Bard PH1224, PH1236, PH1230 User Manual

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INSTALLATION INSTRUCTIONS

SINGLE PACKAGE

HEAT PUMPS

MODELS

PH1224

PH1230

PH1236

Bard Manufacturing Company

Manual :

2100-344

Bryan, Ohio 43506

File:

Volume II Tab 11

Since 1914...Moving ahead, just

Date:

08-21-98

 

 

as planned.

© Copyright 1998

Contents

Getting Other Informations and Publications

........ 1

General Instructions .................................................

3

Important ................................................................

3

Shipping Damage ....................................................

3

General ................................................................

3

Field-Installed Heater Packages (Optional) ..............

3

Installation .................................................................

5

Location ................................................................

5

Typical Installations ..................................................

5

Condensate Drain Trap ............................................

8

Air Filters ................................................................

8

Wiring – Main Power ................................................

9

Wiring – 24V Low Voltage Control Circuit ................

9

Thermostats ...........................................................

10

Thermostat Indicator Lamps ...................................

11

Emergency Heat Position .......................................

11

Transformer Taps ....................................................

11

Compressor Cut-Off Thermostat and Outdoor

 

Thermostat Wiring ..................................................

11

Start Up and Operation ..........................................

12

Three Phase Scroll Compressor Start Up

 

Information .............................................................

12

Sequence of Operation ..........................................

12

Defrost Cycle .........................................................

12

Start Up Notes .......................................................

12

Service and Troubleshooting ................................

14

Service Hints ..........................................................

14

Pressure Service Ports ..........................................

14

Refrigerant Charge ................................................

14

Fan Blade Settings .................................................

14

Solid State Heat Pump Control

 

Troubleshooting Procedure ....................................

14

Troubleshooting Guide ...........................................

15

Checking Temperature Sensor Check Out .............

16

Temperature vs. Resistance of

 

Temperature Sensor Chart .....................................

16

Suction and Discharge Tube Brazing .....................

17

Pressure Tables .....................................................

18

Wiring Diagrams .............................................

19 - 21

Figures

 

 

Figure 1

Prefabricated Rood Curb

 

 

Specifications ..........................................

4

Figure 2

Field Fabricated Curbing .........................

4

Figure 3

Elevated Mounting Platforms ..................

6

Figure 4

Airflow and Service Access

 

 

Clearances ..............................................

6

Figure 5

Roof Top Application ...............................

7

Figure 6

Slab Mounting at Ground Level ...............

7

Figure 7

Condensate Drain Trap ...........................

8

Figure 8

Low Voltage Wiring .................................

9

Figure 9

Compressor Cut-Off Thermostat

 

 

Wiring (5 and 10 KW) ............................

11

Figure 10

Compressor Cut-Off Thermostat

 

 

Wiring )15 KW ONLY) ...........................

11

Figure 11

Heat Pump Control Board .....................

13

Figure 12

Fan Blade Setting Dimensions ..............

14

Figure 13

Brazing Diagram ...................................

17

Tables

 

 

Table 1

Electrical Data .........................................

2

Table 2

Optional Field Installed Heater

 

 

Packages ................................................

2

Table 3

Optional Field Installed Heater Table .......

2

Table 4

Rated CFM and Rated ESP ....................

3

Table 5

Air Filter Area and Size ...........................

8

Table 6

Thermostat Wire Size .............................

9

Table 7

Heat Pump Thermostats .......................

10

Table 8

Volts, KW and Phase - Compressor

 

 

Cut-Off Wiring (5 and 10 KW) ...............

11

Table 9

Volts, KW and Phase - Compressor

 

 

Cut-Off Wiring (15 KW ONLY0 .............

11

Table 10

Refrigerant Charge ...............................

14

Table 11

Pressure Table - Cooling .......................

18

Table 12

Pressure Table - Heating .......................

18

Getting Other Information and Publications

These publications can help you install the air conditioner or heat pump. You can usually find these at your local library or purchase them directly from the publisher. Be sure to consult current edition of each standard.

National Electrical Code ...........................

ANSI/NFPA 70

Standard for the Installation ......................

ANSI/NFPA 90A

of Air Conditioning and

 

Ventilating Systems

 

Standard for Warm Air .............................

ANSI/NFPA 90B

Heating and Air

 

Conditioning Systems

 

Load Calculation for .................................

ACCA Manual J

Residential Winter and

 

Summer Air Conditioning

 

Duct Design for Residential ......................

ACCA Manual D

Winter and Summer Air Conditioning

 

and Equipment Selection

 

Commercial Low Pressure, ....................... ACCA Manual Q

Low Velocity Duct System Design

 

Load Calculation For Commercial ............

ACCA Manual N

Summer and Winter Air Conditioning

 

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

P.O. Box 9101

Quincy, MA 02269-9901

Telephone: (800) 344-3555

Fax: (617) 984-7057

Manual 2100-344

Page 1

TABLE 1

ELECTRICAL DATA

 

 

 

 

Q

 

 

 

 

 

 

 

Maximum

 

R

 

 

 

 

 

External

Minimum

Field

R

 

Rated

Operating

 

Fuses or

Circuit

Power

Ground

 

 

Ckt. Brk.

Ampacity

Wiring

Wire Size

 

Volts &

Voltage

Maximum

 

 

 

 

 

 

 

 

 

 

Model

Phases

Range

Unit Amps

Ckt. A

Ckt. A

Ckt. A

Ckt. A

 

 

 

 

 

 

 

 

PH1224

230/208-1

197 - 253

14.4

25

18

10

10

 

 

 

 

 

 

 

 

PH1230

230/208-1

197 - 253

17.7

30

22

10

10

 

 

 

 

 

 

 

 

PH1236

230/208-1

197 - 253

21.8

40

27

8

8

 

 

 

 

 

 

 

 

PH1236-B

230/208-3

197 - 253

15.6

25

19

10

10

 

 

 

 

 

 

 

 

Q Maximum time delay fuse or HACR type circuit breaker. HACR type not applicable to 460 volt.

R 75 degree C cooper wire size, basic unit only.

TABLE 2

OPTIONAL FIELD INSTALLED HEATER PACKAGES

ONLY TO BE USED WITH THE HEAT PUMP MODELS INDICATED

Heater Package

Volts and

 

 

 

 

Model No.

Phase

PH1224

PH1230

PH1236

PH1236-B

 

 

 

 

 

 

EH3PC-A05

 

X

X

X

 

EH3PB-A10

240/1

 

X

X

 

EH3PC-A10

X

 

 

 

 

 

 

 

EH3PC-A15

 

 

X

X

 

 

 

 

 

 

 

EH3PB-B09

240/3

 

 

 

X

EH3PB-B15

 

 

 

X

 

 

 

 

 

 

 

 

 

 

TABLE 3

OPTIONAL FIELD-INSTALLED ELECTRIC HEATER TABLE

 

 

Htr. KW &

 

 

 

 

 

 

Circuit B

 

 

 

 

Capacity

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

@ 240V (or

Htr. KW &

@ 240V

 

 

 

 

 

 

 

 

 

 

 

Q

R

S

 

 

480V if

Capacity

 

 

 

Heater

 

or 480V as

Heater

No.

Minimum

Maximum

Field

Ground

 

applicable)

@ 208 Volts

Pkg. Model

Unit Volts

applicable

Internal

Field

Circuit

Overcurrent

Power

Wire

 

 

 

 

No.

Phase

KW

BTUH

KW

BTUH

Htr. Amps

Fuses

Ckts.

Ampacity

Protection

Wiring

Size

 

 

 

 

 

 

 

 

 

 

 

 

 

EH3PB-A10

240/208-1

10

34,100

7.50

26,000

41.7

 

1

53

60

6

10

 

 

 

 

 

 

 

 

 

 

 

 

 

EH3PC-A05

240/208-1

5

17,100

3.75

12,800

20.8

 

1

26

30

10

10

EH3PC-A10

240/208-1

10

34,100

7.50

26,000

41.7

 

1

53

60

6

10

EH3PC-A15

240/208-1

15

51,200

11.25

38,400

62.5

30/60

1

79

80

4

8

 

 

 

 

 

 

 

 

 

 

 

 

 

EH3PB-B09

240/208-3

9

30,700

6.75

23,000

21.7

 

1

28

30

10

10

EH3PB-B15

240/208-3

15

51,200

11.25

38,400

36.2

 

1

46

50

8

10

 

 

 

 

 

 

 

 

 

 

 

 

 

QTime delay fuses or “HACR” type circuit breakers must be used for 60 and smaller sizes. Standard fuses or circuit breakers are suitable for sizes 70 and larger. 480V circuit breakers are not “HACR” type.

RBased on wire suitable for 75° C. Other wiring materials must be rated for marked “Minimum Circuit Ampacity” or greater.

SBased upon Table 250-95 of N.E.C. 1993. See electrical data for basic heat pump for Circuit A wiring specification requirements.

IMPORTANT: While this electrical data is presented as a guide, it is important to electrically connect properly size fuses and conductor wires in accordance with the National Electrical Code and all existing local codes.

Manual 2100-344

Page 2

GENERAL INSTRUCTIONS

IMPORTANT

The equipment covered in this manual is to be installed by trained, experienced service and installation technicians. 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 ducts, must be properly sized for the design air flow requirement of the equipment. 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.

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 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 heat pump 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.

FIELD INSTALLED HEATER PACKAGES (OPTIONAL)

These packaged heat pumps are manufactured without supplementary electric heaters. Supplementary heaters EH3P series (to fit PH1224, PH1230, and PH1236) are available for simple, fast, field installation.

A separate field power circuit is required for the supplementary heaters.

IMPORTANT: Refer to Table 4 when designing duct work for maximum available static pressure with heater installed.

Refer to the electrical data shown on pages 2 and 3 for proper application information on all available heater combinations and what units they can be used with. It also shows the applicable circuit ampacities, fuse size, and wire size for each heater combination.

Refer to the installation instructions packed with the heater for details on how to insert it into the basic unit.

TABLE 4

RATED CFM AND

EXTERNAL STATIC PRESSURE (ESP)

WET COIL (COOLING)

 

Rated

Rated

Recommended

Model

CFM

ESP

Air Flow Range

 

 

 

 

 

 

PH1224

800

.20

680

-

880 CFM

 

 

 

 

 

 

 

PH1230

1000

.30

775

-

1100

CFM

 

 

 

 

 

 

PH1236

1100

.20

775

- 1210

CFM

 

 

 

 

 

 

 

Manual 2100-344

Page 3

FIGURE 1

PREFABRICATED ROOF CURB SPECIFICATIONS

HEAVY GAUGE GALVANIZED WITH WOOD NAILING STRIP, WELDED/LEAKPROOF

ONE PIECE CONSTRUCTION – READY TO INSTALL

MIS-1177

CURB AND ROOF DETAILS

Roof

 

 

 

 

 

 

 

 

Roof Hood

Air Conditioning

Curb

A

B

C*

D

E

F

J*

H*

Model

Units

 

 

 

 

 

 

 

 

 

 

 

 

9042-003

80-3/8

40-1/4

37-1/4

38-3/8

35-3/8

42

14-3/4

19-1/8

RHE60

PH1224,

PH1230,

PH1236

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

*Duct Sizing Information

Return Air Dimension “C” is length Return Air Dimension “H” is width

Supply Air Dimension “C” is length Supply Sir Dimension “J” is width

FIGURE 2

FIELD FABRICATED CURBING

Roof Hood

Unit

E

Model

Model

 

 

PH1224

 

RHE36

PH1230

41

 

PH1236

 

MIS-1178

Manual 2100-344

Page 4

INSTALLATION

LOCATION

GENERAL

The unit must be located outside, or in a well ventilated area. It must not be in the space being heated or cooled. A sound absorbing material should be considered if the unit is to be installed in such a position or location that might cause transmission of sound or vibration to the living area or adjacent buildings.

SLAB MOUNTING

In areas where winter temperatures DO NOT go below 32° F for periods over twelve hours, the unit may be slab

mounted at grade level. When installing unit at grade level, install on a concrete slab at least four inches above finished grade level. Slab should have a slope tolerance away from the building structure of at lease 1/4 inch per foot, while being level from side to side. This will prevent ice buildup under the unit during defrost cycles. Place slab in a location where runoff water from higher ground will not collect around unit. See Figure 3.

A minimum of 18 inches should be provided between the coil inlet and any building surfaces. Provide at least four feet between coil outlet and any building wall, fences or other vertical structures. Provide a minimum of three feet clearance on the service access side of the unit. See Figure 4

ROOF MOUNTING

When a unit is installed in areas where low ambient temperatures or strong winter winds exist, it should be placed so prevailing winter winds are not in direct line with the heat pump coil. If this is not possible, a wind barrier should be constructed. Place barrier 24 inches from the coil inlet side of the unit and in the direction of prevailing winds. Size barrier at least the same height and width as the unit. This may be necessary on ground level installations, also. See Figure 5.

WINTER INSTALLATION BELOW 32°F

In areas where winter conditions go below 32°F for extended periods, the unit must be elevated above the mounting surface to prevent snowfall or defrost ice accumulation from interfering with the operation of the unit. A minimum of twelve inch elevation is recommended, while greater elevation may be required for areas of high snow accumulation. Poured concrete, steel framework, brick, cement block, etc., can be utilized to construct a suitable raised mounting platform. See Figure 6.

DUCT WORK

Refer to Tables 4, 5 and 5A when designing duct work for maximum static pressure available with the specific model and heater package being installed. Unit duct work is suitable for 0” clearance to combustible materials.

TYPICAL INSTALLATIONS

1.ROOF MOUNTED – The unit is mounted on a sturdy base on the roof of the building. Return air to the unit is brought through a single return grille (grilles with built-in filters are best since they enable easy access for filter changing). Return air ducts are attached to the lower section of the front panel. Supply air is brought from the unit to attic duct work or to a furred down hall. Supply air duct is attached to the top of the front panel.

CAUTION: All outdoor duct work must be thoroughly insulated and weatherproofed. All attic duct work must be thoroughly insulated. Two inch thick insulation with suitable vapor barrier is recommended for both outdoor and attic runs.

In roof top installation, as in all installations, the heat pump must be level from side to side. However, the unit should have a pitch along the length to assure complete external drainage of precipitation and of defrost condensate.

2.CRAWL SPACE – Duct work installed in crawl space must be well insulated and provided with a vapor barrier. In addition, the crawl space must be thoroughly ventilated and provided with a good vapor barrier as a ground cover. It is most desirable to install the unit outdoors rather than inside the crawl space, so that it will be readily accessible for service. In addition, it is necessary to dispose of the condensate from the outdoor coil on the heating cycle, and this is virtually impossible with the unit installed inside the crawl space.

3.SLAB MOUNTED AT GROUND LEVEL – This type installation is ideal for homes with a slab floor construction where a roof mounted unit is not desired. The supply and return duct work can be run through a furred closet space.

4.THROUGH THE WALL – This type installation requires a suitable framework to be fabricated capable of withstanding the unit weight. Normally the unit will be insulated so as to minimize supply and return duct work.

5.OTHER INSTALLATIONS – Many other installations are possible with the packaged heat pump. No matter what the installation, always consider the following facts:

A.Insure that the discharge air is not obstructed in any way so as to cause operation difficulties.

B.The indoor coil drain pan is equipped with a coupling that must be piped through a condensate drain trap to a suitable drain.

C.Always mount the unit is such a position that it may be easily reached for servicing and maintenance.

D.Insure that the unit is clear so that proper air flow over the outdoor coil will be maintained.

If this unit is operated in cooling below a 65° outdoor ambient temperature, the installation of low ambient controls (CMA-6) to unit is required.

Manual 2100-344

Page 5

FIGURE 3

ELEVATED MOUNTING PLATFORMS

MIS-1183

FIGURE 4

AIRFLOW and SERVICE ACCESS CLEARANCES

MIS-1185

Manual 2100-344

Page 6

FIGURE 5

ROOF TOP APPLICATION

(May also be required for ground level installations.)

MIS-1176

FIGURE 6

SLAB MOUNTING AT GROUND LEVEL (Above 32° F Outside Temperature)

MIS-1184

Manual 2100-344

Page 7

CONDENSATE DRAIN TRAP

It is very important to provide a trap in the condensate drain line to allow a positive liquid seal in the line and assure correct drainage from the coil condensate pan.

Install condensate drain trap shown in Figure 7. Use drain connection size or larger. Do not operate unit without trap. Unit must be level or slightly inclined toward drain. With a trap installed on a unit located in an unconditioned area, water in the trap may freeze. It is recommended that the trap material be of a type that will allow for expansion of water when it freezes.

AIR FILTERS

Air filters for the return air side of the system are not provided as part of the various types of applications for these models, and must be field supplied and installed as part of the final installation.

Prior thought should be given to return air location and placement of the air filter(s). The air filter(s) must be of adequate size and readily accessible to the operator of the equipment. Filters must be adequate in size and properly

maintained for proper operation. If this is not done, excessive energy use, poor performance, and multiple service problems will result. It is impossible to oversize air filters. Generous sizing will result in cleaner air and coils as well as lower operating costs and extend the time between required changes. Table 6 shows minimum filter areas and recommended filter sizes. Actual filter sizes can vary with the installation due to single or multiple returns utilizing a filter/grille arrangement or being placed immediately ahead of the indoor coil face in the return air duct.

TABLE 5

 

Minimum Filter

Recommended

Model

Areas

Size

 

 

 

PH1224

462 square inches

 

PH1230

15 x 30-5/8 x 1

(3.21 square feet)

PH1236

 

 

 

 

 

 

NOTE: If roof hood accessory is to be used, information on air filters may be found under that heading in this manual. Air filters are supplied as part of that package.

FIGURE 7

CONDENSATE DRAIN TRAP

MIS-136

Manual 2100-344

Page 8

WIRING – MAIN POWER

Refer to the unit rating plate for wire sizing information and maximum fuse 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. If field installed heaters are added to the basic unit, a second separate power supply circuit will be required. The heater rating plate located adjacent to the basic unit rating plate will show the appropriate circuit ampacity fuse size, etc. (Also see “Electrical Data” on pages 2.) All models are suitable for connection with copper wire only. These instructions must be adhered to. Refer to the National Electrical Code for complete current carrying capacity data on the various insulation grades of wiring material.

The electrical specifications on page 2 lists fuse and wire sizes (75° F copper) for all models including the most commonly used heater sizes.

The unit rating plate lists a “Maximum Time Delay 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.

WIRING – 24V LOW VOLTAGE CONTROL CIRCUIT

Ten (10 ) wires should be run from thermostat subbase to the 24V terminal board in the unit. A ten conductor,

18 gauge copper, color-coded thermostat cable is recommended. The connection points are shown in Figure 8.

FIGURE 8 – LOW VOLTAGE WIRING

 

 

 

MIS-1187

TABLE 6 – THERMOSTAT WIRE SIZE

 

 

 

 

Transformer

FLA

Wire

Maximum Length

VA

Gauge

In Feet

 

 

 

 

 

55

2.3

20

45

 

 

18

60

 

 

16

100

 

 

14

160

 

 

12

250

 

 

 

 

Manual 2100-344

Page 9

THERMOSTATS

See specific wiring information for the different models, heater KWs, and voltages.

TABLE 7

HEAT PUMP THERMOSTATS

THERMOSTAT

SUBBASE

 

DESCRIPTION

 

 

 

 

 

8403-045

Part of

1 stage cool, 2 stage heat; Mecury bulb; Manual changeover

 

Fan Switch: Auto-On;

System Switch: Em Heat-Heat-Off-Cool

 

(T841A1761)

Thermostat

 

Indicating Lamps: Check-Em Heat-Aux Heat

 

 

 

 

 

 

 

 

8403-017

8404-009

1 stage cool, 2 stage heat; Mercury bulb; Manual changeover

Q

Fan Switch: Auto-On;

System Switch: Em Heat-Heat-Off-Cool

(T874R1129)

Q674L1181

Indicating Lamps: Check-Em Heat

 

 

 

 

 

 

 

 

8403-018

8404-010

1 stage cool, 2 stage heat; Mercury bulb; Auto changeover

 

Fan Switch: Auto-On;

System Switch: Off-Em Heat-Heat-Auto-Cool

R

(T874N1024)

Q674F1261

Indicating Lamps: Check-Em Heat

 

 

 

 

 

 

 

 

 

1 stage cool, 2 stage heat; Digital non-programmable (no battery required)

8403-042

Part of

Automatic or manual changeover

 

(T8511G1070)

Thermostat

Fan Switch: Auto-On;

System Switch: Off-Em Heat-Auto or Cool/Heat

 

 

 

Indicating Lamps: Check Display Indication: Em Heat-Aux Heat

 

 

 

 

 

 

2 stage cool, 2 stage heat; Digital programmable (7 day); Battery backup

8403-034

Part of

Automatic or manual changeover; 1 set-up/set-back period per 24 hours

 

Programmable ventilation terminal for economizer or energy recovery

 

(1F94-80)

Thermostat

 

Fan Switch: Auto-On;

System Switch: Off-Em Heat-Auto or Cool/Heat

 

 

 

 

 

 

Indicating Lamps: Emer-Pump-Malf-Aux

 

 

 

 

 

 

2 stage cool, 3 stage heat; Digital proframmable (5day/2day); Battery backup

8403-027

Part of

Automatic or manual changeover: 4 set-ups/set-back periods per 24 hours

(1F92-71)

Thermostat

Fan Switch: Auto-On;

System Switch: Off-Em Heat-Auto or Cool/Heat

 

 

 

Indicating Lamps: Emer-Pump-Malf-Aux

 

 

 

 

 

 

QNo automatic changeover position – must be manually placed 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.

RAllows thermostat to control both heating and cooling operation when set in “AUTO” position. Reversing valve deenergizes at end of each “ON” heating cycle.

Manual 2100-344

Page 10

THERMOSTAT INDICATOR LAMPS

The red lamp marked “EM. HT.” comes on and stays on whenever the system switch is placed in Em. Ht. 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 outdoor section, or when the green “Check” lamp comes on indicating a problem.

TRANSFORMER TAPS

230/208V, 1 phase and 3 phase equipment employ 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).

COMPRESSOR CUTOFF THERMOSTAT

WIRING (5 and 10 KW)

FIGURE 9

UNIT 24V TERMINAL BOARD

REMOVE FACTORY

JUMPER Y-Y1

MIS-1188

OUTDOOR THERMOSTAT

 

 

USED AS COMPRESSOR CUTOFF

TABLE 8

5 and 10 KW

Model

KW

Volts

Phase

 

 

 

 

PH1224

0, 5, 10

230

1

 

 

 

 

PH1230

0, 5, 10

230

1

 

 

 

 

PH1236

0, 5, 10

230

1

 

 

 

 

COMPRESSOR CUTOFF THERMOSTAT

and OUTDOOR THERMOSTAT WIRING

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 county and most of the equipment is installed in areas not approaching the lower outdoor temperature range, the compressor cutoffs 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. Utilization of the Heating Application Data and the heat loss calculation of the building are useful in determining the correct set points.

COMPRESSOR CUTOFF THERMOSTAT WIRING (15 KW ONLY)

FIGURE 10

UNIT 24V TERMINAL BOARD

REMOVE FACTORY

JUMPER Y-Y1

MIS-1189

OUTDOOR THERMOSTAT

 

 

USED AS COMPRESSOR CUTOFF

TABLE 9

15 KW ONLY

Model

KW

Volts

Phase

 

 

 

 

PH1230

15

230

1

 

 

 

 

PH1236

15

230

1

 

 

 

 

Manual 2100-344

Page 11

START UP AND OPERATION

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. 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 rotation, as well as, substantially reduced current draw compared to tabulated values.

Verification of proper rotation must be made at the time the equipment is put into service. 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.

All three phase ZR*3 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 terminals should maintain proper rotation direction.

The direction of rotation of the motor may be changed by reversing any two line connections to the unit.

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 for 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 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.

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 temperature is sensed by the coil sensor mounted near the bottom of the outdoor coil. Once the coil temperature reaches 32°F or below, the coil sensor sends a signal to the control logic of the heat pump control and defrost timer will start.

After 60 (90 or 30) minutes at 32°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 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.

There are three settings on the heat pump control -- 30 minutes, 60 minutes, and 90 minutes. Most models are shipped wired on the 60 minutes 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. (See Figure 11.)

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.

There is an initial defrost (sen jmp) jumper 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.

START UP NOTES

For improved start up performance, wash the indoor coil with dishwasher detergent

Manual 2100-344

Page 12

FIGURE 11

HEAT PUMP CONTROL BOARD

MIS-1191

Manual 2100-344

Page 13

SERVICE AND TROUBLESHOOTING

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 manual reset 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 that they are the correct rating.

5.Periodic cleaning of the outdoor coil to permit full and unrestricted airflow circulation is essential.

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 in Tables 11 and 12 in this 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.

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 10.

TABLE 10

 

 

95 Degree F

82 Degree F

 

Rated

 

OD

 

 

OD

 

Model

Airflow

Temperature

Temperature

 

 

 

 

 

 

 

 

PH1224

800

56

-

56

61

-

62

PH1230

1000

56

-

56

58

-

60

PH1236

1100

50

-

52

52

-

54

 

 

 

 

 

 

 

 

The above suction line temperatures are based upon 80°F dry bulb/67° F wet bulb (50% RH) temperature and rated airflow across the evaporator during cooling cycle.

FAN BLADE SETTINGS

Shown in Figure 12 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 in

Figure 12 be checked and blade adjusted in or out on the motor shaft accordingly.

FIGURE 12

FAN BLADE SETTING DIMENSIONS

Model

Dimension A

 

 

PH1224

1.00"

PH1230

.75"

PH1236

.75"

 

 

MIS-1190

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 is 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.

Manual 2100-344

Page 14

TROUBLE SHOOTING GUIDE

Symptom

Possible Causes

What to Check

How to Check or Repair

 

 

 

 

Compressor contactor

Contil circuit wiring

Check for R connection at unit

Run R connection to outdoor unit to power heat

does not energize

 

and 24 volt between R-C.

pump control.

(heating or cooling)

 

 

 

Compressor lock out

1. Check for 24V between

1. If no voltage between L1-C, turn thermostat off

 

 

 

L1-C on heat pump control

and on again to reset high pressure switch.

 

 

2. Check across high

2. If high pressure switch is open and will not reset,

 

 

pressure switch.

replace high pressure switch.

 

 

 

 

 

Compressor short cycle

Check for 24V between CC-C

If no voltage between CC-C, jumper speed up

 

protection

and Y-C on heat pump

terminal, and within 10 seconds power should

 

 

control.

appear between CC-C. Remove speed up jumper

 

 

 

after 10 seconds.

 

 

 

 

 

Heat pump control

Check all other possible

Replace heat pump control.

 

defective

causes. Manual 2100-065.

 

 

 

 

 

 

Contactor defective

Check for open or shorted

Replace contactor.

 

 

coil winding.

 

 

 

 

 

Fan outdoor motor

Motor defective

Check for open or shorted

Replace motor.

does not run

 

motor winding.

 

(cooling or heating

 

 

 

Motor capacitor defective

Check capacitor rating.

Replace capacitor.

except during defrost)

 

Check for open or shorted

 

 

 

 

 

 

capacitor.

 

 

 

 

 

 

Heat pump control

Check across fan relay on

Replace heat pump control.

 

defective

heat pump control. (Com-NC)

 

 

 

 

 

Reversing valve does

Reversing volve solenoid

Check for open or shorted

Replace solenoid coil.

not energize

coil defective

coil.

 

(heating only)

 

 

 

Heat pump control

Check for 24V between RV-C

1. Check control circuit wiring.

 

 

defective

and B-C.

2. Replace heat pump control

 

 

 

 

Unit will not go into

Temperature sensor or

Disconnect temperature

1. If unit goes through defrost cycle, replace

defrost

heat pump control

sensor from board and

temperature sensor.

(heating only)

defective

jumper across speed up

 

 

 

terminals and sen jump

2. If unit does not go through defrost cycle, replace

 

 

terminals. This should cause

heat pump control.

 

 

the unit to go through a

 

 

 

defrost cycle within one

 

 

 

minute.

 

 

 

 

 

Unit will not come out

Temperature sensor or

Jumper across speed up

1. If unit comes out of defrost cycle, replace

of defrost

heat pump control

terminals. This should cause

temperature sensor.

(heating only)

defective.

the unit to come out of defrost

2. If unit does not come out of defrost cycle,

 

 

within one minute.

replace heat pump control.

 

 

 

 

Manual 2100-344

Page 15

CHECKING TEMPERATURE SENSOR CHECK OUT

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 SENSOR

 

F

R

F

R

F

R

F

R

-25.0

196871

15.0

53640

55.0

17434

95.0

6531

-24.0

190099

16.0

52051

56.0

16984

96.0

6383

-23.0

183585

17.0

50514

57.0

16547

97.0

6239

-22.0

177318

18.0

49028

58.0

16122

98.0

6098

-21.0

171289

19.0

47590

59.0

15710

99.0

5961

-20.0

165487

20.0

46200

60.0

15310

100.0

5827

-19.0

159904

21.0

44855

61.0

14921

101.0

5697

-18.0

154529

22.0

43554

62.0

14544

102.0

5570

-17.0

149355

23.0

42295

63.0

14177

103.0

5446

-16.0

144374

24.0

41077

64.0

13820

104.0

5326

-15.0

139576

25.0

39898

65.0

13474

105.0

5208

-14.0

134956

26.0

38757

66.0

13137

105.0

5094

-13.0

130506

27.0

37652

67.0

12810

107.0

4982

-12.0

126219

28.0

36583

68.0

12492

108.0

4873

-11.0

122089

29.0

35548

69.0

12183

109.0

4767

-10.0

118108

30.0

34545

70.0

11883

110.0

4663

-9.0

114272

31.0

33574

71.0

11591

111.0

4562

-8.0

110575

32.0

32634

72.0

11307

112.0

4464

-7.0

107010

33.0

31723

73.0

11031

113.0

4367

-6.0

103574

34.0

30840

74.0

10762

114.0

4274

-5.0

100260

35.0

29986

75.0

10501

115.0

4182

-4.0

97064

36.0

29157

76.0

10247

116.0

4093

-3.0

93981

37.0

28355

77.0

10000

117.0

4006

-2.0

91008

38.0

27577

78.0

9760

118.0

3921

-1.0

88139

39.0

26823

79.0

9526

119.0

3838

0.0

85371

40.0

26092

80.0

9299

120.0

3757

1.0

82699

41.0

25383

81.0

9077

121.0

3678

2.0

80121

42.0

24696

82.0

8862

122.0

3601

3.0

77632

43.0

24030

83.0

8653

123.0

3526

4.0

75230

44.0

23384

84.0

8449

124.0

3452

5.0

72910

45.0

22758

85.0

8250

 

 

6.0

70670

46.0

22150

86.0

8057

 

 

7.0

68507

47.0

21561

87.0

7869

 

 

8.0

66418

48.0

20989

88.0

7686

 

 

9.0

64399

49.0

20435

89.0

7507

 

 

10.0

62449

50.0

19896

90.0

7334

 

 

11.0

60565

51.0

19374

91.0

7165

 

 

12.0

58745

52.0

18867

92.0

7000

 

 

13.0

56985

53.0

18375

93.0

6840

 

 

14.0

55284

54.0

17898

94.0

6683

 

 

 

 

 

 

 

 

 

 

Manual 2100-344

Page 16

SUCTION AND DISCHARGE TUBE

To connect:

BRAZING

– Recommended brazing materials: silfos with

 

Compliant Scroll compressors have copper plated steel

minimum 5% silver or silver braze material with

suction and discharge tubes. These tubes are far more

flux.

rugged and less prone to leaks than copper tubes used on

– Reinsert tube into fitting.

other compressors. Due to different thermal properties of

 

steel and copper, brazing procedures may have to be

– Heat tube uniformly in Area 1 moving slowly to

changed from those commonly used.

Area 2. When joint reaches brazing temperature,

To disconnect: heat joint Areas 2 and 3 slowly and

apply brazing material. (See Figure 10.)

 

uniformly until braze material softens and the tube can

– Heat joint uniformly around the circumference to

be pulled out of suction fitting. (See Figure 10.)

flow braze material completely around the joint.

 

– Slowly move torch into Area 3 to draw braze

 

material into joint. (See Figure 10.)

 

Do not overheat joint.

FIGURE 13

BRAZING DIAGRAM

MIS-1179

Manual 2100-344

Page 17

PRESSURE TABLES

TABLE 11

COOLING

Air Temperature Entering Outdoor Coil Degrees F

 

Return Air

 

 

 

 

 

 

 

 

 

 

Model

Temperature

Pressure

75

80

85

90

95

100

105

110

115

 

 

 

 

 

 

 

 

 

 

 

 

 

75 deg. DB

Low Side

73

75

76

78

79

80

81

82

83

 

62 deg. WB

High Side

191

205

219

234

251

267

285

303

323

 

 

 

 

 

 

 

 

 

 

 

 

PH1224

80 deg. DB

Low Side

78

80

81

83

84

88

87

88

89

67 deg. WB

High Side

196

210

225

240

257

274

292

311

331

 

 

 

 

 

 

 

 

 

 

 

 

 

 

85 deg. DB

Low Side

81

83

84

86

87

89

90

91

92

 

72 deg. WB

High Side

203

217

233

248

266

284

302

322

343

 

 

 

 

 

 

 

 

 

 

 

 

 

75 deg. DB

Low Side

73

75

76

78

79

79

81

82

84

 

62 deg. WB

High Side

208

222

237

254

270

288

307

326

346

 

 

 

 

 

 

 

 

 

 

 

 

PH1230

80 deg. DB

Low Side

78

80

81

83

84

85

87

88

90

67 deg. WB

High Side

213

228

243

260

277

295

315

334

355

 

 

 

 

 

 

 

 

 

 

 

 

 

 

85 deg. DB

Low Side

81

83

84

86

87

88

90

91

93

 

72 deg. WB

High Side

220

236

252

269

287

305

326

346

367

 

 

 

 

 

 

 

 

 

 

 

 

 

75 deg. DB

Low Side

72

74

75

77

78

79

80

81

82

 

62 deg. WB

High Side

211

225

242

258

276

294

314

333

355

 

 

 

 

 

 

 

 

 

 

 

 

PH1236

80 deg. DB

Low Side

77

79

80

82

83

84

86

87

88

67 deg. WB

High Side

216

231

248

265

283

302

322

342

364

 

 

 

 

 

 

 

 

 

 

 

 

 

 

85 deg. DB

Low Side

80

82

83

85

86

87

89

90

91

 

72 deg. WB

High Side

224

239

257

274

293

313

333

354

377

 

 

 

 

 

 

 

 

 

 

 

 

TABLE 12

HEATING

Air Temperature Entering Outdoor Coil Degrees F

 

Return

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Model

Air Temp.

Pressure

0

5

10

15

17

20

25

30

35

40

45

47

50

55

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PH1224

70 deg

Low Side

22

24

27

30

31

33

37

41

45

50

56

58

62

68

High Side

174

182

190

198

201

205

213

221

229

237

245

248

253

261

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PH1230

70 deg

Low Side

21

23

25

28

29

31

34

38

43

48

53

55

59

65

High Side

167

170

174

178

179

182

187

192

197

203

210

213

217

224

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PH1236

70 deg

Low Side

24

25

26

28

28

30

33

37

42

47

53

56

60

68

High Side

194

195

197

201

202

205

211

218

226

235

246

250

257

270

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Low side pressure ± 2 PSIG

High side pressure ± 5 PSIG

Tables are based upon rated CFM (airflow across the evaporator coil and should be found under section titled “Refrigerant Charge” elsewhere in manual. 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 instructions.

Manual 2100-344

Page 18

Wiring Diagram (4098-123) printed from CAD to get size needed

Manual 2100-344

Page 19

Wiring Diagram (4098-124) printed from CAD to get size needed

Manual 2100-344

Page 20

Wiring Diagram (4098-211) printed from CAD to get size needed

Manual 2100-344

Page 21