Bard WH183, WH242 User Manual

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INSTALLATION INSTRUCTIONS

WALL MOUNTED

PACKAGE HEAT PUMP

Models

WH183

WH242

Bard Manufacturing Company

Manual :

2100-373A

Bryan, Ohio 43506

Supersedes:

2100-373

Since 1914...Moving ahead just as planned.

File:

Volume III Tab 17

Date:

05-13-02

 

© Copyright 2002

Contents

Getting Other Informations and Publications

........ 1

Wall Mount General Information .............................

2

Heat Pump Wall Mount Model Nomenclature ..........

2

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

2

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

2

Duct Work ................................................................

4

Filters ................................................................

5

Fresh Air Intake ........................................................

5

Condensate Drain ....................................................

5

Installation Instructions ...........................................

6

Wall Mounting Information .......................................

6

Mounting the Unit .....................................................

6

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

10

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

11

Compressor Cutoff Thermostat and

 

Outdoor Thermostats ..............................................

11

Heat Anticipation ....................................................

12

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

12

Compressor Malfunction Light ...............................

12

Figures

 

 

Figure 1

Unit Dimensions ......................................

3

Figure 2

Fresh Air Damper Assembly ...................

5

Figure 3

Mounting Instructions ..............................

7

Figure 4

Wall Mounting Instructions ......................

8

Figure 5

Wall Mounting Instructions ......................

8

Figure 6

Common Wall Mounting Installations ......

9

Figure 7

Unit 24V Terminal Board .......................

10

Figure 8

Compressor Cutoff and Outdoor

 

 

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

11

Figure 9

Start Up Procedure Decal .....................

13

Figure 10 Defrost Control Board ...........................

14

Figure 11

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

17

Figure 12 Compressor Burnout

 

 

Cleanup Procedure ...............................

13

Start Up ...................................................................

13

Important Installer Note .........................................

13

Crankcase Heaters ................................................

13

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

13

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

13

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

14

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

14

Troubleshooting .....................................................

15

Solid State Heat Pump Control

 

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

15

Checking Temperature Sensor Outside

 

Unit Circuit .............................................................

16

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

17

Removal of Fan Shroud .........................................

17

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

17

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

18

Optional Accessories .............................................

19

Tables

 

 

 

Table

1

Electric Heat Table ..................................

1

Table

2

Fuse, HACR Breakers, Wire Size ...........

4

Table

3

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

11

Table

4

Wall Thermostat and Subbase

 

 

 

Combinations ........................................

12

Table

5

Troubleshooting ....................................

15

Table

6

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

17

Table

7

System Charge Ratings ........................

17

Table

8

Indoor Blower Performance ..................

17

Table

9

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

17

Table

10

Maximum ESP of Operation .................

17

Table

11

Pressure Table ......................................

18

Table

12

Pressure Table ......................................

18

Table

13

Optional Accessories ............................

19

Getting Other Information and Publications

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

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

ANSI/NFPA 70

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

ANSI/NFPA

90A

 

of Air Conditioning and

 

Ventilating Systems

 

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

ANSI/NFPA

90B

 

Heating and Air

 

Conditioning Systems

 

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

ACCA Manual J

Residential Winter and

 

Summer Air Conditioning

 

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

ACCA Manual

D Winter and Summer Air Conditioning

and Equipment Selection

For more information, contact these publishers:

ACCA 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, Inc.

1791 Tullie Circle, N.E.

Atlanta, GA 30329-2305

Telephone: (404) 636-8400

Fax: (404) 321-5478

NFPA

National Fire Protection Association

 

Batterymarch Park

 

P.O. Box 9101

 

Quincy, MA 02269-9901

 

Telephone: (800) 344-3555

 

Fax: (617) 984-7057

Manual 2100-373

Page 1

WALL MOUNT GENERAL INFORMATION

HEAT PUMP WALL MOUNT MODEL NOMENCLATURE

MODEL NUMBER

CAPACITY

18 - 1 1/2 Ton

24 - 2 Ton

36 - 3 Ton

48 - 4 Ton

60 - 5 Ton

VOLTS & PHASE A - 230/208/60/1 B - 230/208/60/3 C - 460/60/3

 

WH 24 2 A 08 X X X X X B

CONTROL MODULES

 

 

 

 

 

 

(See Chart Below)

 

 

 

COIL OPTIONS

REVISIONS

 

 

X - Standard

 

COLOR OPTIONS

1 - Phenolic Coated Evaporator

 

VENTILATION OPTIONS

KW

X - Beige

2 - Phenolic Coated Condenser

X - Barometric Fresh Air Damper

(Standard)

3 - Phenolic Coated Evaporator

 

(Standard)

1 - White

and Condenser

 

B - Blank-off Plate

2 - Mesa Tan

 

 

M - Motorized Fresh Air Damper

OUTLET OPTIONS

 

3 - Colonial White

 

V - Commercial Room Ventilator

4 - Buckeye Gray

X - Front (Standard)

 

-

 

T - Top (on WH30 and

 

Motorized with Exhaust

 

WH36 models.

 

E - Economizer (Internal) - Fully

FILTER OPTIONS

 

 

Modulating with Exhaust

X - One Inch Throwaway (Standard)

 

 

R - Energy Recovery Ventilator -

W - One Inch Washable

 

 

with Exhaust

P - Two Inch Pleated

 

NOTE: For 0 KW and circuit breakers (230/208 Volt) or pull disconnects (460 Volt) applications, insert 0Z in the KW field of model number.

TABLE 1

ELECTRIC HEAT TABLE

Models

 

WH183-A

 

 

WH242-A

 

 

WH242-B

 

WH242-C

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

240-1

208-1

240-1

208-1

240-3

208-3

460-3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

KW

A

BTU

A

BTU

A

BTU

A

BTU

A

BTU

A

BTU

A

BTU

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4

16.7

13650

14.4

10240

16.7

13650

14.4

10240

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

8

33.3

27300

28.8

20475

33.3

27300

28.8

20475

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

6

 

 

 

 

 

 

 

 

14.4

20500

12.5

15360

7.2

20475

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SHIPPING DAMAGE

Upon receipt of equipment, the carton should be checked for external signs of shipping damage. If damage is found, the receiving party must contact the last carrier immediately, preferably in writing, requesting inspection by the carrier’s agent.

GENERAL

The equipment covered in this manual is to be installed by trained, experienced service and installation technicians.

The refrigerant system is completely assembled and charged. All internal wiring is complete.

The unit is designed for use with or without duct work. Flanges are provided for attaching the supply and return ducts.

These instructions explain the recommended method to install the air cooled self-contained unit and the electrical wiring connections to the unit.

These instructions and any instructions packaged with any separate equipment required to make up the entire air conditioning system should be carefully read before beginning the installation. Note particularly “Starting Procedure” and any tags and/or labels attached to the equipment.

While these instructions are intended as 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.

Manual 2100-373

Page 2

MIS-992

UNIT DIMENSIONS

FIGURE 1

Manual 2100-373

Page 3

TABLE 2

ELECTRICAL SPECIFICATIONS

SINGLE CIRCUIT

 

 

 

 

j

 

 

 

 

 

 

Maximum

 

 

 

Rated

 

m

External

k

 

 

Volts

No. Field

Minimum

Fuse or

Field

k

 

and

Power

Circuit

Circuit

Power

Ground

Model

Phase

Circuits

Ampacity

Breaker

Wire Size

Wire Size

 

 

 

 

 

 

 

WH183-A00, A0Z

 

1

17

25

12

12

A04

230/208-1

1

38

40

10

10

l A08

 

1

59

60

6

10

 

 

 

 

 

 

 

WH242-A00, A0Z

 

1

18

25

12

12

A04

230/208-1

1

39

40

10

10

l A08

 

1

60

60

6

10

 

 

 

 

 

 

 

WH242-B00, B0Z

230/208-1

1

15

20

12

12

B06

 

1

33

35

8

10

WH242-C00, C0Z

460-3

1

8

15

14

14

C06

1

17

20

12

12

 

 

 

 

 

 

 

 

QMaximum size of the time delay fuse or HACR type circuit breaker for protection of field wiring conductors.

RBased on 75° C copper wire. All wiring must conform to NEC and all local codes.

S Maximum KW that can operate with heat pump on.

TThese “Minimum Circuit Ampacity” values are to be used for sizing the field power conductors. Refer to the National Electric Code (latest revision), article 310, for power conductor sizing. CAUTION: When more than one field power conductor circuit is run through one conduit the conductors must be derated. Pay special attention to note 89 of table 310 regarding Ampacity Adjustment Factors when more than 3 are in a raceway.

Size of unit for a proposed installation should be based on heat loss calculation made according to methods of Air Conditioning Contractors of America (ACCA). The air duct should be installed in accordance with the Standards of the National Fire Protection Association for the Installation of Air Conditioning and Ventilating systems of Other Than Residence Type, NFPA No. 90A, and Residence Type Warm Air Heating and Air Conditioning Systems, NFPA No. 90B. Where local regulations are at a variance with instructions, installer should adhere to local codes.

DUCT WORK

Any heat pump is more critical of proper operating charge and an adequate duct system that 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.

Refer to Table 10 for maximum static pressure available for duct design.

Design the duct work according to methods given by the Air Conditioning Contractors of America (ACCA). When duct runs through unheated spaces, it should be insulated with a minimum of one inch of insulation. Use insulation with a vapor barrier on the outside of the insulation. Flexible joints should be used to connect the duct work to the equipment in order to keep the noise transmission to a minimum.

A 1/4 inch clearance to combustible material for the first three feet of duct attached to the outlet air frame is required. See Pages Wall Mounting Instructions and Figure 3 for further details.

Manual 2100-373

Page 4

Ducts through the walls must be insulated and all joints taped or sealed to prevent air or moisture from entering the wall cavity.

CAUTION

Some installations may not require any return air duct. A metallic return air grille is required with installations not requiring a return air duct. The spacing between louvers on the grille shall not be larger than 5/8 inches.

Any grille that meets the 5/8 inch louver criteria may be used. It is recommended that Bard Return Air Grille Kit RG2 thru RG5 or RFG2 thru RFG5 be installed when no return duct is used. Contact distributor or factory for ordering information. If using a return air filter grille, filters must be of sufficient size to allow a maximum velocity of 400 fpm.

NOTE: If no return air duct is used, applicable installation codes may limit this cabinet to installation only in a single story structure.

FILTERS

A 1 inch throwaway filter is supplied with each unit. The filter slides into position making it easy to service. This filter can be serviced from the outside by removing the service door. A 1 inch washable filter and a 2 inch pleated filter are also available as optional accessories. The internal filter brackets are adjustable to accommodate the 2 inch filter by loosening two (2) screws in each bracket assembly and sliding the brackets apart to the required width and retightening the four (4) screws.

FRESH AIR INTAKE

All units are built with fresh air inlet slots punched in the service panel.

If the unit is equipped with a fresh air damper assembly, the assembly is shipped already attached to the unit. The damper blade is locked in the closed position. To allow the damper to operate, the maximum and minimum blade position stops must be installed. See Figure 2.

All capacity, efficiency, and cost of operation information as required for Department of Energy “Energyguide” Fact Sheets is based upon the fresh air blank-off plate in place and is recommended for maximum energy efficiency.

The blank-off plate is available upon request from the factory and is installed in place of the fresh air damper shipped with each unit.

FIGURE 2

FRESH AIR DAMPER ASSEMBLY

BLADE IS LOCKED

CLOSED FOR

SHIPPING

MIS-938

CONDENSATE DRAIN

A plastic drain hose extends from the drain pan at the top of the unit down to the unit base. There are openings in the unit base for the drain hose to pass through. In the event the drain hose is connected to a drain system of some type, it must be an open or vented type system to assure proper drainage.

Manual 2100-373

Page 5

INSTALLATION INSTRUCTIONS

WALL MOUNTING INFORMATION

1.These units are secured by wall mounting brackets which secure the unit to the outside wall surface at both sides. A bottom mounting bracket is provided for ease of installation, but is not required.

2.On wood frame walls, the wall construction must be strong and rigid enough to carry the weight of the unit without transmitting any unit vibration.

3.Concrete block walls must be thoroughly inspected to insure that they are capable of carrying the weight of the unit being installed.

4.The unit is suitable for 0 inch clearance from the unit, and from the supply and return air ducts.

MOUNTING THE UNIT

1.Two holes for the supply and return air openings must be cut through the wall as shown in Figure 3.

2.Locate and mark lag bolt locations and bottom mounting bracket location, if desired. See Figure 3.

3.Mount bottom mounting bracket, if used.

4.Hook top rain flashing under back bend of top. Top rain flashing is shipped secured to the right side of the back.

5.Position unit in opening and secure with 5/16 lag bolts. Use 5/16” diameter flat washers on the lag bolts.

6.Secure rain flashing to wall and caulk across entire length of top. See Figure 3.

7.For additional mounting rigidity, the return air and supply air frames or collars can be drilled and screwed or welded to the structural wall itself (depending upon wall construction). Be sure to observe required clearance if combustible wall.

8.On side by side installations, maintain a minimum of 20 inches clearance on right side of unit to allow access to control panel and heaters, and to allow proper airflow to the outdoor coil. Additional clearance may be required to meet local or national codes.

Manual 2100-373

Page 6

Page

Manual

7

373-2100

FIGURE 3

MOUNTING INSTRUCTIONS

MIS-353

FIGURE 4

WALL MOUNTING INSTRUCTIONS

SEE FIGURE 3 – MOUNTING INSTRUCTIONS

MIS-548

FIGURE 5

WALL MOUNTING INSTRUCTIONS

SEE UNIT DIMENSIONS, FIGURE 1, FOR ACTUAL DIMENSIONS

MIS-549

Manual 2100-373

Page 8

FIGURE 6

COMMON WALL MOUNTING INSTALLATIONS

 

MIS-550

Manual

2100-373

Page

9

WIRING – MAIN POWER

Refer to the unit rating plate for wire sizing information and maximum fuse or “HACR” type circuit breaker size. Each outdoor unit is marked with a “Minimum Circuit Ampacity”. This means that the field wiring used must be sized to carry that amount of current. Depending on the installed KW of electric heat, there may be two field power circuits required. If this is the case, the unit serial plate will so indicate. All models are suitable only for connection with copper wire. Each unit and/or wiring diagram will be marked “Use Copper Conductors Only”. These instructions must be adhered to. Refer to the National Electrical code (NEC) for complete current carrying capacity data on the various insulation grades of wiring material. All wiring must conform to NEC and all local codes.

The electrical data lists fuse and wire sizes (75° C copper) for all models, including the most commonly used heater sizes. Also shown are the number of field power circuits required for the various models with heaters.

The unit rating plate lists a “Maximum Time Delay Relay Fuse” or “HACR” type circuit breaker that is to be used with the equipment. The correct size must be used for proper circuit protection and also to assure that there will be no nuisance tripping due to the momentary high starting current of the compressor motor.

The disconnect access door on this unit may be locked to prevent unauthorized access to the disconnect. To convert for the locking capability, bend the tab located in the bottom left hand corner of the disconnect opening under the disconnect access panel straight out. This tab will now line up with the slot in the door. When shut a padlock may be placed through the hole in the tab preventing entry.

FIGURE 7

UNIT 24V TERMINAL BOARD

IMPORTANT NOTE: Only the thermostat and subbase combinations as shown in Figure 7 will work with this equipment. The thermostat and subbase must be matched, and the correct operation can be assured only be proper selection and application of these parts.

Manual 2100-373

Page 10

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 is recommended.. The connection points are shown in Figure 7.

TABLE 3

THERMOSTAT WIRE SIZE

 

 

 

Maximum

Transformer

 

 

Distance

VA

FLA

Wire Gauge

In Feet

 

 

 

 

55

2.3

20 gauge

45

 

 

18 gauge

60

 

 

16 gauge

100

 

 

14 gauge

160

 

 

12 gauge

250

 

 

 

 

COMPRESSOR CUTOFF THERMOSTAT AND OUTDOOR THERMOSTATS

Heat pump compressor operation at outdoor temperatures below 0° F are neither desirable not 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 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.

See Figure 8 for compressor cutoff and outdoor thermostat wiring.

FIGURE 8 – COMPRESSOR CUTOFF AND OUTDOOR THERMOSTAT WIRING

4 & 8 KW 1 Phase – 6 KW 3 Phase

MIS-409

Manual 2100-373

Page 11

HEAT ANTICIPATION

Group A and Group B thermostats shown in Table 4 have a fixed heat anticipator for stage 1 with no adjustment required. Stage 2 has an adjustable anticipator for 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 actually measure the load but a good rule is .40A for each heat contactor controlled by W2.

THERMOSTAT INDICATOR LAMPS

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.

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 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

- - -

1 stg. cool; 2 stg. heat; Mercury bulb

(T841A1761)

Manual changeover

 

8403-017

8404-009

2 stg. cool; 2 stg. heat; Mercury bulb

(T874R1129)

(Q674L1181)

Manual changeover

8403-018

8404-010

2 stg. cool; 2 stg. heat; Mercury bulb

(T874N1024)

(Q674F1261)

Auto or Manual changeover

8403-042

 

1 stg. cool; 2 stg. heat

- - -

Electronic Non-Programmable

(T8511G1070)

 

Auto or Manual changeover

 

 

 

 

 

8403-049

 

2 stg. cool; 3 stg. heat

- - -

Programmable Electronic

(1F93-380)

 

Auto or Manual changeover

 

 

 

 

 

IMPORTANT NOTE: The thermostat and subbase combinations shown above incorporate the following features: Man-Auto fan switch, Off-Heat-Cool-Em. Heat Switch, and two (2) indicator lamps; one for emergency heat and one for compressor malfunction.

Manual 2100-373

Page 12

START UP

IMPORTANT INSTALLER NOTE

For improved start up performance, wash the indoor coil with a dish detergent.

CRANKCASE HEATERS

WH241 units are provided with compressor crankcase heat.

These models have an insertion well-type heater located in the lower section of the compressor housing. This is a self-regulating type heater that draws only enough power to maintain the compressor at a safe temperature.

Some form of crankcase heat is essential to prevent liquid refrigerant from migrating to the compressor causing oil pump out on compressor start up and possible valve failure due to compressing a liquid.

The decal in Figure 9 is affixed to all outdoor units detailing start up procedure. This is very important. Please read carefully.

SERVICE HINTS

1.Caution homeowner to maintain clean air filters at all times. Also, not to needlessly close off supply and return air registers. This reduces air flow through the system which shortens equipment service life as well as increasing operating costs.

2.Switching to heating cycle at 75° F or higher outside temperature may cause a nuisance trip of the remote reset high pressure switch. Turn thermostat off, then on, to reset the high pressure switch..

3.The heat pump wall thermostats perform multiple functions. Be sure that all function switches are correctly set for the desired operating mode before trying to diagnose any reported service problems.

4.Check all power fuses or circuit breakers to be sure they are the correct rating.

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

SEQUENCE OF OPERATION

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 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.

FIGURE 9

IMPORTANT

THESE PROCEDURES MUST BE FOLLOWED AT INITIAL START UP AND AT ANY TIME POWER HAS BEEN REMOVED FOR 12 HOURS OR LONGER.

TO PREVENT COMPRESSOR DAMAGE WHICH MAY RESULT FROM THE PRESENCE OF LIQUID REFRIGERANT IN THE COMPRESSOR CRANKCASE:

1.MAKE CERTAIN THE ROOM THERMOSTAT IS IN THE “OFF” POSITION. (THE COMPRESSOR IS NOT TO OPERATE.)

2.APPLY POWER BY CLOSING THE SYSTEM DISCONNECT SWITCH. THIS ENERGIZES THE COMPRESSOR HEATER WHICH EVAPORATES THE LIQUID REFRIGERANT IN THE CRANKCASE.

3.ALLOW 4 HOURS OR 60 MINUTES PER POUND OF REFRIGERANT IN THE SYSTEM AS NOTED ON THE UNIT RATING PLATE, WHICHEVER IS GREATER.

4.AFTER PROPERLY ELAPSED TIME THE THERMOSTAT MAY BE SET TO OPERATE THE COMPRESSOR.

5.EXCEPT AS REQUIRED FOR SAFETY WHILE SERVICING — DO NOT OPEN SYSTEM

DISCONNECT SWITCH.

7961-061

Manual 2100-373

Page 13

PRESSURE SERVICE PORTS

High and low pressure service ports are installed on all units so that the system operating pressures can be observed. Pressure curves can be found later in the manual covering all models on both cooling and heating cycles. It is imperative to match the correct pressure curve to the unit by model number.

DEFROST CYCLE

The defrost cycle is controlled by temperature and time on the solid state heat pump control. See Figure 10.

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 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 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 minute, 60 minute, and 90 minute. Models are shipped wired on the 30 minute setting for greatest operating

FIGURE 10

DEFROST CONTROL BOARD

economy. If special circumstances require a change to another time, remove wire connected to terminal 30 and reconnect to desired terminal. Refer to Figure 10. The manufucturer’s recommendation is for 3 minute defrost cycles.

There is a cycle speed up jumper on the control. This can be used to reduce the time between defrost cycle operation without waiting for time to elapse.

Use a small screwdr4iver or other metallic object, or another 1/4 inch QC, to short between the SPEEDUP terminals to accedlerate the HPC timer and initiate defrost.

Be careful not to touch any other terminals with the instrument used to short the SPEEDUP terminals. It may take up to 10 seconds with the SPEEDUP terminals shorted for the speedup to be completed and the defrost cycle to start.

As soon as the defrost cycle kicks in remove the shorting instrument from the SPEEDUP terminals.

Otherwise the timing will remain accelerated and run through the 1 minute maximum defrost length sequence in a matter of seconds and will automatically terminate the defrost sequence.

There is an initiate defrost jumper (sen jump) on the control that can be used at any outdoor ambient during the heating cycle to simulate a 0° coil temperature. This can be used to check defrost operation of the unit without waiting for the outdoor ambient to fall into the defrost region.

By placing a jumper across the SEN JMP terminals (a 1/ 4 inch QC terminal works best) the defrost sensor mounted on the outdoor coil is shunted out and will activate the timing circuit. This permits the defrost cycle to be checked out in warmer weather conditions without the outdoor temperature having to fall into the defrost region.

In order to terminate the defrost test the SEN JMP jumper must be removed. If left in place too long the compressor could stop due to the high pressure control opening because of high pressure condition created by operating in the cooling mode with outdoor fan off. Pressure will rise fairly fast as there is likely no actual frost on the outdoor coil in this artificial test condition.

There is also a 5 minute compressor time delay function built into the HPC. This is to protect the compressor from short cycling conditions. In some instances it is helpful to the service technician to override or speed up this timing period, and shorting out the SPEEDUP terminals for a few seconds can do this.

MIS-1174

Manual 2100-373

Page 14

TROUBLESHOOTING

SOLID STATE HEAT PUMP CONTROL TROUBLESHOOTING PROCEDURE

1.Turn on AC power supply to indoor and outdoor units.

2.Turn thermostat blower switch to “fan on” – the indoor blower should start. (If it doesn’t, troubleshoot indoor unit and correct problem.)

3.Turn thermostat blower switch to “auto” position. Indoor blower should stop.

4.Set system switch to “heat” or “cool”. Adjust thermostat to call for heat or cool – the indoor blower, compressor and outdoor fan should start.

NOTE: If there was no power to 24 volt transformer, the compressor and outdoor fan motor will not start for 5 minutes. This is because of the compressor short cycle protection.

TABLE 5

TROUBLESHOOTING

SYMPTOM

POSSIBLE CAUSES

WHAT TO CHECK

HOW TO CHECK OR REPAIR

 

 

 

 

Compressor contactor

Control circuit wiring

Check for R connection at

Run R connection to outdoor unit to power

does not energize

 

unit, and 24V between R-C

heat pump control

(cooling or heating)

 

 

 

Compressor lock out

1. Check for 24V between

1. If no voltage between L-C turn thermostat

 

 

 

L1-C on heat pump control

off and on again to reset high pressure

 

 

 

switch.

 

 

2. Check across high

2. If high pressure switch is open and will not

 

 

pressure switch.

reset, replace high pressure switch.

 

 

 

 

 

Compressor short cycle

Check for 24V between CC-C

If no voltage betwwen CC-C, jumper speed

 

protection

and Y-C on heat pump control

up terminal and within 10 seconds power

 

 

 

should 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 coil

Replace contactor

 

 

winding.

 

 

 

 

 

Fan outdoor motor

Motor defective

Check for open or shorted

Replace motor

does not run (cooling

 

motor winding

 

or heating except

 

 

 

Motor capacitor defective

Check capacitor rating.

Replace capacitor

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 valve solenoid

Check for open or shorted coil

Replace solenoid coil

not energize

coil defective

 

 

(heating only)

 

 

 

Heat pump control

Check for 24V between RV-C

1. Check control circuit wiring

 

 

defective

and B-C

2. Replace heat pump control

 

 

 

 

Unit will not go into

Temperature sensor or

Disconnect termperature

1. If unit goes through defrost cycle, replace

defrost

heat pump control

sensor from board and jumper

temperature sensor

(heating only)

defective

across speed up terminals

2. If unit does not go through defrost cycle,

 

 

and sen jump terminals. This

replace heat pump control

 

 

should cause 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

termperature 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 2100-373

Page 15

CHECKING TEMPERATURE SENSOR OUTSIDE UNIT CIRCUIT.

1.Disconnect temperature sensor 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 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

-25.0

196871

25.0

39898

75.0

10501

-24.0

190099

26.0

38757

76.0

10247

-23.0

183585

27.0

37652

77.0

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

Manual 2100-373

Page 16

FAN BLADE SETTING DIMENSIONS

Shown in the drawing below are the correct fan blade setting dimensions for proper air delivery across the outdoor coil.

Any service work requiring removal or adjustment in the fan and/or motor area will require that the dimensions below be check and blade adjusted in or out on the motor shaft accordingly.

FIGURE 11

TABLE 6

Model

Dimension

A

WH183

1.00

WH242

REMOVAL OF THE FAN SHROUD

1.Disconnect all power to unit.

2.Remove the screws holding both grilles, one on each side of unit, and remove grilles.

3.Remove screws (9) holding fan shroud to condenser and bottom.

4.Unwire condenser fan motor.

5.Slide complete motor, fan blade, and shroud assembly out the left side of the unit.

6.Service motor/fan as needed.

7.Reverse steps to reinstall.

REFRIGERANT CHARGE

The correct system R-22 charge is shown on the unit rating plate. Optimum unit performance will occur with a refrigerant charge resulting in a suction line temperature

(6” from compressor) as shown in Table 7.

TABLE 7

(Temperatures °F)

 

Rated

95o OD

82o OD

Model

Airflow

Temperature

Temperature

 

 

 

 

 

 

 

 

WH183

650

56

-

58

63

-

65

WH242

800

57

-

59

65

-

67

 

 

 

 

 

 

 

 

The suction line temperatures in Table 7 are based upon 80° F dry bulb/67° F wet bulb (50% R.H.) temperature and rated airflow across the evaporator during cooling cycle.

TABLE 8

INDOOR BLOWER PERFORMANCE

CFM @ 230V

E.S.P.

WH183,

WH242

In H2O

 

 

 

Dry

/

Wet

 

 

 

 

 

.0

1020

/

975

.1

960

/

905

.2

865

/

800

.3

820

/

735

.4

735

/

650

.5

615

/

535

.6

- -

/

- -

 

 

 

 

TABLE 9

Model

Rated

Rated

Recommended

CFM *

ESP *

Airflow Range

 

 

 

 

 

 

 

WH183

650

.40

575

---

725

 

 

 

 

 

 

WH242

800

.20

700

---

950

 

 

 

 

 

 

* Rated CFM and ESP on high speed tap.

TABLE 10

MAXIMUM ESP OF OPERATION

Model

 

ESP

 

 

 

WH183

A00

.50

A04

.50

WH242

A08

.40

 

 

 

 

WH242

B00

.50

B06

.50

 

 

 

 

WH242

C00

.50

C06

.50

 

 

 

 

Values shown are for units equipped with standard throwaway filter or 1” washable filter. Derate ESP by .15 for 2” pleated filter.

Manual 2100-373

Page 17

TABLE 11 – 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

77

78

80

81

83

84

86

 

87

89

 

62 deg. WB

High Side

193

209

224

240

255

271

287

 

302

318

 

 

 

 

 

 

 

 

 

 

 

 

 

WH183

80 deg. DB

Low Side

82

84

85

87

89

90

92

 

93

95

67 deg. WB

High Side

198

214

230

246

262

278

294

 

310

326

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

85 deg. DB

Low Side

88

90

92

94

95

97

99

 

100

102

 

72 deg. WB

High Side

205

222

238

255

271

288

304

 

321

337

 

 

 

 

 

 

 

 

 

 

 

 

 

 

75 deg. DB

Low Side

75

76

77

79

80

81

83

 

84

86

 

62 deg. WB

High Side

216

229

242

256

271

286

302

 

318

336

 

 

 

 

 

 

 

 

 

 

 

 

 

WH242

80 deg. DB

Low Side

80

81

83

84

85

87

88

 

90

92

67 deg. WB

High Side

221

235

248

263

278

293

310

 

327

344

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

85 deg. DB

Low Side

86

88

89

90

92

93

95

 

97

99

 

72 deg. WB

High Side

229

243

257

272

288

304

321

 

338

356

 

 

 

 

 

 

 

 

 

 

 

 

 

TABLE 12 – PRESSURE TABLE

HEATING

 

 

 

 

 

Air Temperature Entering Outdoor Coil °F

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Return Air

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Model

Temperature

Pressure

0

5

10

15

17

20

25

30

35

40

45

47

50

55

60

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WH183

70

Low Side

20

24

27

31

32

35

39

44

49

54

59

62

65

71

78

High Side

178

181

184

189

191

194

201

208

216

225

235

239

249

257

270

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WH242

70

Low Side

30

30

31

32

33

34

37

41

45

50

56

59

63

71

79

High Side

158

158

159

162

164

167

175

184

195

208

223

230

241

260

281

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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 operation charge being in the system, the charge should be removed, system evacuated, and recharged to serial plate instructions.

Manual 2100-373

Page 18

TABLE 13

OPTIONAL ACCESSORIES

MODEL

DESCRIPTION

WH183-A

WH242-A

WH242-B

WH242-C

 

 

 

 

 

 

 

 

 

 

EHWH02A-A04

Heater Packages

X

X

 

 

EHWA02A-A08

Heater Packages

X

X

 

 

EHWH14-B06

Heater Packages

 

 

X

 

EHWH24B-C06

Heater Packages

 

 

 

X

 

 

 

 

 

 

BOP-2

Blank Off Plate

X

X

X

X

BFAD-2

Barometric Fresh Air Damper

X

X

X

X

MFAD-2

Motorized Fresh Air Damper

X

X

X

X

CRV-2

Classroom Ventilator with Exhaust

X

X

X

X

EIFM-2

Economizer with Exhaust

X

X

X

X

WERV-A24

Energy Recovery Ventilator

X

X

X

 

 

 

 

 

 

 

CMH-3

Low Pressure Control (LPC)

X

X

X

X

CMH-7

Low Ambient Control (LAC)

X

X

X

 

CMH-9

LAC + LPC

X

X

X

 

CMH-14

Outdoor Thermostat (ODT)

X

X

 

 

CHM-15

Start Kit (SK)

X

X

 

 

 

 

 

 

 

 

WMCB-02A

Circuit Breaker Kit

X

 

 

 

WMCB-03A

Circuit Breaker Kit

 

X

 

 

WMBC-02B

Circuit Breaker Kit

 

 

X

 

WMBC-01C

Pull Disconnect Kit

 

 

 

X

 

 

 

 

 

 

Manual 2100-373

Page 19