Bard WH611 wall mounted heat pump Installation instructions
Below you will find brief information for wall mounted heat pump WH611. This heat pump is designed to provide both heating and cooling for your home. It includes features such as a high-pressure switch, a two-speed outdoor fan motor, and a defrost cycle.
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INSTALLATION INSTRUCTIONS WALL MOUNTED PACKAGE HEAT PUMPS MODEL WH611 i Bard Manufacturing Company Bryan, Ohio 43506 Since 1914...Moving ahead, just as planned. Manual : 2100-347 A Supersedes: 2100-347 File: Volume {il Tab 19 Date: 01-15-99 © Copyright 1999 Contents Getting Other Information and Publications .......... 1 Wall Mount General a... noveanananencar 2 Heat Pump Wall Mount Model Nomenclature .......... 2 Shipping Damage ...................=wemmvereirecere een oe 4 Сепега! ices sen, 4 Duct WOrK ….….….…...…..….earirererrecenrensaanearrranarreences 5 FIEIS eee eee EEE 5 Fresh Air Intake .........................ermeiceecio ete 5 Condensate Drain — Evaporator .................e ==... 6 Condensate Drain — Condenser ........................e... 6 Installation instructions 7 Wall Mounting information .........................-——-—————.... 7 Mounting the Unit .......................e...e.e. em. ee evene 7 Wiring - Main Power ................——.——.—. een 12 Wiring — Low Voltage Wiring .........................e-e...... 12 Compressor Cutoff Thermostat and Outdoor Thermostats ...........................eseerrenececeres 13 Heat Anticipation .....................——er.—........e.eerrevecee 13 Thermostat Indicator Lamps e... 13 Emergency Heat Position 14 Compressor Malfunction Light een 14 Figures Figure 1 Unit Dimensions ces 3 Figure 2 Fresh Air Damper Assembly ................... 5 Figure 3 Condensate Drains..................... eee 6 Figure4 Mounting Instructions ...................————————.. 8 Figure 4A Electric Heat Ciearance ........................ 9 Figure 5 Wall Mounting Instructions ..................... 10 Figure 6 Wall Mounting Instructions ..............e..... 10 Figure 7 Common Wall Mounting Installations...... 11 Figure 8 Unit 24V Terminal Board ....................... 12 Figure 9 Compressor Cutoff and Outdoor Thermostat Wiring ......................——....... 13 Figure 10 Compressor Cutoff and Outdoor Thermostat Wiring ......................——————... 13 Figure 11 Start Up Procedure Decal ..................... 15 rigure 12 Detrost Control Board ............................ 17 Figure 13 Fan Blade Setting ........................ ere... 20 Start Up ...... Important installer Note ercer re Crankcase Heaters ….....…….......…...………..…ersreeneansrnss nes High Pressure Switch ………….…….......eeecsresrerer neue. Two Speed outdoor Fan motors Three Phase Scroll Compressor Start Up.............. Phase Monitor ...................-_...._.eee.enarenrece ene Service HINts .......................e..mvecimei ice eee Sequence of Operation .................... erre Pressure Service Ports ................... enemies Defrost Cycle ...........................=meemeneaniteeae nene Troubleshooting ..........—...—eseser2aenenanaoo nave ioa nara neo Lee Solid State Heat Pump Control Troubleshooting Procedure .................e.eriesiarinererenrracacen ener Checking Temperature Sensor Outside Unit Слгеый O Fan Blade Setting Dimensions ..........................e.... Removal of Fan Shroud ...............ew_e..e..eeeseererroie Refrigerant Charge ......................-.erresercerccier e Pressure Tables .................e.—.e.er00icirerrreii re e eZ Tables Table 1 Fuse, HACR Breakers, Wire Size .......... Table 2 Thermostat Wire Size ....................._.... Table 3 Wall thermostat and Subbase Combinations .................— reee... Table4 — Troubleshooting Table5 — Fan Blade Dimensions es Table6 System Charge Ratings ........................ Table 7 Rated CFM and Rated ESP.................. Table 8 Indoor Blower Performance .................. Table 9 Pressure Table .........................emmva Table 10 Pressure Table ........................2.00e 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 econo. ANSI/NFPA 70 Standard for the Installation ...................... ANSI/NFPA 90A of Air Conditioning and Ventilating Systems Standard for Warm Air ……………rsscssssonsennens ANSUNFPA 90B Heating and Air Conditioning Systems Load Calculation for ..............2....- rc... ACCA Manual J Residential Winter and Summer Air Conditioning Duct Design for Residential ...................... ACCA Manual D Winter and Summer Air Conditioning and Equipment Selection For more information, contact these publishers: ACCA — Air Conditioning Contractors of America 1712 New Hampshire Ave. N.W. Washington, DC 20009 Telephone: (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 ASHRAE — American Society of Heating Refrigerating, and Air Conditioning Engineers, Incorporated 1791 Tullie Circle, N.E. Atlanta, GA 30329-2305 Telephone: (404) 636-8400 Fax: (404) 321-5478 NFPA — National Fire Protection Association Batterymarch Park Р.О. Вох 9101 Quincy, MA 02269-9901 Telephone: (800) 344-3555 Fax: (617) 984-7057 Manual 2100-347 Page 1 WALL MOUNT GENERAL INFORMATION HEAT PUMP WALL MOUNT MODEL NOMENCLATURE VOLTS & PHASE A - 230/208/60/1 В - 230/208/60/3 С - 460/60/3 REVISIONS MODEL EN MH 61 1 = A 0 Xx CAPACITY 38 - 3 Ton 43 - 3-1/2Ton 49 - 4ton VENTILATION OPTIONS X - Barometric Fresh Air Damper (Standard) B - Blank-off Plate C - Commercial Ventilator - Motorized without Exhaust M - Motorized Fresh Air Damper A - Adjustable Fresh Air Damper B__ MODULES COILOPTIONS 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) FILTER OPTIONS X - 1(nch Throwaway (Standard) W- 1 Inch Washable P - 2inchPleated NOTE: All vent options are without exhaust capability. May require separate field supplied barometric relief in building. Manual Page 2 2100-347 MAA HI V а МЭЛ 305 M3IA LNOHA ол 5 | JXOVHE mur NIYUC 1100 NIYOO 1109 ] NOILYTTVISNI MOLLON —— | he — MOCON! UN a YODO: 0 oy ATNO SLINN 9EWM - OCYM * | me [ Г NOILY 11 NIA 7х | | | | | | ни | В | | LN SID 831114 — EL | | " у ЗОНА М3 a | | OND) : MISNIANOO | fh 1901949313 \ | ` X | | E — oi 08 ; «e о ET _ | IE \ I HL IN s=s= | | H 19181731 = = == |; div NUNIIA \ SAONVEINI 7 = = = = 4 tl mona; (3180007) Td | Ш S e NOILVOOT INI ddIHS UN 5519 19INN0ISIO | | |, INIHSY 1S NIYY dD] | | | TH / 499308 110091) ла || ; NI-1TING ` [Po] В | 13NYd a S | | sima | | Ol | — ss399v 33H | INTN3d0 | ONLLNNON e | E dl Alddns | 30 | Ÿ 4 [VIH ! H == 11031] "A 0 le 1 — | a | 0 T= 3 11d of GD0H NIVà N3 1118 OL 18/2-E€ 1 EV | y/L-E | c/1-ct|v/€-vt | ZE 19L/11-e# 10€ 18/S-Lt 161 18/2-Etb |8/2-Ge [8/2-S1 |8/Z-6e |8/2-6 |8/Z-F6 [V/L-ZE | cv |LLIVM я J g Y H а M Ol 4 |O] N WN 1 A Г | > |3 3 1Ч Hun uinjay Aiddng | -Gioyy (Y1d@Q | UIPIAR SNOISN3INIA LINN I 3HNOI4 Manual 2100-347 Page 3 TABLE 1 ELECTRICAL SPECIFICATIONS SINGLE CIRCUIT DUAL CIRCUIT o D Maximum| © © Maximum No. a External | Field © Minimum Externa! Fuse © @ Rated Fleid | Minimum | Fuse or | Power | Ground Circuit or Field Power Ground Volta & | Power | Circuit Ckt. Wire | Wire Ampecity Ct. Breaker Wire Size Wire Size Model Phase | Circults | Ampacity | Breaker | Size Size |CKTA|CKTB|CKTA|CKTB|CKTA|CKTB|CKTA|CKTB WHE11-A00, AOZ | 230/208-1 1 52 60 6 10 --- --- --- ... _ .. WH611-B00, BOZ | 230/208-3 1 36 50 8 10 ... WH6&11-C00, COZ 460-3 1 18 25 10 10 - - O Maximum size of the time delay fuse or HACR typs 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 powar conductor sizing. CAUTION. When more than one field power conductor circuit is run thru 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 camer 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 assembied 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 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 instalied 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. Manual Page 4 2100-347 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 bamer on the outside of the insulation. Fiexible 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 3A 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 ajr duct. A metallic return air grille is required with installations not requinng 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 RGS or RFG2 through RFGS 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 À 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 1s 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 1s 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. MIS-938 Manual 2100-347 Page 5 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 1s 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 LLL] EVAPORATOR CONDENSATE DRAIN A CONDENSER CONDENSATE DRAIN MIS-1276 Manual 2100-347 Page 6 INSTALLATION INSTRUCTIONS WALL MOUNTING INFORMATION 1. Two holes for the supply and return air openings must A WA R N I N G be cut through the wall as shown in Figure 4, 2. On wood frame walls, the wall construction must be Failure to provide the 1/4 inch clearance strong and rigid enough to carry the weight of the unit between the supply duct and a combustible without transmitting any unit vibration. surface for the first 3 feet of duct can result in fire causing property damage, injury or death. A WA R | № С 3. Locate and mark lag bolt locations and bottom mounting bracket location. See Figure 4. Fire hazard can result if 1/4 inch clearance to 4. Mount bottom mounting bracket. combustible materials for supply air duct is not 5. Hook top rain flashing uder back bend of top. Top rain maintained. See Figure 4. flashing is shipped with unit attached to back of unit on the nght side. 3 Concrete block walls must be thoroughly Inspected to 6. Position unit in opening and secure with 5/16 lag bolts; insure that they are capable of carrying the weight of the use 3/4 inch diameter flat washers on the lag bolts. installed unit. 7. Secure rain flashing to wall and caulk across entire ] ftop. See Fi 4. MOUNTING THE UNIT ength of top. See Figure 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. 8. For additional mounting rigidity, the return air and supply air frames or collars can be dnlied and screwed or welded to the structural wall itself (depending upon wall construction). Be sure to observe required clearance if combustible wail. 2. The unit itself is suitable for Ô 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 | 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 4A for details. 9. On side by side installations, maintain a minimum of 20 inches clearance on nght side to allow access to control panel and heat stnps, and to allow proper airflow to the outdoor coil. Additional clearance may be required to meet local or national codes. Manual 2100-347 Page 7 9EZ-SIW НТУ ® MIL Y DINSYI JUL ONO ONY STONY MI LNDON 3015 3H! QNIHIE 030¥18 38 NIN) MONIS 10 0938 Y 1YHI OMNTAROON SI 1) SY IMILVA HI@v1SN8M00 MOA 03840034 SI 1200 HY 14915 40 53015 404 ТУ № ИЗО „ЖИ JENES THR MINI NY MTL — | 100 BY AS 2h Г T° "о р №6 yy 0007 91 3 000751 7 4 WE JY Ay 931 14475 INIRSYI4 NI 13а | | 55329 BLM _ ph y) Le 1 w= — a + S 18290 1197 SNA) NY] TVIYITO «E CIONDARION a we | VS 1 à 3 | HIVINIYA OL SHOISNFAIQ ЗА ПОЗ | SILUIIVA 31811509000 ROL НАТО NIM LBL dl GURL OS Lg [LUO | UO | RIYINIYR BL SNOISNIMG ORINDIY ] 0 2 q Y "dbl JO KIONIT LING SNOTV SHIT 20 0739 HINA IIS SNOILONHLSNI ONILNNOW v 3894 2100-347 Manual Page 8 FIGURE 4A ELECTRIC HEAT CLEARANCE TYPICAL BUILDING OUTSIDE SHEETING AN UNIT WALL FRAME INSIDE SHEETING 5 SUPPLY N y AIR DUCT \ 8 1/47 NIN. SUPPLY AIR DUCT SEE NOTE | FLANGE OF WALL MOUNTED UNIT SS SIDE SECTION VIEW OF SUPPLY AIR DUCT FOR WALL MOUNTED UNIT SHOWING 1/4 INCH CLEARANCE TO COMBUSTIBLE SURFACES. ПИТ MIS-277 A 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 Page 9 FIGURE 5 WALL MOUNTING INSTRUCTIONS SEE FIGURE 4 — MOUNTING INSTRUCTIONS SUPPLY AIR OPENING RETUAN AIR OPENING SUPPLY AIR OPENING RETUAN AIR OPENING WOOD OR STEEL SIDING CONCRETE BLOCK WALL INSTALLATION WOOD FRAME WALL INSTALLATION FIGURE 6 WALL MOUNTING INSTRUCTIONS FRAMING MATERIAL 2X 4'S,2X 6'S AND/OR MIS-549 STRUCTURAL STEEL INTERIOR FINISHED WALL OVER FRAME EXTERIOR FINISHED WALL OVER FRAME ATTACH TO BOTTOM PLATE OF WALL ATTACHTO TOP pa Bl PLATE OFWALL N 1.000" CLEARANCE ALL AROUND Da 1.000" CLEARANCE ALL AROUND SA WALL STRUCTURE FACTORY SUPPLIED RAIN / | FLASHING. MOUNT ON UNIT | BEFORE INSTALLATION | Л SUPPLY AIR OPENING RETURN AIR OPENING a O9 BOTTOM MOUNTING BRACKET, MOUNT ON WALL BEFORE INSTALLING UNIT, _MIS-546 SEE UNIT DIMENSIONS, FIGURE 1, FOR ACTUAL DIMENSIONS F+1000 re = — = = = | Bi SUPPLY DUCT OPENING — RETURN DUCT OPENING +, 1 + 1 = TE af о == НЫ — -—-— uz ch THIS STRUCTURAL MEMBER LOCATED TO MATCH STUD SPACING FOR HEST OF WALL. À SECOND MEMBER MAY BE REQUIRED FOR SOME WALLS. Manual 2100-347 Page 10 da FIGURE 7 COMMON WALL MOUNTING INSTALLATIONS SUPPLY DUCT MAYBE LOCATED IN AN A:TIC OR BELOW CEILING RAFTERS AS SHOWN RAIN FLASHING RAFTERS $ RAIN — FLASHING [T= SUPPLY AIR DUCT W/ GRILLE WHER > ; > — FINISHED CEILING | SUPPLY AIR DUCT ——= { | SURFACE — 7 ` 7 RETURN AIR |. FINISHED CELLING SURFACE % OPENING W/ GRILLE laa RETURN AIR } OPENING W/ GRILLE ed CUTSIDE WALL = DUTSIDE WALL FREE AIR FLOW NO DUCT DUCTED SUPPLY RETURN AT UNIT SUPPLY DUCT MAYBE LOCATED IN AN ATTIC SUPPLY DUCT MAYBE LOCATED 18 AN ATTIC OR BELOW CEILING RAFTERS AS SHOWN OR BELOW CEILING RAFTERS AS SHOWN RAIN RAIN FLASHING | NN RAFTERS > vs) RAFTERS 2 ha ñ SUPPLY AIR DUCT ———— € SUPPLY AIR — ? AY ] 7 LOWERED CEILING FINISHED CE/LING SURFACE SUPPLY AIR —] GRILLE —R\ RETURN AIR SPACE | N и ЧЕМ : FINISHED CEL ING ня coserwu | | VE FALSE WALL Se N e | = Nm % RETURN AIR GRILLE SLEEVE OUTSIDE WALL $ OUTSIDE WALL LL RAISED FLOOR В RETURN AIR 7 RETURN AIR GRILLE FALSE WALL INSTALLATION CLOSET INSTALLATION MIS-550 Manual 2100-347 Page 11 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”. Thus 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 maternal. All wiring muse conform to NEC and all local codes. The electrical data lists fuse and wire sizes (75° C copper) for all models inciuding 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 comer of the disconnect opening under the disconnect access panel straight out. This tab will now line up with the slot in the door. When shut a padlock may be placed through the hole in the tab preventing entry. See “Start Up” section for important information on three phase scroll compressor start ups. WIRING —- LOW VOLTAGE WIRING 230 / 208V, 1 phase and 3 phase equipment dual primary voltage transformers. All equipment leaves the factory wired on 240V tap. For 208V operation, reconnect from 240V to 208V tap. The acceptable operating voltage range for the 240 and 208V taps are: TAP RANGE 240 253 - 216 208 220 — 187 NOTE: The voltage should be measured at the field power connection point in the unit and while the unit is operating at full load (maximum amperage operating condition). 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 1s recommended. The connection points are shown in Figure 8: FIGURE 8 UNIT 24V TERMINAL BOARD OPOPE © om 0000 o 0000 == 6008 ё 9000 nun 000000 0000 rs 0008 0000 ma 8000 € 6} 0600 m8 bOOOPOOOOCOEE HILT _ FACTORY JUMPER MIS-440 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 Distance VA FLA | Wire Gauge In Feet 20 gauge 45 18 gauge 60 55 2.3 16 gauge 100 14 guage 160 12 guage 250 Manual 2100-347 Page 12 FIGURE 9 4 —- 10KW 1 Ph ~ - 6 &9KW 3 Ph IOVYHOSOOOUES SE | Da | REMOVE FACTORY ! JUMPER Y-Y! | 5 —BR- | OUTDOOR THERMOSTAT USED AS COMPRESSOR CUTOFF MIS 408 FIGURE 10 15 — 20KW 1 Ph and 3 Ph O (O MW) 1 E) W WM WOW ww] | | | | REMOVE FACTORY ' | JUMPER Y-Y1 | | (3) — — —м- — — — — — L OUTDOOR THERMOSTAT USED MIS-409 AS COMPRESSOR CUTOFF COMPRESSOR CUT OFF THERMOSTAT AND QUTDOOR THERMOSTATS Heat pump compressor operation at outdoor temperatures below 0° F are neither desirabie 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. HEAT ANTICIPATION All of the thermostats shown in Table 4 have a fixed heat anticipator for stage 1 with no adjustment required. Stage 2 has an adjustable anticipator of the W2 connection and fixed for the W3 connection. Both the W2 and W3 circuits are controlled by the stage 2 bulb. The only heat anticipator that needs to be checked is stage 2 and it should be set to match the load carried by the W2 circuit. The normal factory wiring provides for only one electric heat contactor to be controlled by W2, and the anticipator should be set at .40A. If special field wiring is done, it is best to acutually measure the load but a good rule is .40A for each heat contactor controled by W2. THERMOSTAT INDICATOR LAMPS The red lamp marked “Em. Ht.” comes on and stays on whenever the system switch 1s 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. Manual 2100-347 Page 13 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. TABLE 4 WALL THERMOSTAT and SUBBASE COMBINATIONS Thermostat Subbase Predominant Features 8403-045 I 1 stg. cool; 2 stg. heat; Mercury bulb (TB41A1761) Manual changeover 8403-017 8404-009 [2 stg. coof; 2 stg. heat, Mercury bulb (T874R1129) | (Q674L1181) [Manual changeover M B403-018 8404-010 |2 stg. cool; 2 stg. heat, Mercury bulb (T874N1024) | (Q674F1261) | Auto or Manual changeover @ 1 stg. cool; 2 stg. heat 8403-042 (T8511G 1070) --- Electronic Non-Programmable Auto or Manual changeover 2 stg. Cool; 2 stg. heat -034 , (1604-80) --- Programmable Electronic Auto or Manual changeover @ No automatic changeover position —must manually place in heat or cool. Reversing valve remains energized at all times system switch is in heat position (except during defrost cycle). No pressure equalization noise when thermostat is satisfied on either heating or cooling. @ Allows thermostatto control both heating and cooling operation when setin “Auto” position. Reversing valve de-energizes at end of each “ON" heating cycle. IMPORTANT compressor malfunction. Both thermostat and subbase combinations shown above incorporate the following features: Man — Auto fan switch, Off — Heat — Em. Heat switch, and two (2) indicator lamps; one for emergency heat and one for Manual 2100-347 Page 14 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 11 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. 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. FIGURE 11 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 THERMO- STAT IS IN THE “OFF* POSITION. (THE COMPRESSOR IS NOT TO OPERATE.) 2. APPLY POWER BY CLOSING THE SYS- TEM DISCONNECT SWITCH. THIS ENERGIZES THE COMPRESSOR HEATER WHICH EVAPORATES THE LIQUID REFRIGERANT IN THE CRANK- CASE. 3. ALLOW 4 HOURS OR 60 MINUTES PER POUND OF REFRIGERANT {N THE SYS- TEM AS NOTED ON THE UNIT RATING PLATE, WHICHEVER IS GREATER. 4. AFTER PROPER ELAPSED TIME THE THERMOSTAT MAY BE SET TO OPER- ATE THE COMPRESSOR. 5. EXCEPT AS REQUIRED FOR SAFETY WHILE SERVICING, DO NOT OPEN SYSTEM DISCONNECT SWITCH. 7961-411 All three phase ZR3 compressors are wired identically intemally. 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 Page 15 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 destred 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 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 sensor mounted near the bottom of the outdoor coil. Once coil temperature reaches 30° F or below, the coil sends a signal to the control logic of the heat pump control and the defrost timer will start. After 60 (90 or 30) 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 nses to approximately 57° F the coil 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 controi will restore the system to heating operation automatically after 10 minutes. There are three settings on the heat pump control — 30 minutes, 60 minutes, and 90 minutes. Most models are shipped wired on the 60 minute setting for greatest operating economy. If special circumstances require a change to another time, remove wire connected to terminal 60 and reconnect to desired terminal. 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 ume to elapse. There is an initial defrost (INIT. DEF.) jumper on the control than can be used at any outdoor ambient dunng the heating cycle to simulate a 0° coil temperature. See Figure 12. This can be used to check defrost operation of the unit without waiting for the outdoor ambient to fall into the defrost region. Manual 2100-347 Page 16 FIGURE 12 DEFROST CONTROL BOARD | — a DN O , | я O О, — NON rR Ma oR Y | — — CONTROL CIRCUIT ao C —— | | SENSOR | SPEEDUP 0 у > | - NIT DEF 90 O | MIS-1174 Manual 2100-347 Page 17 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.) TROUBLESHOOTING 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. 3. Tum thermostat blower switch to auto position. Indoor blower should stop. TABLE 4 TROUBLESHOOTING SYMPTOM POSSIBLE CAUSES WHAT TO CHECK HOW TO CHECK OR REPAIR Compressor comtactor does not energize (cooling or heating) Control circuit wiring Check for R connection at unit, and 24V between R-C Aun À connection to outdoor unit to power heat purnp control Compressor lock out 1. Check for 24V between L1-C on heat purnp control 2. Check across high pressure switch. 1. If no voltage between L-C turn thermostat off and on again to reset high pressure switch. 2. If high pressure switch is open and will not reset, replace high pressre switch. Compressor short cycle protection Check for 24V between CC-C and Y-C on heat pump control tt no voltage between CC-C, jumper speed up terminal and within 10 seconds power should appear between CC-C. Remove speed up jumper after 10 seconds Heat pump control defective Check ali other possible causes. Manual 2100-065 Replace heat pump control (cooling or heating except during defrost) Contactor defective Check for open or shorted coil [Replace contactor winding Fan outdoor motor Motor defective Check for open or shorted Replace motor does not run motor winding Motor capacitor defective Check capacitor rating. Check for open or shorted capacitor. Replace capacitor Heat pump control defective Check across fan relay on heat pump control (Com-NC) Replace heat pump contro! Reversing valve does not energize (heating only) Reversing valve solenoid coil defective Check for open or shorted coil Replace solenoid coil Heat pump control defective Check for 24V between RV-C and B-C 1. Check control circuit wiring 2. Replace heat pump control Unit will not go into defrost {heating only) Temperature sensor or heat pump control defective Disconnect temperature sensor from board and jumper across speed up terminals and sen jump terminals. This should cause the unit to go through a defrost cycle within one minute, 1. If unit goes through defrost cycle, replace temperature sensor 2. If unit does not go through defrost cycle, replace heat pump control. 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. If unit comes out of defrost cycle, replace termperature sensor. 2. If unit does not come out of defrost cycle, replace heat purnp control. Manual 2100-347 Page 18 CHECKING TEMPERATURE SENSOR OUTSIDE UNIT CIRCUIT |. 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. TEMPERATURE F VS RESISTANCE R OF TEMPERATURE F R F R F R 25.0 196871 25.0 39898 | 75.0 10501 24.0 190099 26.0 38757 | 76.0 10247 -23.0 183585 27.0 37652 | 177.0 10000 -22.0 177318 28.0 36583 | 78.0 9760 21.0 171289 29.0 35548 79.0 9526 -20.0 165487 30.0 34545 | 80.0 9299 -19.0 159904 31.0 33574 | 81.0 9077 -18.0 154529 32.0 32634 | — 82.0 8862 -17.0 149355 33.0 31723 | 83.0 8653 -16.0 144374 34.0 30840 | 84.0 8449 -15.0 139576 35.0 29986 | 85.0 8250 -14.0 134956 36.0 29157 | 86.0 8057 -13.0 130506 37.0 28355 | 87.0 7869 -12.0 126219 38.0 27577 | 88.0 7686 -11.0 122089 39.0 26823 | 89.0 7507 -10.0 118108 40.0 26092 | 90.0 7334 -9.0 114272 41.0 25383 | 91.0 7165 -8.0 110575 42.0 24696 | — 92.0 7000 -7.0 107010 43.0 24030 | 93.0 6840 -6.0 103574 44.0 23384 | 94.0 6683 -5.0 100260 45.0 22758 [ 95.0 6531 -4.0 97064 46.0 22150 | 96.0 6383 -3.0 93981 47.0 21561 97.0 6239 -2.0 91008 48.0 20989 | — 98.0 6098 -1.0 88139 49.0 20435 | 99.0 5961 0.0 85371 50.0 19896 | 100.0 5827 1.0 82699 51.0 19374 | 101.0 5697 2.0 80121 52.0 18867 | 102.0 5570 3.0 77632 53.0 18375 | 103.0 5446 4.0 75230 54.0 17898 | 104.0 5326 5.0 72910 55.0 17434 | 105.0 5208 6.0 70670 56.0 16984 | 106.0 5094 7.0 68507 57.0 16547 | 107.0 4982 8.0 66418 58.0 16122 | 108.0 4873 9.0 64399 59.0 15710 | 109.0 4767 10.0 62449 60.0 15310 | 110.0 4663 11.0 60565 61.0 14921 | 111.0 4562 12.0 58745 62.0 14544 | 112.0 4464 13.0 56985 63.0 14177 | 113.0 4367 14.0 55284 64.0 13820 | 114.0 4274 15.0 53640 65.0 13474 | 115.0 4182 16.0 52051 66.0 13137 | 116.0 4093 17.0 50514 67.0 12810 | 117.0 4006 18.0 49028 68.0 12492 | 118.0 3921 19.0 47590 69.0 12183 | 119.0 3838 20.0 46200 70.0 11883 | 120.0 3757 21.0 44855 71.0 11591 | 121.0 3678 22.0 43554 72.0 11307 | 122.0 3601 23.0 42295 73.0 11031 | 123.0 3526 24.0 41077 74.0 10762 | _ 124.0 3452 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. Manual Page 2100-347 19 FAN BLADE SETTING DIMENSIONS Shown in Figure 13 are the correct fan blade setting dimensions for proper air delivery across the outdoor coil. Any service work requining removal or adjustment in the fan and/or motor area will require that the dimensions below be checked and blade adjusted in or out on the motor shaft accordingly. FIGURE 13 || 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 1s shown on the unit rating plate. Optimum umt performance will occur with a refrigerant charge resulting in a suction line temperature (6” from compressor) as shown in Table 6. || || AIRFLOW || TABLE 6 — N REFRIGERANT CHARGE ||| Rated 95 OD 82 OD N Model Airfiow | Temperature | Temperature | WH611 1350 48 - 51 50 - 53 TABLE 5 || Dimension The suction line temperatures in Table 6 are based upon Model A A te 80° F dry bulb / 67° F wet bulb (50% R.H.) temperature and WHE 11 1.00 MIS-1272 rated airflow across the evaporator during cooling cycle. TABLE 7 REMOVAL OF FAN SHROUD RECOMMENDED OPERATING RANGES 1. Disconnect all power to the unit. Model Rated Rated Recommended 2. Remove the screws holding both grilles, one on each CFM “ ESP © Airflow Range side of unit, and remove grilles. WH611 1350 ‚20 1475 1000 3. Remove screws holding fan shroud to condenser and bottom. Nine (9) screws. TABLE 8 INDOOR BLOWER PERFORMANCE -— CFM @ 230V / 460V WH611 High Speed | Medium Speed | Low Speed E.S.P. Dry Wet Dry Wet Dry Wet in HO Coil Coil Coil Coil Coil Coil .0 1700| 1550 1475| 13751 1200) 1150 À 1550| 1400] 1375] 1250| 1150] 1050 2 1400] 1250| 1250} 1100] 1050 850 3 1250j 1100 1100 825 4 900| 800 Subtract .08 static for 2” filter ducted applications. NOTE: WH611 is shipped with the indoor blower on medium speed for free blow applications. Move to high speed for *Rated CFM and ESP on high speed tap. Manual 2100-347 Page 20 TABLE 9 PRESSURE TABLE COOLING Air Temperature Entering Outdoor Coil °F Return Air Model | Temperature| Pressure 75 80 85 90 95 100 | 105 | 110 | 115 75 deg. DB | Low Side 65 65 67 68 70 71 71 72 73 62 deg. WB | High Side 176| 202} 223| 241] 254| 265| 271| 274| 273 WH611 80 deg. DB | Low Side 69 70 72 73 75 76 76 77 78 67 deg. WB | High Side 181| 207) 2291 247| 2611 2721 278] 281| 280 85 deg. DB | Low Side 71 72 75 76 78 79 79 80 81 72 deg. WB | High Side 187| 214| 237| 256| 2701 282] 288| 291} 290 TABLE 10 PRESSURE TABLE HEATING Air Temperature Entering Outdoor Coil °F Return Air Model | Temperature | Pressure | 0 5 10 | 15 | 20 | 25 | 30 | 35 | 40 | 45 | 50 | 55 | 60 WH611 70 de Low Side | 23] 24| 261 28] 31| 35| 38| 43| 48| 531 2591 65) 72 9 High Side | 153] 171| 188] 2051 220| 2341 247| 2601 271| 281| 289) 297! 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 chrge being in the system, the charge shouid be removed, system evacuated and recharged to serial plate instruction. 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Key features
- Wall mounted unit
- Heating and cooling
- High pressure switch
- Two speed fan
- Defrost cycle
Frequently asked questions
A minimum of 1/4 inch clearance is required between the supply air duct and combustible materials for the first three feet of ducting.
Verify proper rotation 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.
If tripped, the high pressure switch may be reset by turning the thermostat off then back on again.
The defrost cycle is controlled by temperature and time on the solid state heat pump control. When the outdoor temperature is in the lower 40° F temperature range or colder, the outdoor coil temperature is 32° F or below. This coil temperature is sensed by the coil sensor mounted near the bottom of the outdoor coil.