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INSTALLATION INSTRUCTIONS
WALL MOUNTED
PACKAGE HEAT PUMPS
Model
WH611
Bard Manufacturing Company, Inc.
Bryan, Ohio 43506
Since 1914...Moving ahead just as planned.
Manual : 2100-347
I
Supersedes: 2100-347H
File: Volume III Tab 17
Date: 10-21-08
Manual 2100-347 I
Page 1 of 23
CONTENTS
Getting Other Information and Publications
For More Information ............................................... 3
Wall Mount General
Heat Pump Wall Mount Model Nomenclature ....... 4
Shipping Damage ................................................. 6
General .............................................................. 6
Duct Work ....................................................... 6 & 7
Filters .............................................................. 7
Fresh Air Intake ..................................................... 7
Condensate Drain – Evaporator ........................... 8
Condensate Drain – Condenser ........................... 8
Installation Instructions
Wall Mounting Information .................................... 9
Mounting the Unit .................................................. 9
Wiring – Main Power ........................................... 14
Wiring – Low Voltage Wiring ............................... 14
Optional Outdoor Thermostats Applications ........ 15
Electric Heat Hold-Off ......................................... 16
Thermostat Indicators ......................................... 17
Emergency Heat Position ................................... 17
Compressor Malfunction Light ............................ 17
Start Up
Important Installer Note ....................................... 17
Crankcase Heaters ............................................. 17
High Pressure Switch ......................................... 17
Two Speed Outdoor Fan motors ......................... 17
Three Phase Scroll Compressor Start Up ........... 17
Phase Monitor ..................................................... 18
Service Hints ....................................................... 18
Sequence of Operation ....................................... 18
Pressure Service Ports ....................................... 18
Defrost Cycle .............................................. 18 & 19
Troubleshooting
Solid State Heat Pump Control
Troubleshooting Procedure ................................. 20
Checking Temperature Sensor
Outside Unit Circuit ............................................. 21
Temperature vs. Resistance of Temperature ...... 21
Fan Blade Setting Dimensions ........................... 22
Removal of Fan Shroud ...................................... 22
Refrigerant Charge ............................................. 22
Pressure Tables .................................................. 23
Figures
Figure 1 Unit Dimensions .................................. 5
Figure 2 Fresh Air Damper Assembly ................ 7
Figure 3 Condensate Drains .............................. 8
Figure 4 Mounting Instructions ........................ 10
Figure 5 Electric Heat Clearance ..................... 11
Figure 6 Wall Mounting Instructions ................. 12
Figure 7 Wall Mounting Instructions ................. 12
Figure 8 Common Wall Mounting Installations . 13
Figure 9 Unit 24V Terminal Board .................... 14
Figure 10 Compressor Cutoff Thermostat
Wiring ................................................ 15
Figure 11 Compressor Cutoff Thermostat
Wiring ................................................ 15
Figure 12 Electric Heat Hold-Off Wiring ............. 16
Figure 13 Electric Heat Hold-Off Wiring ............. 16
Figure 14 Start Up Procedure Decal .................. 17
Figure 15 Defrost Control Board ........................ 19
Figure 16 Fan Blade Setting .............................. 22
Tables
Table 1 Electric Heat Table ................................ 4
Table 2 Electrical Specifications ........................ 6
Table 3 Thermostat Wire Size ......................... 14
Table 4 Wall Thermostat .................................. 16
Table 5 Troubleshooting .................................. 20
Table 6 Fan Blade Dimensions ........................ 22
Table 7 Refrigerant Charge ............................. 22
Table 8 Rated CFM and Rated ESP ............... 22
Table 9 Indoor Blower Performance ................ 22
Table 10 Maximum ESP of Operation ............... 22
Table 11 Pressure Table - Cooling .................... 23
Table 12 Pressure Table - Heating .................... 23
Manual 2100-347 I
Page 2 of 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.
National Electrical Code ...................... ANSI/NFPA 70
Standard for the Installation .............. ANSI/NFPA 90A of Air Conditioning and Ventilating Systems
Standard for Warm Air ...................... ANSI/NFPA 90B
Heating and Air Conditioning Systems
Load Calculation for ............................ ACCA Manual J
Residential Winter and Summer Air Conditioning
Duct Design for Residential .............. ACCA Manual D
Winter and Summer Air Conditioning and Equipment
Selection
FOR MORE INFORMATION, CONTACT
THESE PUBLISHERS:
ACCA
ANSI
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
ASHRAE American Society of Heating Refrigerating, and Air Conditioning Engineers, Inc.
1791 Tullie Circle, N.E.
Atlanta, GA 30329-2305
Telephone: (404) 636-8400
Fax: (404) 321-5478
NFPA National Fire Protection Association
Batterymarch Park
P.O. Box 9101
Quincy, MA 02269-9901
Telephone: (800) 344-3555
Fax: (617) 984-7057
Manual 2100-347
I
Page 3 of 23
WALL MOUNT GENERAL INFORMATION
HEAT PUMP WALL MOUNT MODEL NOMENCLATURE
MODEL NUMBER
CAPACITY
61 - 5 ton
WH 61 1 – A 08 X X X X X B
REVISIONS
VOLTS & PHASE
A - 230/208/60/1
B - 230/208/60/3
C - 460/60/3
KW
CONTROL
MODULES
COIL OPTIONS
X - Standard
1 - Phenolic Coated Evaporator
2 - Phenolic Coated Condenser
3 - Phenolic Coated Evaporator and Condenser
COLOR OPTIONS
X - Beige (Standard)
4 - Buckeye Gray
OUTLET OPTIONS
X - Front (Standard)
VENTILATION OPTIONS
A - Adjustable Fresh Air Damper
B - Blank-off Plate
C - Commercial Ventilator - Motorized w/o Exhaust
M - Motorized Fresh Air Damper
R - Energy Recovery Ventilator w/Built-In Exhaust
X - Barometric Fresh Air Damper (Standard)
FILTER OPTIONS
X - 1-Inch Throwaway (Standard)
W- 1-Inch Washable
P - 2-Inch Pleated
NOTE: All vent options are without exhaust capability, except Energy Recovery Ventilator. May require separate field supplied barometric relief in building.
TABLE 1
ELECTRIC HEAT TABLE
M o d e l s
A m p
2 4 0 1 s B
W H 6 1 1 A
T U
2 0 8 1
A m p s B T U K W
5
8
9
1 0
2
3
4
-
0
3
1
-
.
.
.
8
3
6
1
2
3
7
7
4
-
,
,
-
0
2
, 1
-
6
8
5
0
3 0
1
2
3
-
8
8
-
6
-
.
.
.
1
8
2
1
2
2
2
0
5
-
,
,
-
8
4
, 6
-
0
5
0
0
0 0
W H 6 1 1 B
2 4 0 3
A m p s B T U A m p
2 0 8 3 s B T U
2
-
-
-
-
-
1
-
-
-
.
-
7 3 0
-
-
-
-
-
-
, 6
-
0 0 1
-
-
-
-
-
8
-
-
-
.
7 2 3
-
-
-
-
-
, 0
-
-
-
-
3 0
W H 6 1 1 C
4 6 0 3
A m p s B T U
1
-
-
-
-
0
-
-
-
-
.
8 3 0
-
-
-
-
-
-
, 7 0 0
-
Manual 2100-347
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Page 4 of 23
Manual 2100-347
I
Page 5 of 23
TABLE 2
ELECTRICAL SPECIFICATIONS
M o d e l
W H 6 1 1 A 0 0 , A 0 Z
W H 6 1 1 B 0 0 ,
W H 6 1 1 C 0 0 ,
A 0 5
A 0 8
A
B
C
C
1 0
B 0 Z
0 9
0
0
Z
9
R a t e d
V o l t s &
P h a s e
2 3 0 / 2 0 8 1
2 3 0 / 2 0 8 1
2 3 0 / 2 0 8 1
2 3 0 / 2
2 3 0 / 2
2 3 0 / 2
4
4
6
6
0
0
0 8 1
0 8 1
0 8 1
-
-
3
3
P
C
F i
N o r o i e w u l d i
.
e t
1
1 o r 2
1 o r 2
1 o r
1
1
1
1
2
r s
S I N G L E C I R C U I T
M
A i
C n i r m p i
3
8
9
3
6
1
3
m c u a
5 2
7 4
8
8
6
0
8
2
u c i i t m t y
M a x
1
F u s e
C i r
B r e
1 0 0
1
1
i
E x t e m r n a l o r c u i t a k e r
6 0
5
7
2
3
1 0
2
0
0
5
5
0
u m
P
F
2
i e l d o w
W i
S i z e r r e
6
4
3
3
8
6
1 0
8
e
G r
W i
S
2
o u
1
1
1
1
1
i z e
8
6
6
r e
0
0
0
0
0
n d A
C
-
5 2
5 2
5 2
-
-
k
A
C m
-
-
-
-
t .
i r p
3
M i n i m u m c a u c i i
C
-
-
t t
B y k
-
2 6
4 2
5 2
-
-
-
-
t .
M a x i m u m
E x t e r n a l
F u s e o r
C i r c u i t
B r e a k e r
C
-
-
k
A
-
6 0
6 0
6 0
-
-
-
-
t .
D U A L C I R C U I T
1
C
-
-
k
B
-
3 0
5 0
6 0
-
-
-
-
t .
C k t .
A
-
-
-
-
-
-
-
-
6
6
6
-
-
-
-
2
F i e l d
P o w e r
W i r e S i z e
C k
B
-
1 0
8
-
-
6
-
-
-
-
t .
-
2
G r o u n d
W
C
-
k
A
1 0
-
-
-
-
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 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 revision), article 310 for power conductor sizing.
i
-
1 0
1 0
t r e
.
S i z e
C k t .
B
-
1 0
1 0
1 0
-
-
-
-
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.
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 wiring is complete.
The unit is designed for use with or without duct work.
Flanges are provided for attaching the supply and return ducts.
These instructions explain the recommended method to install the air cooled self-contained unit and the electrical wiring connections to the unit.
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 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 2100-347
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Page 6 of 23
Design the duct work according to methods given by the
Air Conditioning Contractors of America (ACCA).
When duct runs through unheated spaces, it should be insulated with a minimum of one inch of insulation.
Use insulation with a vapor barrier on the outside of the insulation. Flexible joints should be used to connect the duct work to the equipment in order to keep the noise transmission to a minimum.
A 1/4 inch clearance to combustible material for the first three feet of duct attached to the outlet air frame is required. See Wall Mounting Instructions and Figures
4, 5, 6 and 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: If no return air duct is used, applicable installation codes 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 1-inch throwaway 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 service door. A 1-inch washable filter and a 2-inch pleated filter are also available as optional accessories.
The internal filter brackets are adjustable to accommodate the 2-inch filter by bending down the two horizontal tabs on each filter bracket.
FRESH AIR INTAKE
All units are built with fresh air inlet slots punched in the service panel.
If the unit is equipped with a fresh air damper assembly, the assembly is shipped already attached to the unit.
The damper blade is locked in the closed position. To allow the damper to operate, the maximum and minimum blade position stops must be installed. See
Figure 2.
All capacity, efficiency and cost of operation information as required for Department of Energy
“Energyguide” Fact Sheets is based upon the fresh air
Blank-off plate in place and is recommended for maximum energy efficiency.
The blank-off plate is available upon request from the factory and is installed in place of the fresh air damper shipped with each unit.
FIGURE 2
FRESH AIR DAMPER
Manual 2100-347
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Page 7 of 23
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.
CONDENSATE DRAIN – CONDENSER
A hole is provided in the unit base to accept a Drain
Connection Kit 8620-160. This allows connection of the unit base pan to a drain if so desired. (See Figure 3 and instructions provided with the 8620-160 kit.) In the event the drain hose is connected to a drain system of some type, it must be an open or vented type system to assure proper drainage.
FIGURE 3
CONDENSATE DRAINS
Manual 2100-347
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Page 8 of 23
EVAPORATOR
CONDENSATE DRAIN
CONDENSER
CONDENSATE DRAIN
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 4.
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.
WARNING
Fire hazard can result if 1/4 inch clearance to combustible materials for supply air duct is not maintained. See Figure 5.
3. Concrete block walls must be thoroughly inspected to insure that they are capable of carrying the weight of the installed unit.
MOUNTING THE UNIT
1. These units are secured by wall mounting brackets which secure the unit to the outside wall surface at both sides. A bottom mounting bracket is provided for ease of installation, but is not required.
2. The unit itself is suitable for 0 inch clearance, but the supply air duct flange and the first 3 feet of supply air duct require a minimum of 1/4 inch clearance to combustible material. If a combustible wall use a minimum of 30½" x 10½" 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 4 and 5 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 causing property damage, injury or death.
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 with unit attached to back of unit on the right side.
6. Position unit in opening and secure with 5/16 lag bolts; use 3/4 inch diameter flat washers on the lag bolts.
7. Secure rain flashing to wall and caulk across entire length of top. See Figure 4.
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.
9. On side-by-side installations, maintain a minimum of 20 inches clearance on right side to allow access to control panel and heat strips, and to allow proper airflow to the outdoor coil. Additional clearance may be required to meet local or national codes.
Manual 2100-347
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Manual 2100-347
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Page 10 of 23
FIGURE 5
ELECTRIC HEAT CLEARANCE
SIDE SECTION VIEW OF SUPPLY AIR DUCT FOR WALL
MOUNTED UNIT SHOWING 1/4 INCH CLEARANCE TO
COMBUSTIBLE SURFACES.
WARNING
A minimum of 1/4 inch clearance must be maintained between the supply air duct and combustible materials. This is required for the first 3 feet of ducting.
It is important to insure that the 1/4 inch minimum spacing is maintained at all points.
Failure to do this could result in overheating the combustible material and may result in a fire causing property damage, injury or death.
Manual 2100-347
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FIGURE 6
WALL MOUNTING INSTRUCTIONS
SEE FIGURE 4 – MOUNTING INSTRUCTIONS
FIGURE 7
WALL MOUNTING INSTRUCTIONS
SEE UNIT DIMENSIONS, FIGURE 1, FOR
ACTUAL DIMENSIONS
Manual 2100-347
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Page 12 of 23
FIGURE 8
COMMON WALL MOUNTING INSTALLATIONS
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WIRING – MAIN POWER
Refer to the unit rating plate for wire sizing information and maximum fuse or “HACR” type circuit breaker size. Each outdoor unit is marked with a “Minimum
Circuit Ampacity”. This means that the field wiring used must be sized to carry that amount of current.
Depending on the installed KW of electric heat, there may be two field power circuits required. If this is the case, the unit serial plate will so indicate. All models are suitable only for connection with copper wire. Each unit and/or wiring diagram will be marked “Use Copper
Conductors Only”. These instructions must be adhered to. Refer to the National Electrical Code (NEC) for complete current carrying capacity data on the various insulation grades of wiring material. All wiring must conform to NEC and all local codes.
The electrical data lists fuse and wire sizes (75°C copper) for all models including the most commonly used heater sizes. Also shown are the number of field power circuits required for the various models with heaters.
The unit rating plate lists a “Maximum Time Delay
Relay Fuse” or “HACR” type circuit breaker that is to be used with the equipment. The correct size must be used for proper circuit protection and also to assure that there will be no nuisance tripping due to the momentary high starting current of the compressor motor.
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 locate 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
240
208
RANGE
253 – 216
220 – 187
FIGURE 9
UNIT 24V TERMINAL BOARD
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).
Ten (10) wires should be run from thermostat subbase to the 24V terminal board in the unit. A nine conductor,
18 gauge copper color-coded thermostat cable is recommended. The connection points are shown in
Figure 9.
T r a n s f o r m e r
V A
5 5
TABLE 3
THERMOSTAT WIRE SIZE
F L A
2 .
3
W i r e G a u g e
2 0 g a u g e
1 8
1 6 g g a a u u g g e e
1 4
1 2 g a u g e g a u g e
M a x i m u m
D i s t a n c e i n F e e t
4 5
6 0
1 0 0
1 6 0
2 5 0
IMPORTANT
Only the thermostats shown in this Manual have been tested with this equipment for proper operation. Proper unit operation with thermostats not listed in this Manual, cannot be assured.
You assume responsibility for proper operation of the unit when using thermostats other than those listed above.
Manual 2100-347
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FIGURE 10
COMPRESSOR CUTOFF THERMOSTAT WIRING
4 – 10KW 1 PH – 6 & KW 3 PH
FIGURE 11
COMPRESSOR CUTOFF THERMOSTAT WIRING
15 – 20KW 1 PH AND 3 PH
OPTIONAL OUTDOOR THERMOSTAT
APPLICATIONS
Since most equipment at the time of manufacture is not designated for any specific destination of the country and are installed in areas not approaching the lower outdoor temperature range, outdoor thermostats are not factory installed as standard equipment, but are offered as an option. There are also different applications for applying outdoor thermostats. The set point of either type of outdoor thermostat application is variable with geographic region and sizing of the heating equipment to the individual structure. Utilization of the heating
Application Data, and the heat loss calculation of the building are useful in determining the correct set points.
NOTE: The additional LAB (low ambient bypass) relay is required to prevent heater operation during low temperature cooling operation.
OPTIONAL COMPRESSOR CUTOFF
THERMOSTAT (See Figures 10 and 11)
Heat pump compressor operation at outdoor temperatures below 0°F are neither desirable not advantageous in term of efficiency. An outdoor thermostat can be applied to take the mechanical heating
(compressor) off line, and send the (compressor) signal to energize electric heat in its place (to make electric heat first stage heating). This can also be applied to bank the quantity of available electric heat. For example: A heat pump operates with 10KW second stage heat – once the outdoor thermostat has switched then operates 15KW without the compressor as first stage heat.
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Page 15 of 23
ELECTRIC HEAT HOLD-OFF
(See Figures 12 and 13)
In other applications, it is desirable to disable the operation of the electric heat until outdoor temperatures have reached a certain design point. This won't allow the electric heat to come on as second stage heating unless the outdoor temperature is below the set point of the outdoor thermostat. This is done to maximize efficiency by utilizing the heat pump to bring the conditioned space temperature up, rather than cycling on the electric heat due a second stage call for heat from the thermostat on start-up coming off a night set-back condition or someone increasing the thermostat set point. (NOTE: Some programmable thermostats do have a built-in time delay for pulling in second stage heat when coming off set-back conditions.)
TABLE 4
WALL THERMOSTAT
T h e r m o s t a t
(
8
1
4
1
0
2
3
0 -
0
4
6
4
0
5 )
P r e d o m i n a n t F e a t u r e s
8 4 0 3 0 5 8
( T H 5 2 2 0 D 1 1 5 1 )
2 s t a g e C o o l ; 2 s t a g e H e a t
E l e c t r o n i c
A u t o o r
N o n
M a n u a l
P r o g r a m m a b l e c h a n g e o v e r
3 s t a g e C o o l ; 3 s t a g e H e a t
P r o g r a m m a b l e / N o n P r o g r a m m a b l e E l e c t r o n i c
H P
A u t o o r o r
C o n v e n t i o n a l
M a n u a l c h a n g e o v e r
FIGURE 12
ELECTRIC HEAT HOLD-OFF WIRING
4 – 10KW 1 PH – 6 & 9KW 3 PH
FIGURE 13
ELECTRIC HEAT HOLD-OFF WIRING
15 – 20KW 1 PH AND 3 PH
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START UP
IMPORTANT INSTALLER NOTE
For improved start up performance wash the indoor coil with a dish washing detergent.
CRANKCASE HEATERS
WH611-B and -C are provided with compressor crankcase heat. All other models are not provided with crankcase heat. They are either single phase or the system refrigerant charge is not of sufficient quantity to require crankcase heat.
The WH611-B and -C models have a wrap around type heater located on the lower section of the compressor housing. This is an on/off heater that is controlled by the compressor contactor.
The label in Figure 14 is affixed to all WH611-B and -C units detailing start up procedure. This is very important. Please read carefully.
HIGH PRESSURE SWITCH
All models are supplied with a remote reset high pressure switch. If tripped, this pressure switch may be reset by turning the thermostat off then back on again.
TWO SPEED OUTDOOR FAN MOTORS
All units have two speed outdoor fan motors.
The two speed outdoor fan motor is controlled with an outdoor thermostat and operates on low speed below
80°F outdoor temperature in cooling mode. In heating mode it operates on high speed only.
THREE PHASE SCROLL COMPRESSOR
START UP INFORMATION
Scroll compressors, like several other types of compressors, will only compress in one rotational direction. Direction of rotation is not an issue with single phase compressors since they will always start and run in the proper direction.
However, three phase compressors will rotate in either direction depending upon phasing of the power. Since there is a 50-50 chance of connecting power in such a way as to cause rotation in the reverse direction, verification of proper rotation must be made. 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.
FIGURE 14
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 proper 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.
7961-411
However, reverse operation for over one hour may have a negative impact on the bearing due to oil pump out.
NOTE: If compressor is allowed to run in reverse rotation for several minutes, the compressor’s internal protector will trip.
All three phase 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.
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.
Manual 2100-347
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Page 17 of 23
PHASE MONITOR
All units with three phase compressors are equipped with a 3 phase line monitor to prevent compressor damage due to phase reversal.
The phase monitor in this unit is equipped with two
LEDs. If the Y signal is present at the phase monitor and phases are correct, the green LED will light. If phases are reversed, the red fault LED will be lit and compressor operation is inhibited.
If a fault condition occurs, reverse two of the supply leads to the unit. Do not reverse any of the unit factory wires as damage may occur.
SERVICE HINTS
1. Caution owner/operator to maintain clean air filters at all times. Also, not to needlessly close off supply and return air registers. This reduces airflow through the system, which shortens equipment service life as well as increasing operating costs.
2. 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 – Circuit R-Y makes at thermostat pulling in compressor contactor, starting the compressor and outdoor motor. The G (indoor motor) circuit is automatically completed on any call for cooling operation or can be energized by manual fan switch on subbase of constant air circulation.
HEATING – A 24V solenoid coil on reversing valve controls heating cycle operation. Two thermostat options, one allowing “Auto” changeover from cycle to cycle and the other constantly energizing solenoid coil during heating season and thus eliminating pressure equalization noise except during defrost, are to be used.
On “Auto” option a circuit is completed from R-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 heat completes R-Y circuit, pulling in compressor contactor starting compressor and outdoor motor. R-G also make starting indoor blower motor.
PRESSURE SERVICE PORTS
High and Low pressure service ports are installed on all units so that the system operating pressures can be observed. Pressure tables can be found later in the manual covering all models on both cooling and heating cycles. It is imperative to match the correct pressure table to the unit by model number.
DEFROST CYCLE
The defrost cycle is controlled by temperature and time on the solid state heat pump control. See Figure 15.
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 temporary condition such as a high wind causes the heat pump to have a prolonged defrost cycle, the heat pump control will restore the system to heating operation automatically after 10 minutes.
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 15.
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.
Manual 2100-347
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Page 18 of 23
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 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 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.
FIGURE 15
DEFROST CONTROL BOARD
Manual 2100-347
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Page 19 of 23
TROUBLESHOOTING
SOLID STATE HEAT PUMP CONTROL
TROUBLESHOOTING PROCEDURE
1. NOTE: A thorough understanding of the defrost cycle sequence is essential. Review that section earlier in this manual prior to troubleshooting the control. Turn on AC power supply to unit.
2. Turn thermostat blower switch to “fan on” – the indoor blower should start. (If it doesn’t, troubleshoot indoor unit and correct problem.)
3. Turn thermostat blower to “auto” position. Indoor blower should stop. NOTE: Many models have a
1-minute blower time delay on “off” command; wait for this to time-out.
4. Set system switch to “heat” or “cool”. Adjust thermostat to call for heat or cool. The indoor blower, compressor and outdoor fan should start.
NOTE: If there was no power to 24 volt transformer, the compressor and outdoor fan motor will not start for
5 minutes. This is because of the compressor short cycle protection.
TABLE 5
TROUBLESHOOTING
S y m p t o m P o s s i b l e C a u s e s W h a t & H o w t o C h e c k / R e p a i r
C n o
U i n
U o r o n n o u t t i s t a c o t o
( h e i m p t t o w i d w i r e r t il n ll ll s s o r
( h e a g ) n n o t e f r o s t a t i n g o o n l t g y ) o c o m e o f d e f r o s t
( h e a t i n g o n l y ) w i ll t i n g
C h e c k o n t h e f o r h e a
2 4 V t p u f r m o p m R t o c o n t r o l
C I f 2 a n d
4 V o u i t s p n u t o t r a n s f o r m e r .
t v o p r e s e n t l t a g e .
a t R , c h e c k w i r i n
I f t r a n s f o r m e r h a s g f r n o o
2 m
4 b o a r d t o
V o u t p u t , t r a n s f o r m e r a n d d e t e r m i n e c a u s e c h e c a n d k t r a n s f o r e p l a c e r m e r i n p u t
C h e c k f o r o n l o w v o l t
2 4 V a g e f r o m Y t o C t e r m i n a l s t r i p
I f 2 4 V p h a s e i s n m o o n t i t p r e s e n t , c h e c k t h e r m o s t a t a n d o r ( i f e q u i p p e d , u s e d o n s o m e t h e r m o s t a t
3 p h a s e m o w i r i n g d e l s ) .
, o u t d o o r
I f 2 4 V i s t h e r m o s t a t p r e s e n t c o
( i f e q u i p p e d ) n t i n u e t o n e x t s t e p .
C h e c k f o r 2 4 V f r o m C t o
C C o n h e a t p u m p c o n t r o l
C o m p r e s s o r l o c k o u t
I f 2 4 V i s s p e e d u p p r e s e n t , t e r m i n a l c h e c k a n d / o r r e p l a c e f o r 1 0 s e c o n d s .
I f c o c o m p r e s s o r c o n t a c t o r .
m p r e s s o r d o e s n o t s t a r t
I f 2 4 V i s n o t c h e c k f o r p r
2 4 V e s e n t , j u f r o m C m p t o L t h e
1 o n t h e h e a t p u m p c o n t r o l .
I f 2 4 V i s n o t p r e s s u r e b y p p r e s e n t a t L 1 a s s r e l a y ( i f o f t h e h e e q u i p p e d ) a t p u a n d m p c o n t r o l , c h a ll a s s o c i a t e d e c k w i r i t h e h i g h p r e s s u r e n g a n d t e r m i n a l s .
s w i t c h a n d l o w
T h e s a f e t y c i r c u i t i s a c l o s e d c i r c u i t .
I f t h e h i g h p r e s s u r e s w i t c h o r l o w p r e s s u r e b y p a c o n t r o l w i ll l o c k r e s e t l o c k o u t .
o u t
J u m t h p e s p c o m p r e s s o r .
e e d u p t e r m i
R e p n a l s l a c f o r e d
1 0 e f e s e c t i v e c o n d c s o m t o p o o n e n t .
v e r r i d e s s
C r e l a y a r e y c l e p o w e o p e n , t h e r
5 m i n u t e t i m e o f f a n d d e l a y .
o n t o
F a n o u t d o o r m o t o r d o e s n o
( c o o il n g t o r u n r h e a t i n g e x c e p t d u r i n g d e f r o s t )
H e a t p u m p c o n t r o l d e f e c t i v e
M o t o r d e f e c t i v e
M o t o r c a p a c i t o r d e f e c t i v e
C h e c k a c r o s s f a n r e l a y o n h e a t p u m p c o n t r o l .
( C o m N C )
R e p l a c e h e a t p u m p c o n t r o l .
C h e c k f o r o p e n o r s h o r t e d m o t o r w i n d i n g .
R e p l a c e m o t o r .
C h e c k c a p a c i t o r r a t i n g .
C h e c k f o r o p e n o r s h o r t e d c a p a c i t o r .
R e p l a c e c a p a c i t o r .
R e v e r s i n g v a l v e d o e s n o
( h e a t i n g t e n e o n l y ) r g i z e
D e f e c t i v e h e a t p u m p c o n t r o l I f 2 4 V i s p o v e r r i d d e n r e s o r e e n t x p f r o m i r e d
C t o a n d
Y , a n d C t o L 1 o n t h n o 2 4 V i s p r e s e n t a t e h e a t p u m p
C C , r e p l a c e c o n t r o l , t h e t h e h e a t p u t i m m p e c d e l a y h a s o n t r o l .
b e e n
H e a t p u m p c o n t r o l d e f e c t i v e C h e c k f o r 2 4 V b e t w e e n R V C
1 .
C h e c k c o n t r o
2 .
R e p l a c e h e a t l c i r c u i t p u m p c w i r i n g .
o n t r o l a n d B C .
R e v e r s i n g v a c o i l d e f e c t i v e l v e s o l e n o i d C h e c k f o r o p e n o r s h o r t e d c o i l .
R e p l a c e s o l e n o i d c o i l .
T e m p e r a t u r e s e n s o r o r h e a t p u m p c o n t r o l d e f e c t i v e
D i s c o n n e c t t e m p e r a t u r e s e n s o r f r o m b o a r d a n d j u m p e r a c r o s s " S P E E D U P " t e r m i n a l s a n d " S E N
J M P "
1 .
I f u n t e i t r m i n a l s .
g o e s t h
T r o h i s u g h s h o u l d c a u s e d e f r o s t c y c l e , t h e r e u n p l a i t c e t o g o t e m t h p e r o u g h r a t u r e a d e f r o s e n s o r .
s t c y c l e w i t h i n o n e m i n u t e .
2 .
I f u n i t d o e s n o t g o t h r o u g h d e f r o s t c y c l e , r e p l a c e h e a t p u m p c o n t r o l .
T e m p e r a t u r e p u m p c o n t r o l s e n s o r o r d e f e c t i v e .
h e a t J u m p e r a c r o s s " S P E E D U P " t e r m i n a l .
T h i s s h o u l d c a u s e t h e u n i t t o c o m e o u t o f d e f r o s t w i t h i n o n e m i n u t e .
1 .
I f u n i t c o m e s o
2 .
I f u n i t d o e s n o t u t o f c o m d e f e o r o u t s t c y c l e , r e o f d e f r o s t p l a c e c y c l e , t e m p e r a t u r e s e n s o r .
r e p l a c e h e a t p u m p c o n t r o l .
Manual 2100-347
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Page 20 of 23
CHECKING TEMPERATURE SENSOR
OUTSIDE UNIT CIRCUIT
1. Disconnect temperature sensor from board and from outdoor coil.
2. Use an ohmmeter and measure the resistance of the sensor. Also use ohmmeter to check for short or open.
3. Check resistance reading to chart of resistance use sensor ambient temperature. (Tolerance of part is
± 10%)
4. If sensor resistance reads very low, then sensor is shorted and will not allow proper operation of the heat pump control.
5. If sensor is out of tolerance, shorted, open, or reads very low ohms then it should be replaced.
118108
114272
110575
107010
103574
100260
97064
93981
91008
88139
85371
82699
80121
77632
75230
72910
R
196871
190099
183585
177318
171289
165487
159904
154529
149355
144374
139576
134956
130506
126219
122089
55284
53640
52051
50514
49028
47590
46200
44855
70670
68507
66418
64399
62449
60565
58745
56985
43554
42295
41077
48.0
49.0
50.0
51.0
52.0
53.0
54.0
55.0
40.0
41.0
42.0
43.0
44.0
45.0
46.0
47.0
F
25.0
26.0
27.0
28.0
29.0
30.0
31.0
32.0
33.0
34.0
35.0
36.0
37.0
38.0
39.0
64.0
65.0
66.0
67.0
68.0
69.0
70.0
71.0
56.0
57.0
58.0
59.0
60.0
61.0
62.0
63.0
72.0
73.0
74.0
TEMPERATURE F VS RESISTANCE R OF TEMPERATURE
-2.0
-1.0
0.0
1.0
2.0
3.0
4.0
5.0
-10.0
-9.0
-8.0
-7.0
-6.0
-5.0
-4.0
-3.0
F
-25.0
-24.0
-23.0
-22.0
-21.0
-20.0
-19.0
-18.0
-17.0
-16.0
-15.0
-14.0
-13.0
-12.0
-11.0
14.0
15.0
16.0
17.0
18.0
19.0
20.0
21.0
6.0
7.0
8.0
9.0
10.0
11.0
12.0
13.0
22.0
23.0
24.0
26092
25383
24696
24030
23384
22758
22150
21561
20989
20435
19896
19374
18867
18375
17898
17434
R
39898
38757
37652
36583
35548
34545
33574
32634
31723
30840
29986
29157
28355
27577
26823
16984
16547
16122
15710
15310
14921
14544
14177
13820
13474
13137
12810
12492
12183
11883
11591
11307
11031
10762
98.0
99.0
100.0
101.0
102.0
103.0
104.0
105.0
90.0
91.0
92.0
93.0
94.0
95.0
96.0
97.0
F
75.0
76.0
77.0
78.0
79.0
80.0
81.0
82.0
83.0
84.0
85.0
86.0
87.0
88.0
89.0
114.0
115.0
116.0
117.0
118.0
119.0
120.0
121.0
106.0
107.0
108.0
109.0
110.0
111.0
112.0
113.0
122.0
123.0
124.0
6098
5961
5827
5697
5570
5446
5326
5208
7334
7165
7000
6840
6683
6531
6383
6239
R
10501
10247
10000
9760
9526
9299
9077
8862
8653
8449
8250
8057
7869
7686
7507
4274
4182
4093
4006
3921
3838
3757
3678
5094
4982
4873
4767
4663
4562
4464
4367
3601
3526
3452
Manual 2100-347
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Page 21 of 23
FAN BLADE SETTING DIMENSIONS
Shown in Figure 16 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.
FIGURE 16
FAN BLADE SETTING
TABLE 7
1
REFRIGERANT CHARGE
SUBCOOLING LEVEL
C O O L I N G
M o d e l
R a t e d
A i r f l o w
9 5 O D
T e m p e r a t u r e
8 2 O D
T e m p e r a t u r e
4 7 O D
T e m p e r a t u r e
1 7 O D
T e m p e r a t u r e
W H 6 1 1 1 3 5 0 1 0 1 3 1 0 1 3 8 1 2
H E A T I N G
1 1 1 5
1 Expected subcooling levels during cooling 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
RATED CFM & RATED ESP
M o d e l
R a t e d
C F M *
R a t e d
E S P *
R e c o m m e n d e d
A i r f l o w R a n g e
W H 6 1 1 1 3 5 0 .
2 0
* Rated CFM and ESP on high speed tap.
1 4 7 5 1 1 0 0
TABLE 6
FAN BLADE
SETTING DIMENSION
M o d e l
D i m e n s i o n
A
W H 6 1 1 1 .
0 0
E .
S .
P .
I n H
2
O
.
0
.
1
.
2
.
3
.
4
TABLE 9
INDOOR BLOWER PERFORMANCE
CFM
@
230V / 460V
H i g h S p e e d
W H 6 1 1
M e d i u m S p e e d
D r y C o i l W e t C o i l D r y C o i l W e t C o i l
1 7 0 0
1 5 5 0
1 4 0 0
1 2 5 0
-
1 5 7 5
1 4 7 5
1 3 5 0
1 1 5 0
-
1 4 7 5
1 3 7 5
1 2 5 0
1 1 0 0
-
1 3 7 5
1 2 5 0
1 1 0 0
8 2 5
-
Subtract .08 static for 2" filter
REMOVAL OF FAN SHROUD
1. Disconnect all power to the unit.
2. Remove the screws holding both grilles, one on each side of unit, and remove grilles.
3. Remove screws holding fan shroud to condenser and bottom. Nine (9) screws.
4. Unwire condenser fan motor.
5. Slide complete motor, fan blade, and shroud assembly out the left side of the unit.
6. Service motor/fan as needed.
7. Reverse steps to reinstall.
REFRIGERANT CHARGE
The correct system R-22 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.
NOTE: WH611 is shipped with the indoor blower on high speed for ducted applications. Move to medium speed for free blow applications.
TABLE 10
MAXIMUM ESP OF OPERATION
A 0 5
A 0 8
A 1 0
B 0 9
C 0 9
H i g h S p e e d
.
3
.
3
.
3
.
3
.
3
M e d i u m S p e e d
.
3
.
3
.
3
.
3
.
3
Manual 2100-347
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Page 22 of 23
TABLE 11
PRESSURE TABLE
COOLING
Air Temperature Entering Outdoor Coil °F
M
W
o
H
d
6
e
1
l
1
R
T e m
7 5
6 2
8 0
e t u r n p e r a
d e g .
d e g .
A i r
d e g .
D B
6 7 d e g .
8 5
7 2 d e g .
d e g .
t u
D
W
W
D
W
r e
B
B
B
B
B
P r e
L o w
L o w
L o w
s
H i g h
H i g h
H i g h
s u r e
S i d e
S i d e
S i d e
S i d e
S i d e
S i d e
7 5
6 5
1 7 6
6 9
1 8 1
7 1
1 8 7
8 0
6 5
2 0 2
7 0
2 0 7
7 2
2 1 4
8 5
6 7
2 2 3
7 2
2 2 9
7 5
2 3 7
9 0
6 8
2 4 1
7 3
2 4 7
7 6
2 5 6
9 5
7 0
2 5 4
7 5
2 6 1
7 8
2 7 0
1 0 0
7 1
2 6 5
7 6
2 7 2
7 9
2 8 2
1 0 5
7 1
2 7 1
7 6
2 7 8
7 9
2 8 8
1 1 0
7 2
2 7 4
7 7
2 8 1
8 0
2 9 1
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.
1 1 5
7 3
2 7 3
7 8
2 8 0
8 1
2 9 0
TABLE 12
PRESSURE TABLE
HEATING
M o d e l
W H 6 1 1
Air Temperature Entering Outdoor Coil °F
R e t u r n A i r
T e m p e r a t u r e
7 0 d e g .
P r e s s u r e
L o w S i d e
H i g h S i d e
0
2 3
1 5 3
5
2 4
1 7 1
1 0
2 6
1 8 8
1
2
5
2 8
0 5
2 0
3 1
2 2 0
2 5
3 5
2 3 4
3 0
3 8
2 4 7
3 5
4 3
2 6 0
4 0
4 8
2 7 1
4 5
5 3
2 8 1
5 0
5 9
2 8 9
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.
5 5
6 5
2 9 7
6 0
7 2
3 0 4
Manual 2100-347
I
Page 23 of 23
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