Bard WH361, WH-301 User Manual

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WALL MOUNTED

INSTALLATION INSTRUCTIONS

PACKAGED HEAT PUMP

Models:

WH301, WH361

Bard Manufacturing Company, Inc. Bryan, Ohio 43506

Since 1914. . .Moving ahead just as planned.

Manual No.: 2100-193O Supersedes: 2100-193N File: Volume III, Tab 17 Date: 05-04-07

Manual 2100-193O Page 1 of 26

CONTENTS

etting Other Information and Publications

For more information,

contact these publishers ........................................3

Wall Mount General Information

Heat Pump Wall Mount Model Nomenclature ........ 4

Shipping Damage .................................................. 4

General ............................................................. 4

Duct Work ...................................................... 4 & 8

Filters ............................................................. 8

Fresh Air Intake ...................................................... 8

Condensate Drain .................................................. 8

Installation Instructions

Wall Mounting Information ..................................... 9

Mounting the Unit................................................... 9

Top Outlet Only ...................................................... 9

Wiring — Main Power .......................................... 15

Wiring — Low Voltage Wiring............................... 15

Low Voltage Connections .................................... 15

Optional Outdoor Thermostat Applications .......... 17

Thermostat Indicator ............................................ 19

Start Up

Important Installer Note........................................ 20

Crankcase Heaters .............................................. 20

Service Hints ........................................................20

Sequence of Operation ........................................20

Pressure Service Ports ........................................ 21

Defrost Cycle ....................................................... 21

Troubleshooting

Solid State Heat Pump Control

Troubleshooting Procedures ................................ 22

Checking Temperature Sensor Outside

Unit Circuit ........................................................... 23

Fan Blade Setting Dimensions ............................ 24

Removal of Fan Shroud ....................................... 24

Refrigerant Charge .............................................. 24

Pressure Tables ................................................... 25

Optional Accessories ...........................................26

Figures

Figure 1 Unit Dimensions ................................... 6

Figure 2 Fresh Air Damper Assembly ................. 8

Figure 3 Mounting Instructions ......................... 10

Figure 4 Electric Heat Clearance ...................... 11

Figure 5 Attaching Top Outlet to Unit ................ 12

Figure 6 Top Outlet Model Mounted ................. 12

Figure 7 Wall-Mounting Instructions ................. 13

Figure 8 Wall-Mounting Instructions ................. 13

Figure 9 Common Wall-Mounting Installations . 14

Figure 10 Low Voltage Wiring ............................. 16

Figure 11 Compressor Cutoff

Thermostat Wiring .............................. 17

Figure 12 Compressor Cutoff

Thermostat Wiring .............................. 17

Figure 13 Electric Heat Hold-Off Wiring ..............18

Figure 14 Electric Heat Hold-Off Wiring ..............18

Figure 15 Start Up Label ..................................... 20

Figure 16 Defrost Control Board ......................... 21

Figure 17 Fan Blade Setting ...............................24

Tables

Table 1 Electric Heat Table ................................5

Table 2 Dimensions of Basic Unit ......................6

Table 3 Electrical Specifications ........................ 7

Table 4 Operating Voltage Range ...................15

Table 5 Thermostat Wire Size ......................... 16

Table 6 Wall Thermostat .................................. 19

Table 7 Troubleshooting .................................. 22

Table 8 Fan Blade Dimensions ....................... 24

Table 9 Suction Line Temperatures ................. 24

Table 10 Indoor Blower Performance ................ 24

Table 11 CFM and ESP..................................... 24

Table 12 Maximum ESP of Operation

Electric Heat Only ............................... 24

Table 13 Cooling Pressures .............................. 25

Table 14 Heating Pressures ..............................25

Table 15 Optional Accessories .......................... 26

Manual 2100-193O Page 2 of 26

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 Avenue NW 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

Manufactured under the following U.S. patent numbers:

5,485,878; 5,301,744; 5,002,116; 4,924,934;

4,875,520; 4,825,936

Manual 2100-193O Page 3 of 26

WALL MOUNT GENERAL INFORMATION

HEAT PUMP WALL MOUNT MODEL NOMENCLATURE

WH 36 1 A 10 X X X X X A

MODEL NUMBER

CAPACITY

30 - 2½ Ton 36 - 3 Ton

VENTILATION OPTIONS

X - Barometric Fresh Air Damper (Standard) B - Blank-off Plate M - Motorized Fresh Air Damper V - Commercial Room Ventilator - Motorized with Exhaust E - Economizer (Internal - Fully Modulating with Exhaust R - Energy Recovery Ventilator - with Exhaust

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.

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.

REVISIONS

VOLTS & PHASE

A - 230/208/60/1 B - 230/208/60/3 C - 460/60/3

COLOR OPTIONS

X - Beige (Standard) 1 - White 2 - Mesa Brown 4 - Buckeye Gray 5 - Desert Brown 8 - Dark Bronze

FILTER OPTIONS

X - 1-Inch Throwaway (Standard) W- 1-Inch Washable P - 2-Inch Pleated

While these instructions are intended as a general recommended guide, they do not supersede any national and/or local codes in any way. Authorities having jurisdiction should be consulted before the installation is made. See Page 3 for information on codes and standards.

COIL OPTIONS X - Standard

1 - Phenolic Coated Evaporator 2 - Phenolic Coated Condenser 3 - Phenolic Coated Evaporator

and Condenser

OUTLET OPTIONS

X - Front (Standard) T - Top on WH30 and WH36

Models

CONTROL MODULES

Size of unit for a proposed installation should be based

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.

on heat loss calculations 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

The unit is designed for use with or without duct work.

should adhere to local codes.

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.

DUCT WORK

Any heat pump is more critical of proper operating charge and an adequate duct system than a straight air conditioning unit. All duct work, supply and return, must be properly sized for the design airflow requirement of the equipment. Air Conditioning Contractors of America (ACCA) is an excellent guide to proper sizing. All duct work or portions thereof not in the conditioned space should be properly insulated in order to both conserve energy and prevent condensation or moisture damage.

Manual 2100-193O Page 4 of 26

UTB

TABLE 1

ELECTRIC HEAT TABLE

1-0421-8023-0423-8023-0641-0421-8023-0423-8023-064

sledoMA-103HWB-103HWC-103HWA-163HWB-163HWC-163HW

WKAUTBAUTBAUTBAUTBAUTBAUTBAUTBAUTBAUTBA

51 5.26002151.4500483

016.14031432.63006526.14031432.6300652

58.02560711.81008218.02560711.8100821

64.41005025.21063512.7574024.41005025.21063512.757402

510.81002152.63002152.13004830.8100215

97.12006037.81030328.01007037.12006037.81030328.0100703

Manual 2100-193O Page 5 of 26

TABLE 2

FIGURE 1

UNIT DIMENSIONS

EFGIJKLMNOPQRSTABCB

DIMENSIONS OF BASIC UNIT (NOMINAL)

ylppuSnruteR

thgieH

)H(

htpeD

)D(

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Manual 2100-193O Page 6 of 26

03HW

FRONT VIEW BACK VIEWSIDE VIEW

002.83521.71365.0788.788.7288.3188.7200.0405.8157.5239.7157.6257.8252.9200.7257.291.9357.2241.991.400.2100.5

OPTIONAL TOP OUTLET (FACTORY INSTALLED ONLY) FOR WH30 AND WH36 MODELS ONLY.

63HW

---

eziSeriW

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eziSeriW

---

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tiucriCro

mumixaM

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eriW

tiucriC

---

ATKCBTKCATKCBTKCATKCBTKCATKCBTKC

---

eziS

rekaerB

530508

yticapmA

muminiM

tiucriC

dnuorG

rewoP

TABLE 3

dleiF

lanretxE

roesuF

mumixaM

ELECTRICAL SPECIFICATIONS

---

210101

025203

---

010101

520405

---

------

---

210101

025203

---

--8

---

--6

---

060809

---

010101

888

520405

---

yticapmA

muminiM

tiucriC

.oN

detaR

111

dnAstloV

esahP

stiucriC

rewoP

dleiF

Z0A-,00A-103HW

111

1-802/032

50A-

Z0B-,00B-103HW

ledoM

3 01A-

111

723597

1-802/032

3-802/032

837405

2ro1

111

3-802/032

3-064

60B-

60C-

Z0C-,0

0C-103HW

3 90B-

3 90C-

50A-

Z0A-,00A-163HW

5 51C-

3 01A-

60B-

Z0B-,00B-163HW

5 51A-

0252

111

3-064

60C-

Z0C-,00C-163HW

5 51C-

5 51B-

3 90B-

3 90C-

National Electric Code (latest revision), Article 310 for power conductor sizing.

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

2 Based on 75° copper wire. All wiring must conform to the National Electrical Code and all local codes.

3 Maximum KW that can operate with heat pump on these "Minimum Circuit Ampacity" values are to be used for sizing the field power conductors. Refer to the

power conductor sizing.

4 These “Minimum Circuit Ampacity” values are to be used for sizing the field power conductors. Refer to the National Electrical Code (latest version), Article 310 for

310 regarding Ampacity Adjustment Factors when more than three conductors are in a raceway.

Not available on dehumidification models.

CAUTION: When more than one field power conductor circuit is run through one conduit, the conductors must be derated. Pay special attention to note 8 of table

Not available in top outlet version.

Manual 2100-193O Page 7 of 26

Refer to Table 12 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 (3) feet of duct attached to the outlet air frame is required. See Wall Mounting Instructions and Figures 3, 4, 7 & 8 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.

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.

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 RG-2 through RG-5 or RFG-2 through RFG-5 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 two inch filter by loosening two screws in each bracket assembly and sliding the brackets apart to the required width and retightening the four screws.

FIGURE 2

FRESH AIR DAMPER ASSEMBLY

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 2100-193O Page 8 of 26

INSTALLATION INSTRUCTIONS

WALL MOUNTING INFORMATION

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

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

WARNING

Fire hazard can result if 1/4 inch clearance to combustible materials for supply air duct is not maintained. See Figure 3.

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

MOUNTING THE UNIT

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

2. The unit itself is suitable for “0” inch clearance, but the supply air duct flange and the first 3 feet of supply air duct require a minimum of 1/4 inch clearance to combustible material. If a combustible wall, use a minimum of 28½" x 8½" dimensions for sizing. However, it is generally recommended that a 1-inch clearance is used for ease of installation and maintaining the required clearance to combustible material. The supply air opening would then be 30" x 10". See Figures 3, 4, 7 and 8 for details.

3. Locate and mark lag bolt locations and bottom mounting bracket location. See Figure 3.

4. Mount bottom mounting bracket, if used.

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

6. Position unit in opening and secure with 5/16 lag bolts; use 7/8 inch diameter flat washers on the lag bolts.

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

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

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

TOP OUTLET ONLY

1. Remove airframe angles from the back of the unit.

2. Coat angles with two 1/8" beads of silicone as shown. Silicone is shipped in the control panel. See Figure 5.

3. Secure angles to the top of the unit with 14 screws provided. Use prepunched holes provided. Do not relocate. See Figure 5.

4. After installation of duct work, seal around airframe and duct work to provide a rain tight seal.

5. It is strongly recommended, but not required, that this unit be installed under a soffit area large enough to shield the top of the unit. See Figure 6.

WARNING

Failure to provide the 1/4 inch clearance between the supply duct and a combustible surface for the first 3 feet of duct can result in fire.

Manual 2100-193O Page 9 of 26

FIGURE 3

MOUNTING INSTRUCTIONS

Manual 2100-193O Page 10 of 26

FIGURE 4

ELECTRIC HEAT CLEARANCE

Side section view of supply air duct for wall mounted unit showing 1/4" clearance to combustible surfaces.

WARNING

A minimum of 1/4" clearance must be maintained between the supply air duct and combustible materials. This is required for the fist three (3) feet of ducting.

It is important to insure that the 1/4" minimum spacing is maintained at all points.

Failure to do this could result in overheating the combustible material and may result in a fire.

Manual 2100-193O Page 11 of 26

FIGURE 5

ATTACHING TOP OUTLET AIRFRAMES TO UNIT

FIGURE 6

UNIT WITH TOP OUTLET MOUNTED UNDER OVERHANG

Manual 2100-193O Page 12 of 26

FIGURE 7

WALL-MOUNTING INSTRUCTIONS

SEE FIGURE 3 – MOUNTING INSTRUCTIONS

FIGURE 8

WALL-MOUNTING INSTRUCTIONS

SEE UNIT DIMENSIONS, FIGURE 1,

FOR ACTUAL DIMENSIONS

SEE FIGURE 1 FOR

DUCT DIMENSIONS

Manual 2100-193O Page 13 of 26

FIGURE 9

COMMON WALL-MOUNTING INSTALLATIONS

Manual 2100-193O Page 14 of 26

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 (75ºC 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.

If no motorized vent option is used, nine (9) wires should be run from the thermostat subbase to the 24V terminal board in the unit. A nine (9) conductor, 18 gauge copper color-coded thermostat cable is recommended. If a motorized vent option is used, terminal O1 on the unit low voltage terminal block will also be used. This requires a ten (10) conductor thermostat cable to be run. The connection points are shown in Figure 10.

LOW VOLTAGE CONNECTIONS

These units use a grounded 24 volt AC low voltage circuit.

The "R" terminal is the hot terminal and the "C" terminal is grounded.

"G" terminal is the fan input.

"Y" terminal is the compressor input for cooling and heat pump.

"B/W1" terminal is the reversing valve input. The

reversing valve must be energized for heating mode.

"R" terminal is 24 VAC hot.

"C" terminal is 24 VAC grounded.

"L" terminal is compressor lockout output. This

terminal is activated on a high or low pressure trip by the electronic heat pump control. This is a 24 VAC output.

"W2" terminal is second stage heat (if equipped).

"01" terminal is the ventilation input. This terminal

energizes any factory installed ventilation option.

"E" terminal is the emergency heat input. This terminal energizes the emergency heat relay.

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 shown in Table 4:

TABLE 4

OPERATING VOLTAGE RANGE

PATEGNAR

V042612-352 V802781-022

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.)

LOW VOLTAGE CONNECTIONS

FOR DDC CONTROL

Fan Only Energize G

Cooling Mode Energize Y, G

Heat Pump Heating Energize Y, G, B

2nd Stage Heating Energize G, W2, Y, B/W1

(if employed)

Ventilation Energize G, O1

Emergency Heat Energize B, W2, E, G

Manual 2100-193O Page 15 of 26

FIGURE 10

LOW VOLTAGE WIRING

Manual 2100-193O Page 16 of 26

TABLE 5

THERMOSTAT WIRE SIZE

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AVALFeguaGeriW

553.2

mumixaM

ecnatsiD

teeFnI

eguag02 eguag81 eguag61 eguag41 eguag21

54 06

001 061 052

OPTIONAL OUTDOOR THERMOSTAT APPLICATIONS

Thus, not requiring the optional compressor cut-off thermostat or the electric heat cut-off thermostat option.

Since most equipment at the time of manufacture is not designated for any specific destination of the country and are installed in areas not approaching the lower outdoor temperature range, outdoor thermostats are not factory installed as standard equipment, but are offered as an option. There are also different applications for applying outdoor thermostats. The set point of either type of outdoor thermostat application is variable with geographic region and sizing of the heating equipment to the individual structure. Utilization of the heating Application Data, and the heat loss calculation of the building are useful in determining the correct set points.

Temperature and Humidity Controller #8403-060, along with the Outdoor Sensor option Part #8403-061, can be used to:

•Limit minimum outdoor temperature for cooling option.

• Limit minimum outdoor temperature for heat pump option.

•Inhibit electric heat operation for heat pumps above selected outdoor temperature.

FIGURE 11

COMPRESSOR CUTOFF THERMOSTAT WIRING

4 & 10KW 1 PH — 6 & 9KW 3 PH

OPTIONAL COMPRESSOR CUTOFF THERMOSTAT (See Figures 11 and 12)

Heat pump compressor operation at outdoor temperatures below 0°F are neither desirable nor advantageous in term of efficiency. An outdoor thermostat can be applied to take the mechanical heating (compressor) off line, and send the (compressor) signal to energize electric heat in its place (to make electric heat first stage heating). This can also be applied to bank the quantity of available electric heat. For example: A heat pump operates with 10KW second stage heat – once the outdoor thermostat has switched then operates 15KW without the compressor as first stage heat.

NOTE: The additional LAB (low ambient bypass) relay is required to prevent heater operation during low temperature cooling operation.

FIGURE 12

COMPRESSOR CUTOFF THERMOSTAT WIRING

15KW 1 PH & 3 PH

Manual 2100-193O Page 17 of 26

ELECTRIC HEAT HOLD-OFF (See Figures 13 and 14)

In other applications, it is desirable to disable the operation of the electric heat until outdoor temperatures have reached a certain design point. This won't allow the electric heat to come on as second stage heating unless the outdoor temperature is below the set point of the outdoor thermostat. This is done to maximize

ELECTRIC HEAT HOLD-OFF WIRING

4 & 10KW 1 PH — 6 & 9KW 3 PH

efficiency by utilizing the heat pump to bring the conditioned space temperature up, rather than cycling on the electric heat due a second stage call for heat from the thermostat on start-up coming off a night setback condition or someone increasing the thermostat set point. (NOTE: Some programmable thermostats do have a built-in time delay for pulling in second stage heat when coming off setback conditions.)

FIGURE 13

Manual 2100-193O Page 18 of 26

FIGURE 14

ELECTRIC HEAT HOLD-OFF WIRING

15KW 1 PH & 3 PH

TABLE 6

WALL THERMOSTAT

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850-3048

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060-3048

)544-0211(

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taehegats3,loocegats2

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Manual 2100-193O Page 19 of 26

START UP

IMPORTANT INSTALLER NOTE

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

FIGURE 15

START UP LABEL

IMPORTANT

CRANKCASE HEATERS

All units are provided with some form of compressor crankcase heat.

All single and three phase 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 15 is affixed to all outdoor units detailing start up procedure. This is very important. Please read carefully.

SERVICE HINTS

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

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

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

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

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

SEQUENCE OF OPERATION

COOLING – Circuit R-Y makes at thermostat pulling in compressor contactor, starting the compressor and outdoor motor. The G (indoor motor) circuit is automatically completed on any call for cooling operation or can be energized by manual fan switch on subbase for constant air circulation.

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 poind 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.

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 make starting indoor blower motor.

7961-061

Manual 2100-193O Page 20 of 26

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 on Page 25 covering all models. It is imperative to match the correct pressure table to the unit by model number.

DEFROST CYCLE

The defrost cycle is controlled by temperature and time on the solid state heat pump control. See Figure 16.

When the outdoor temperature is in the lower 40° F temperature range or colder, the outdoor coil temperature is 32° F or below. This coil temperature is sensed by the coil temperature sensor mounted near the bottom of the outdoor coil. Once coil temperature reaches 30° F or below, the coil temperature sensor sends a signal to the control logic of the heat pump control and the defrost timer will start.

After 60 minutes at 30° F or below, the heat pump control will place the system in the defrost mode.

During the defrost mode, the refrigerant cycle switches back to the cooling cycle, the outdoor motor stops, electric heaters are energized, and hot gas passing through the outdoor coil melts any accumulated frost. When the temperature rises to approximately 57° F, the coil temperature sensor will send a signal to the heat pump control, which will return the system to heating operations automatically.

If some abnormal or temporary condition such as a high wind causes the heat pump to have a prolonged defrost cycle, the heat pump control will restore the system to heating operation automatically after 10 minutes.

The heat pump defrost control board has an option of 30, 60 or 90-minute setting. All models are shipped from the factory on the 60-minute pin. If special

FIGURE 16

DEFROST CONTROL BOARD

circumstances require a change to another time, remove the wire from the 60 minute terminal and reconnect to the desired terminal. The manufacturer's recommendation is for 60 minute defrost cycles. Refer to Figure 16.

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

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

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

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

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

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

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

In order to terminate the defrost test the SEN JMP jumper must be removed. If left in place too long the

compressor could stop due to the high pressure control opening because of high pressure condition created 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.

Manual 2100-193O Page 21 of 26

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).

TROUBLESHOOTING

MOTPMYSSESUACELBISSOPKCEHCOTTAHWRIAPERROKCEHCOTWOH

ezigrenetonseod

rotomroodtuonaF

nurtonseod

gnitaehrognilooc(

ezigreneton

)ylnognitaeh(

otniogtonlliwtinU

tsorfed

)ylnognitaeh(

tsorfedfo

)ylnognitaeh(

Manual 2100-193O Page 22 of 26

rotcatnocrosserpmoC

)gnitaehrognilooc(

evitcefed

.tcerroc

)tsorfedgnirudtpecxe

seodevlavgnisreveR

tuoemoctonlliwtinU

evitcefed

gniriwtiucriclortnoC,tinutanoitcennocRrofkcehC

tuokcolrosserpmoC.1

trohsrosserpmoC

noitcetorpelcyc

lortnocpmuptaeH

evitcefedrotcatnoCliocdetrohsroneporofkcehC

tongnisahprewoP

evitcefedrotoMdetrohsroneporofkcehC

roticapacrotoM

lortnocpmuptaeH

evlavgnisreveR

evitcefedliocdionelos

lortnocpmuptaeH

rosneserutarepmeT

lortnocpmuptaehro

rosneserutarepmeT

lortnocpmuptaehro

TABLE 7

gnidniw

C-Bdna

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.

C-RneewtebV42dna

neewtebV42rofkcehC

hgihssorcakcehC

.hctiwserusserp

elbissoprehtollakcehC

560-0012launaM.sesuac

gnidniwrotom

)CN-moC(lortnocpmup

pudeepsssorcarepmuJ

.etunimenonihtiw

lortnocpmuptaehnoC-1L

C-CCneewtebV42rofkcehC

lortnocpmuptaehnoC-Ydna

esahpnoDELderrofkcehC

).ylnostinuesahp3(.rotinom

kcehC.gnitarroticapackcehC

.roticapacdetrohsroneporof

taehnoyalernafssorcakcehC

liocdetrohsroneporofkcehCliocdionelosecalpeR

C-VRneewtebV42rofkcehC

.1 .2

rosneserutarepmettcennocsiD

ssorcarepmujdnadraobmorf nesdnaslanimretpudeeps dluohssihT.slanimretpmuj

ahguorhtogottinuehtesuac

.etunimenonihtiwelcyctsorfed

esuacdluohssihT.slanimret

tsorfedfotuoemocottinueht

lortnocpmuptaeh

.hctiws

sdnoces01retfarepmuj

lortnocpmuptaehecalpeR

rotcatnocecalpeR

rotomecalpeR

roticapacecalpeR

lortnocpmuptaehecalpeR

gniriwtiucriclortnockcehC

lortnocpmuptaehecalpeR

rosneserutarepmet

.lortnocpmuptaehecalper

.rosneserutarepmret

.lortnocpmuptaehecalper

rewopottinuroodtuootnoitcennocRnuR

tatsomrehtnrutC-LneewtebegatlovonfI

erusserphgihteserotniaganodnaffo

tonlliwdnaneposihctiwserusserphgihfI

.hctiwsersserphgihecalper,teser

pudeepsrepmuj,C-CCneewtebegatlovonfI

dluohsrewopsdnoces01nihtiwdnalanimret

pudeepsevomeR.C-CCneewtebraeppa

.tinuehtotsdaelrewopowthctiwS

ecalper,elcyctsorfedhguorhtseogtinufI

,elcyctsorfedhguorhtogtonseodtinufI

ecalper,elcyctsorfedfotuosemoctinufI

,elcyctsorfedfotuoemoctonseodtinufI

CHECKING TEMPERATURE SENSOR OUTSIDE UNIT CIRCUIT

1. Disconnect temperature sensor from board and from outdoor coil.

2. Use an ohmmeter and measure the resistance of the sensor. Also use ohmmeter to check for short or open.

3. Check resistance reading to chart of resistance use sensor ambient temperature. (Tolerance of part is ± 10%.)

4. If sensor resistance reads very low, then sensor is shorted and will not allow proper operation of the heat pump control.

5. If sensor is out of tolerance, shorted, open or reads very low ohms then it should be replaced.

TEMPERATURE "F" VS. RESISTANCE "R" OF TEMPERATURE SENSOR

FR FR FR FR

0.52-

0.42-

0.32-

0.22-

0.12-

0.02-

0.91-

0.81-

0.71-

0.61-

0.51-

0.41-

0.31-

0.21-

0.11-

0.01-

0.9-

0.8-

0.7-

0.6-

0.5-

0.4-

0.3-

0.2-

0.1-

0.0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

0.01

0.11

0.21

178691 990091 585381 813771 982171 784561 409951 925451 553941 473441 675931 659431 605031 912621 980221 801811 272411 575011 010701 475301 062001 46079

18939 80019 93188

17358 99628

12108 23677 03257 01927 07607 70586 81466 99346 94426 56506 54785

0.31

0.41

0.51

0.61

0.71

0.81

0.91

0.02

0.12

0.22

0.32

0.42

0.52

0.62

0.72

0.82

0.92

0.03

0.13

0.23

0.33

0.43

0.53

0.63

0.73

0.83

0.93

0.04

0.14

0.24

0.34

0.44

0.54

0.64

0.74

0.84

0.94

0.05

58965 48255 04635

15025 41505 82094 09574 00264 55844 45534 59224 77014 89893 75783 25673 38563 84553 54543 47533 43623 32713 04803 68992 75192 55382 77572 32862 29062 38352 69642 03042 48332 85722 05122

16512 98902 53402 69891

0.35

0.25

0.35

0.45

0.55

0.65

0.75

0.85

0.95

0.06

0.16

0.26

0.36

0.46

0.56

0.66

0.76

0.86

0.96

0.07

0.17

0.27

0.37

0.47

0.57

0.67

0.77

0.87

0.97

0.08

0.18

0.28

0.38

0.48

0.58

0.68

0.78

0.88

47391 76881 57381 98971 43471 48961 74561 22161 01751 01351

12941 44541 77141 02831 47431 73131 01821 29421 38121 38811

19511 70311

13011 26701

10501 74201 00001 0679 6259 9929 7709 2688 3568 9448 0528 7508 9687 6867

0.98

0.09

0.19

0.29

0.39

0.49

0.59

0.69

0.79

0.89

0.99

0.001

0.101

0.201

0.301

0.401

0.501

0.601

0.701

0.801

0.901

0.011

0.111

0.211

0.311

0.411

0.511

0.611

0.711

0.811

0.911

0.021

0.121

0.221

0.321

0.421

7057 4337 5617 0007 0486 3866

1356 3836 9326 8906

1695 7285 7965 0755 6445 6235 8025 4905 2894 3784 7674 3664 2654 4644 7634 4724 2814 3904 6004

1293 8383 7573 8763

1063 6253 2543

Manual 2100-193O Page 23 of 26

FAN BLADE SETTING DIMENSIONS

Shown in Figure 17 are the correct fan blade setting dimensions for proper air delivery across the outdoor coil.

The suction line temperatures in Table 9 are based upon 80ºF dry bulb/67ºF wet bulb (50 percent R.H.) temperature and rated airflow across the evaporator during cooling cycle.

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

FIGURE 17

FAN BLADE SETTING

TABLE 8

FAN BLADE DIMENSION

ledoMAnoisnemiD

103HW 163HW

"52.1

REMOVAL OF 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 holding fan shroud to condenser and bottom – nine (9) screws.

4. Unwire condenser fan motor.

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

6. Service motor/fan as needed.

7. Reverse steps to reinstall.

REFRIGERANT CHARGE

The correct system R-22 charge is shown on the unit rating plate. Optimum unit performance will occur with a refrigerant charge resulting in a suction line temperature (6 inches from compressor) as shown in Table 9.

TABLE 9

SUCTION LINE TEMPERATURES

detaR

ledoM

103HW001,185-6556-36 163HW001,115-9486-66

wolfriA

DOF59

erutarepmeT

DOF28

erutarepmeT

TABLE 10

INDOOR BLOWER PERFORMANCE

CFM AT 230 VOLTS

163HW,103HW

.P.S.E

HnI2O

0./059539/593,1513,1

1./039519/043,1072,1

2./019588/582,1091,1

3./558038/502,1001,1

4./008557/011,1000,1

5./------/500,1078

6./------/------

deepSwoLdeepShgiH

/lioCyrDlioCteW/lioCyrDlioCteW

TABLE 11

CFM AND ESP

detaR

ledoM

103HW 163HW

 Rated CFM and ESP on high speed tap

MFC

000,1 001,1

detaR

PSE

03.

003,1-039 053,1-039

TABLE 12

MAXIMUM ESP OF OPERATION

ELECTRIC HEAT ONLY

teltuOtnorFteltuOpoT

woL

ledoM

00A

103HW

50A

163HW

01A 51A

00B

103HW

60B

163HW

90B 51B

00C

103HW

60C

163HW

90C 51C

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

deepS

05.

04.

53.

05.

04.

53.

05.

03.

hgiH

deepS

05.

04.

05.

54.

05.

04.

woL

deepS

05.

04.

52.

05.

03.

05.

53.

05.

04.

05.

04.

05.

54.

dednemmoceR

egnaRwolfriA

hgiH

deepS

Manual 2100-193O Page 24 of 26

TABLE 13

COOLING PRESSURE (PSI) – OUTDOOR TEMPERATURE °F

AIR TEMPERATURE ENTERING OUTDOOR COIL °F

riAnruteR

ledoM

103HW

163HW

erutarepmeTerusserP5708580959001501011511

BDged57

BWged26

BDged08

BWged76

BDged58

BWged27

BDged57

BWged26

BDged08

BWged76

BDged58

BWged27

ediSwoL ediShgiH

532

942

362

142

552

962

052

462

972

012

622

242

612

232

842

322

042

652

772

192

503

913

333

482

892

213

723

001

492

803

323

833

353

752

372

092

603

323

462

182

792

413

372

092

803

523

243

88 743

143

653 101

863 38

933 98

133

843 59

063

TABLE 14

HEATING PRESSURE (PSI) – OUTDOOR TEMPERATURE °F

AIR TEMPERATURE ENTERING OUTDOOR COIL °F

riAnruteR

ledoM

103HW07

163HW07

erutarepmeTerusserP050151025203530454055506

ediSwoL

ediShgiH

341

841

351

951

561

271

081

881

791

702

712

ediShgiH

541

251

951

761

771

681

791

802

022

332

642

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” on Page 24 in manual. If there is any doubt as to correct charge being in the system, the charge should be removed, system evacuated and recharged to serial plate instructions

822

932

062

572

Manual 2100-193O Page 25 of 26

TABLE 15

OPTIONAL ACCESSORIES

LEDOMNOITPIRCSED

50A-03HWHEsegakcaPretaeH 1 X 01A-03HWHEsegakcaPretaeH 1 X 50A-63HWHEsegakcaPretaeH 1 X 01A-63HWHEsegakcaPretaeH 1 X 51A-63HWHEsegakcaPretaeH 1 X 60B-30HWHEsegakcaPretaeH 1 XX 90B-30HWHEsegakcaPretaeH 1 XX 51B-30HWHEsegakcaPretaeH 1 X

60C-30HWHEsegakcaPretaeH 1 XX 90C-30HWHEsegakcaPretaeH 1 XX 51C-30HWHEsegakcaPretaeH 1 XX

3-POBetalPffOknalB

3-DAFBrepmaDriAhserFcirtemoraB XXXXXX

3-DAFMrepmaDriAhserFdezirotoM XXXXXX

3-VRCtsuahxEhtiwrotalitneVlaicremmoC XXXXXX

3-MFIEtsuahxEhtiwrezimonocE

WH301-A

XXXXXX

WH301-B

WH301-C

WH361-A

WH361-B

WH361-C

3-HMC)CPL(lortnoCerusserPwoL 7-HMC)CAL(lortnoCtneibmAwoL XXXXXX 9-HMCCPL+CAL XXXXXX

A41-HMC)TDO(tatsomrehTroodtuO XXXXXX

51-CMC)KS(tiKtratSXX

10-DPMWtiKrekaerBtiucriCXX

Manual 2100-193O Page 26 of 26

A3A-VREWrotalitneVyrevoceRygrenEXXXX

A3C-VREWrotalitneVyrevoceRygrenEXX

XXXXXX

A50-BCMWtiKrekaerBtiucriCX B30-BCMWtiKrekaerBtiucriCX

A60-BCMWtiKrekaerBtiucriCX

Bard WH361, WH-301 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual