Bard WH-301, WH361 User Manual

WALL MOUNTED INSTALLATION PACKAGED HEAT PUMP INSTRUCTIONS

Models: WH301, WH361

	Bard Manufacturing Company, Inc.	Manual No.:	2100-193O
	Bryan, Ohio 43506	Supersedes:	2100-193N
	Since 1914. . .Moving ahead just as planned.	File:	Volume III, Tab 17
		Date:	05-04-07

	© Copyright 2003		Manual	2100-193O
			Page	1 of 26

CONTENTS

Getting 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

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

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

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
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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: [phone]
	Fax: [phone]
ANSI	American National Standards Institute
	11 West Street, 13th Floor
	New York, NY 10036
	Telephone: [phone]
	Fax: [phone]

ASHRAE American Society of Heating Refrigerating,

and Air Conditioning Engineers, Inc.

1791 Tullie Circle, N.E.

Atlanta, GA 30329-2305

Telephone: [phone]

Fax: [phone]

NFPA	National Fire Protection Association
	Batterymarch Park
	P.O. Box 9101
	Quincy, MA 02269-9901
	Telephone: [phone]
	Fax: [phone]

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
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WALL MOUNT GENERAL INFORMATION

HEAT PUMP WALL MOUNT MODEL NOMENCLATURE
WH	36	1	A	10	X	X	X	X	X	A
MODEL NUMBER		REVISIONS								CONTROL

MODULES

CAPACITY			VOLTS & PHASE	KW
30	-	2½ Ton	A - 230/208/60/1
			B - 230/208/60/3
36	-	3 Ton
			C - 460/60/3

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

COIL OPTIONS

COLOR OPTIONS

X- Standard

X - Beige (Standard)

1 - Phenolic Coated Evaporator

1 - White

2 - Phenolic Coated Condenser

2 - Mesa Brown

3 - Phenolic Coated Evaporator

4 - Buckeye Gray

and Condenser

5 - Desert Brown

8 - Dark Bronze

	OUTLET OPTIONS
	X- Front (Standard)
	T - Top on WH30 and WH36
FILTER OPTIONS	Models
X - 1-Inch Throwaway (Standard)
W- 1-Inch Washable
P - 2-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.

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 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. See Page 3 for information on codes and standards.

Size of unit for a proposed installation should be based 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 should adhere to local codes.

DUCT WORK

Any heat pump is more critical of proper operating charge and an adequate duct system than a straight air conditioning unit. All duct work, supply and return, must be properly sized for the design 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.

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TABLE 1

ELECTRIC HEAT TABLE

Models		WH301-A				WH301-B			WH301-C			WH361-A				WH361-B			WH361-C
	240-1		208-1		240-3		208-3		460-3		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	A	BTU	A	BTU	A	BTU
5	20.8	17065	18.1	12800							20.8	17065	18.1	12800
10	41.6	34130	36.2	25600							41.6	34130	36.2	25600
15											62.5	51200	54.1	38400
6					14.4	20500	12.5	15360	7.2	20475					14.4	20500	12.5	15360	7.2	20475
9					21.7	30600	18.7	23030	10.8	30700					21.7	30600	18.7	23030	10.8	30700
15									18.0	51200					36.2	51200	31.2	38400	18.0	51200

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										TABLE 2
							DIMENSIONS OF BASIC UNIT (NOMINAL)
	Width	Depth	Height	Supply		Return
Model	(W)	(D)	(H)	A	B	C	B	E	F	G	I		J	K	L	M	N	O	P	Q	R	S	T
WH30	38.200	17.125	70.563	7.88	27.88	13.88	27.88	40.00	18.50	25.75	17.93		26.75	28.75	29.25	27.00	2.75	39.19	22.75	9.14	4.19	12.00	5.00
WH36
										FIGURE		1
									UNIT DIMENSIONS

FRONT VIEW

SIDE VIEW

BACK VIEW

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

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TABLE 3

ELECTRICAL SPECIFICATIONS

				4	1	2	2		4			1			2			2
											Maximum
								Minimum
					Maximum						External Fuse
			No.					Circuit			or Circuit			Field Power			Ground
	Model				External	Field
		Rated						Ampacity			Breaker			Wire Size			Wire Size
			Field	Minimum	Fuse or	Power	Ground
		Volts And	Power	Circuit	Circuit	Wire	Wire
								CKT A		CKT B	CKT A		CKT B	CKT A		CKT B	CKT A		CKT B
		Phase	Circuits	Ampacity	Breaker	Size	Size
	WH301-A00, -A0Z		1	24	35	8	10	- - -		- - -	- - -		- - -	- - -		- - -	- - -		- - -
	-A05	230/208-1	1	50	50	8	10	- - -		- - -	- - -		- - -	- - -		- - -	- - -		- - -
	3 -A10		1	76	80	4	8	50		26	50		30	8		10	10		10
	WH301-B00,-B0Z		1	19	25	10	10	- - -		- - -	- - -		- - -	- - -		- - -	- - -		- - -
	-B06	230/208-3	1	37	40	8	10	- - -		- - -	- - -		- - -	- - -		- - -	- - -		- - -
	3 -B09		1	46	50	8	10	- - -		- - -	- - -		- - -	- - -		- - -	- - -		- - -
	WH301-C00,-C0Z		1	10	15	14	14	- - -		- - -	- - -		- - -	- - -		- - -	- - -		- - -
	-C06	460-3	1	19	20	12	12	- - -		- - -	- - -		- - -	- - -		- - -	- - -		- - -
	3 -C09		1	24	25	10	10	- - -		- - -	- - -		- - -	- - -		- - -	- - -		- - -
	5 -C15		1	26	30	10	10	- - -		- - -	- - -		- - -	- - -		- - -	- - -		- - -
	WH361-A00,-A0Z		1	27	40	10	10	- - -		- - -	- - -		- - -	- - -		- - -	- - -		- - -
	-A05	230/208-1	1	53	60	6	10	- - -		- - -	- - -		- - -	- - -		- - -	- - -		- - -
	3 -A10		1 or2	79	80	4	8	53		26	60		30	6		10	10		10
	5 -A15		1 or 2	83	90	4	8	53		52	60		60	6		6	10		10
	WH361-B00,-B0Z		1	20	25	10	10	- - -		- - -	- - -		- - -	- - -		- - -	- - -		- - -
	-B06	230/208-3	1	38	40	8	10	- - -		- - -	- - -		- - -	- - -		- - -	- - -		- - -
	3 -B09		1	47	50	8	10	- - -		- - -	- - -		- - -	- - -		- - -	- - -		- - -
	5 -B15		1	50	50	8	10	- - -		- - -	- - -		- - -	- - -		- - -	- - -		- - -
	WH361-C00,-C0Z		1	11	15	14	14	- - -		- - -	- - -		- - -	- - -		- - -	- - -		- - -
	-C06	460-3	1	20	20	12	12	- - -		- - -	- - -		- - -	- - -		- - -	- - -		- - -
	3 -C09		1	25	25	10	10	- - -		- - -	- - -		- - -	- - -		- - -	- - -		- - -
	5 -C15		1	26	30	10	10	- - -		- - -	- - -		- - -	- - -		- - -	- - -		- - -

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

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

3Maximum 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 National Electric Code (latest revision), Article 310 for power conductor sizing.

4These “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 power conductor sizing.

5Not 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 310 regarding Ampacity Adjustment Factors when more than three conductors are in a raceway.

Not available in top outlet version.

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.

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.

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

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.

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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 weightoftheunitinstalled.

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.

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.

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.

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FIGURE 3 MOUNTING INSTRUCTIONS
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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.

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FIGURE 5

ATTACHING TOP OUTLET AIRFRAMES TO UNIT

FIGURE 6

UNIT WITH TOP OUTLET MOUNTED UNDER OVERHANG

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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

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FIGURE 9

COMMON WALL-MOUNTING INSTALLATIONS

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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.

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

TAP	RANGE
240V	253	-	216
208V	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.)

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.

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

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FIGURE 10

LOW VOLTAGE WIRING

TABLE 5

THERMOSTAT WIRE SIZE

			Maximum
Transformer			Distance
VA	FLA	Wire Gauge	In Feet
		20 gauge	45
		18 gauge	60
55	2.3	16 gauge	100
		14 gauge	160
		12 gauge	250

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OPTIONAL OUTDOOR THERMOSTAT APPLICATIONS

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.

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

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 11

COMPRESSOR CUTOFF THERMOSTAT WIRING

4 & 10KW 1 PH — 6 & 9KW 3 PH

FIGURE 12

COMPRESSOR CUTOFF THERMOSTAT WIRING

15KW 1 PH & 3 PH

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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

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

ELECTRIC HEAT HOLD-OFF WIRING 4 & 10KW 1 PH — 6 & 9KW 3 PH

FIGURE 14

ELECTRIC HEAT HOLD-OFF WIRING

15KW 1 PH & 3 PH

Manual	2100-193O
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TABLE 6

WALL THERMOSTAT

	Thermostat	Predominate Features
	8403-058	2 stage cool, 2 stage heat
		Electronic Non-Programmable
	(TH5220D1151)
		Auto or Manual changeover
		2 stage cool, 3 stage heat
	8403-060	Programmable Electronic
	(1120-445)	Auto or Manual changeover
		with built-in Humidistat

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START UP

IMPORTANT INSTALLER NOTE

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

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.

FIGURE 15

START UP LABEL

IMPORTANT

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

TO PREVENT COMPRESSOR DAMAGE WHICHMAYRESULTFROMTHEPRESENCE 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.

7961-061

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.

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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.

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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 7

TROUBLESHOOTING

	SYMPTOM	POSSIBLE CAUSES		WHAT TO CHECK		HOW TO CHECK OR REPAIR
	Compressor contactor	Control circuit wiring	Check for R connection at unit,		Run R connection to outdoor unit to power
	does not energize		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
			2.	Check across high		switch.
					2. If high pressure switch is open and will not
				pressure switch.		reset, replace high pressre switch.
		Compressor short	Check for 24V between CC-C		If no voltage between CC-C, jumper speed up
		cycle protection	and Y-C on heat pump control		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
		Power phasing not	Check for red LED on phase		Switch two power leads to the unit.
		correct.	monitor. (3 phase units only.)
	Fan outdoor motor	Motor defective	Check for open or shorted		Replace motor
	does not run		motor winding
	(cooling or heating
		Motor capacitor	Check capacitor rating. Check		Replace capacitor
	except during defrost)
		defective	for open or shorted capacitor.
		Heat pump control	Check across fan relay on heat		Replace heat pump control
		defective	pump control (Com-NC)
	Reversing valve does	Reversing valve	Check for open or shorted coil		Replace solenoid coil
	not energize	solenoid 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	Disconnect temperature sensor		1. If unit goes through defrost cycle, replace
	defrost	or heat pump control	from board and jumper across			temperature sensor
	(heating only)	defective	speed up terminals and sen
			jump terminals. This should		2. If unit does not go through defrost cycle,
			cause the unit to go through a			replace heat pump control.
			defrost cycle within one minute.
	Unit will not come out	Temperature sensor	Jumper across speed up		1. If unit comes out of defrost cycle, replace
	of defrost	or 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.

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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

F	R	F	R	F	R	F	R
-25.0	196871	13.0	56985	53.0	19374	89.0	7507
-24.0	190099	14.0	55284	52.0	18867	90.0	7334
-23.0	183585	15.0	53640	53.0	18375	91.0	7165
-22.0	177318	16.0	52051	54.0	17989	92.0	7000
-21.0	171289	17.0	50514	55.0	17434	93.0	6840
-20.0	165487	18.0	49028	56.0	16984	94.0	6683
-19.0	159904	19.0	47590	57.0	16547	95.0	6531
-18.0	154529	20.0	46200	58.0	16122	96.0	6383
-17.0	149355	21.0	44855	59.0	15710	97.0	6239
-16.0	144374	22.0	43554	60.0	15310	98.0	6098
-15.0	139576	23.0	42295	61.0	14921	99.0	5961
-14.0	134956	24.0	41077	62.0	14544	100.0	5827
-13.0	130506	25.0	39898	63.0	14177	101.0	5697
-12.0	126219	26.0	38757	64.0	13820	102.0	5570
-11.0	122089	27.0	37652	65.0	13474	103.0	5446
-10.0	118108	28.0	36583	66.0	13137	104.0	5326
-9.0	114272	29.0	35548	67.0	12810	105.0	5208
-8.0	110575	30.0	34545	68.0	12492	106.0	5094
-7.0	107010	31.0	33574	69.0	12183	107.0	4982
-6.0	103574	32.0	32634	70.0	11883	108.0	4873
-5.0	100260	33.0	31723	71.0	11591	109.0	4767
-4.0	97064	34.0	30840	72.0	11307	110.0	4663
-3.0	93981	35.0	29986	73.0	11031	111.0	4562
-2.0	91008	36.0	29157	74.0	10762	112.0	4464
-1.0	88139	37.0	28355	75.0	10501	113.0	4367
0.0	85371	38.0	27577	76.0	10247	114.0	4274
1.0	82699	39.0	26823	77.0	10000	115.0	4182
2.0	80121	40.0	26092	78.0	9760	116.0	4093
3.0	77632	41.0	25383	79.0	9526	117.0	4006
4.0	75230	42.0	24696	80.0	9299	118.0	3921
5.0	72910	43.0	24030	81.0	9077	119.0	3838
6.0	70670	44.0	23384	82.0	8862	120.0	3757
7.0	68507	45.0	22758	83.0	8653	121.0	3678
8.0	66418	46.0	22150	84.0	8449	122.0	3601
9.0	64399	47.0	21561	85.0	8250	123.0	3526
10.0	62449	48.0	20989	86.0	8057	124.0	3452
11.0	60565	49.0	20435	87.0	7869
12.0	58745	50.0	19896	88.0	7686

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FAN BLADE SETTING DIMENSIONS

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

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

FIGURE 17

FAN BLADE SETTING

TABLE 8

FAN BLADE DIMENSION

Model Dimension A

WH301 1.25"

WH361

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.

TABLE 10

INDOOR BLOWER PERFORMANCE

CFM AT 230 VOLTS

		WH301, WH361
E.S.P.	Low Speed		High Speed
In H2O	Dry Coil /	Wet Coil	Dry Coil / Wet Coil
.0	950 /	935	1,395 / 1,315
.1	930 /	915	1,340 / 1,270
.2	910 /	885	1,285 / 1,190
.3	855 /	830	1,205 / 1,100
.4	800 /	755	1,110 / 1,000
.5	--- / ---		1,005 / 870
.6	--- / ---		--- / ---

TABLE 11

CFM AND ESP

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

	Rated	95 F OD	82 F OD
Model	Airflow	Temperature	Temperature
WH301	1,100	56 - 58	63 - 65
WH361	1,100	49 - 51	66 - 68

	j	j
	Rated	Rated	Recommended
Model	CFM	ESP	Airflow Range
WH301	1,000	.30	930 - 1,300
WH361	1,100	.30	930 - 1,350

Rated CFM and ESP on high speed tap

TABLE 12

MAXIMUM ESP OF OPERATION

ELECTRIC HEAT ONLY

		Front Outlet		Top Outlet
		Low	High	Low	High
Model		Speed	Speed	Speed	Speed
	A00	.50	.50	.50	.50
WH301	A05	.40	.50	.40	.50
WH361	A10	.35	.40	.25	.40
	A15	.35	.40	NA	NA
	B00	.50	.50	.50	.50
WH301	B06	.40	.50	NA	NA
WH361	B09	.35	.45	.30	.40
	B15	.35	.45	NA	NA
	C00	.50	.50	.50	.50
WH301	C06	.50	.50	NA	NA
WH361	C09	.30	.40	.35	.45
	C15	.30	.40	NA	NA

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

.15 for 2" pleated filter.

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TABLE 13

COOLING PRESSURE (PSI) – OUTDOOR TEMPERATURE °F

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	76	78	80	81	83	84	85	87	88
		62 deg WB	High Side	235	249	263	277	291	305	319	333	347
	WH301	80 deg DB	Low Side	81	83	85	87	88	90	91	93	94
		67 deg WB	High Side	241	255	269	284	298	312	327	341	356
		85 deg DB	Low Side	88	90	92	93	95	97	98	100	101
		72 deg WB	High Side	250	264	279	294	308	323	338	353	368
		75 deg DB	Low Side	69	71	73	75	76	78	80	82	83
		62 deg WB	High Side	210	226	242	257	273	290	306	323	339
	WH361	80 deg DB	Low Side	73	76	78	80	82	84	85	87	89
		67 deg WB	High Side	216	232	248	264	281	297	314	331	348
		85 deg DB	Low Side	79	81	84	86	88	90	92	94	95
		72 deg WB	High Side	223	240	256	273	290	308	325	342	360

TABLE 14

HEATING PRESSURE (PSI) – OUTDOOR TEMPERATURE °F

AIR TEMPERATURE ENTERING OUTDOOR COIL °F

		Return Air
	Model	Temperature	Pressure	0	5	10	15	20	25	30	35	40	45	50	55	60
	WH301	70o	Low Side	21	25	28	32	36	39	43	47	51	55	59	63	67
			High Side	143	148	153	159	165	172	180	188	197	207	217	228	239
	WH361	70o	Low Side	22	25	28	31	34	38	42	46	50	55	60	65	70
			High Side	145	152	159	167	177	186	197	208	220	233	246	260	275

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.

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TABLE 15

OPTIONAL ACCESSORIES

MODEL DESCRIPTION

WH301-A

WH301-B

WH301-C

WH361-A

WH361-B

WH361-C

EHWH30-A05	Heater Packages	1	X
EHWH30-A10	Heater Packages	1	X
EHWH36-A05	Heater Packages	1				X
EHWH36-A10	Heater Packages	1				X
EHWH36-A15	Heater Packages	1				X
EHWH03-B06	Heater Packages	1		X			X
EHWH03-B09	Heater Packages	1		X			X
EHWH03-B15	Heater Packages	1						X
EHWH03-C06	Heater Packages	1			X			X
EHWH03-C09	Heater Packages	1			X			X
EHWH03-C15	Heater Packages	1			X			X
BOP-3	Blank Off Plate		X	X	X	X	X	X
BFAD-3	Barometric Fresh Air Damper		X	X	X	X	X	X
MFAD-3	Motorized Fresh Air Damper		X	X	X	X	X	X
CRV-3	Commercial Ventilator with Exhaust		X	X	X	X	X	X
EIFM-3	Economizer with Exhaust		X	X	X	X	X	X
WERV-A3A	Energy Recovery Ventilator		X	X		X	X
WERV-C3A	Energy Recovery Ventilator				X			X
CMH-3	Low Pressure Control (LPC)		X	X	X	X	X	X
CMH-7	Low Ambient Control (LAC)		X	X	X	X	X	X
CMH-9	LAC + LPC		X	X	X	X	X	X
CMH-14A	Outdoor Thermostat (ODT)		X	X	X	X	X	X
CMC-15	Start Kit (SK)		X			X
WMCB-05A	Circuit Breaker Kit		X
WMCB-03B	Circuit Breaker Kit			X			X
WMPD-01	Circuit Breaker Kit				X			X
WMCB-06A	Circuit Breaker Kit					X

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