the Unit .................................................... 8 Typical Installations ................................................. 8 Wiring – Main Power ................................. 8 -9 & 12 Wiring – Low Voltage Wiring ............................... 12 Dirty Filter Switch & Relay ..................................... 12 Figures Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Unit Dimensions ..................................... 5 Mounting Instructions ............................. 9 Wall-Mounting Instructions .................. 10 Wall-Mounting Instructions .................. 10 Common Wall-Mounting Instructions .... 11 Electric Heat Clearance ....................... 12 Start-Up Label ...................................... 14 Fan Blade Setting ................................ 17 Control Disassembly ............................ 20 Winding Test ........................................ 20 Drip Loop ............................................. 20 Manual 2100-573 Page 2 of 23 Start Up General ............................................................. Topping Off System Charge ................................... Safety Practices ..................................................... Important Installer Note ......................................... Crankcase Heaters ................................................ High & Low Pressure Switch ................................. Service Hints ......................................................... Blower Time Delay Disable .................................... Compressor Control Module .................................. Adjustments ........................................................... Motor Start Device ................................................. Pressure Service Ports .......................................... 13 13 13 14 14 14 15 15 15 16 16 16 Troubleshooting Compressor Solenoid ............................................ 17 Fan Blade Setting Dimensions .............................. 17 Removal of Fan Shroud ......................................... 17 R-410A Refrigerant Charge ................................... 18 Pressure Chart ...................................................... 18 GE ECM™Motors ................................................... 19 GE ECM™Motors ................................................... 20 Optional Accessories ..................................... 22 & 23 Tables Table 1 Table 2 Table 3 Table 4 Table 5 Table 6 Table 7 Table 8 Table 9 Electric Heat Table ................................. 4 Dimensions of Basic Unit ....................... 5 Electrical Specifications ......................... 6 Fan Blade Dimensions ......................... 17 Cooling Pressure ................................. 18 Indoor Blower Performance ................. 21 Maximum ESP of Operation Electric Heat Only ................................ 21 Opt. Accessories (HA) ......................... 22 Opt. Accessories (HL) .......................... 23 Getting Other Information and Publications These publications can help you install the air conditioner or heat pump. You can usually find these at your local library or purchase them directly from the publisher. Be sure to consult current edition of each standard. 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 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 or Residential Winter and Manual N Summer Air Conditioning Low Pressure, Low Velocity .......... ACCA Manual D or Duct System Design for Winter Manual Q and Summer Air Conditioning ASHRAE American Society of Heating Refrigerating, and Air Conditioning Engineers, Inc. 1791 Tullie Circle, N.E. Atlanta, GA 30329-2305 Telephone: (404) 636-8400 Fax: (404) 321-5478 NFPA National Fire Protection Association Batterymarch Park P.O. Box 9101 Quincy, MA 02269-9901 Telephone: (800) 344-3555 Fax: (617) 984-7057 Manufactured under the following U.S. patent numbers: 5,485,878; 5,301,744 Manual Page 2100-573 3 of 23 WALL MOUNT GENERAL INFORMATION AIR CONDITIONER WALL MOUNT MODEL NOMENCLATURE HA 4S MODEL NUMBER HA – Right Hand HL – Left Hand 3 K A 08 B P X X K – Accumulator COIL OPTIONS X – Standard 1 - Phenolic Coated Evaporator 2 - Phenolic Coated Condenser 3 - Phenolic Coated Evaporator and Condenser VOLTS & PHASE A – 230/208-1 CAPACITY 4S – 4 Ton 5S – 5 Ton 05 08 10 15 20 OUTLET OPTIONS X – Front (Standard) VENTILATION OPTIONS X – Barometric Fresh Air Damper B – Blank-off Plate (Standard) w/Circuit Breaker or Pull Disconnect J CONTROL MODULES J – Only REVISION KW 0Z – No KW X – 5 KW – 8 KW – 10 KW – 15 KW – 20 KW FILTER OPTIONS X – Two Inch Pleated COLOR OPTIONS X – Beige (Standard) 4 – Buckeye Gray 5 – Desert Brown 8 – Dark Bronze A – Aluminum S – Stainless Steel NOTE: For 0KW and circuit breakers (230/208 V) or rotary disconnects (460 V) applications, insert 0Z in the KW field of model number. TABLE 1 ELECTRIC HEAT TABLE At 240V (1) At 208V (1) Nominal KW Kw 1-Ph Amps 5.0 5.0 8.0 8.0 10.0 10.0 41.7 34,130 7.50 36.1 25,598 15.0 15.0 62.5 51,195 11.25 54.1 38,396 20.0 20.0 83.3 68,260 15.00 72.1 51,195 Btuh Kw 1-Ph Amps 20.8 17,065 3.75 18.0 12,799 33.3 27,304 6.00 28.8 20,478 (1) These electric heaters are available in 230/208V units only. See Table 3 for Heater Availability by Model Manual 2100-573 Page 4 of 23 Btuh TABLE 2 DIMENSIONS OF BASIC UNIT FOR ARCHITECTURAL & INSTALLATION REQUIREMENTS (NOMINAL) Supply Unit Return Width W Depth D Height H A B C B E F G I J K L M N O P Q R S T 42.19 22.44 84.94 9.88 29.88 15.88 29.88 43.88 13.50 30.94 30.00 32.69 26.94 34.69 32.44 3.31 43.00 23.88 10.00 1.44 16.00 1.88 HA/L4S HA/L5S All dimensions in inches. Dimensional Drawings are not to scale. FIGURE 1 UNIT DIMENSIONS HA*S* RIGHT UNIT E O D Built In Rain Hood 4° Pitch W 7.88 2 1.00 Heater Access Panel 31.88 2 .44 2.13 Side Wall Mounting Brackets (Built In) A Electric Heat Supply Air Opening R S B C. Breaker/ Disconnect Access Panel (Lockable) I Top Rain Flashing Shipping Location Filter Access Panel 5.88 2 Vent Option Door C H S Optional Electrical Entrances Return Air Opening S Ventilation Air F S Low Voltage Electrical Entrance G K Cond. Air Inlet High Voltage Electrical Entrance Condenser Air Outlet 1 J L M S P 1 T Front View Drain Side View N Back View Q 1 Bottom Installation Bracket MIS-2487 C Dimension is 21.00 inches on HA/L4S* & HA/L5S* models. HL*S* LEFT UNIT E O .44 D Side Wall Mounting Brackets (Built In) Supply Air Opening S B S 1 Filter Access Panel Ventilation Air Vent Option Door C H L M S C. Breaker/ Disconnect Access Panel (Lockable) I Optional Electrical Entrances Return Air Opening S S A Top Rain Flashing Shipping Location 1 P W Electric Heat Heater Access Panel 2.13 R Built In Rain Hood 4° Pitch 5.88 F Low Voltage Electrical Entrance K J Cond. Air Inlet High Voltage Electrical Entrance Condenser Air Outlet G T Drain Bottom Installation Bracket N Back View Side View Front View MIS-2488 C Q Manual Page 2100-573 5 of 23 Manual 2100-573 Page 6 of 23 230/208-1 230/208-1 Model HA/L4S A 0Z - A 05 - A 08 - A 10 - A 15 - A 20 HA/L5S A 0Z - A 05 - A 08 - A 10 - A 15 - A 20 1 1 1 1 or 2 1 or 2 1 or 3 1 1 1 1 or 2 1 or 2 1 or 3 No. Field Power Circuits 44 44 53 63 89 115 38 38 53 63 89 115 3 Minimum Circuit Ampacity 50 50 60 70 90 120 45 45 60 70 90 120 1 Maximum External Fuse or Ckt. Brkr. 8 8 6 6 3 2 8 8 6 4 3 2 2 Field Power Wire Size Single Circuit 10 10 10 8 8 6 10 10 10 8 8 6 2 Ground Wire 44 44 44 37 37 37 Ckt. A 26 52 52 26 52 52 Ckt. B 3 Minimum Circuit Ampacity 26 26 Ckt. C 50 50 50 45 45 45 Ckt. A 30 60 60 30 60 60 Ckt. B 30 30 Ckt. C 8 8 8 8 8 8 Ckt. A Multiple Circuit 1 Maximum External Fuse or Ckt. Brkr. 10 6 6 10 6 6 Ckt. B 2 Field Power Wire Size 10 10 Ckt. C 10 10 10 10 10 10 Ckt. A 10 10 10 10 10 10 Ckt. B 2 Ground Wire 1 Maximum size of the time delay fuse or HACR type circuit breaker for protection of field wiring conductors. 2 Based on 75°C copper wire. All wiring must conform to the National Electric Code (NEC) and all local codes. 3 These “Minimum Circuit Ampacity” values are to be used for sizing the field power conductors. Refer to the National Electric Code (latest version), Article 310 for power conductor sizing. CAUTION: When more than one filed power conductor circuit is run through one conduit, the conductors must be derated. Pay special attention to Note * of Table 310 regarding Ampacity Adjustment Factors when more than 3 conductors are in a raceway. Rated Volts and Phase TABLE 3 ELECTRICAL SPECIFICATIONS 10 10 Ckt. C SHIPPING DAMAGE Upon receipt of equipment, the carton should be checked for external signs of shipping damage. If damage is found, the receiving party must contact the last carrier immediately, preferably in writing, requesting inspection by the carrier’s agent. GENERAL The equipment covered in this manual is to be installed by trained, experienced service and installation technicians. Refer to Table 7 for maximum static pressure available for duct design. 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 1-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. The refrigerant system is completely assembled and charged. All internal wiring is complete. 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 3 and 4 for further details. The unit is designed for use with or without duct work. Flanges are provided for attaching the supply and return ducts. Ducts through the walls must be insulated and all joints taped or sealed to prevent air or moisture entering the wall cavity. These instructions explain the recommended method to install the air cooled self-contained unit and the electrical wiring connections to the unit. These instructions and any instructions packaged with any separate equipment required to make up the entire 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 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 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. 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. CAUTION Some installations may not require any return air duct. A 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 inches. Any grille that meets the 5/8 inch louver criteria, may be used. It is recommended that Bard Return Air Grille Kit RG-5 or RFG-5 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 2-inch pleated filter is supplied 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. The internal filter brackets are adjustable to accommodate the 1-inch filter by bending up the tabs to allow spacing for the 1-inch filters. 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 Page 2100-573 7 of 23 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. See Figures 4 and 5. WARNING 3. Locate and mark lag bolt locations and bottom mounting bracket location. See Figure 4. 4. Mount bottom mounting bracket. 5. Hook top rain flashing under back bend of top. Top rain flashing is shipped secured to the right side of the back. 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 Figure 2. Fire hazard can result if 1/4 inch clearance to combustible materials for supply air duct is not maintained. See Figure 3. 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. 3. Concrete block walls must be thoroughly inspected to insure that they are capable of carrying the weight of the installing unit. 9. On side-by-side installations, maintain a minimum of 20 inches clearance on right side to allow access to heat strips and control panel and to allow proper airflow to the outdoor coil. Additional clearance may be required to meet local or national codes. 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 is provided for ease of installation. 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. If a combustible wall, use a minimum of 30-1/2" x 10-1/2" dimensions for sizing. However, it is generally recommended that a 1-inch clearance is used for ease of installation and maintaining the required clearance to combustible material. The supply air opening would then be 32" x 12". See Figures 2, 3 and 6 for details. WARNING 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. Manual 2100-573 Page 8 of 23 TYPICAL INSTALLATIONS See Figure 5 for common ways to install the wall mount unit. 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 (75ºC 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. 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. The disconnect access door on this unit may be locked to prevent unauthorized access to the disconnect. See Start-up section for information on three phase scroll compressor start-ups. FIGURE 2 MOUNTING INSTRUCTIONS NOTE: It is recommended that a bead of silicone caulking be placed behind the side mounting flanges and under the top flashing at the time of installation. A B C D E REQUIRED DIMENSIONS TO MAINTAIN 1/4" MIN. CLEARANCE FROM COMBUSTIBLE MATERIALS 30 1/2 10 1/2 6 1/4 1 1/4 29 3/4 REQUIRED DIMENSIONS TO MAINTAIN RECOMMENDED 1" CLEARANCE FROM COMBUSTIBLE MATERIALS 32 12 5 1/2 2 29 SEAL WITH BEAD OF CAULKING ALONG ENTIRE LENGTH OF TOP. RAIN FLASHING SUPPLIED FOAM AIR SEAL TOP WALL STRUCTURE 1/4" CLEARANCE ON ALL FOUR SIDES OF SUPPLY AIR DUCT IS REQUIRED FROM COMBUSTABLE MATERIALS WALL C D A C HEATER ACCESS PANEL SUPPLY AIR DUCT B Supply Opening 16" 16" E 16" Return Opening 16" RETURN AIR OPENING 16" 1 1 62" 30" NOTES: 16" 2 1 3" 1 1" 7 18" 1 62" 1 2 3 4" Typ. 4" Typ. 38" IT IS RECOMMENDED THAT A BEAD OF SILICONE CAULKING BE PLACED BEHIND THE SIDE MOUNTING FLANGES AND UNDER TOP FLASHING AT TIME OF INSTALLATION. 7 8" 1 1 28" 3 62" Dimension is 21" on 95" tall units. Dimension is 10" on T48H1 & T60H1. Dimension is 6" on T48H1 & T60H1. Wall Opening and Hole Location View Right Side View MIS-416 E Manual Page 2100-573 9 of 23 FIGURE 3 WALL-MOUNTING INSTRUCTIONS SEE FIGURE 3 — MOUNTING INSTRUCTIONS WALL STRUCTURE FACTORY SUPPLIED RAIN FLASHING. MOUNT ON UNIT BEFORE INSTALLATION SUPPLY AIR OPENING SUPPLY AIR OPENING SUPPLY AIR DUCT RETURN AIR OPENING RETURN AIR OPENING RETURN AIR OPENING BOTTOM MOUNTING BRACKET. MOUNT ON WALL BEFORE INSTALLING UNIT. WOOD OR STEEL SIDING CONCRETE BLOCK WALL INSTALLATION WOOD FRAME WALL INSTALLATION MIS-548 A SIDE VIEW FIGURE 4 WALL-MOUNTING INSTRUCTIONS SEE UNIT DIMENSIONS, FIGURE 1, FOR ACTUAL DIMENSIONS SEE UNIT DIMENSIONS, FIGURE 2, FOR ACTUAL DIMENSIONS. E + 1.000 ATTACH TO TOP PLATE OF WALL B 1.000 1.000" CLEARANCE ALL AROUND DUCT INTERIOR FINISHED WALL OVER FRAME SUPPLY DUCT OPENING A I 1.000" CLEARANCE ALL AROUND DUCT RETURN DUCT OPENING EXTERIOR FINISH WALL OVER FRAME MIS-549 B Manual 2100-573 Page 10 of 23 ATTACH TO BOTTOM PLATE OF WALL C K 2x6 FRAMING MATERIAL 2 x 4'S, 2 x 6'S &/OR STRUCTURAL STEEL SEE FIGURE 1 FOR DUCT DIMENSIONS CL THIS STRUCTURAL MEMBER LOCATED TO MATCH STUD SPACING FOR REST OF WALL. A SECOND MEMBER MAY BE REQUIRED FOR SOME WALLS. FIGURE 5 COMMON WALL-MOUNTING INSTALLATIONS SUPPLY DUCT MAY BE LOCATED IN AN ATTIC OR BELOW CEILING RAFTERS AS SHOWN RAIN FLASHING RAFTERS RAIN FLASHING FINISHED CEILING SURFACE SUPPLY AIR DUCT SUPPLY AIR DUCT W/ GRILLE FINISHED CEILING SURFACE RETURN AIR OPENING W/ GRILLE RETURN AIR OPENING W/ GRILLE OUTSIDE WALL RAFTERS OUTSIDE WALL FREE AIR FLOW NO DUCT DUCTED SUPPLY RETURN AT UNIT SUPPLY DUCT MAYBE LOCATED IN AN ATTIC OR BELOW CEILING RAFTERS AS SHOWN RAIN FLASHING RAFTERS SUPPLY DUCT MAYBE LOCATED IN AN ATTIC OR BELOW CEILING RAFTERS AS SHOWN RAIN FLASHING SUPPLY AIR DUCT SUPPLY AIR DUCT LOWERED CEILING FINISHED CEILING SURFACE OUTSIDE WALL RAFTERS RETURN AIR SPACE WALL SLEEVE CLOSET WALL FALSE WALL WALL SLEEVE RETURN AIR GRILLE FALSE WALL INSTALLATION OUTSIDE WALL SUPPLY AIR GRILLE FINISHED CEILING SURFACE RETURN AIR GRILLE RAISED FLOOR RETURN AIR CLOSET INSTALLATION MIS-550 B Manual Page 2100-573 11 of 23 FIGURE 6 ELECTRIC HEAT CLEARANCE 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 fire. NOTE 1: Side section view of supply air duct for wall mounted unit showing 1/4 inch clearance to combustible surfaces. WIRING – MAIN POWER WIRING – LOW VOLTAGE WIRING Low Voltage Connection These units use a 24-volt AC low voltage circuit. The “R” terminal is the hot terminal and the “C” terminal is grounded. “G” terminal is the fan input. “Y1” terminal is the compressor input for cooling 1-Stage units only “W1” terminal is the 1st stage electric heat. “W2” terminal is the 2nd stage heat (if equipped). “1” NC (normally closed) lockout alarm. “2” NO (normally open) lockout alarm. “3” COM lockout alarm. “4” & “5” dirty filter alarm NC (normally closed). 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 240 208 RANGE 253 – 216 220 – 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 MV4000 Controller Manual 2100-571. DIRTY FILTER SWITCH & RELAY These units include a dirty filter switch and relay. The alarm output of relay is normally closed, open on alarm and is connected to terminals 4 and 5 of the unit low voltage terminal block. Manual 2100-573 Page 12 of 23 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. 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. 7. R-410A has an ozone depletion potential of zero, but must be reclaimed due to its global warming potential. 8. Store cylinders in a cool area, out of direct sunlight. 8. R-410A compressors use Polyol Ester oil. 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. 9. Polyolester oil is hygroscopic; it will rapidly absorb moisture and strongly hold this moisture in the oil. 10. A liquid line dryer must be used - even a deep vacuum will not separate moisture from the oil. 9. Never heat cylinders above 125°F. 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. 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. Manual Page 2100-573 13 of 23 START UP CONTINUED IMPORTANT INSTALLER NOTE HIGH & LOW PRESSURE SWITCH For improved start-up performance, wash the indoor coil with a dishwasher detergent. All models covered by this Manual are supplied with a remote reset high pressure switch and low pressure switch. If tripped, this pressure switch may be reset by turning the thermostat off then back on again. CRANKCASE HEATERS All units covered in this manual are provided with compressor crankcase heat. This crankcase heater is a band type heater located around the bottom of the compressor. This heater is controlled by the crankcase heater relay. The heater is only energized when the compressor is not running. Crankcase heat is essential to prevent liquid refrigerant from migrating to the compressor, preventing oil pump out on compressor start-up and possible bearing or scroll vane failure due to compressing a liquid. The decal in Figure 7 is affixed to all model units detailing start-up procedure. This is very important. Please read carefully. FIGURE 7 START-UP LABEL IMPORTANT These procedures must be followed at initial start-up and at any time power has been removed for 12 hours or longer. To prevent compressor damage which may result from the presence of liquid refrigerant in the compressor crankcase. 1. Make certain the room thermostat is in the "off" position (the compressor is not to operate). 2. Apply power by closing the system disconnect switch. This energizes the compressor heater which evaporates the liquid refrigerant in the crankcase. 3. Allow 4 hours or 60 minutes per pound of refrigerant in the system as noted on the unit rating plate, whichever is greater. 4. After properly elapsed time, the thermostat may be set to operate the compressor. 5. Except as required for safety while servicing – Do not open system disconnect switch. 7961-061 Manual 2100-573 Page 14 of 23 SERVICE HINTS COMPRESSOR CONTROL MODULE 1. Maintain clean air filters at all times. Also, do not close off or block supply and return air registers. This reduces air flow through the system, which shortens equipment service life as well as increasing operating costs. The compressor control module is standard on the models covered by this manual. The compressor control is an anti-short cycle/lockout timer with high and low pressure switch monitoring and alarm relay output. 2. Check all power fuses or circuit breakers to be sure they are the correct rating. Adjustable Delay On Make And Break Timer 3. Periodic cleaning of the outdoor coil to permit full and unrestricted airflow circulation is essential. Frequency of coil cleaning will depend on duty cycle of equipment, type of use and installation site variables. Telecommunication type installations in high traffic areas or in areas none too frequent to airborne debris, will require more frequent coil maintenance than those in areas not subject to those conditions. SEQUENCE OF OPERATION NON-ECONOMIZER Stage 1 (Y1) cooling call activates Step 1 (partial capacity, 66%) of compressor capacity. Stage 2 (Y2) cooling call activates Step 2 (full capacity, 100%) of compressor capacity. BLOWER TIME DELAY DISABLE In certain applications, there is a requirement/desire to disable the blower one-minute delay (where blower runs for 1 minute after thermostat has satisfied). This could be in a situation that has requirements for fire dampers, or just otherwise desirable. To disable the blower time delay on the HA/L*S models, it can be done by simply disconnecting a single wire at the Compressor Control Module (CCM). Disconnect power to the unit, remove both the inner and outer control panel covers, locate the CCM (left side of control panel above low voltage box). Next, locate the “gray” wire attached to the “R” terminal of the CCM. Remove the “gray” wire and tape the end off. Reverse the steps installing the inner and outer control panel covers, and turn the power back on. On initial power up or anytime power is interrupted to the unit, the delay on make period begins, which will be 2 minutes plus 10% of the delay on break setting. When the delay on make is complete and the high pressure and low pressure switches are closed, the compressor contactor is energized. Upon shutdown the delay or break timer starts and prevents restart until the delay on break and delay on make periods have expired. During routine operation of the unit with no power interruptions, the compressor will operate on demand with no delay. High Pressure Switch and Lockout Sequence If the high pressure switch opens, the compressor contactor will de-energize immediately. The lockout timer will go into a soft lockout and stay in soft lockout until the high pressure switch closes and the delay on break time has expired. If the high pressure switch opens again in this same operating cycle, the unit will go into manual lockout condition and the alarm relay circuit will energize. Recycling the wall thermostat resets the manual lockout. Low Pressure Switch, Bypass and Lockout Sequence If the low pressure switch opens for more than 120 seconds, the compressor contactor will de-energize and go into a soft lockout. Regardless the state of the low pressure switch, the contactor will reenergize after the delay on make time delay has expired. If the low pressure switch remains open, or opens again for longer than 120 seconds the unit will go into manual lockout condition and the alarm relay circuit will energize. Recycling the wall thermostat resets the manual lockout. Optional Low Ambient Control An optional low ambient control is available for both factory and field installed options. The low ambient control is to be applied to the HA4S/HA5S models when operation below 50°outdoor conditions are anticipated. Without this device, the evaporating pressure would fall off, and the indoor coil would ice over. The fan cycling control cycles the fan motor on, once the liquid refrigerant pressure reaches 350 psig, and off, once it has dropped to 225 psig. It will continue to cycle between these parameters depending on outdoor temperatures and the load/stage of the system. This cycling maintains a minimum liquid pressure affecting the minimum suction pressure. This effect insures an evaporating temperature that is slightly above the point of ice formation on the evaporator. Manual Page 2100-573 15 of 23 Alarm Relay Output MOTOR START DEVICE Alarm terminal is output connection for applications where alarm relay is employed. This terminal is powered whenever compressor is locked out due to HPC or LPC sequences as described. Single Phase (-A) model compressor circuits are equipped with a 25 ohm PTCR (Positive Temperature Coefficient Resistor) motor starting device as standard equipment. NOTE: Both high and low pressure switch controls are inherently automatic reset devices. The high pressure switch and low pressure switch cut out and cut in settings are fixed by specific air conditioner or heat pump unit model. The lockout features, both soft and manual, are a function of the Compressor Control Module. The PTCR is wired in parallel with the run capacitor. When voltage is applied, and device is cool, its low resistance permits a large current to flow in the auxiliary windings - increasing the motors available starting torque. The device then rapidly heats up, and the current levels drop to a few milliamperes. The PTCR then becomes self-regulating, passing just enough current to maintain its temperature to remain in the high resistance state. Once the voltage source is removed, the device then cools down and the resistance drops, and is then ready for the next compressor start cycle. ADJUSTMENTS Adjustable Delay on Make and Delay on Break Timer The potentiometer is used to select Delay on Break time from 30 seconds to 5 minutes. Delay on Make (DOM) timing on power-up and after power interruptions is equal to 2 minutes plus 10% of Delay on Break (DOB) setting: 0.5 minute 1.0 minute 2.0 minute 3.0 minute 4.0 minute 5.0 minute (30 seconds) (60 seconds) (120 seconds) (180 seconds) (240 seconds) (300 seconds) DOB =123 DOB =126 DOB =132 DOB =138 DOB =144 DOB =150 second DOM second DOM second DOM second DOM second DOM second DOM During routine operation of the unit with no power interruptions the compressor will operate on demand with no delay. Typical Settings for Dual Unit Installation: Unit 1: DOB set at 2 minutes, and DOM is 132 seconds Unit 2: DOB set at 4 minutes, and DOM is 144 seconds Manual 2100-573 Page 16 of 23 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. Be careful to observe whether unit is operating in high cool or low cool when utilizing the charts. TROUBLESHOOTING COMPRESSOR SOLENOID FAN BLADE SETTING DIMENSIONS A nominal 24-volt direct current coil activates the internal compressor solenoid. The input control circuit voltage must be 18 to 28 volt ac. The coil power requirement is 20 VA. The external electrical connection is made with a molded plug assembly. This plug contains a full wave rectifier to supply direct current to the unloader coil. Shown in the drawing below are the correct fan blade setting dimensions for proper air delivery across the outdoor coil. See Figure 8. Compressor Solenoid Test Procedure If it is suspected that the unloader is not working, the following methods may be used to verify operation. 1. Operate the system and measure compressor amperage. Cycle the compressor solenoid on and off at ten-second intervals. The compressor amperage should go up or down at least 25 percent. 2. If step one does not give the expected results, shut unit off. Apply 18 to 28 volt ac to the solenoid molded plug leads and listen for a click as the solenoid pulls in. Remove power and listen for another click as the solenoid returns to its original position. 3. If clicks can’t be heard, shut off power and remove the control circuit molded plug from the compressor and measure the solenoid coil resistance. The resistance should be 32 to 60 ohms depending on compressor temperature. 4. Next, check the molded plug. Voltage check: Apply control voltage to the plug wires (18 to 28 volt ac). The measured dc voltage at the female connectors in the plug should be around 15 to 27 vdc. Resistance check: Measure the resistance from the end of one molded plug lead to either of the two female connectors in the plug. One of the connectors should read close to zero ohms, while the other should read infinity. Repeat with other wire. The same female connector as before should read zero, while the other connector again reads infinity. Reverse polarity on the ohmmeter leads and repeat. The female connector that read infinity previously should now read close to zero ohms. Replace plug if either of these test methods does not show the desired results. 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. See Table 4. FIGURE 8 FAN BLADE SETTING AIRFLOW "A" MIS-1724 TABLE 4 FAN BLADE DIMENSIONS Model HA/L4S HA/L5S Dimension A 1.75" REMOVAL OF FAN SHROUD 1. Disconnect all power to unit. 2. Remove the screws holding both grills – one on each side of unit – and remove grills. 3. Remove screws holding fan shroud to condenser and bottom – (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. Manual Page 2100-573 17 of 23 TROUBLESHOOTING CONT’D. 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. 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. TABLE 5 COOLING PRESSURE – (ALL TEMPERATURES °F) HIGH CAPACITY COOLING RETURN AIR MODEL TEMPERATURE PRESSURE HA4S HL4S HA5S HL5S AIR TEMPERATURE ENTERING OUTDOOR COIL DEGREE F 5 0 oF 5 5 oF 6 0 oF 6 5 oF 7 0 oF 7 5 oF 8 0 oF 8 5 oF 9 0 oF 9 5 oF HA4S HL4S HA5S HL5S 110oF 115oF 75° D B 62° WB LOW SIDE HIGH SIDE 117 197 119 216 121 235 123 255 125 274 127 293 128 316 130 339 131 361 132 383 133 410 135 438 136 466 137 494 80° D B 67° WB LOW SIDE HIGH SIDE 127 201 129 220 131 239 134 259 136 278 138 298 138 318 139 341 139 364 143 400 143 415 144 443 146 471 149 500 85° D B 72° WB LOW SIDE HIGH SIDE 141 203 143 223 145 243 148 263 150 283 152 303 152 326 153 349 153 372 154 396 156 422 158 449 160 478 162 508 75° D B 62° WB LOW SIDE HIGH SIDE 118 199 119 217 120 236 122 260 123 285 125 309 126 333 128 357 129 381 130 405 132 432 133 460 135 487 136 514 80° D B 67° WB LOW SIDE HIGH SIDE 129 205 130 224 131 247 131 270 132 292 132 315 134 339 137 363 139 387 141 425 143 438 145 465 146 492 148 519 85° D B 72° WB LOW SIDE HIGH SIDE 137 216 139 237 140 258 141 279 142 300 143 321 146 346 148 370 151 395 153 419 155 447 157 474 158 502 160 529 110oF 115oF LOW CAPACITY COOLING MODEL 1 0 0 oF 1 0 5 oF RETURN AIR PRESSURE TEMPERATURE AIR TEMPERATURE ENTERING OUTDOOR COIL DEGREE F 5 0 oF 5 5 oF 6 0 oF 6 5 oF 7 0 oF 7 5 oF 8 0 oF 8 5 oF 9 0 oF 9 5 oF 1 0 0 oF 1 0 5 oF 75° D B 62° WB LOW SIDE HIGH SIDE 122 184 124 201 125 218 127 236 129 254 131 272 131 291 132 312 133 335 134 359 135 381 137 407 139 435 141 463 80° D B 67° WB LOW SIDE HIGH SIDE 132 185 134 203 136 221 138 239 140 257 142 275 145 298 146 317 147 339 148 362 149 384 150 410 151 438 152 467 85° D B 72° WB LOW SIDE HIGH SIDE 145 187 147 205 149 223 152 241 154 259 156 278 156 397 157 319 158 343 159 369 161 390 163 415 164 443 165 472 75° D B 62° WB LOW SIDE HIGH SIDE 123 187 125 207 127 226 129 245 131 263 133 282 134 305 135 328 136 350 137 373 139 399 141 425 143 451 145 477 80° D B 67° WB LOW SIDE HIGH SIDE 134 192 136 211 138 230 139 248 141 267 143 286 145 308 147 331 149 353 151 375 153 402 155 429 156 456 158 483 85° D B 72° WB LOW SIDE HIGH SIDE 146 200 148 217 149 235 151 252 152 270 154 287 156 311 159 335 161 358 163 382 165 408 166 434 168 460 169 486 Low side pressure ± 4 psig High side pressure ± 10 psig Manual 2100-573 Page 18 of 23 TROUBLESHOOTING GE ECM™ MOTORS CAUTION: Symptom Cause/Procedure 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. • 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 Symptom Cause/Procedure Motor rocks slightly when starting • This is normal start-up for ECM • “Hunts” or “puffs” at high CFM (speed) • Does removing panel or filter reduce “puffing”? - Reduce restriction - Reduce max. airflow Motor won’t start • No movement • Check blower turns by hand • 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 • Motor rocks, but won’t start • Check for loose or compliant motor mount • Make sure blower wheel is tight on shaft • Perform motor/control replacement check Motor oscillates up & down while being tested off of blower • It is normal for motor to oscillate with no load on shaft Motor starts, but runs erratically • Varies up and down or intermittent • Check line voltage for variation or “sag” • 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 Evidence of Moisture • Motor failure or malfunction has occurred and moisture is present • Replace motor and Perform Moisture Check • Evidence of moisture present inside air mover • Perform Moisture Check Do Don’t • Check out motor, controls, wiring and connections thoroughly before replacing motor • Orient connectors down so water can’t get in - Install “drip loops” • Use authorized motor and model #’s for replacement • Keep static pressure to a minimum: - Recommend high efficiency, low static filters - Recommend keeping filters clean. - Design ductwork for min. static, max. comfort - Look for and recommend ductwork improvement, where necessary • Automatically assume the motor is bad. • Size the equipment wisely • “Hunts” or “puffs” at high CFM (speed) • Does removing panel or filter reduce “puffing”? - Reduce restriction - Reduce max airflow • Stays at low CFM despite system call for cool or heat CFM • Check low voltage (Thermostat) wires and connections • 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 • Check orientation before inserting motor connectors • Locate connectors above 7 and 4 o’clock positions • Replace one motor or control model # with another (unless an authorized replacement) • Use high pressure drop filters some have ½" H20 drop! • Use restricted returns • Oversize system, then compensate with low airflow • Plug in power connector backwards • Force plugs Moisture Check • Blower won’t shut off • Current leakage from controls into G, Y or W? Check for Triac switched thermostat or solidstate relay Excessive noise • Determine if it’s air noise, cabinet, duct or motor noise; interview customer, if necessary • High static creating high blower speed? - Is airflow set properly? - Does removing filter cause blower to slow down? Check filter - Use low-pressure drop filter - Check/correct duct restrictions • Air noise • 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 Page 2100-573 19 of 23 TROUBLESHOOTING GE ECM™ MOTORS CONT’D. Replacing ECM Control Module To replace the control module for the GE variable-speed indoor blower motor you need to take the following steps: 1. You MUST have the correct replacement module. The controls are factory programmed for specific operating modes. Even though they look alike, different modules may have completely different functionality. USING THE WRONG CONTROL MODULE VOIDS ALL PRODUCT WARRANTIES AND MAY PRODUCE UNEXPECTED RESULTS. 2. Begin by removing AC power from the furnace or air handler being serviced. DO NOT WORK ON THE MOTOR WITH AC POWER APPLIED. To avoid electric shock from the motor’s capacitors, disconnect power and wait at least 5 minutes before opening motor. 3. It is usually not necessary to remove the motor from the blower assembly. However, it is recommended that the whole blower assembly, with the motor, be removed from the furnace/air handler. (Follow the manufacturer’s procedures). Unplug the two cable connectors to the motor. There are latches on each connector. DO NOT PULL ON THE WIRES. The plugs remove easily when properly released. 4. Locate the two standard 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 9. 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 10. (Measure to unpainted motor end plate.) If any motor lead fails this test, do not proceed to install the control module. THE MOTOR IS DEFECTIVE AND MUST BE REPLACED. Installing the new control module will cause it to fail also. 7. Verify that the replacement control is correct for your application. Refer to the manufacturer's authorized replacement list. USING THE WRONG CONTROL WILL RESULT IN IMPROPER OR NO BLOWER OPERATION. Orient the control module so that the 3-wire motor plug can be inserted into the socket in the control. Carefully insert the plug and press it into the socket until it latches. A SLIGHT CLICK WILL BE HEARD WHEN PROPERLY INSERTED. Finish installing the replacement control per one of the three following paragraphs, 8a, 8b or 8c. 8a. IF REPLACING AN ECM 2.0 CONTROL (control in cast aluminum can with air vents on the back of the can) WITH AN ECM 2.3 CONTROL (control containing black potting for water protection in black deep-drawn steel case with no vents in the bottom of the can), locate the two through-bolts and plastic tab that are packed with the replacement control. Insert the plastic tab into the slot at the perimeter of the open end of the can so that the pin is located on the inside of the perimeter of the can. Rotate the can so that the tab inserts into the tab locater hole in the endshield of the motor. Using the two through-bolts provided with the replacement control, reattach the can to the motor. THE TWO THROUGH-BOLTS PROVIDED WITH THE REPLACEMENT ECM 2.3 CONTROL ARE SHORTER THAN THE BOLTS ORIGINALLY REMOVED FROM THE ECM 2.0 CONTROL AND MUST BE USED IF SECURE ATTACHMENT OF THE CONTROL TO THE MOTOR IS TO BE ACHIEVED. DO NOT OVERTIGHTEN THE BOLTS. Manual 2100-573 Page 20 of 23 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 11. The installation is now complete. Reapply the AC power to the HVAC equipment and verify that the new motor control module is working properly. Follow the manufacturer's procedures for disposition of the old control module. Figure 410 Figure Winding Test Figure 9 3 Control Disassembly Motor Connector (3-pin) Only remove From Motor Hex Head Bolts Push until Latch Seats Over Ramp Circuit Board Motor ECM 2.0 Motor OK when R > 100k ohm Note: Use the shorter bolts and alignment pin supplied when replacing an ECM 2.0 control. Figure Figure11 5 Drip Loop ECM 2.3/2.5 Motor Connector (3-pin) Back of Control Connector Orientation Between 4 and 8 o'clock Control Connector (16-pin) Power Connector (5-pin) Hex-head Screws Drip Loop TABLE 6 INDOOR BLOWER PERFORMANCE 1 Rated ESP MAX ESP 2 Continuous C FM HA/L4S 0.20 0.80 825 1100 1500 1100 1500 HA/L5S 0.20 0.80 850 1300 1700 1100 1500 Model 3 Rated 1st Stage CFM 4 Rated 2nd Stage CFM 5 5-10 KW C FM 6 15-20 KW C FM 1 Motor will deliver consistent CFM through voltage supply range with no deterioration. (197-253V for 230/208V models, 414-506V for 460V models) 2 Continuous CFM is the total air being circulated during continuous (manual) fan mode. 3 Will occur automatically with a call for "Y1" signal from thermostat. 4 Will occur automatically with a call for "Y2" signal from thermostat. 5 Will occur automatically with a call for "W1" signal from thermostat. 6 Will occur automatically with a call for "W2" or "Emergency Heat" signal from thermostat. TABLE 7 MAXIMUM ESP OF OPERATION ELECTRIC HEAT ONLY KW-Heat -A05 -A08 -A10 -A15 -A20 HA/L4S .80 .80 .80 .80 .80 HA/L5S .80 .80 .80 .80 .80 Manual Page 2100-573 21 of 23 DESCRIPTION EHWA4S-A05 Heater Package X EHWA4S-A10 Heater Package X EHWA4S-A15 Heater Package X EHWA4S-A20 Heater Package X EHWA5S-A05 Heater Package EHWA5S-A08 Heater Package EHWA5S-A10 Heater Package X EHWA5S-A15 Heater Package X EHWA5S-A20 Heater Package X BOP-5 Blank Off Plate (Standard) X X CRVMP-5 Classroom Ventilator with Exhaust (3-Position) X X EIFM-5C Economizer with Exhaust X X WERV-A5B Energy Recovery Ventilator X X WERV-C5B Energy Recovery Ventilator Manual 2100-573 Page 22 of 23 HA5S3KA MODEL HA4S3KA TABLE 8 OPTIONAL ACCESSORIES X X X HL5S2KA MODEL DESCRIPTION HL4S2KA TABLE 9 OPTIONAL ACCESSORIES EHWA4S-A05L Heater Package X EHWA4S-A10L Heater Package X EHWA4S-A15L Heater Package X EHWA4S-A20L Heater Package X EHWA5S-A05L Heater Package EHWA5S-A08L Heater Package EHWA5S-A10L Heater Package X EHWA5S-A15L Heater Package X EHWA5S-A20L Heater Package X EHWA3S-B06L Heater Package EHWA5S-B06L Heater Package EHWA5S-B09L Heater Package EHWA5S-B15L Heater Package EHWA5S-C06L Heater Package EHWA5S-C09L Heater Package EHWA5S-C15L Heater Package BOP-5 Blank Off Plate (Standard) X X CRVMP-5 Classroom Ventilator with Exhaust (3-Position) X X EIFM-5C Economizer with Exhaust X X WERV-A5B Energy Recovery Ventilator X X WERV-C5B Energy Recovery Ventilator X X X Manual Page 2100-573 23 of 23 ">

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Key features
- R-410A refrigerant
- Ductless or ducted
- Compressor control module
- High & Low pressure switch
- 2-inch pleated filter
- Crankcase heater