Barco R9010510 Projector User Manual
Contents
1. 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 ANSI ASHRAE NFPA Air Conditioning Contractors of America 1712 New Hampshire Ave N W Washington DC 20009 Telephone 202 483 9370 Fax 202 234 4721 American National Standards Institute 11 West Street 13th Floor New York NY 10036 Telephone 212 642 4900 Fax 212 302 1286 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 National Fire Protection Association Batterymarch Park P O Box 9101 Quincy MA 02269 9901 Telephone 800 344 3555 Fax 617 984 7057 Manual 2100 455A Page 3 of 25 WALL MOUNT GENERAL INFORMATION HEAT PUMP WALL MOUNT MODEL NOMENCLATURE CH 4S 1 A 05 B X X X MODEL NUMBER CAPACITY 3S 3 ton 4S 4 ton 5S 5ton VOLTS amp PHASE A 230 208 60 1 B 230 208 60 3 C 460 60 3 VENTILATION OPTIONS B Blank off Plate R Energy Recovery V Commercial Ventilator Motorized with Exhaust REVISIONS FILTER OPTIONS P 2 Inch Pleated TABLE 1 ELECTRIC HEAT TABLE2. N 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 but is not required The unit itself is suitable for 0 inch clearance Ifa combustible wall use a minimum of 30 x 10 dimensions for sizing However it is generally recommended that a 1 inch clearance is used for ease of installation The supply air opening would then be 32 x 12 See Figures 3 and 4 for details Locate and mark lag bolt locations and bottom mounting bracket location See Figure 3 Mount bottom mounting bracket Hook top rain flashing under back bend of top Top rain flashing 1s shipped with unit attached to back of unit on the right side Position unit in opening and secure with 5 16 lag bolts use 3 4 inch diameter flat washers on the lag bolts Secure rain flashing to wall and caulk across entire length oftop See Figure 3 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 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 l
3. 316 340 364 389 413 439 464 489 CH5S1 80 DB LOW SIDE 145 147 149 151 152 153 154 155 155 67 WB HIGH SIDE 300 324 349 373 399 424 450 476 502 85 DB LOWSIDE 150 152 154 156 157 158 159 160 160 72 WB HIGH SIDE 311 335 361 386 443 439 466 493 520 Low side pressure 2 PSIG High side pressure 5 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 instruction Manual 2100 455A Page 240f25 uononJjsul ejejd jenes o peBjeuoeJ pue pejenoe e ulejs s parowa eq pjnous eBJeuo y uiejs s y ui Buraq eBueuo Buneiu do 1284109 o se jqnop Aue si alay J llo5 JojeJodena ay ssoJoe moje W49 pejeJ uodn peseq ae se qe ISd S eJnsseJd epis ufi DISd Z F eJnssaJd epis M07 90t 18 8se 8 6 90 tez S82 67e Sc Ke S42 ACIS H IH e SG 6LL 901 G6 38 OZ v9 09 8S 9S 8S 3015 MOT Hv 88 79 Bre Lee 91 SOE 62 v8c Ble amp ezc Le End 301S HOIH 0ZL 6v 0 L ELL 66 28 Z OZ v9 c9 19 9 Adis MOI civ 68 69 OSE VEE Oze 80 86c L6Z 98c 8z 82 083 Sz 301S H IH 9vL vel cc LLL LOL L6 8 GZ 89 29 ZS S 6v 9r 3qIS MOI SYNLVYAdWAL 33 33H93Q 109 YOOGLNO ONIYALNA SYNLVYAdWAL div SNILV3H ALIOVdVO MOT d 18Vlaunssasd tL 3
4. SWIG Q33In034 SWWIUVN 318uSn8WNO25 NOY3 JINVIVIT9 NIW D NIVINIVIN OL SWIG Q331n034 suononugsu Dununoy IeM SSHO PUE SPHO Manual 2100 455A Page 11 of 25 FIGURE 5 ELECTRIC HEAT CLEARANCE Typical Building Outside Sheeting Wall Frame Inside Sheeting Supply Air D Unit 1 OPTIONAL CLEARANCE Supply Air Duct RECOMMENDED Flange of Wall Side section view of supply air duct for wall mounted unit showing 0 clearance to combustible surfaces A MIS 2210 Note This unit is approved for 0 clearance but the optional I clearance is recommended See Figures 3 amp 4 Manual 2100 455A Page 120f25 Exterior wood or steel siding wall Factory supplied rain flashing Attach to unit before installing CH Unit FIGURE 6 WALL MOUNTING INSTRUCTIONS Interior finished wall Supply opening Framing material 2x4 s 2x6 s and or structural steel Return IL opening Bottom mounting bracket Mount on wall before installing unit Follow all local building codes when framing wall to support unit MIS 2024 FIGURE 7 WALL MOUNTING INSTRUCTIONS 44 7 8 i 29 7 8 9 13 16 Y E Supply Opening i 1 clearance 6 1 8 ry 15 7 8 Y ry AR gt o S 75 D
5. a 1 clearance gt m 51 1 4 Locate stud to match spacing for rest of wall A second member may be required for some walls These structural members must be able to support the entire weight of the I unit Follow all local building codes when framing wall to support unit MIS 2025 Manual 2100 455A Page 13 of 25 FIGURE 8 COMMON WALL MOUNTING INSTALLATIONS Unit outside Free Air Flow No Duct Rafters Outside Wall ly Air Return Air Grille Finished Ceiling Free Air Flow No Duct Low Sound With Acoustical Plenums And Isolation Curbs Isolation Curb Supply Plenum WAFB51 X WAPR11 X Unit outside False Wall Installation Note duct maybe in attic or below rafters as shown Rafters Supply Air Duct Finished Ceiling Wall Sleeve Ducted Supply Retum At Unit Note duct maybe in attic or below rafters as shown Unit outside Rafters Supply Air gt Duct CR Finished Ceiling Outside Wall Return Air False Wall Grille oo Outside Wall Note direction of return grille louvers is pointed down
6. CH3S1 A CH3S1 B L CONTROL MODULES COIL OPTIONS X Standard OUTLET OPTIONS X Front Standard T Top Outlet COLOR OPTIONS X Beige Standard 4 Buckeye Gray 5 Desert Brown 8 Dark Bronze CH4S1 A CH4S1 B CH4S1 C CH3S1 C CH5S1 A CH5S1 B CH5S1 C aor 2081 2003 2083 asos 20091 201 2003 2083 aeos A BTU A pru A pru A Bu A BTU A BTU A BTU A ETU A TU A Bru CEA sp soie 5 aos iuo 1e 12800 swa n qeez meso 14 4 rozo F s E 0 l E NT RES pwepese ws swe zz oe s sa 2006 tzs 1596o 72 aos Ls E pee pee er ee es soo peer pen pe rn es sro e E EC EC E ret LH T T pet ll T T Manual 2100 455A Page 40f25 me DII Jes eem s en os ua sew 1 Ll 9t LCSIW s joH Buyuno y eM Z S ouenug eBeyoA yH dO lic 49 6 8 Bulyse 4 uley dol mal yoeg 8IL 9 94 1 8r I 8l 9 9WeL 6 Buiuedo unay Buiuedo Kjddng 48 1 62 r M8IA 9pIS JUDI Jooq 8020 18 2 94 6 9 Suoisuaulig HUN S H9 M8I u01J ued uieJp guondo Jo ueq Jooq SS9IMY uondo Jue Jooq Ssoooy J l4 100 Sseooy JOMO g B E V 18 8 LE eouenu3 eDeyoA UBIH eouenu3 oDeyoA MoT oog ssaooy 8 l Jeyealg 9 1 v9 L EL S Jooq eued jo3uo2 l
7. SOLID STATE HEAT PUMP CONTROL 3 Turn thermostat blower switch to auto position TROUBLESHOOTING PROCEDURE Indoor blower should stop 1 Turn on AC power supply to indoor and outdoor 4 Set system switch to heat or cool Adjust thermostat units to call for heat or cool The indoor blower E i compressor and outdoor fan should start 2 Turn thermostat blower switch to fan on The indoor P blower should start If it doesn t troubleshoot NOTE Ifthere was no power to 24 volt transformer indoor unit and correct problem the compressor and outdoor fan motor will not start for 5 minutes This is because of the compressor short cycle protection TABLE 5 TROUBLESHOOTING SYMPTOM POSSIBLE CAUSES WHAT TO CHECK HOW TO CHECK OR REPAIR Compressor Control circuit wiring Check for R connection at unit Run R connection to outdoor unit to power heat contactor does not and 24 volt between R C pump control energize heating or Compressor lock out 1 Check for 24V between 1 If no voltage between L1 C turn thermostat cooling L1 C on heat pump control off and on again to reset high pressure switch 2 Check across high 2 If high pressure switch is open and will not pressure switch reset replace high pressure switch Compressor short cycle Check for 24 V between CC C If no voltage between CC C jumper speed up protection and Y C on heat pump control terminal and within 10 seconds power should appear between CC C Remove speed up jump
8. assembly out the left side of the unit 6 Service motor fan as needed 7 Reverse steps to reinstall R 410A REFRIGERANT CHARGE The correct system R 410A charge is shown on the unit rating plate Optimum unit performance will occur with a refrigerant charge shown on the unit serial plate If correct charge is in doubt recover the refrigerant and recharge per the charge on the unit rating plate See Table 7 for proper subcooling levels for evaluation of proper charge TABLE 7 9 REFRIGERANT CHARGE SUBCOOLING LEVEL COOLING HEATING Rated 95 OD 80 OD 47 OD 35 OD Airflow Temperature Temperature Temperature Temperature CH3S1 1100 16 20 15 19 28 32 26 30 CH4S1 1500 18 22 17 21 20 24 15 19 CH5S1 1700 26 30 20 24 31 35 27 31 Expected subcooling levels during high capacity Stage 2 operation Above subcooling levels are provided to troubleshoot low charge or overcharged conditions If charge is in doubt evacuate and recharge the unit to the refrigerant charge listed on the serial plate TABLE 8 INDOOR BLOWER PERFORMANCE Rated E n a Model ESP Max 2nd Stage Cooling 1st Stage Cooling Blower Only Electric Heat ESP 2nd Stage Heating 1st Stage Heating or Vent Mode CH3S1 15 5 800 800 1100 CH4S1 2 5 1100 850 1700 CH5S1 2 5 1300 850 1700 NOTE These units are equipped with a variable speed ECM indoor motor that automatically adjusts itself to maintain approximately the same rate o
9. for lowest sound level as shown MIS 2027 Manual 2100 455A 14 of 25 Page FIGURE 9 COMMON WALL MOUNTING INSTALLATIONS Closet Installation Note duct maybe in attic or below rafters as shown Rafters pua J y u Finished Ceiling Grille DL E y Wall Sleeve E Unit outside L Outside Wall Retum Air Closet Wall Closet Wall Raised Closet Floor Grille C Ceu O E MIS 2240 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
10. 17 0 50514 18 0 49028 19 0 47590 20 0 46200 21 0 44855 22 0 43554 23 0 42295 24 0 41077 Manual 2100 455A Page 21 of 25 COMPRESSOR SOLENOID 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 PN 029 0311 00 This plug contains a full wave rectifier to supply direct current to the unloader coil 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
11. 91 11 v8 Jooq Sseooy JejeoH NT w9L E cv a 48 1 EV M8IA do snnm dni pandas 7 89 J8 no dol jeuondo 48 2 6 SNOISN3MIG LINN L 3YNDIA M8IA PIS 491 2100 455A Manual 5 of 25 Page V 0202 SIN M8IA epis 144 IA JUOL M8IA 1988 ued uleJp soH Padi com Jeuondo 10 ureJq uleiq deny SH E TT Butui eM cL LI 100g sseooy suas i eDeyoA u iH Ido jd 8 S LY s B lloA uBiH liz 191 68 pu Miss NN 1 ms ace MA lt lt lt gt uondo quen used 3 uley dol 9er G i l Jooq i lt was 8 1 6 BuiuedQ Jeueg jo3u05 i I Ss800V 19 d 1 wnay V 8r i ILE D Mo Jomolg 48 1 9 00d A QUEL 6 Ssoo9y JojeoH y 5 E lt 91 zg G L 67 94 69 AE d r M8IA do i I EI 48 2 6 suoisueuli HUN wLSGHO PUE LSTHO SNOISN3WIG LINN 34N913 Bl M8IA 9pIS 487 2100 455A 6 of 25 Manual Page TABLE 2 ELECTRICAL SPECIFICATIONS SINGLE CIRCUIT DUAL CIRCUIT Rated No 0 0 Volts amp Field Minimum Maximum Fi ini ircui Maximum Field Power Ground Phase Power Circuit External i i External Fuse Wire Size Wire Size Ciruits Ampacity Fuse or Wi i or Circuit Circuit Breaker Breaker CH381 A0Z 230 208 1 230 208 1
12. 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 ofthe 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 FAN BLADE SETTING DIMENSIONS Shown in Figure 13 are the correct fan blade setting dimensions for proper air delivery across the outdoor coil Any service work requiring removal or adjustment in the fan and or motor area will require that the dimensions below be checked and blade adjusted in or out on the motor shaft accordingly Manual 2100 455A Page 220f25 FIGURE 13 FAN BLADE SETTING AIRFLOW MIS 1272 TABLE 6 FAN BLADE DIMENSION REMOVAL OF FAN SHROUD Disconnect all power to the unit m 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
13. jumper sen jump on the control that can be used at any outdoor ambient during the heating cycle to simulate a 0 coil temperature This can be used to check defrost operation of the unit without waiting for the outdoor ambient to fall into the defrost region By placing a jumper across the SEN JMP terminals a 1 4 inch QC terminal works best the defrost sensor mounted on the outdoor coil is shunted out and will activate the timing circuit This permits the defrost cycle to be checked out in warmer weather conditions without the outdoor temperature having to fall into the defrost region In order to terminate the defrost test 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 SH x E CONTROL CIRCUIT O 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 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 60 O 9 O SN JP 00 MIS 1174 Manual 2100 455A Page 19 of 25 TROUBLESHOOTING
14. make starting indoor blower motor HEATING STAGE 2 Circuit R Y2 makes at the thermostat energizing the 2nd stage solenoid in the compressor COMPRESSOR CURRENT amp PRESSURE CONTROL MODULE The compressor control module monitors compressor current and pressure and prevents internal overload trips due to low voltage or extremely high ambient temperatures by de energizing the full capacity compressor solenoid The control monitors current to the compressor and discharge pressure If current is sensed that is in excess of 93 of the compressor maximum continuous current rating or pressure is sensed greater than 525 PSI the compressor control module de energizes for a time as determined by the time potentiometer on the compressor control module This will drop the current draw and pressure and allow the compressor to run at 75 percent of capacity rather than not at all Once the time period has elapsed the full capacity compressor solenoid will re energize and try again to run at full capacity If the pressure or current is exceeded again the coil will again de energize This sequence will repeat until the ambient temperature drops or the line voltage increases enough that the trip values are not exceeded The relay on the compressor control module is a single pole double throw relay The full capacity compressor solenoid connects to the common terminal of the relay Once current is sensed by the compressor control module the relay cl
15. may limit this cabinet to installation only in a single story structure 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 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 door CONDENSATE DRAIN EVAPORATOR 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 INSTALLATION INSTRUCTIONS WALL MOUNTING INFORMATION 1 2 3 J Two holes for the supply and return air openings must be cut through the wall as shown in Figure 3 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 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
16. operating charge and an adequate duct system than a straight air conditioning unit 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 Manual 2100 455A Page 80f25 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 These units are suitable for 0 inch clearance to combustible material See Wall Mounting Instructions and Figures 3 4 5 6 amp 7 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 NOTE Ifno return air duct is used applicable installation codes
17. 1 143 144 146 148 150 67 WB HIGH SIDE 345 368 391 416 441 467 494 523 552 85 DB LOW SIDE 144 145 145 146 148 149 151 153 155 72 WB HIGH SIDE 357 381 405 431 456 483 511 541 571 High side pressure 5 PSIG Low side pressure 2 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 instruction TABLE 11 PRESSURE TABLE LOW CAPACITY COOLING AIR TEMPERATURE ENTERING OUTDOOR COIL DEGREE F RETURN AIR 7 ha ha A T T T MODEL TEMPERATURE PRESSURE 100 F 105 F 110 F 115 75 DB LOW SIDE 139 140 141 142 143 145 147 149 151 62 WB HIGH SIDE 259 284 308 333 359 385 410 438 464 CH3S1 80 DB LOWSIDE 149 150 151 152 153 155 157 159 161 67 WB HIGH SIDE 266 291 316 342 368 395 421 449 476 85 DB LOW SIDE 154 155 156 157 158 160 162 165 167 72 WB HIGH SIDE 275 301 327 354 381 409 436 465 493 75 DB LOW SIDE 137 137 139 140 141 143 144 146 147 62 WB HIGH SIDE 281 301 323 345 370 394 419 447 475 CHAS1 80 DB LOW SIDE 146 147 149 150 151 1153 154 156 1577 67 WB HIGH SIDE 288 309 331 354 379 404 430 458 487 85 DB LOW SIDE Sil 152 154 155 156 158 159 161 162 72 WB HIGH SIDE 298 320 343 366 392 418 445 474 504 75 DB LOWSIDE 136 137 139 141 142 143 144 145 145 62 WB HIGH SIDE 293
18. 18V1 uononuasur ajejd jenes o paBieyoas pue pejenoe e uiejs s parowa eq pinoys eBJeuo ay waysAs eu u Bulaq eBueuo Buneiu do 1284102 o se jqnop Aue si alay J jIo9 JojeJodena ay ssoJoe moje N32 pe es uodn peseq ae se qe DISd S eJnsseJd epis yH Sd Z F eJnsseJd epis Mo Adis H9IH Addis MOT 30 S HSIH 3qIS MOI 062 adis HOM by aas MOT 3univH3dWaL ccc ODER 3 334930 109 dOOULAO SNIH3LN3 38i vga3diWat HIY SNI1V3H ALIOVdVO H9IH 319VW13Y4NSSIYA cl 318V1 2100 455A Manual Page 25 of 25
19. 230 208 1 230 208 1 230 208 3 230 208 3 230 208 3 230 208 3 CH3S1 C0Z C06 230 208 1 230 208 1 230 208 1 230 208 1 230 208 1 230 208 1 230 208 3 230 208 3 230 208 3 230 208 3 230 208 3 230 208 1 230 208 1 230 208 1 230 208 1 230 208 1 230 208 1 230 208 3 230 208 3 230 208 3 230 208 3 230 208 3 Maximum size of the time delay fuse or HACR type circuit breaker for protection of field wiring conductors Based on 75 C copper wire All wiring must conform to NEC and all local codes These Minimum Circuit Ampacity values are to be used for sizing the field power conductors Refer to the National Electric Code latest revision Article 310 for power conductor sizing CAUTION When more than one field power conductor 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 3 conductors are in a raceway Manual 2100 455A Page 7 of 25 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 The refrigerant system is completely assembled and charged All internal w
20. 52H1000 THERMOSTAT BARD PART 8403 052 I ooeeopeo e 9 1F93 380 THERMOSTAT BARD PART 8403 049 e nome oec UNIT LOW VOLTAGE TERMINAL BLOCK 56 paa Factory Jumper MIS 2026 A Nine 9 wires should be run from thermostat subbase to the 24V terminal board in the unit A nine conductor 18 gauge copper color coded thermostat cable is recommended The connection points are shown in Figure 10 IMPORTANT Only the thermostat combinations as shown above will work with this equipment TABLE 3 THERMOSTAT WIRE SIZE Transformer VA FLA Wire Gauge Maximum Distance In Feet 20 gauge 18 gauge 55 2 3 16 gauge 14 guage 12 guage Manual 2100 455A Page 15 of 25 LOW VOLTAGE CONNECTIONS These units use a grounded 24 volt AC low voltage circuit and require at least a 2 stage heating and a 2 stage cooling thermostat The R terminal is the kot terminal and the C terminal is grounded G terminal is the fan input Y terminal is the compressor Stage 1 input YI terminal is the compressor Stage 2 input B terminal is the reversing valve input The reversing valve must be energized for heating mode R terminal is 24 VAC hot C terminal is 24 VAC grounded L terminal is compressor lockout output This terminal is activated on a high or low pressure trip by the electronic heat pump control This is a 24 VAC output W2 terminal is second
21. Fan Blade Setting Dimensions 22 Removal of Fan Shroud 22 Refrigerant Charge R 410A 22 Pressure Tables 24 25 Tables Table 1 Electric Heat Table 4 Table2 Electrical Specifications 7 Table 3 Thermostat Wire Size 15 Table 4 Wall Thermostat 16 Table5 Troubleshooting 20 Table 6 Fan Blade Dimensions 22 Table 7 Refrigerant Charge 23 Table 8 Indoor Blower Performance 23 Table 9 Maximum ESP of Operation 23 Table 10 Pressure Table High Cooling 24 Table 11 Pressure Table Low Cooling 24 Table 12 Pressure Table High Heating 25 Table 13 Pressure Table Low Heating 25 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
22. INSTALLATION INSTRUCTIONS WALL MOUNTED PACKAGE HEAT PUMPS Models CH3 S1 CH4S1 CH5 S1 NOTE Tuis Is AN R 410A HIGH PRESSURE REFRIGERANT SYSTEM 1 Bard Manufacturing Company Inc Manual 2100 455A f Bryan Ohio 43506 Supersedes 2100 455 ile Volume III Tab 17 Since 1914 Moving ahead just as planned Date 08 18 06 CLIMATE CONTROL SOLUTIONS Page 1 of 25 Copyright 2004 CONTENTS Getting Other Information and Publications For More Information 3 Wall Mount General Heat Pump Wall Mount Model Nomenclature 4 Shipping Damage 8 c r 8 Duct WOIK u u acicate arisen ess Dea da 8 A xni denieiileladies apu iasi 8 Condensate Drain Evaporator 8 Installation Instructions Wall Mounting Information 9 Mounting the Unit ooooonccncccccccnonnccnocononnccnnnnarnnos 9 Wiring Main Power 15 Wiring Low Voltage Wiring 15 Low Voltage Connections 16 Figures Figure 1 Unit Dimensions CH3S1 5 Figure 2 Unit Dimensions CH4S1 8 CH5S1 6 Figure 3 Mounting Instructions CH3S1 10 Figure 4 Mounting Instructions CH4S1 CH5S1 11 Figure 5 Electric Heat Clearance 12 Figure 6 Wall M
23. er after 10 seconds Heat pump control Check all other possible Replace heat pump control defective causes Manual 2100 065 Contactor defective Check for open or shorted coil Replace contactor winding Power phasing not Check for red LED on phase Switch two power leads to the unit correct monitor 3 phase units only Fan outdoor motor Motor defective Check for open or shorted Replace motor does not run motor winding Side As heating Motor capacitor Check capacitor rating Check Replace capacitor er duning defective for open or shorted capacitor defrost Heat pump control Check across fan relay on Replace heat pump control defective heat pump control Com NC Reversing valve Reversing valve solenoid Check for open or shorted coil Replace solenoid coil does not energize coil defective heating only Heat pump control Check for 24V between RV C 1 Check control circuit wiring defective and B C 2 Replace heat pump control Unit will not go into Temperature sensor or Disconnect temperature 1 If unit goes through defrost cycle replace defrost heat pump control sensor from board and jumper temperature sensor heating only defective across speed up terminals and sen jump terminals This 2 If unit does not go through defrost cycle should cause the unit to go replace heat pump control through a defrost cycle within one minute Unit will not come Temperature sensor or Jumper across speed up 1 If unit com
24. es out of defrost cycle replace out of defrost heat pump control terminals This should cause temperature sensor heating only defective the unit to come out of defrost 2 If unit does not come out of defrost cycle within one minute replace heat pump control Manual 2100 455A Page 200f25 CHECKING TEMPERATURE SENSOR 3 Check resistance reading to chart of resistance use OUTSIDE UNIT CIRCUIT sensor ambient temperature Tolerance of part is 10 1 Disconnect temperature sensor from board and from outdoor coil 4 If sensor resistance reads very low then sensor is shorted and will not allow proper operation of the 2 Use an ohmmeter and measure the resistance of the heat pump control sensor Also use ohmmeter to check for short or open 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 F R F R F R 25 0 196871 24 0 190099 23 0 183585 22 0 177318 21 0 171289 20 0 165487 19 0 159904 18 0 154529 17 0 149355 16 0 144374 15 0 139576 14 0 134956 13 0 130506 12 0 126219 11 0 122089 10 0 118108 9 0 114272 8 0 110575 7 0 107010 6 0 103574 5 0 100260 4 0 97064 3 0 93981 2 0 91008 1 0 88139 0 0 85371 1 0 82699 2 0 80121 3 0 77632 4 0 75230 5 0 72910 6 0 70670 7 0 68507 8 0 66418 9 0 64399 10 0 62449 11 0 60565 12 0 58745 13 0 56985 14 0 55284 15 0 53640 16 0 52051
25. f indoor airflow in both heating and cooling dry and wet coil conditions and at both 230 208 or 460 volts Maximum ESP inches WC shown is with 2 thick disposable filter Rated CFM for 2nd Stage Operation required for maximum performance rating O 1st Stage the CFM output on 1st Stage Heating or Cooling Blower only CFM is the total air being circulated during continuous fan mode TABLE 9 MAXIMUM ESP OF OPERATION Manual 2100 455A Page 23 of 25 TABLE 10 PRESSURE TABLE HIGH CAPACITY COOLING RETURN AIR 5 5 5 5 E E MODEL TEMPERATURE PRESSURE 1005 AOS AO Ao 75 DB LOW SIDE 134 134 134 135 137 138 140 143 146 62 WB HIGH SIDE 298 318 339 363 388 415 445 476 510 CH3S1 80 DB LOW SIDE 143 143 143 144 146 148 150 153 156 67 WB HIGH SIDE 306 326 348 372 398 426 456 488 523 85 DB LOW SIDE 148 148 148 149 151 153 155 158 161 72 WB HIGH SIDE 317 337 360 385 412 441 472 505 541 75 DB LOW SIDE 131 133 135 S 138 139 139 140 140 62 WB HIGH SIDE 308 332 356 380 406 431 456 483 509 CHAS1 80 DB LOW SIDE 140 142 144 146 148 149 149 150 150 67 WB HIGH SIDE 316 340 365 390 416 442 468 495 522 85 DB LOW SIDE 145 147 149 151 153 154 154 155 155 72 WB HIGH SIDE 327 352 378 404 431 457 484 512 540 75 DB LOW SIDE 130 131 131 132 134 135 137 138 140 62 WB HIGH SIDE 336 359 381 406 430 455 482 510 538 CH5S1 80 DB LOW SIDE 139 140 140 14
26. facturing 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 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 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 MAXIMUM 12 If compressor removal is necessary always plug compressor immediately after removal Purge with small amount of nitrogen when inserting plugs Manual 2100 455A Page 16 0f25 START UP CONT D 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 sys
27. iring is complete The unit is designed for use with or without duct work Flanges are provided for attaching the supply and return ducts These instructions explain the recommended method to install the air cooled self contained unit and the electrical wiring connections to the unit These instructions and any instructions packaged with any separate equipment required to make up the entire 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 Any heat pump is more critical of proper
28. mporary condition such as a high wind causes the heat pump to have a prolonged defrost cycle the heat pump control will restore the system to heating operation automatically after 10 minutes The heat pump defrost control board has an option of 30 60 or 90 minute setting All models are shipped from the factory on the 60 minute pin If special circumstances require a change to another time remove the wire from the 60 minute terminal and reconnect to the desired terminal The manufacturer s recommendation is for 60 minute defrost cycles Refer to Figure 12 FIGURE 12 DEFROST CONTROL BOARD There is a cycle speed up jumper on the control This can be used to reduce the time between defrost cycle operation without waiting for time to elapse Use a small screwdriver or other metallic object or another 1 4 inch QC to short between the SPEEDUP terminals to accelerate the HPC timer and initiate defrost Be careful not to touch any other terminals with 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
29. ocal or national codes Manual 2100 455A Page 9 of 25 60c SIN jenno do euondo 29 Huljunow apis pulyeq pue do Jo uyfBue auyua Buoje y neo jo peaq e ddy paljddns Buiyse 4 wey leM NX Bio m 8i 7 u pun eJojeq e 4 109818 em ulonog 9h 94 seoe d Z S JOH pa 9L Bugunoy pun 19 m a94 1 En Bue urge 94 1 9l E i 1 1 I pd E q 9 V 9 St STVIMALVW JIAILSNANOO S s ql Ze WO 4 3ONVEV319 ub IVNOILAO NIVLNIVA OL Wid GaYINOsY STVIMALVW JIAILSNANOO 9 a9 Ob oe INO amp 4 3ONVHV31O NIN NIVLNIV OL Wid Q3lno3 3 q 5 g V suononajsu Bugunoyw eM 1S HO SNOLLINYALSNI SNILNDOIN 34N913 Manual 2100 455A Page 10 of 25 V 1Z03 SIIN BuiuadQ y unay J9 29H uB V s Bue J Bununoui epis pury q pue do Jo y 6ua aunua Buoje y neo yo peeq e ddy ES p llddns Buruse uey weo4 SNOILONUYLSNI ONILNNOIN r 3un5i4 yun exojeq esu jexoeJg IeM Woyog seoel d Z sejoH Buyunoyy ot LES to i e d osscssosol 20 98 9 l 9 l 19 a9 E 08 E i al 9 6ulu do unoy 9 Y L 3 4 9 8 Sumado Adans Y co eo SviM3LVIN 318uS08WNO2 WO3 39NYHY312 t TVNOU dO NIVINIVA OL
30. ompressors 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 homeowner to maintain clean air filters at all times Also not to needlessly close off supply and return air registers This reduces airflow through the system which shortens equipment service life as well as increasing operating costs 2 Switching to heating cycle at 75 F or higher outside temperature may cause a nuisance trip of the remote reset high pressure switch Turn thermostat off then on to reset the high pressure switch 3 The heat pump wall thermostats perform multiple functions Be sure that all function switches are correctly set for the desired operating mode before trying to diagnose any reported service problems 4 Check all power fuses or circuit breakers to be sure they are the correct rating 5 Periodic cleaning of the outdoor coil to permit full and unrestricted airflow circulation is essential SEQUENCE OF OPERATION COOLING STAGE 1 Circuit R Y makes at thermostat pulling in compressor contact
31. or 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 of constant air circulation COOLING STAGE 2 Circuit R Y1 makes at the thermostat energizing the 2nd stage solenoid in the compressor Default position is not energized Compressor will run at low capacity until this solenoid is energized Manual 2100 455A Page 18 0f25 HEATING STAGE 1 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 W1 and R Y on each heating on cycle energizing reversing valve solenoid and pulling in compressor contactor starting compressor and outdoor motor R G also make starting indoor blower motor Heat pump heating cycle now in operation The second 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 Stage 1 heat completes R Y circuit pulling in compressor contactor starting compressor and outdoor motor R G also
32. oses and the second stage cooling call 1f present is sent to the full capacity compressor solenoid This sequence prevents damage to the full capacity compressor solenoid by ensuring that the solenoid 1s not energized when the compressor is not running A brief time delay in this sequence also prevents locked rotor amperage during start up from tripping the device and engaging the time delay period DEFROST CYCLE The defrost cycle is controlled by temperature and time on the solid state heat pump control See Figure 12 When the outdoor temperature is in the lower 40 F temperature range or colder the outdoor coil temperature is 32 F or below This coil temperature is sensed by the coil 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 After 60 minutes at 30 F or below the heat pump control will place the system in the defrost mode During the defrost mode the refrigerant cycle switches back to the cooling cycle the outdoor motor stops electric heaters are energized and hot gas passing through the outdoor coil melts any accumulated frost When the temperature rises to approximately 57 F the coil temperature sensor will send a signal to the heat pump control which will return the system to heating operations automatically If some abnormal or te
33. ounting Instructions 13 Figure 7 Wall Mounting Instructions 13 Figure8 Common Wall Mounting Installations 14 Figure9 Common Wall Mounting Installations 15 Figure 10 Unit 24V Terminal Board 15 Figure 11 Low Pressure Control Bypass Timer 17 Figure 12 Defrost Control Board 19 Figure 13 Fan Blade Setting 22 Manual 2100 455A Page 2 of 25 Start Up ApplICatlon 3 enr o a 16 Safety Practice See a EEA 17 Important Installer Note 17 Pressure Service Ports 17 High 8 Low Pressure Switch 17 Three Phase Scroll Compressor Start Up 17 amp 18 Phase Monitor 18 Service Hints aa a r 18 Sequence of Operation 18 Compressor Current amp Pressure Control Module a a i 18 Defrost Cycle 19 Troubleshooting Solid State Heat Pump Control Troubleshooting Procedure 20 Checking Temperature Sensor Outside Unit Circuit 21 Temperature vs Resistance of Temperature 21 Compressor Solenoid 22
34. 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 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 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 FIGURE 10 UNIT 24V TERMINAL BOARD T76
35. sor In the event system pressures go above 540 PSI or below 35 PSI in either cooling or heating mode the compressor will be stopped This will activate the L terminal of the low voltage terminal strip This terminal can be used for remote indication of a pressure lockout The lockout circuit will hold compressor off line When the system problem is corrected the unit operation can be restored by turning the main power supply off and then back on or reset the room thermostat The low pressure control has a bypass to eliminate nuisance lockout on cold start up The bypass timer should be set to 200 seconds and this is to assure there is no nuisance tripping of the low pressure control during startup in heating mode under cold weather conditions See Figure 10 FIGURE 11 LOW PRESSURE CONTROL BYPASS TIMER SECONDS THIS MARK ENUALS 200 LLM 500 PART NU 1CM175 SECINDS E BYPASS 1000 VAN GA oa LOAD MAX LPC INPUT B Tel j MIS 1817 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 s
36. stage heat 1f equipped OI terminal is the ventilation input This terminal energizes any factory installed ventilation option E terminal is the emergency heat input This terminal energizes the emergency heat relay if equipped NOTE For total and proper control using DDC a total of 7 controlled outputs are required 6 if no ventilation system is installed For proper system operation under Emergency Heat conditions where the compressor needs to be deactivated the B W2 E outputs need to be energized Removing the Y compressor signal alone turns the compressor off but does not activate the additional circuitry embedded in the heat pump for proper and complete operation LOW VOLTAGE CONNECTIONS FOR DDC CONTROL Fan Only Energize G Cooling Mode 1st Stage Energize Y G Cooling Mode 2nd Stage Energize Y Y1 G Heat Pump Heating ist Stage Energize Y G B Heat Pump Heating 2nd Stage Energize Y Y1 G B 3rd Stage Heating w Heat Pump if employed Energize G W2 Y B Y1 Ventilation Energize G O1 Emergency Heat Energize B W2 E G TABLE 4 WALL THERMOSTAT Thermostat Predominant Features 2 stg cool 2 stg heat Programmable Electronic Auto or Manual changeover 8403 049 1F93 380 2 stg cool 3 stg heat Programmable Electronic Auto or Manual changeover 8403 052 START UP These units require R 410A refrigerant amp Polyol Ester oil APPLICATION 1 Use separate service and manu
37. tem 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 Use only cylinders rated DOT4BA 4BW 400 Never fill cylinders over 80 of total capacity Store cylinders in a cool area out of direct sunlight oo 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 IMPORTANT INSTALLER NOTE For improved start up performance wash the indoor coil with a dish washing detergent PRESSURE SERVICE PORTS R 410A requires high pressure hose connections and gauges 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 on both cooling and heating cycles It is imperative to match the correct pressure table to the unit by model number HIGH amp LOW PRESSURE SWITCH All models are supplied with a remote reset high and low pressure switch If tripped this pressure switch may be reset by turning the thermostat off then back on again High Low Pressure control provides protection for the compres
38. uch a way as to cause rotation in the reverse direction verification of proper rotation must be made All three phase units incorporate a phase monitor to ensure proper field wiring See the Phase Monitor section later in this manual Verification of proper rotation must be made any time a compressor is changed or rewired 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 Ifcompressor is allowed to run in reverse rotation for several minutes the compressor s internal protector will trip All three phase ZR3 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 Manual 2100 455A Page 17 of 25 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 rotations as well as substantially reduced current draw compared to tabulate values The direction of rotation of the compressor may be changed by reversing any two line connections to the unit PHASE MONITOR All units with three phase c
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