Bard WH602, WH483, WH421 User Manual

INSTALLATION INSTRUCTIONS

WALL MOUNTED

PACKAGE HEAT PUMPS

MODELS:

WH421

WH483

WH602

	BARD MANUFACTURING COMPANY	Manual:	2100-399
	Bryan, Ohio 43506	Supersedes:
	Since 1914...Moving ahead, just as planned.	File:	Volume III Tab 17
		Date:	03-01-02

Copyright 2002

CONTENTS

Getting Other Information and Publications ..........	1
For more information, contact these publishers: ......	1
Wall Mount General Information .............................	2
Air Conditioner Wall Mount Model Nomenclature .....	2
Shipping Damage ....................................................	5
General ...............................................................	5
Duct Work ...............................................................	5
Filters ...............................................................	5
Fresh Air Intake ........................................................	6
Condensate Drain ....................................................	6
Installation Instructions ...........................................	7
Wall Mounting Information .......................................	7
Mounting the Unit .....................................................	7
Typical Installations ..................................................	7
Wiring – Main Power .............................................	11
Wiring – Low Voltage Wiring .................................	11
Thermostat Wiring .................................................	12
Heat Anticipation ....................................................	12
Thermostat Indicator Lamps ..................................	13
Emergency Heat Position ......................................	13
Compressor Malfunction ........................................	13

Figures
Figure 1	Unit Dimensions .....................................	3
Figure 2	Blower Damper Assembly ......................	6
Figure 3	Mounting Instructions ..............................	8
Figure 3A	Electric Heat Clearance .........................	8
Figure 4	Wall-Mounting Instructions .....................	9
Figure 5	Wall-Mounting Instructions .....................	9
Figure 6 Common Wall-Mounting Instructions ....		10
Figure 7	Unit 24V Terminal Board .......................	11
Figure 8	Compressor Cutoff and Outdoor
	Thermostat Wiring ................................	12
Figure 9	Start-Up Label ......................................	14
Figure 10	Defrost Control Board ..........................	16
Figure 11	Fan Blade Setting ................................	19

Start Up ...................................................................	14
Important Installer Note ..........................................	14
High Pressure Switch .............................................	14
Three Phase Scroll Compressor Start Up
Information .............................................................	14
Phase Monitor ........................................................	15
Service Hints ..........................................................	15
Sequence of Operation ..........................................	15
Pressure Service Ports ..........................................	15
Defrost Cycle .........................................................	15
Troubleshooting .....................................................	17
Solid State Heat Pump Control
Troubleshooting Procedure ....................................	17
Checking Temperature Sensor Outdoor
Unit Circuit .............................................................	18
Fan Blade Setting Dimensions ...............................	19
Removal of Fan Shroud .........................................	19
Refrigerant Charge ................................................	19
Pressure Chart ..................................................	20-21
Optional Accessories .............................................	21

Tables
Table	1	Electrical Specifications .........................	2
Table	2	Electric Heat Table .................................	4
Table	3	Thermostat Wire Size ..........................	12
Table	4	Wall Thermostat and
		Subbase Combinations ........................	13
Table	5	Troubleshooting ....................................	17
Table	6	Fan Blade Dimensions .........................	19
Table	7	Suction Line Temperatures...................	19
Table	8	Recommended Operating Ranges ......	19
Table	9	Indoor Blower Performance .................	19
Table	10	Maximum ESP of Operation ................	20
Table	11	Cooling Pressures ................................	20
Table	12	Heating Pressures ................................	21
Table	13	Optional Accessories ...........................	21

i

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 or
Residential Winter and	Manual N
Summer Air Conditioning
Low Pressure, Low Velocity ..........	ACCA Manual D or
Duct System Design for Winter	Manual Q
and Summer Air Conditioning

FOR MORE INFORMATION, CONTACT THESE PUBLISHERS:

ACCA Air Conditioning Contractors of America

1712 New Hampshire Ave. N.W.

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:

5,301,744; 5,002,116; 4,924,934; 4,875,520; 4,825,936; 4,432,409

Other patents pending.

Manual 2100-399

Page 1

WALL MOUNT GENERAL INFORMATION

HEAT PUMP WALL MOUNT MODEL NOMENCLATURE

MODEL NUMBER

WH

CAPACITY
42	– 3-1/2 Ton	REVISION
48	– 4 Ton
60	– 5 Ton

VOLTS & PHASE

A – 230/208/60-1

B – 230/208/60-3

C – 460/60-3 KW

00 – No KW

05 – 5 KW

06 – 6KW

09 – 9 KW

10 – 10 KW

15 – 15 KW

18 – 18 KW

20 – 20 KW

						CONTROL MODULES
48 1 – A 10 X X X X X B						(See Chart Below)
					COIL OPTIONS
					X – Standard
VENTILATION OPTIONS					1 – Phenolic Coated Evaporator
					2 – Phenolic Coated Condenser
X – Barometric Fresh Air Damper					3 – Phenolic Coated Evaporator
(Standard)				COLOR OPTIONS	and Condenser
B – Blank-off Plate
M – Motorized Fresh Air Damper				X – Beige (Standard)
V – Commercial Room Ventilator				1 – White
- Motorized with Exhaust				2 – Mesa Tan
E – Economizer (Internal) - Fully				3 – Colonial White		OUTLET OPTIONS
Modulating with Exhaust				4 – Buckeye Gray
						X – Front (Standard)
R – Energy Recovery Ventilator -
Motorized with Exhaust	FILTER OPTIONS

X– One Inch Throwaway (Standard)

W – One Inch Washable

P – Two Inch Pleated

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

TABLE 1

ELECTRIC HEAT TABLE

Models		WH421-A				WH421-B			WH421-C			WH483-A				WH483-B			WH483-C
						WH483-B						WH602-A				WH602-B			WH602-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
4											16.7	13650	14.4	10240
5	20.8	17065	18.1	12800							20.8	17065	18.1	12800
6					14.4	20500	12.5	15360	7.2	20480
9					21.7	30600	18.7	23030	10.8	30700					21.7	30600	18.7	23030	10.8	30700
10	41.6	34130	36.2	25600							41.6	34130	36.2	25600
15	62.5	51200	54.1	38400	36.2	51200	31.2	38400	18.0	51200	62.5	51200	54.1	38400	36.2	51200	31.2	38400	18.0	51200
18															43.3	61400	37.5	46050
20											83.2	68250	72.1	51200

Manual 2100-399

Page 2

Page	Manual
3	399-2100

FIGURE 1

UNIT DIMENSIONS

MIS-411

TABLE 2

ELECTRICAL SPECIFICATIONS

SINGLE CIRCUIT

DUAL CIRCUIT

				4	1	2	2	4		1		2		2
					Maximum			Minimum		Maximum
			No.			Field				External		Field Power		Ground Wire
		Rated			External			Circuit		Fuse or
			Field	Minimum	Fuse or	Power	Ground	Ampacity		Ckt .Breaker		Wire Size		Size
		Volts	Power	Circuit	Circuit	Wire	Wire
	Model	& Phase	Ckts.	Ampacity	Breaker	Size	Size	Ckt A	Ckt B	Ckt A	Ckt B	Ckt A	Ckt B	Ckt A	Ckt B
	WH421-A00, A0Z		1	34	50	8	10	N/A	N/A	N/A	N/A	N/A	N/A	N/A	N/A
	A05	230/208-1	1 or 2	60	70	6	8	34	26	50	30	8	10	10	10
	3 A10		1 or 2	86	90	3	8	34	52	50	60	8	6	10	10
	A15		1 or 2	86	90	3	8	34	52	50	60	8	6	10	10
	WH421-B00, B0Z		1	26	35	8	10	N/A	N/A	N/A	N/A	N/A	N/A	N/A	N/A
	B06	230/208-3	1	44	50	8	10	N/A	N/A	N/A	N/A	N/A	N/A	N/A	N/A
	3 B09		1	53	60	6	10	N/A	N/A	N/A	N/A	N/A	N/A	N/A	N/A
	B15		1	53	60	6	10	N/A	N/A	N/A	N/A	N/A	N/A	N/A	N/A
	WH421-C00, C0Z		1	13	20	12	12	N/A	N/A	N/A	N/A	N/A	N/A	N/A	N/A
	C06	460-3	1	23	25	10	10	N/A	N/A	N/A	N/A	N/A	N/A	N/A	N/A
	3 C09		1	27	30	10	10	N/A	N/A	N/A	N/A	N/A	N/A	N/A	N/A
	C15		1	27	30	10	10	N/A	N/A	N/A	N/A	N/A	N/A	N/A	N/A
	WH483-A00, A0Z		1	36	50	8	10	N/A	N/A	N/A	N/A	N/A	N/A	N/A	N/A
	A04		1	57	60	6	8	N/A	N/A	N/A	N/A	N/A	N/A	N/A	N/A
	A05	230/208-1	1 or 2	62	70	6	8	36	26	50	30	8	10	10	10
	3 A10		1 or 1	88	100	3	8	36	52	50	60	8	6	10	10
	A15		1 or 2	88	100	3	8	36	52	50	60	8	6	10	10
	A20		1 or 2	110	110	2	6	59	52	60	60	6	6	10	10
	WH483-B00, B0Z		1	25	35	8	10	N/A	N/A	N/A	N/A	N/A	N/A	N/A	N/A
	B06		1	43	50	8	10	N/A	N/A	N/A	N/A	N/A	N/A	N/A	N/A
	3 B09	230/208-3	1	52	60	6	10	N/A	N/A	N/A	N/A	N/A	N/A	N/A	N/A
	B15		1	52	60	6	10	N/A	N/A	N/A	N/A	N/A	N/A	N/A	N/A
	B18		1	60	60	6	10	N/A	N/A	N/A	N/A	N/A	N/A	N/A	N/A
	WH483-C00, C0Z		1	13	15	14	14	N/A	N/A	N/A	N/A	N/A	N/A	N/A	N/A
	3 C09	460-3	1	26	30	10	10	N/A	N/A	N/A	N/A	N/A	N/A	N/A	N/A
	C15		1	27	30	8	10	N/A	N/A	N/A	N/A	N/A	N/A	N/A	N/A
	WH602-A00, A0Z		1	45	60	8	10	N/A	N/A	N/A	N/A	N/A	N/A	N/A	N/A
	A05		1 or 2	71	90	4	8	45	26	60	60	8	10	10	10
	3 A10	230/208-1	1 or 1	97	110	3	6	45	52	60	60	8	6	10	10
	A15		1 or 2	97	110	3	6	45	52	60	60	8	6	10	10
	A20		1 or 2	110	110	2	6	59	52	60	60	6	6	10	10
	WH602-B00, B0Z		1	33	45	8	10	N/A	N/A	N/A	N/A	N/A	N/A	N/A	N/A
	3 B09	230/208-3	1	60	60	6	10	N/A	N/A	N/A	N/A	N/A	N/A	N/A	N/A
	B15		1	60	60	6	10	N/A	N/A	N/A	N/A	N/A	N/A	N/A	N/A
	B18		1	60	60	6	10	N/A	N/A	N/A	N/A	N/A	N/A	N/A	N/A
	WH602-C00, C0Z		1	16	20	12	12	N/A	N/A	N/A	N/A	N/A	N/A	N/A	N/A
	3 C09	460-3	1	29	35	8	10	N/A	N/A	N/A	N/A	N/A	N/A	N/A	N/A
	C15		1	29	35	8	10	N/A	N/A	N/A	N/A	N/A	N/A	N/A	N/A

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

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

S Maximum KW that can operate with heat pump on.

TThese Minimum Circuit Ampacity" values are to be used for sizing the field power conductors. Refer to the National Electrical Code (latest version), article 310 for power conductor sizing. CAUTION: When more than one field power conductor circuit is run through one conduit, the conductors must be derated. Pay special attention to note 8 of table 310 regarding Ampacity Adjustment Factors when more than 3 conductors are in a raceway.

Manual 2100-399

Page 4

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 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 1 for information on codes and standards.

Size of unit for a proposed installation should be based on heat loss calculation made according to methods of Air Conditioning Contractors of America (ACCA). The air duct should be 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 air flow requirement of the equipment. Air Conditioning Contractors of America (ACCA) is an excellent guide to proper sizing. All duct work or portions thereof not in the conditioned space should be properly insulated in order to both conserve energy and prevent condensation or moisture damage.

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

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

A 1/4 inch clearance to combustible material for the first three feet (3') of duct attached to the outlet air frame is required. See Wall Mounting Instructions and Figures 4 and 4 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 thru RG-5 or RFG-2 thru 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 2 inch pleated filter are also available as optional accessories. The internal filter brackets are adjustable to accommodate the 2 inch filter by bending down the tabs to allow spacing for the 2 inch filters.

Manual 2100-399

Page 5