2100-414
INSTALLATION INSTRUCTIONS
WALL MOUNTED
PACKAGE HEAT PUMPS
Model
SH611D
Bard Manufacturing Company
Bryan, Ohio 43506
Since 1914...Moving ahead just as planned.
Manual :
Supersedes:
File:
Date:
2100-414A
2100-414
Volume III Tab 17
09-01-03
© Copyright 2003
CONTENTS
Getting Other Information and Publications
For More Information ............................................... 1
Wall Mount General
Heat Pump Wall Mount Model Nomenclature ........ 2
Shipping Damage ................................................... 4
General ............................................................... 4
Duct Work ............................................................... 4
Filters
............................................................... 5
Fresh Air Intake ...................................................... 5
Condensate Drain – Evaporator ............................. 5
Installation Instructions
Wall Mounting Information ...................................... 6
Mounting the Unit ................................................... 6
Wiring – Main Power ............................................ 11
Wiring – Low Voltage Wiring ................................ 11
Compressor Cutoff Thermostat and
Outdoor Thermostats ............................................ 14
Thermostat Indicator Lamps ................................. 14
Emergency HeatPosition ...................................... 14
Compressor Malfunction Light .............................. 14
Low Voltage Connections ..................................... 15
Figures
Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10
Unit Dimensions .................................... 3
Fresh Air Damper Assembly ................. 5
Mounting Instructions ............................ 7
Electric Heat Clearance ........................ 8
Wall Mounting Instructions .................... 9
Wall Mounting Instructions .................... 9
Common Wall Mounting Installations .. 10
Wiring with CS2000 Monitor ............... 12
Wiring with Programmable Themostat 13
Compressor Cutoff and Outdoor
Thermostat Wiring .............................. 14
Figure 11 Start Up Procedure Decal ................... 16
Figure 12 Defrost Control Board ......................... 18
Figure 13 Fan Blade Setting ............................... 21
Start Up
Important Installer Note ........................................ 16
Crankcase Heaters ............................................... 16
High Pressure Switch ........................................... 16
Three Phase Scroll Compressor Start Up ............ 16
Phase Monitor ...................................................... 17
Service Hints ........................................................ 17
Sequence of Operation ......................................... 17
Pressure Service Ports ......................................... 17
Defrost Cycle ........................................................ 18
Troubleshooting
Solid State Heat Pump Control
Troubleshooting Procedure .................................. 19
Checking Temperature Sensor
Outside Unit Circuit ............................................... 20
Temperature vs. Resistance of Temperature ........ 20
Fan Blade Setting Dimensions ............................. 21
Removal of Fan Shroud ........................................ 21
Refrigerant Charge ............................................... 21
Pressure Tables .................................................... 22
Tables
Table 1
Table 2
Table 3
Table 4
Electric Heat Table ................................. 2
Electrical Specifications ......................... 4
Thermostat Wire Size .......................... 11
Wall thermostat and
Subbase Combinations ........................ 15
Table 5 Troubleshooting .................................... 19
Table 6 Fan Blade Dimensions ......................... 21
Table 7 Refrigerant Charge ............................... 21
Table 8 Rated CFM and Rated ESP ................. 21
Table 9 Indoor Blower Performance ................. 21
Table 10 Maximum ESP of Operation ................. 21
Table 11 Pressure Table - Cooling ...................... 22
Table 12 Pressure Table - Heating ...................... 22
Getting Other Information and Publications
These publications can help you install the air
conditioner or heat pump. You can usually find these at
your local library or purchase them directly from the
publisher. Be sure to consult current edition of each
standard.
FOR MORE INFORMATION, CONTACT
THESE PUBLISHERS:
ACCA
Air Conditioning Contractors of America
1712 New Hampshire Ave. N.W.
Washington, DC 20009
Telephone: (202) 483-9370
Fax: (202) 234-4721
ANSI
American National Standards Institute
11 West Street, 13th Floor
New York, NY 10036
Telephone: (212) 642-4900
Fax: (212) 302-1286
National Electrical Code ...................... ANSI/NFPA 70
Standard for the Installation .............. ANSI/NFPA 90A
of Air Conditioning and
Ventilating Systems
Standard for Warm Air ...................... ANSI/NFPA 90B
Heating and Air
Conditioning Systems
Load Calculation for ............................ ACCA Manual J
Residential Winter and
Summer Air Conditioning
Duct Design for Residential .............. ACCA Manual D
Winter and Summer Air Conditioning
and Equipment Selection
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 2100-414
Page 1
WALL MOUNT GENERAL INFORMATION
HEAT PUMP WALL MOUNT MODEL NOMENCLATURE
MODEL NUMBER
CAPACITY
38 - 3 Ton
43 - 3-1/2 Ton
49 - 4 ton
SH
61
1
D
A
10
X
X
X
X
REVISIONS
COLOR OPTIONS
X - Beige (Standard)
1 - White
4 - Buckeye Gray
5 - Desert Brown
8 - Dark Bronze
KW
VOLTS &
PHASE
A - 230/208/60/1
B - 230/208/60/3
C - 460/60/3
VENTILATION OPTIONS
X - Barometric Fresh Air Damper (Standard) j
B - Blank-off Plate
M - Motorized Fresh Air Damper j
V - Commercial Room Ventilator - Motorized
with Exhaust
E - Economizer -Fully Modulating with Exhaust
R - Energy Recovery Ventilator - Motorized
with Exhaust
D - Economizer - Fully Modulating with Exhaust
(For use only with “V” Control Module and
TCS20 DDC Controller)
CONTROL MODULES
X B
COIL OPTIONS
X - Standard
1 - Phenolic Coated Evaporator
2 - Phenolic Coated Condenser
3 - Phenolic Coated Evaporator
and Condenser
OUTLET OPTIONS
X - Front (Standard)
FILTER OPTIONS
X - 1 Inch Throwaway (Standard)
W - 1 Inch Washable
P - 2 Inch Pleated
j Vent options are without exhaust capability. May require separate field supplied barometric relief in building.
TABLE 1
ELECTRIC HEAT TABLE
Models
SH611DA
240-1
KW
A
B TU
SH611DB
208-1
A
B TU
9
10
Manual 2100-414
Page 2
41.6
34130 36.2
25600
240-3
SH611DC
208-3
460-3
A
B TU
A
B TU
A
B TU
21.7
30600
18.7
23030
10.8
30700
FIGURE 1
UNIT DIMENSIONS
Unit
Width
W
SH611D
42
Depth Height
D
H
22-1/4
94-7/8
Manual 2100-414
Page 3
FRONT
VIEW
Supply
A
B
Return
C
B
E
9-7/8 29-7/8 15-7/8 29-7/8 43-7/8
F
G
I
J
K
19
41-5/8
30
42-11/16
37
SIDE VIEW
L
M
44-3/4 42-1/2
N
O
P
Q
3-1/4
43
33-7/8
10
BACK VIEW
MIS-1261
TABLE 2
ELECTRICAL SPECIFICATIONS
SINGLE CIRCUIT
3
Rated
Volts &
P h ase
Model
N o.
Field
Minimum
P o w er
Circuit
Ciruits Ampacity
1
DUAL CIRCUIT
2
2
Maximum
External Field
Fuse or Pow er Ground
Wire
Wire
Circuit
Siz e
Siz e
Breaker
1
3
Minimum
Circuit
Ampacity
Maximum
External
F u se o r
Circuit
Breaker
2
2
Field
P o w er
Wire Siz e
Ground
Wire Siz e
Ckt.
A
Ckt.
B
Ckt.
A
Ckt.
B
Ckt.
A
Ckt.
B
Ckt.
A
Ckt.
B
SH611DA00, A0Z 230/208-1
A10 230/208-1
1
1 or 2
52
98
60
120
6
3
10
6
--52
--52
--60
--60
--6
--6
--10
--10
SH611DB00, B0Z 230/208-1
B09 230/208-1
1
1
36
60
50
70
8
6
10
10
-----
-----
-----
-----
-----
-----
-----
-----
1
1
18
32
25
35
10
8
10
10
-----
-----
-----
-----
-----
-----
----
-----
SH611C00, C0Z
C 09
j
k
l
460-3
460-3
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.
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.
Manual 2100-414
Page 4
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 1 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 air flow
requirement of the equipment. Air Conditioning
Contractors of America (ACCA) is an excellent guide
to proper sizing. All duct work or portions thereof not
in the conditioned space should be properly insulated in
order to both conserve energy and prevent condensation
or moisture damage.
Design the duct work according to methods given by the
Air Conditioning Contractors of America (ACCA).
When duct runs through unheated spaces, it should be
insulated with a minimum of one inch of insulation.
Use insulation with a vapor barrier on the outside of the
insulation. Flexible joints should be used to connect the
duct work to the equipment in order to keep the noise
transmission to a minimum.
A 1/4 inch clearance to combustible material for the
first three feet of duct attached to the outlet air frame is
required. See Wall Mounting Instructions and Figures 3
and 4 for further details.
Ducts through the walls must be insulated and all joints
taped or sealed to prevent air or moisture entering the
wall cavity.
Some installations may not require any return air duct.
A metallic return air grille is required with installations
not requiring a return air duct. The spacing between
louvers on the grille shall not be larger than 5/8 inch.
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.
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
BLADE IS LOCKED
CLOSED FOR
SHIPPING.
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.
MIS-938
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.
Manual 2100-414
Page 5
INSTALLATION INSTRUCTIONS
WALL MOUNTING INFORMATION
1. Two holes for the supply and return air openings
must be cut through the wall as shown in Figure 3.
2. On wood frame walls, the wall construction must be
strong and rigid enough to carry the weight of the
unit without transmitting any unit vibration.
WARNING
Fire hazard can result if 1/4 inch clearance to
combustible materials for supply air duct is not
maintained. See Figure 4.
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 30-1/2” x 10-1/2”
dimensions for sizing. However it is generally
recommended that a 1 inch clearance is used for
ease of installation and maintaining the required
clearance to combustible material. The supply air
opening would then be 32” x 12”. See Figures 3 and
4 for details.
Manual 2100-414
Page 6
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 3.
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 3.
8. For additional mounting rigidity, the return air and
supply air frames or collars can be drilled and
screwed or welded to the structural wall itself
(depending upon wall construction). Be sure to
observe required clearance if combustible wall.
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.
FIGURE 3
MOUNTING INSTRUCTIONS
Manual 2100-414
Page 7
MIS-796
FIGURE 4
ELECTRIC HEAT CLEARANCE
SIDE SECTION VIEW OF SUPPLY AIR DUCT FOR WALL
MOUNTED UNIT SHOWING 1/4 INCH CLEARANCE TO
COMBUSTIBLE SURFACES.
MIS-277
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 2100-414
Page 8
FIGURE 5
WALL MOUNTING INSTRUCTIONS
SEE FIGURE 4 – MOUNTING INSTRUCTIONS
WALL STRUCTURE
FACTORY SUPPLIED RAIN
FLASHING. MOUNT ON UNIT
BEFORE INSTALLATION
SUPPLY AIR
OPENING
SUPPLY AIR
OPENING
SUPPLY AIR
OPENING
RETURN AIR
OPENING
RETURN AIR
OPENING
RETURN AIR
OPENING
BOTTOM MOUNTING
BRACKET. MOUNT ON WALL
BEFORE INSTALLING UNIT.
MIS-548
FIGURE 6
WALL MOUNTING INSTRUCTIONS
SEE UNIT DIMENSIONS, FIGURE 1, FOR
ACTUAL DIMENSIONS
ATTACH TO TOP
PLATE OF WALL
1.000” CLEARANCE
ALL AROUND
INTERIOR FINISHED WALL
OVER FRAME
SUPPLY DUCT
OPENING
1.000” CLEARANCE
ALL AROUND
RETURN DUCT
OPENING
EXTERIOR FINISHED WALL
OVER FRAME
MIS-549
FRAMING MATERIAL
2 X 4’S, 2 X 6’S AND/OR
STRUCTURAL STEEL
ATTACH TO BOTTOM
PLATE OF WALL
THIS STRUCTURAL MEMBER LOCATED TO MATCH
STUD SPACING FOR REST OF WALL. A SECOND
MEMBER MAY BE REQUIRED FOR SOME WALLS.
Manual 2100-414
Page 9
FIGURE 7
COMMON WALL MOUNTING INSTALLATIONS
FREE AIR FLOW NO DUCT
FALSE WALL INSTALLATION
DUCTED SUPPLY RETURN AT UNIT
CLOSET INSTALLATION
MIS-550
Manual 2100-414
Page 10
WIRING – MAIN POWER
WIRING – LOW VOLTAGE WIRING
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.
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:
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.
TAP
240
208
RANGE
253 – 216
220 – 187
NOTE: The voltage should be measured at the field
power connection point in the unit and while
the unit is operating at full load (maximum
amperage operating condition).
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 9.
IMPORTANT
Only the thermostat and subbase combinations
as shown above will work with this equipment.
The thermostat and subbase must be matched,
and the correct operation can be assured only by
proper selection and application of these parts.
TABLE 3
THERMOSTAT WIRE SIZE
Transformer
VA
55
FLA
Wire Gauge
Maximum
Distance
in Feet
2.3
20 gauge
18 gauge
16 gauge
14 gauge
12 gauge
45
60
100
160
250
Manual 2100-414
Page 11
FIGURE 8
SHXXXDX – HOT GAS REHEAT DURING DEHUMIDIFICATION
WITH CS2000 ENERGY MONITOR FULL TIME DEHUMIDIFICATION
IMPORTANT NOTE:
Only the thermostat and subbase combinations as shown above and in Table 4 will work with this
equipment. The thermostat and subbase must be matched and the correct operation can be assured only
by proper selection and application of these parts.
Manual 2100-414
Page 12
FIGURE 9
SHXXXDX – HOT GAS REHEAT DURING DEHUMIDIFICATION
WITH PROGRAMMABLE THERMOSTAT FULL TIME DEHUMIDIFICATION
IMPORTANT NOTE:
Only the thermostat and subbase combinations as shown in Table 4 will work with this
equipment. The thermostat and subbase must be matched, and the correct operation can
be assured only be proper selection and application of these parts.
Manual 2100-414
Page 13
FIGURE 10
4 – 10KW 1 PH – 6 & KW 3 PH
MIS-409
COMPRESSOR CUT OFF THERMOSTAT AND
OUTDOOR THERMOSTATS
Heat pump compressor operation at outdoor
temperatures below 0° F are neither desirable nor
advantageous in terms of efficiency. Since most
equipment at time of manufacture is not designated for
any specific destination of the country and most of the
equipment is installed in areas not approaching the
lower outdoor temperature range, the compressor cut
offs are not factory installed.
Outdoor thermostats are available to hold off various
banks of electric heat until needed as determined by
outdoor temperature. The set point of either type of
thermostat is variable with geographic region and sizing
of the heating equipment to the structure. See Figures 9
and 10. Utilization of the Heating Application Data and
the heat loss calculation of the building are useful in
determining the correct set points.
Manual 2100-414
Page 14
THERMOSTAT INDICATOR LAMPS
The red lamp marked “Em. Ht.” comes on and stays on
whenever the system switch is placed in the emergency
heat position. The green lamp marked “check” will
come on if there is any problem that prevents the
compressor from running when it is supposed to be.
EMERGENCY HEAT POSITION
The operator of the equipment must manually place the
system switch in this position. This is done when there
is a known problem with the unit, or when the green
“check” lamp comes on indicating a problem.
COMPRESSOR MALFUNCTION LIGHT
Actuation of the green “check” lamp is accomplished
by a relay output from the heat pump control board
which is factory installed. Any condition such as loss of
charge, high head pressure, etc., that will prevent
compressor from operating will cause the green lamp to
activate. This is a signal to the operator of the
equipment to place system in emergency heat position.
LOW VOLTAGE CONNECTIONS
These units use a grounded 24 volt AC low voltage
circuit.
The “R” terminal is the hot terminal and the “C”
terminal is grounded.
“G” terminal is the fan input.
“Y” terminal is the compressor 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.
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
Energize Y, G
Heat Pump Heating
Energize Y, G, B
“W2” terminal is second stage heat (if equipped).
"O1" 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.
"W3" terminal is the dehumidification input. This
terminal energizes compressor, blower and three-way
valve.
2nd Stg Heating
Energize G, W2, Y, B
w/Heat Pump (if employed)
Ventilation
Energize G, O1
Emergency Heat
Energize B, W2, E, G
Dehumidification
Energize W3
TABLE 4
WALL THERMOSTAT AND SUBBASE COMBINATIONS
Thermostat
S u b b ase
Predominant Features
8403-042
(T8511G1070)
---
1 stg. cool; 2 stg. heat
Electronic Non-Programmable
Auto or Manual changeover
8403-049
(1F93-380)
---
2 stg. cool; 3 stg. heat
Programmable Electronic
Auto or Manual changeover
Manual 2100-414
Page 15
START UP
IMPORTANT INSTALLER NOTE
FIGURE 11
START UP LABEL
For improved start up performance wash the indoor coil
with a dish washing detergent.
CRANKCASE HEATERS
SH611-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 SH611-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 12 is affixed to all SH611-B and -C
units detailing start up procedure. This is very
important. Please read carefully.
HIGH PRESSURE SWITCH
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.
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.
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.
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.
Manual 2100-414
Page 16
7961-411
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.
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 homeowner to maintain clean air filters at
all times. Also, not to needlessly close off supply
and return air registers. This reduces air flow
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
OCCUPIED MODE
VENTILATION SEQUENCE – The ERV and indoor
blower will be continuously energized when the A1
terminal is energized.
COOLING SEQUENCE – On a call for cooling, the
compressor of the unit is energized to provide cooling.
A call for cooling cancels dehumidification mode.
Cooling mode is only available when the timer is
energized.
HEATING SEQUENCE – On a call for heating, the
compressor and reversing valve of the unit are energized
to provide heat pump heating. If the room temperature
falls below the 2nd stage heating set point backup
electric heat is energized. Heat pump heating is only
available when the timer is energized. If heating is
energized any call for dehumidification is ignored. If
dehumidification is already energized a call for 2nd
stage heating is needed to cancel dehumidification
mode.
A 24V solenoid coil on reversing valve controls heating
cycle operation. A thermostat demand for heat
completes R-W1 circuit, pulling in compressor
contactor starting compressor and outdoor motor. R-G
also make starting indoor blower motor.
DEHUMIDIFICATION SEQUENCE – On a call for
dehumidification the compressor and three way valve of
the unit are energized to provide dehumidification.
Dehumidification mode will continue until the
humidistat is satisfied. If the room temperature falls
below 1st stage heating setpoint, electric heat will be
energized by the room thermostat and cycle to maintain
room temperature. If 2nd stage heating setpoint is
reached, dehumidification is de-energized and heat
pump heating is energized. A call for cooling cancels
dehumidification mode.
UNOCCUPIED MODE
Cooling, heating, emergency heat and ventilation are
inhibited.
DEHUMIDIFICATION SEQUENCE – On a call for
dehumidification the compressor and three way valve of
the unit are energized to provide dehumidification.
Dehumidification mode will continue until the
humidistat is satisfied. If the room temperature falls
below 65 degrees and dehumidification is energized,
electric heat will be energized by the return air
thermostat and cycle to maintain room temperature.
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.
Circuit R-Y makes at thermostat pulling in compressor
contactor, starting the compressor and outdoor motor.
The G (indoor motor) circuit is automatically completed
on any call for cooling operation or can be energized by
manual fan switch on subbase for constant air
circulation.
Manual 2100-414
Page 17
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 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 minutes 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.
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 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
FIGURE 12
by operating in the cooling
DEFROST CONTROL BOARD
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.
MIS-1174
Manual 2100-414
Page 18
TROUBLESHOOTING
SOLID STATE HEAT PUMP CONTROL
TROUBLESHOOTING PROCEDURE
1. Turn on AC power supply to indoor and outdoor
units.
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 switch to auto position.
Indoor blower should stop.
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
Symptom
Possible Causes
Compressor
Control circuit wiring
contactor does not
energize (heating or
Compressor lock out
cooling)
Compressor short cycle
protection
What to Check
Check for R connectio at unit
and 24 volt between R - C
How to Dheck or Repair
Run R connection to outdoor unit to power heat
pump control.
1. Check for 24V between
1. If no voltage between L1-C, turn thermostat
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.
Check for 24 V between CC-C If not voltage between C C -C , jumper speed
and Y-C on heat pump control. up termi nal, and wi thi n 10 seconds power
should appear between CC-C. Remove
speed up jumper after 10 seconds.
Fan outdoor motor
does not run
(cooling or heating
except during
defrost)
Heat pump control
defective
Check all other possible
causes. Manual 2100-065
Contactor defective
Check for open or shorted coil Replace contactor.
winding.
Power phasing not
correct
Check for red LED on phase
monitor (3 phase units only).
Switch two power leads to the unit.
Motor defective
Check for open or shorted
motor winding.
Replace motor.
Motor capacitor
defective
Check capacitor ratng. Check Replace capaci tor.
for open or shorted capacitor.
Heat pump control
defective
Check across fan relay on
heat pump control (Com-NC).
Replace heat pump control.
Replace heat pump control.
Reversing valve
does not energize
(heating only)
Reversing valve solenoid Check for open or shorted coil. Replace solenoi d C oi l.
coil defective
Heat pump control
defective
Check for 24V between RV-C
and B-C.
Unit will not go into
defrost
(heating only)
Temperature sensor or
heat pump control
defective
Disconnect temperature
1. If unit goes through defrost cycle, replace
sensor from board and jumper
temperature sensor.
across speed up terminals and
sen jump terminals. This
2. If unit does not go through defrost cycle,
should caruse the unit to go
replace heat pump control.
through a defrost cycle within
one minute.
Unit will not come
out of defrost
(heating only)
Temperature sensor or
heat pump control
defective
Jumper across speed up
terminals. This should cause
the unit to come out of defrost
within one minute.
1. Check control circuit wiring.
2. Replace heat pump control.
1. If unit comes out of defrost cycle replace
temperature sensor.
2. If unit does not come out of defrost
cycle, replace heat pump control.
Manual 2100-414
Page 19
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.
TEMPERATURE F VS RESISTANCE R OF TEMPERATURE
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
-10.0
-9.0
-8.0
-7.0
-6.0
-5.0
-4.0
-3.0
-2.0
-1.0
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
11.0
12.0
13.0
14.0
15.0
16.0
17.0
18.0
19.0
20.0
21.0
22.0
23.0
24.0
Manual 2100-414
Page 20
R
196871
190099
183585
177318
171289
165487
159904
154529
149355
144374
139576
134956
130506
126219
122089
118108
114272
110575
107010
103574
100260
97064
93981
91008
88139
85371
82699
80121
77632
75230
72910
70670
68507
66418
64399
62449
60565
58745
56985
55284
53640
52051
50514
49028
47590
46200
44855
43554
42295
41077
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
40.0
41.0
42.0
43.0
44.0
45.0
46.0
47.0
48.0
49.0
50.0
51.0
52.0
53.0
54.0
55.0
56.0
57.0
58.0
59.0
60.0
61.0
62.0
63.0
64.0
65.0
66.0
67.0
68.0
69.0
70.0
71.0
72.0
73.0
74.0
R
39898
38757
37652
36583
35548
34545
33574
32634
31723
30840
29986
29157
28355
27577
26823
26092
25383
24696
24030
23384
22758
22150
21561
20989
20435
19896
19374
18867
18375
17898
17434
16984
16547
16122
15710
15310
14921
14544
14177
13820
13474
13137
12810
12492
12183
11883
11591
11307
11031
10762
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
90.0
91.0
92.0
93.0
94.0
95.0
96.0
97.0
98.0
99.0
100.0
101.0
102.0
103.0
104.0
105.0
106.0
107.0
108.0
109.0
110.0
111.0
112.0
113.0
114.0
115.0
116.0
117.0
118.0
119.0
120.0
121.0
122.0
123.0
124.0
R
10501
10247
10000
9760
9526
9299
9077
8862
8653
8449
8250
8057
7869
7686
7507
7334
7165
7000
6840
6683
6531
6383
6239
6098
5961
5827
5697
5570
5446
5326
5208
5094
4982
4873
4767
4663
4562
4464
4367
4274
4182
4093
4006
3921
3838
3757
3678
3601
3526
3452
FAN BLADE SETTING DIMENSIONS
TABLE 7
REFRIGERANT CHARGE
Shown in Figure 14 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.
Model
Rated
Airflow
SH611D
1350
FIGURE 13
FAN BLADE SETTING
95 OD
82 OD
Temperature Temperature
48 - 51
50 - 53
TABLE 8
RATED CFM & RATED ESP
AIRFLOW
Model
Rated
CFM*
Rated
ESP*
Recommended
Airflow Range
SH611D
1350
.20
1475 – 1100
* Rated CFM and ESP on high speed tap.
MIS-1424
"A"
TABLE 6
FAN BLADE DIMENSION
Model
Dimension A
SH611D
1.75
REMOVAL OF FAN SHROUD
1. Disconnect all power to the unit.
2. Remove the screws holding both grilles, one on each
side of unit, and remove grilles.
3. Remove screws holding fan shroud to condenser and
bottom. Nine (9) screws.
4. Unwire condenser fan motor.
5. Slide complete motor, fan blade, and shroud
assembly out the left side of the unit.
TABLE 9
INDOOR BLOWER PERFORMANCE
CFM @ 230V / 460V
SH611D
E.S.P.
In H2O
.0
.1
.2
.3
.4
High Speed
Medium Speed
Dry Coil Wet Coil
Dry Coil Wet Coil
1700
1550
1400
1250
---
1575
1475
1350
1150
---
1475
1375
1250
1100
---
1375
1250
1100
825
---
Subtract .08 static for 2” filter
NOTE: SH611D is shipped with the indoor
blower on medium speed for free
blow applications. Move to high
speed for ducted applications.
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 resulting in a suction line
temperature (6” from compressor) as shown in Table 7.
The suction line temperatures in Table 7 are based upon
80° F dry bulb / 67° F wet bulb (50% R.H.) temperature
and rated airflow across the evaporator during cooling
cycle.
TABLE 10
MAXIMUM ESP OF OPERATION
High Speed
Medium Speed
A 10
.3
.3
B 09
.3
.3
C 09
.3
.3
Manual 2100-414
Page 21
TABLE 11
PRESSURE TABLE
COOLING
Air Temperature Entering Outdoor Coil °F
Model
Return Air
Temperature
Pressure
75
80
85
90
95
75 deg. D B
62 deg. WB
Low S i de
High Side
65
176
65
202
67
223
68
241
70
254
71
265
71
271
72
274
73
273
80 deg. D B
67 deg. WB
Low S i de
High Side
69
181
70
207
72
229
73
247
75
261
76
272
76
278
77
281
78
280
85 deg. D B
72 deg. WB
Low S i de
High Side
71
187
72
214
75
237
76
256
78
270
79
282
79
288
80
291
81
290
SH611D
100
105
110
115
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.
TABLE 12
PRESSURE TABLE
HEATING
Model
SH611D
Air Temperature Entering Outdoor Coil °F
Return Air
Temperature Pressure
70 deg.
Low S i de
High Side
0
23
153
5
10
24
26
171 188
15
20
25
28
205
31
35
220 234
30
35
40
45
50
38
247
43
260
48
271
53
59
281 289
55
60
65
297
72
304
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 2100-414
Page 22
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