Bard WH602, WH483, WH421 User Manual

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INSTALLATION INSTRUCTIONS

WALL MOUNTED

PACKAGE HEAT PUMPS

MODELS:

WH421 WH483 WH602

BARD MANUFACTURING COMPANY Bryan, Ohio 43506

Since 1914...Moving ahead, just as planned.

Manual: 2100-399 Supersedes: File: Volume III Tab 17 Date: 03-01-02

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

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 T emperature 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

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 .......................1 1

Figure 8 Compressor Cutoff and Outdoor

Thermostat Wiring................................ 12

Figure 9 Start-Up Label...................................... 14

Figure 10 Defrost Control Board .......................... 16

Figure 1 1 Fan Blade Setting ................................ 19

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

T able 6 Fan Blade Dimensions ......................... 19

T able 7 Suction Line T emperatures................... 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

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: (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

ASHRAEAmerican 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: 5,301,744; 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 48 1 – A 10 X X X X X B

CAPACITY 42 – 3-1/2 T on 48 – 4 T on 60 – 5 T on

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

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

REVISION

KW 00 – No KW 05 – 5 KW 06 – 6KW 09 – 9 KW 10 – 10 KW 15 – 15 KW 18 – 18 KW 20 – 20 KW

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 -

Motorized with Exhaust

COLOR OPTIONS X – Beige (Standard) 1 – White 2 – Mesa Tan 3 – Colonial White 4 – Buckeye Gray

FILTER OPTIONS X – One Inch Throwaway

(Standard) W – One Inch Washable P – Two Inch Pleated

COIL OPTIONS X – Standard 1 – Phenolic Coated Evaporator 2 – Phenolic Coated Condenser 3 – Phenolic Coated Evaporator

CONTROL MODULES (See Chart Below)

and Condenser

OUTLET OPTIONS X – Front (Standard)

TABLE 1

ELECTRIC HEAT TABLE

sledoM

AUTBA UTBAUTBAUTBAUTBA UTBAUTBAUTBA UTBAUTB

4 7.61056314.4104201

58.02560711.81008218.02560711.8100821

64.41005025.21063512.708402

97.12006037.81030328.01007037.12006037.81030328.0100703

016.14031432.63006526.14031432.6300652

515.26002151.45004832.63002152.13004830.81002155.26002151.45004832.63002152.13004830.8100215

81 3.34004165.7305064

02 2.38052861.2700215

A-124HW

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

B-124HW B-384HW

C-124HW

A-384HW A-206HW

B-384HW B-206HW

C-384HW C-206HW

Manual 2100-399 Page 2

FIGURE 1

UNIT DIMENSIONS

Manual 2100-399

Page 3

MIS-411

TABLE 2

ELECTRICAL SPECIFICATIONS

TIUCRICELGNIS TIUCRICLAUD

detaR

stloV

ledoM

Z0A,00A-124HW 50A 01A 51A

Z0B,00B-124HW 60B 90B 51B

Z0C,00C-124HW 60C 90C 51C

Z0A,00A-384HW 40A 50A 01A 51A 02A

Z0B,00B-384HW 60B 90B 51B 81B

Z0C,00C-384HW 90C 51C

Z0A,00A-206HW 50A 01A 51A 02A

Z0B,00B-206HW 90B 51B 81B

Z0C,00C-206HW 90C 51C

3-064

.oN dleiF

esahP&

1-802/032

3-802/032

1-802/032

3-802/032

1-802/032

3-802/032

rewoP

.stkC

1 1 1 1

1 1

1 1 1 1 1

1 1 1

1 1 1 1

1 1 1

2ro1

62 44 35 35

31 32 72 72

63 75

2ro1

1ro1

2ro1

2ro1 1ro1 2ro1 2ro1

011

52 34 25 25 06

31 62 72

54 17 79 79

011

33 06 06 06

61 92 92

muminiM tiucriC

yticapmA

05 07 09 09

53 05 06 06

02 52 03 03

05 06 07

53 05 06 06 06

51 03 03

06 09

54 06 06 06

02 53 53

mumixaM

lanretxE

roesuF

tiucriC

rekaerB

001 001 011

011 011 011

dleiF

rewoP eriW eziS

8 6 3 3

8 8 6 6

21 01 01 01

8 6 6 3 3 2

8 8 6 6 6

41 01

8 4 3 3 2

8 6 6 6

21 8 8

dnuorG eriW eziS

01 8 8 8

01 8 8 8 8 6

01 8 6 6 6

muminiM tiucriC

yticapmA

AtkCBtkCAtkCBtkCAtkCBtkCAtkCBtkC

A/N

mumixaM

lanretxE

roesuF

A/N

rewoPdleiF

rekaerB.tkC

eziSeriW

A/N

A/N 8 8 8

A/N A/N A/N A/N

A/N

A/N 8 8 8 6

A/N

A/N 8 8 8 6

A/N

eriWdnuorG

eziS

A/N 01 01 01

A/N

A/N 01 01 01 01

A/N

A/N 01 01 01 01

A/N

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

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

Maximum KW that can operate with heat pump on.

S T

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 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

FRESH AIR INTAKE

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

If the unit is equipped with the 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 minium 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.

BLOWER 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.

FIGURE 2

BLADE IS LOCKED CLOSED FOR SHIPPING

MIS-938

Manual 2100-399 Page 6

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. See Figures 4 and 5.

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.

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 installing unit. See Figure 4.

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 it 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 30-1/2" x 10-1/2" 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 32" x 12". See Figures 3, 4 and 7 for details.

3. Locate and mark lag bolt locations and bottom mounting bracket location. See Figure 4.

4. Mount bottom mounting bracket.

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

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.

TYPICAL INSTALLATIONS

See Figure 6 for common ways to install the wall-mount unit.

Manual 2100-399 Page 7

FIGURE 3

MOUNTING INSTRUCTIONS

NOTE: It is recommended that a bead of silicone caulking be placed behind the side mounting flanges and under the top flashing at the time of installation.

ELECTRIC HEAT CLEARANCE

MIS-277

Manual 2100-399 Page 8

FIGURE 3A

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

MIS-796

WARNING

• A minimum of 1/4 inch clearance must be maintained between the supply air duct and combustible materials. This is required for the first 3 feet of ducting.

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

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

FIGURE 4

WALL-MOUNTING INSTRUCTIONS

SEE FIGURE 3 — MOUNTING INSTRUCTIONS

FIGURE 5

WALL-MOUNTING INSTRUCTIONS

SEE UNIT DIMENSIONS, FIGURE 1,

FOR ACTUAL DIMENSIONS

MIS-548

SEE FIGURE 1 FOR DUCT DIMENSIONS

MIS-549

Manual 2100-399 Page 9

FIGURE 6

COMMON WALL-MOUNTING INSTALLATIONS

Manual 2100-399 Page 10

MIS-550

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.

NOTE:The voltage should be measured at the field power

connection point in the unit and while the unit is operating at full load (maximum amperage operating condition).

Nine (9) wires should be run from thermostat subbase to the 24V terminal board in the unit. A nine conductor, 18 gauge copper, color-coded thermostat cable is recommended. The connection points are shown in Figure 7.

FIGURE 7

UNIT 24V TERMINAL BOARD

See Note 1

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.

See Start-up section for information on three phase scroll compressor start-ups.

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:

paTegnaR

042 802

612-352 781-022

MIS-440

FACTOR Y JUMPER

IMPORTANT NOTE:

Only the thermostat and subbase combinations as shown at the right will work with this equipment. The thermostat and subbase must be matched and the correct operation can be assured only by proper selection and application of these parts.

Note 1: 1F93-380 thermostat must be set to "Heat Pump"

mode to operate properly. Press the program"RUN" button to make sure the

thermostat is in run program model. Press time "FWD" and "BACK" at the same time to

enter User Configuration Menu. Press and hold set "TIME" and "DAY" for about

3 seconds to enter Installer Menu. The thermostat will display "MULTI STG" Press the "UP" or "DOWN" button until the display

reads "HEAT PUMP" Press program "RUN" button to resume operation.

Manual 2100-399 Page 11

TABLE 3

THERMOSTAT WIRE SIZE

mumixaM

remrofsnarT

AVALFeguaGeriW

553.2

eguag02 eguag81 eguag61 eguag41 eguag21

ecnatsiD

teeFnI

54 06

001 061 052

THERMOSTAT WIRING

COMPRESSOR CUTOFF THERMOSTAT AND OUTDOOR THERMOSTATS

Heat pump compressor operation at outdoor temperatures below 0° F are neither desirable nor advantageous in terms of efficiency. Since most equipment at time of manufacture is not designated for any specific destination of the country and most of the equipment is installed in areas not approaching the lower outdoor temperature range, the compressor cutoffs are not factory installed.

Outdoor thermostats are available to hold off various banks of electric heat until needed as determined by outdoor temperature. The set point of either type of thermostat is variable with geographic region and sizing of the heating equipment to the structure Utilization of the Heating Application Data and the heat loss calculation of the building are useful in determining the correct set points.

HEAT ANTICIPATION

Both of the thermostats in Groups A and B below have a fixed heat anticipator for stage 1 with no adjustment required. Stage 2 has an adjustable anticipator for the W2 connection and fixed for the W3 connection. Both the W2 and W3 circuits are controlled by the stage 2 bulb. The only heat anticipator that needs to be checked is stage 2 and it should be set to match the load carried by the W2 circuit. The normal factory wiring provides for only on electric heat contactor to be controlled by W2, and the anticipator should be set at .40A. If special field wiring is done, it is best to actually measure the load but a good role is .40A for each heat contactor controlled by W2.

FIGURE 8

COMPRESSOR CUTOFF AND OUTDOOR THERMOSTAT WIRING

4 - 10KW 1PH --- 6 & 9KW 3-PH

15 - 20KW 1-PH & 3-PH

Manual 2100-399 Page 12

MIS-409

TABLE 4

WALL THERMOSTAT AND SUBBASE COMBINATIONS

tatsomrehTesabbuSserutaeFtnanimoderP

540-3048

)1671A148T(

710-3048

)9211R478T(

810-3048

)4201N478T(

---

900-4048

)1811L476Q(

010-4048

)1621F476Q(

revoegnahclaunaM

revoegnahclaunaMrootuA

blubyrucreM;taeh.gts2;looc.gts1

blubyrucreM;taeh.gts2;looc.gts2

240-3048

)0701G1158T(

940-3048

)083-39F1(

(1) No automatic changeover position -- must be manually placed in heat or cool.

Reversing valve remains energized at all times system switch is in heat position (except during defrost cycle). No pressure equalization noise when thermostat is satisfied on either heating or cooling.

(2) Allows thermostat to control both heating and cooling operation when set in "Auto"

position. Reversing valve de-energizes at end of each "On" heating cycle.

---

taeh.gts2;looc.gts1

elbammargorP-noNcinortcelE

revoegnahclaunaMrootuA

taeh.gts2;looc.gts2

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IMPORTANT NOTE:

Both thermostat and subbase combinations shown above in Groups A and B incorporate the following features: Man-Auto fan switch, Off-Heat-Cool-Em. Heat switch, and two (2) indicator lamps – one for emergency heat and one for compressor malfunction.

THERMOSTAT INDICATOR LAMPS

The red lamp marked "Em. Ht." comes on and stays on whenever the system switch is placed in the emergency heat position. The green lamp marked "Check" will come on if there is any problem that prevents the compressor from running when it is supposed to be.

EMERGENCY HEAT POSITION

The operator of the equipment must manually place the system switch in this position. This is done when there is a know problem with the unit, or when the green "Check" lamp comes on indicating a problem.

COMPRESSOR MALFUNCTION LIGHT

Actuation of the green "Check" lamp is accomplished by a relay output from the heat pump control board which is factory installed. Any condition such as loss of charge, high head pressure, etc., that will prevent compressor for operating will cause green lamp to activate. This is a signal to the operator of the equipment to place system in emergency heat position.

Manual 2100-399 Page 13

START UP

IMPORTANT INSTALLER NOTE

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

CRANKCASE HEATERS

WA421 units are provided with compressor crankcase heat. WH602 and WH483 units are not provided with crankcase heat. These units utilize scroll compressors which do not require crankcase heat in this application.

The WH421 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 on these units.

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

The decal in Figure 9 is affixed to all WA421 units detailing start-up procedure. This is very important.

Please read carefully.

HIGH PRESSURE SWITCH

The WH483 and WH602 models are supplied with a remote reset high pressure switch. If tripped, this pressure switch may be reset by turning the thermostat off then back on again.

THREE PHASE SCROLL COMPRESSOR START UP INFORMATION

Scroll compressors, like several other types of compressors, will only compress in one rotational direction. Direction of rotation is not an issue with single phase compressors since they will always start and run in the proper direction.

However, three phase compressors will rotate in either direction depending upon phasing of the power. Since there is a 50-50 chance of connecting power in such a way as to cause rotation in the reverse direction, verification of proper rotation must be made. All three phase units incorporate a phase monitor to ensure proper field wiring. See the Phase Monitor" on page 15 of this manual.

Verification of proper rotation must be made any time a compressor is change or rewired. If improper rotation is corrected at this time there will be no negative impact on the durability of the compressor. However, reverse operation for over one hour may have a negative impact on the bearing due to oil pump out.

FIGURE 9

START UP LABEL

IMPORTANT

THESE PROCEDURES MUST BE FOLLOWED A T INITIAL ST ART 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 CERT AIN THE ROOM THERMOST A T IS IN THE “OFF“ POSITION. (THE COMPRESSOR IS NOT TO OPERA TE.)

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

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

4. AFTER PROPER ELAPSED TIME THE THERMOSTA T MA Y BE SET TO OPERATE THE COMPRESSOR.

5. EXCEPT AS REQUIRED FOR SAFETY WHILE SERVICING, DO NOT OPEN SYSTEM DISCONNECT SWITCH.

7961-411

NOTE:If compressor is allowed to run in reverse

rotation for several minutes, the compressor's internal protector will trip.

All three phase ZR3 compressors are wired identical internally. As a result, once the correct phasing is determined for a specific system or installation, connecting properly phased power leads to the same Fusite terminal should maintain proper rotation direction.

Verification of proper rotation direction is made by observing that suction pressure drops and discharge pressure rises when the compressor is energized. Reverse rotation also results in an elevated sound level over that with correct rotations, as well as, substantially reduced current draw compared to tabulated values.

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

Manual 2100-399 Page 14

PHASE MONITOR

All units with three phase compressors are equipped with a 3 phase line monitor to prevent compressor damage due to phase reversal.

The phase monitor in this unit is equipped with two LEDs. If the Y signal is present at the phase monitor and phases are correct, the green LED will light. If phases are reversed, the red fault LED will be lit and compressor operation is inhibited.

now in operation. The second option has no "Auto" changeover position, but instead energizes the reversing valve solenoid constantly whenever the system switch on subbase is placed in "Heat" position, the "B" terminal being constantly energized from R. A Thermostat demand for heat completes r-Y circuit, pulling in compressor contactor starting compressor and outdoor motor. R-G also make starting indoor blower motor.

If a fault condition occurs, reverse two of the supply leads to the unit. Do not reverse any of the unit factory wires as damage may occur.

SERVICE HINTS

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

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

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

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

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

SEQUENCE OF OPERATION

COOLING –

compressor contactor, starting the compressor and outdoor motor. The G (indoor motor) circuit is automatically completed on any call for cooling operation or can be energized by manual fan switch on subbase for constant air circulation.

HEATING –

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

Circuit R-Y makes at thermostat pulling in

A 24V solenoid coil on reversing valve

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 later in the manual covering all models on both cooling and heating cycles. It is imperative to match the correct pressure curve to the unit by model number.

DEFROST CYCLE

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

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

After 60 (90 or 30) minutes at 30° F or below, the heat pump control will place the system in the defrost mode.

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

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

There is a cycle SPEEDUP 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.

Manual 2100-399 Page 15

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 10-minute maximum defrost length sequence in a matter of seconds and will automatically terminate the defrost sequence.

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

The jumper connection (SEN JMP) on the heat Pump Control (HPC) that can be used during the heating cycle to simulate a 0 degree coil condition and initiate the defrost sequence. By placing a jumper across the SEN JMP terminals (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.

There are three time settings on the HPC — 30, 60 or on minutes. These are elapsed run-time values, and the outdoor coil temperature sensor must be below the 30 degree equivalent resistance value for the timer to accumulate time towards the actual defrost cycle event. Using the SEN JMP terminals will force the timer to run continuously.

The next event is the actual defrost cycle when the reversing valve shifts the refrigerant system back to the cooling mode, and the outdoor fan motor is turned off to speed the heating of the outdoor coil and melting of any accumulated frost. The SPEEDUP terminals can be used to reduce the 30,60 or 90 minute real-time periods to a matter of seconds. Electric heat is typically turned on to temper the supply air temperature being delivered into the building during the defrost cycle.

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 speedup this timing period, and shorting out the SPEEDUP terminals for a few seconds can do this.

FIGURE 10

DEFROST CONTROL BOARD

Manual 2100-399 Page 16

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.

TROUBLESHOOTING

motpmySsesuaCelbissoPkcehCottahWriapeRrokcehCotwoH

rosserpmoC

tonseodrotcatnoc

rognitaeh(ezigrene

)gnilooc

noitcetorp

evitcefed

tcerroc

rotomroodtuonaF

nurtonseod

gnitaehrognilooc(

gnirudtpecxe

)tsorfed

evlavgnisreveR

ezigrenetonseod

)ylnognitaeh(

otniogtonlliwtinU

tsorfed

)ylnognitaeh(

emoctonlliwtinU tsorfedfotuo )ylnognitaeh(

evitcefed

gniriwtiucriclortnoCtinutaoitcennocRrofkcehC

tuokcolrosserpmoC.1

elcyctrohsrosserpmoC

lortnocpmuptaeH

evitcefedrotcatnoCliocdetrohsroneporofkcehC

tongnisahprewoP

evitcefedrotoMdetrohsroneporofkcehC

roticapacrotoM

lortnocpmuptaeH

dionelosevlavgnisreveR

evitcefedlioc

lortnocpmuptaeH

rorosneserutarepmeT

lortnocpmuptaeh

rorosneserutarepmeT

lortnocpmuptaeh

TABLE 5

lortnoc

.hctiws

.gnidniw

.gnidniwrotom

.C-Bdna

.etunimeno

4. Set system 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-Rneewtebtlov42dna

neewtebV42rofkcehC

pmuptaehnoC-1L

elbissoprehtollakcehC

560-0012launaM.sesuac

noyalernafssorcakcehC

eruserphgihssorcakcehC

C-CCneewtebV42rofkcehC

.lortnocpmuptaehnoC-Ydna

esahpnoDELderrofkcehC

.)ylnostinuesahp3(rotinom

kcehC.gntarroticapackcehC

.roticapacdetrohsroneporof

.)CN-moC(lortnocpmuptaeh

.liocdetrohsroneporofkcehC

C-VRneewtebV42rofkcehC

.1 .2

erutarepmettcennocsiD

sihT.slanimretpmujnes

ogottinuehtesuracdluohs

pudeepsssorcarepmuJ

.etunimenonihtiw

repmujdnadraobmorfrosnes

dnaslanimretpudeepsssorca

nihtiwelcyctsorfedahguorht

esuacdluohssihT.slanimret

tsorfedfotuoemocottinueht

.lortnocpmup

erusserphgihteserotniaganodnaffo

.hctiws

.hctiwserusserphgihecalper,teser

evomeR.C-CCneewtebraeppadluohs

.sdnoces01retfarepmujpudeeps

.lortnocpmuptaehecalpeR

.rotcatnocecalpeR

.tinuehtotsdelrewopowthctiwS

.rotomecalpeR

.roticapacecalpeR

.lortnocpmuptaehecalpeR

.lioCdionelosecalpeR

.gniriwtiucriclortnockcehC .lortnocpmuptaehecalpeR

.rosneserutarepmet

.lortnocpmuptaehecalper

.rosneserutarepmet

tsorfedfotuoemoctonseodtinufI

.lortnocpmuptaehecalper,elcyc

taehrewopottinuroodtuootnoitcennocRnuR

tatsomrehtnrut,C-1LneewtebegatlovonfI

tonlliwdnaneposihctiwserusserphgihfI

deepsrepmuj,C-CCneewtebegatlovtonfI

rewopsdnoces01nihtiwdna,lanimretpu

ecalper,elcyctsorfedhguorhtseogtinufI

,elcyctsorfedhguorhtogtonseodtinufI

ecalperelcyctsorfedfotuosemoctinufI

Manual 2100-399 Page 17

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 2100-399 Page 18

FAN BLADE SETTING DIMENSIONS

ledoM

detaR

MFC

detaR

PSE

dednemmoceR

egnaRwolFriA

124HW004103.0511--0061

384HW055102.5821--0571

206HW007103.5731--0591

Shown in the drawing in Figure 11 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 11

FAN BLADE SETTING

TABLE 6

FAN BLADE DIMENSIONS

ledoMAnoisnemiD

124HW 384HW 206HW

57.1

MIS-1190

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 – (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 the Table 7.

TABLE 7

SUCTION LINE TEMPERATURES

detaR

ledoM

124HW 384HW 206HW

wolfriA

0041 0551 0071

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

TABLE 8

RECOMMENDED OPERATING RANGES

* Rated CFM and ESP on high speed tap.

.D.OF°59

erutarepmeT

45--25 55--35 45--25

.D.OF°28

46--26 46--26 36--16

erutarepmeT

.P.S.E

HnI

TABLE 9

INDOOR BLOWER PERFORMANCE

CFM @ 230V

384HW,124HW206HW

V032woLV032hgiHV032woLV032hgiH

lioCyrDlioCteWlioCyrDlioCteWlioCyrDlioCteWlioCyrDlioCteW

0561 0551 0541 0531

0031

-----

0061 0051 0041 0031

5711

-----

5881 0771 5361 0051

0731 0521

0081 5661 0451 0041

5821

0511

0061 5251

0541 5731

0022 0012 0002 5781

5771 0561

Manual 2100-399 Page 19

0002 0091 0081 0071

0061 5741

TABLE 10

MAXIMUM ESP OF OPERATION

ELECTRIC HEAT ONLY

ledoM

WKdeepS

00A40A50A01A51A02A-

00B90B51B81B-

00C90C51C-

Values shown are for unites equipped with STD 1 inch throwaway filter on 1 inch washable filter. Derate ESP by .15 for 2 inch pleated filters.

05.

-----

05.

-----

05.

-----

05.

124HW384HW206HW

deepShgiHdeepSwoLdeepShgiHdeepSwoLdeepShgiHdeepSwoL

05.

-----

05.

54.

-----

05.

54.

-----

05.

04.

05.

54.

05.

54.

05.

04.

05.

-----

05.

04.

-----

52.

04.

03.

04.

53.

COOLING PRESSURE – (ALL TEMPERATURES °F)

riAnruteR

ledoM

124HW

384HW

206HW

Low side pressure ± 2 psig High side pressure ± 5 psig

erutarepmeTerusserP5708580959001501011511

BD.ged57

BW.ged26

BD.ged08

BW.ged76

BD.ged58

BW.ged27

BD.ged57

BW.ged26

BD.ged08

BW.ged76

BD.ged58

BW.ged27

BD.ged57

BW.ged26

BD.ged08

BW.ged76

BD.ged58

BW.ged27

TABLE 11

ediSwoL

ediShgiH

ediSwoL

ediShgiH

ediSwoL

ediShgiH

ediSwoL

ediShgiH

ediSwoL

ediShgiH

ediSwoL

ediShgiH

ediSwoL

ediShgiH

ediSwoL

ediShgiH

ediSwoL

ediShgiH

502

022

532

012

622

712

332

052

512

922

542

022

532

08 822

07 522

57 312

042

342

062

332

642

932

252

842

152

662

282

792

313

923

142

752

372

982

503

123

733

662

382

003

613

333

943

162

872

592

313

233

153

152

862

582

303

123

043

063

772

592

413

233

253

373

262

282

603

333

962

982

313

143

373

162

872

992

423

353

683

463

993

78 904

59 014

Tables are based upon rated CFM (airflow) across the evaporator coil. If there is any doubt as to correct operating charge being in the system, the charge should be removed, system evacuated and recharged to serial plate instruction.

Manual 2100-399 Page 20

TABLE 12

HEATING PRESSURES – (ALL TEMPERATURES °F)

riAnruteR

ledoM

124HW.ged07

384HW.ged07

206HW.ged07

Low side pressure ± 2 psig High side pressure ± 5 psig

erutarepmeTerusserP050151025203530454055506

ediSwoL

ediShgiH

141

741

251

851

361

961

471

081

091

102

ediSwoL

ediShgiH

171

371

671

871

081

481

091

791

502

412

ediSwoL

ediShgiH

871

281

581

981

291

491

691

502

812

632

TABLE 13

OPTIONAL ACCESSORIES

412

922

642

522

732

052

752

382

313

Model Description

50A-24HWHE 01A-24HWHE 51A-24HWHE

60C-24HWHE

40A-40HWHE 50A-40HWHE 01A-40HWHE 51A-40HWHE

02A-40HWHE 90B-40HWHE 51B-40HWHE

81B-40HWHE

90C-40HWHE 51C-40HWHE

5-POB

5-DAFB

5-DAFM

5-VRC

4-MFIE

B5A-VREW

B5C-VREW

3-HMC 7-HMC 9-HMC

41-HMC 51-HMC

B50-BCMW B60-BCMW

10-DPMW

B70-BCMW A90-BCMW B80-BCMW

CPL+CAL

WH421-A

WH421-B

WH421-C

WH483-A

WH483-B

WH483-C

WH602-A

WH602-B

WH602-C

segakcaPretaeH segakcaPretaeH segakcaPretaeH segakcaPretaeH

segakcaPretaeH segakcaPretaeH segakcaPretaeH

etalPffOknalB

repmaDriAhserFcirtemoraB

repmaDriAhserFdezirotoM

tsuahxEhtiwrotalitneVmoorssalC

tsuahxEhtiwrezimonocE

rotalitneVyrevoceRygrenE rotalitneVyrevoceRygrenE

)CPL(lortnoCerusserPwoL

)CAL(lortnoCtneibmAwoL

)TDO(tatsomrehTroodtuO

)KS(tiKtratSX

rekaerBtiucriC rekaerBtiucriC rekaerBtiucriC rekaerBtiucriC rekaerBtiucriC rekaerBtiucriCX

X X X

X X

X X X XXX

X X X X

X X

X X X

X X

XXX

X X

X X X

X X

X X X

X X

Manual 2100-399 Page 21

Bard WH602, WH483, WH421 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual