INSTALLATION INSTRUCTIONS WALL MOUNTED PACKAGE HEAT PUMPS MODELS WH W24H WH W3H W42H W4H W0H Bard Manufacturing Company, Inc. Bryan, Ohio 43 Since 94...Moving ahead just as planned. Manual : 20-5B Supersedes: 20-5A File: Volume III Tab 7 Date: -5-09 Copyright 200 Manual 20-5B Page of 27
Contents Getting Other Information and Publications 3 Wall Mount General Information Wall Mount Model Nomenclature... 4 Shipping Damage... 4 General... 4 Duct Work... 5 Filters... 5 Fresh Air Intake... 5 Condensate Drain... 5 Installation Instructions Wall Mounting Information... Mounting the Unit... Clearances Required... Minimum Clearances... Wiring Main Power... 4 Wiring Low Voltage Wiring... 4 Start Up General... 5 Topping Off System Charge... 5 Safety Practices... 5 Important Installer Note... Wall Mounted Air Conditioner... Three Phase Scroll Compressor... Phase Monitor... Condenser Fan Operation... Service Hints... Sequence of Operation... 7 Pressure Service Ports... 7 Defrost Cycle... 7 Troubleshooting Solid State Heat Pump Control... 9 Checking Temperature Sensor... 20 Fan Blade Setting Dimensions... 2 Removal of Fan Shroud... 2 Refrigerant Charge... 2 Figures Figure Fresh Air Damper Assembly... 5 Figure 2 Unit Dimensions... 7 Figure 3A Mounting Instructions... Figure 3B Mounting Instructions - W, W24, W, W3... 9 Figure 3C Mounting Instructions - W42, W4, W0... Figure 4 Electric Heat Clearance... Figure 5 Wall Mounting Instructions... 2 Figure Wall Mounting Instructions... 2 Figure 7 Common Wall Mounting Installations... 3 Figure Defrost Control Board... Figure 9 Fan Blade Setting... 2 Tables Table Troubleshooting... 9 Table 2 Fan Blade Dimension... 2 Table 3 Refrigerant Charge... 2 Table 4A Cooling Pressure... 22 Table 4B Heating Pressure... 22 Table 5 Electrical Specifications W**H... 23 Table Recommended Airflow... 24 Table 7 Indoor Blower Performance... 24 Tables Maximum ESP Electric Heat Only... 25 Table 9 Electric Heat... 25 Table Optional Accessories... 2 Table Vent & Control Options... 27 Manual 20-5B Page 2 of 27
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 FOR MORE INFORMATION, CONTACT THESE PUBLISHERS: ACCA Air Conditioning Contractors of America 72 New Hampshire Ave. N.W. Washington, DC 20009 Telephone: (202) 43-9370 Fax: (202) 234-472 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 ANSI American National Standards Institute West Street, 3th Floor New York, NY 03 Telephone: (22) 42-4900 Fax: (22) 2-2 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 ASHRAE American Society of Heating, Refrigeration and Air Conditioning Engineers, Inc. 79 Tullie Circle, N.E. Atlanta, GA 329-25 Telephone: (404) 3-400 Fax: (404) 32-547 NFPA National Fire Protection Association Batterymarch Park P.O. Box 9 Quincy, MA 0229-990 Telephone: (00) 344-3555 Fax: (7) 94-7057 Manufactured under the following U.S. Patent numbers: 5,45,7; 5,,777; 5,002, Manual 20-5B Page 3 of 27
WALL MOUNT GENERAL INFORMATION HEAT PUMP WALL MOUNT MODEL NOMENCLATURE W 42 H A A MODEL NUMBER CAPACITY - ½ Ton 24-2 Ton - 2½ Ton 3-3 Ton 42-3½ Ton 4-4 Ton 0-5 Ton H - Heat Pump REVISIONS VOLTS & PHASE A - 2/20/0/ B - 2/20/0/3 C - 40/0/3 KW VENTILATION OPTIONS - Barometric Fresh Air Damper (Standard) B - Blank-off Plate M - Motorized Fresh Air Damper V - Commercial Ventilator - Motorized with Exhaust E - Economizer (Internal) - Fully Modulating with Exhaust R - Energy Recovery Ventilator - Motorized with Exhaust (See Spec. Sheet S339) COLOR OPTIONS - Beige (Standard) - White 2 - Mesa Tan 4 - Buckeye Gray 5 - Desert Brown - Dark Bronze FILTER OPTIONS - One Inch Throwaway (Standard) W - One Inch Washable P - Two Inch Pleated CONTROL MODULES (See Spec. Sheet S3397) COIL OPTIONS - Standard - Phenolic Coated Evaporator 2 - Phenolic Coated Condenser 3 - Phenolic Coated Evaporator and Condenser OUTLET OPTIONS - Front (Standard) T - Top Outlet (WH, W3H Only) NOTE: Vent options, B and M are without exhaust capability. May require separate field supplied barometric relief in building. SHIPPING DAMAGE Upon receipt of equipment, the carton should be checked for external signs of shipping damage. If damage is found, the receiving party must contact the last carrier immediately, preferably in writing, requesting inspection by the carrier s agent. GENERAL The equipment covered in this manual is to be installed by trained, experienced service and installation technicians. The refrigerant system is completely assembled and charged. All internal wiring is complete. The unit is designed for use with or without duct work. Flanges are provided for attaching the supply and return ducts. These instructions explain the recommended method to install the air cooled self-contained unit and the electrical wiring connections to the unit. These instructions and any instructions packaged with any separate equipment required to make up the entire air conditioning system should be carefully read before beginning the installation. Note particularly Starting Procedure and any tags and/or labels attached to the equipment. While these instructions are intended as 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/gain 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. Manual 20-5B Page 4 of 27
DUCT WORK 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. Refer to Maximum ESP of operation Electric Heat Tables. 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. Models W & W24 are approved for zero inch clearance to the supply duct. For model series W, W3, W42, W4 and W0 a /4 inch clearance to combustible material for the first three feet of duct attached to the outlet air frame is required. See Wall Mounting Instructions and Figures 3 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. 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/ inch. Any grille that meets with 5/ inch louver criteria may be used. It is recommended that Bard Return Air Grille Kit RG2 through RG5 or RFG2 through RFG5 be installed when no return duct is used. Contact distributor or factory for ordering information. If using a return air filter grille, filters must be of sufficient size to allow a maximum velocity of 400 fpm. NOTE: If no return air duct is used, applicable installation codes may limit this cabinet to installation only in a single story structure. FIGURE FRESH AIR DAMPER FILTERS A -inch throwaway filter is standard with each unit. The filter slides into position making it easy to service. This filter can be serviced from the outside by removing the filter access panel. A -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 two (2) tabs down on each side of the filter support bracket. FRESH AIR INTAKE All units are built with fresh air inlet slots punched in the service door. 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. All capacity, efficiency and cost of operation information 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. CONDENSATE DRAIN A plastic drain hose extends from the drain pan at the top of the unit down to the unit base. There are openings in the unit base for the drain hose to pass through. In the event the drain hose is connected to a drain system of some type, it must be an open or vented type system to assure proper drainage. Manual 20-5B Page 5 of 27
INSTALLATION INSTRUCTIONS WALL MOUNTING INFORMATION. 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. 3. Concrete block walls must be thoroughly inspected to insure that they are capable of carrying the weight of the installed unit. MOUNTING THE UNIT. These units are secured by wall mounting brackets which secure the unit to the outside wall surface at both sides. A bottom mounting bracket, attached to skid for shipping, 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 /4 inch clearance to combustible material for model series W, W3, W42, W4 and W0. However, it is generally recommended that a -inch clearance is used for ease of installation and maintaining the required clearance to combustible material. See Figure 3 for details on opening sizes. 3. Locate and mark lag bolt locations and bottom mounting bracket location. See Figure 3. 4. Mount bottom mounting bracket. 5. Hook top rain flashing, attached to front - right of supply flange for shipping, under back bend of top. WARNING Failure to provide the /4 inch clearance between the supply duct and a combustible surface for the first 3 feet of duct can result in fire causing damage, injury or death.. Position unit in opening and secure with 5/ lag bolts; use 7/ inch diameter flat washers on the lag bolts. 7. Secure rain flashing to wall and caulk across entire length of top. See Figure 3.. 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 control panel and heat strips, and to allow proper airflow to the outdoor coil. Additional clearance may be required to meet local or national codes. Clearances Required for Service Access and Adequate Condenser Airflow MODELS LEFT SIDE RIGHT SIDE W H, W24H, WH, W3H 5" 20" W 42H, W4H, W0H 20" 20" Minimum Clearances Required to Combustible Materials MODELS SUPPLY AIR DUCT FIRST THREE FEET CABINET W H / W24H 0 " 0" W H / W3H /4" 0" W 42H / W4H / W0H /4" 0" Manual 20-5B Page of 27
FIGURE 2 Dimensions of Basic Unit for Architectural and Installation Requirements (Nominal) WIDTH MODEL (W) WH W24H 3.0 WH W3H.200 W42H W4H 2.075 W0H 2.075 DEPTH HEIGHT (D) (H) SUPPLY RETURN A B C B E F G I J K L M N O P Q R S T 3 7.25 70.53 7. 9.. 9. 35.00 25.75 20.5 2.75 2.0 29.25 27.00 2.3 34.3 22.0.55 5.00 2.00 5.00 3 7.25 70.53 7. 27. 3. 27. 40.00 25.75 7.93 2.75 2.75 29.25 27.00 2.3 39.3 22.75 9.4 5.00 2.00 5.00 4 22.432 4.75 9. 29. 5. 29. 43. 9. 3..00 32. 2.94 34.9 32.43 3.37 43.00 23..00.44.00. 4 22.432 94.75 9. 29. 5. 29. 43. 9. 4..00 42. 3.94 44.9 42.43 3.37 43.00 33..00.44.00. All dimensions are in inches. Dimensional drawings are not to scale. W**H RIGHT UNIT FRONT VIEW SIDE VIEW BACK VIEW *Optional top outlet (factory installed only) for WH and W3H models only. Manual 20-5B Page 7 of 27
FIGURE 3A WH, W24H MOUNTING INSTRUCTIONS Manual 20-5B Page of 27
FIGURE 3B WH, W3H MOUNTING INSTRUCTIONS Manual 20-5B Page 9 of 27
FIGURE 3C W42H, W4H, W0H MOUNTING INSTRUCTIONS Manual 20-5B Page of 27
FIGURE 4 ELECTRIC HEAT CLEARANCE WH, W3H, W42H, W4H, W0H SIDE SECTION VIEW OF SUPPLY AIR DUCT FOR WALL MOUNTED UNIT SHOWING /4 INCH CLEARANCE TO COMBUSTIBLE SURFACES. WARNING A minimum of /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 /4 inch minimum spacing is maintained at all points. Failure to do this could result in overheating the combustible material and may result in a fire causing damage, injury or death. Manual 20-5B Page of 27
FIGURE 5 WALL MOUNTING INSTRUCTIONS SEE FIGURE 3 MOUNTING INSTRUCTIONS FIGURE WALL MOUNTING INSTRUCTIONS SEE UNIT DIMENSIONS, FIGURE 2, FOR ACTUAL DIMENSIONS IF REQUIRED IF REQUIRED Manual 20-5B Page 2 of 27
FIGURE 7 COMMON WALL MOUNTING INSTALLATIONS Manual 20-5B Page 3 of 27
WIRING MAIN POWER Refer to the unit rating plate for wire sizing information and maximum fuse or HACR type circuit breaker size. Each outdoor unit is marked with a Minimum Circuit Ampacity. This means that the field wiring used must be sized to carry that amount of current. Depending on the installed KW of electric heat, there may be two field power circuits required. If this is the case, the unit serial plate will so indicate. All models are suitable only for connection with copper wire. Each unit and/or wiring diagram will be marked Use Copper Conductors Only. These instructions must be adhered to. Refer to the National Electrical Code (NEC) for complete current carrying capacity data on the various insulation grades of wiring material. All wiring must conform to NEC and all local codes. The electrical data lists fuse and wire sizes (75 C copper) for all models including the most commonly used heater sizes. Also shown are the number of field power circuits required for the various models with heaters. The unit rating plate lists a Maximum Time Delay Relay Fuse or HACR type circuit breaker that is to be used with the equipment. The correct size must be used for proper circuit protection and also to assure that there will be no nuisance tripping due to the momentary high starting current of the compressor motor. The disconnect access door on this unit may be locked to prevent unauthorized access to the disconnect. To convert for the locking capability, bend the tab located in the bottom left-hand corner of the disconnect opening under the disconnect access panel straight out. This tab will now line up with the slot in the door. When shut, a padlock may be placed through the hole in the tab preventing entry. See Start Up section for important information on three phase scroll compressor start ups. See Table 5 for Electrical Specifications. WIRING LOW VOLTAGE WIRING 2/20V, phase and 3 phase equipment dual primary voltage transformers. All equipment leaves the factory wired on 240V tap. For 20V operation, reconnect from 240V to 20V tap. The acceptable operating voltage range for the 240 and 20V taps are: NOTE: TAP RANGE 240 253 2 20 220 7 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). For wiring size and connections, refer to Wiring Manual 20-5. Manual 20-5B Page 4 of 27
START UP THESE UNITS REQUIRE R-4A REFRIGERANT AND POLYOL ESTER OIL. GENERAL:. Use separate service equipment to avoid cross contamination of oil and refrigerants. 2. Use recovery equipment rated for R-4A refrigerant. 3. Use manifold gauges rated for R-4A (00 psi/2 psi low). 4. R-4A is a binary blend of HFC-32 and HFC-25. 5. R-4A is nearly azeotropic - similar to R-22 and R-2. Although nearly azeotropic, charge with liquid refrigerant.. R-4A operates at 40-70% higher pressure than R-22, and systems designed for R-22 cannot withstand this higher pressure. 7. R-4A has an ozone depletion potential of zero, but must be reclaimed due to its global warming potential.. R-4A compressors use Polyol Ester oil. 9. Polyol Ester oil is hygroscopic; it will rapidly absorb moisture and strongly hold this moisture in the oil.. A liquid line dryer must be used - even a deep vacuum will not separate moisture from the oil.. Limit atmospheric exposure to 5 minutes. 2. If compressor removal is necessary, always plug compressor immediately after removal. Purge with small amount of nitrogen when inserting plugs. TOPPING OFF SYSTEM CHARGE If a leak has occurred in the system, Bard Manufacturing recommends reclaiming, evacuating (see criteria above), and charging to the nameplate charge. If done correctly, topping off the system charge can be done without problems. With R-4A, there are no significant changes in the refrigerant composition during multiple leaks and recharges. R-4A refrigerant is close to being an azeotropic blend (it behaves like a pure compound or single component refrigerant). The remaining refrigerant charge, in the system, may be used after leaks have occurred and then top-off the charge by utilizing the charging charts on the inner control panel cover as a guideline. REMEMBER: When adding R-4A refrigerant, it must come out of the charging cylinder/tank as a liquid to avoid any fractionation, and to insure optimal system performance. Refer to instructions for the cylinder that is being utilized for proper method of liquid extraction. WARNING Failure to conform to these practices could lead to damage, injury or death. SAFETY PRACTICES:. Never mix R-4A with other refrigerants. 2. Use gloves and safety glasses, Polyol Ester oils can be irritating to the skin, and liquid refrigerant will freeze the skin. 3. Never use air and R-4A to leak check; the mixture may become flammable. 4. Do not inhale R-4A the vapor attacks the nervous system, creating dizziness, loss of coordination and slurred speech. Cardiac irregularities, unconsciousness and ultimate death can result from breathing this concentration. 5. Do not burn R-4A. This decomposition produces hazardous vapors. Evacuate the area if exposed.. Use only cylinders rated DOT4BA/4BW 400. 7. Never fill cylinders over 0% of total capacity.. Store cylinders in a cool area, out of direct sunlight. 9. Never heat cylinders above 25 F.. Never trap liquid R-4A in manifold sets, gauge lines or cylinders. R-4A expands significantly at warmer temperatures. Once a cylinder or line is full of liquid, any further rise in temperature will cause it to burst. Manual 20-5B Page 5 of 27
START UP (Continued) IMPORTANT INSTALLER NOTE For improved start up performance wash the indoor coil with a dish washing detergent. HIGH & LOW PRESSURE SWITCH All W**H wall mounted air conditioner series models are supplied with a remote reset for the high and low 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 - chance of connecting power in such a way as to cause rotation in the reverse direction, verification of proper rotation must be made. 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 rotation, as well as substantially reduced current draw compared to tabulated values. Verification of proper rotation must be made at the time the equipment is put into service. 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. NOTE: If compressor is allowed to run in reverse rotation for several minutes, the compressor s internal protector will trip. All three phase ZP compressors are wired identically 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. The direction of rotation of the compressor may be changed by reversing any two line connections to the unit. PHASE MONITOR All units with three phase scroll 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. 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. CONDENSER FAN OPERATION Applies to W42, W4 and W0 models only. The condenser fan motor on 2/20 volt, one and three phase, 0 HZ units is a two-speed motor that comes factory wired on high speed for peak performance. If ambient conditions permit, it can be reconnected to low speed (red wire) for lower sound level. See wiring diagram. HZ models must have fan wired on low speed. These models are factory wired on low speed. SERVICE HINTS. 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. Check all power fuses or circuit breakers to be sure they are the correct rating. 3. Periodic cleaning of the outdoor coil to permit full and unrestricted airflow circulation is essential. Manual 20-5B Page of 27
SEQUENCE OF OPERATION COOLING Circuit R-Y makes at thermostat pulling in compressor contactor, starting the compressor and outdoor motor. The G (indoor motor) circuit is automatically completed on any call for cooling operation or can be energized by manual fan switch on subbase for constant air circulation. HEATING A 24V solenoid coil on reversing valve controls heating cycle operation. Two thermostat options, one allowing Auto changeover from cycle to cycle and the other constantly energizing solenoid coil during heating season, and thus eliminating pressure equalization noise except during defrost, are to be used. On Auto option a circuit is completed from R-W and R-Y on each heating on cycle, energizing reversing valve solenoid and pulling in compressor contactor starting compressor and outdoor motor. R-G also make starting indoor blower motor. Heat pump heating cycle now in operation. The second option has no Auto changeover position, but instead energizes the reversing valve solenoid constantly whenever the system switch on subbase is placed in Heat position, the B terminal being constantly energized from R. A Thermostat demand for heat completes R-Y circuit, pulling in compressor contactor starting compressor and outdoor motor. R-G also make starting indoor blower motor. PRESSURE SERVICE PORTS 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. It is imperative to match the correct pressure table to the unit by model number. See Tables 4A & 4B. DEFROST CYCLE The defrost cycle is controlled by temperature and time on the solid state heat pump control. See Figure. 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 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 0 minutes at 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 minutes. The heat pump defrost control board has an option of, 0 or 90-minute setting. All models are shipped from the factory on the 0-minute pin. If special circumstances require a change to another time, remove the wire from the 0-minute terminal and reconnect to the desired terminal. The manufacturer s recommendation is for 0-minute defrost cycles. Refer to Figure. 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 ¼ 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 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 -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 ¼ 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. The board s LED will have a fast blink rate when in the compressor time delay. 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. Low Pressure Switch Bypass Operation - The control has a selectable (SW) low pressure switch bypass set up to ignore the low pressure switch input during the first (, 0, 20 or 0 seconds) of Y operation. After this period expires, the control will then monitor the low pressure switch input normally to make sure that the switch is closed during Y operation. Manual 20-5B Page 7 of 27
FIGURE DEFROST CONTROL BOARD LOW PRESSURE BYPASS TIMER SWITCH (FACTORY SETTING 20 SECONDS) SW SW 2 TIME (SEC) OFF ON OFF ON OFF OFF ON ON 0 20* 0 COMPRESSOR ANTI-SHORT CYCLE TIMER (FACTORY SETTING 0 MIN.) MIS-2 Manual 20-5B Page of 27
TROUBLESHOOTING SOLID STATE HEAT PUMP CONTROL TROUBLESHOOTING PROCEDURE. NOTE: A thorough understanding of the defrost cycle sequence is essential. Review that section earlier in this manual prior to troubleshooting the control. Turn on AC power supply to unit. 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 to auto position. Indoor blower should stop. NOTE: Many models have a -minute blower time delay on off command; wait for this to time-out. 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. CODES FUNCTION Slow Blink Normal Operation Fast Blink Compressor Time Delay Blink Low Pressure Switch Failure 2 Blink Pressure Switch Failure 3 Blink Defrost Mode Active Symptom Compressor will not start (heating or cooling) Fan outdoor motor does not run (cooling or heating except during defrost) Reversing valve does not energize (heating only) Unit will not go into defrost (heating only) Unit will not come out of defrost (heating only) Description, Check & Possible Causes. Check for LED illumination. Is there an LED illuminated on the board (flashing)? 2. Check for error codes. Is the LED flashing a Code? 3. Check for power at board. Is there 24 volts AC between R and C? 4. Check codes. What code is blinking? 5. Compressor delay active. Wait for 5 minute delay or jump board's "speed up pins". TABLE TROUBLESHOOTING Yes = go to Step #2; No = go to Step #3 Yes = go to Step #4; No = go to Step # Yes = go to Step #3; No = go to Step #9 What & How to Check / Repair Code "", go to Step #; Code "2", go to Step#7; Fast Blink, go to Step #5 Check for proper operation; if still needed, go back to Step #.. Low pressure fault. Check wiring circuit and unit pressures. 7. pressure fault. Check wiring circuit and unit pressures.. Check for Compressor input signal. Is there 24 volts AC between Y and C? 9. No power to board.. Check for Compressor output signal. Is there 24 volts AC between CC & C? Yes = go to Step #; No = go to Step # The unit either does not have unit voltage, the transformer is bad or the unit wiring is incorrect. Yes = go to Step #2; No = go to Step #3. No "Y" compressor input signal. Check thermostat wiring, incorrect phase of unit (see section on Phase Monitor), and finally unit wiring. 2. No "CC" compressor output signal. 3. Faulty board. Replace defrost board. Check compressor contactor for proper operation and finally check compressor. H eat pump control defective Check across fan relay on heat pump control. (Com-NC) Replace heat pump control. M otor defective Check for open or shorted motor winding. Replace motor. M otor capacitor defective Check capacitor rating. Check for open or shorted capacitor. Replace capacitor. H eat pump control defective Check for 24V between RV-C and B-C.. Check control circuit wiring. 2. Replace heat pump control R eversing valve solenoid coil defective Check for open or shorted coil. Replace solenoid coil. Temperature sensor or heat pump control defective Disconnect temperature sensor from board and jumper across "SPEEDUP" terminals and "SEN JMP" terminals. This should cause the unit to go through a defrost cycle within one minute.. If unit goes through defrost cycle, replace temperature sensor. 2. If unit does not go through defrost cycle, replace heat pump control. T emperature sensor or heat pump control defective. Jumper across "SPEEDUP" terminal. This should cause the unit to come out of defrost within one minute.. If unit comes out of defrost cycle, replace temperature sensor. 2. If unit does not come out of defrost cycle, replace heat pump control. Manual 20-5B Page 9 of 27
CHECKING TEMPERATURE SENSOR OUTSIDE UNIT CIRCUIT. 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 ± %.) 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 -25.0-24.0-23.0-22.0-2.0-20.0-9.0 -.0-7.0 -.0-5.0-4.0-3.0-2.0 -.0 -.0-9.0 -.0-7.0 -.0-5.0-4.0-3.0-2.0 -.0 0.0.0 2.0 3.0 4.0 5.0.0 7.0.0 9.0.0.0 2.0 97 90099 355 773 729 547 59904 54529 49355 44374 3957 3495 229 2209 4272 575 70 3574 020 9704 939 90 39 537 299 02 7732 752 729 7070 7 4 4399 2449 055 5745 3.0 4.0 5.0.0 7.0.0 9.0 20.0 2.0 22.0 23.0 24.0 25.0 2.0 27.0 2.0 29.0.0 3.0 32.0 33.0 34.0 35.0 3.0 37.0 3.0 39.0 40.0 4.0 42.0 43.0 44.0 45.0 4.0 47.0 4.0 49.0.0 595 5524 5340 5205 54 4902 47590 4200 4455 43554 42295 477 399 3757 3752 353 3554 34545 33574 3234 3723 40 299 2957 2355 27577 223 2092 2533 249 240 2334 2275 22 25 2099 20435 99 53.0 52.0 53.0 54.0 55.0 5.0 57.0 5.0 59.0 0.0.0 2.0 3.0 4.0 5.0.0 7.0.0 9.0 70.0 7.0 72.0 73.0 74.0 75.0 7.0 77.0 7.0 79.0 0.0.0 2.0 3.0 4.0 5.0.0 7.0.0 9374 7 375 799 7434 94 547 22 57 53 492 4544 477 320 3474 337 2 2492 23 3 59 7 3 72 247 000 970 952 9299 9077 2 53 449 2 057 79 7 9.0 90.0 9.0 92.0 93.0 94.0 95.0 9.0 97.0 9.0 99.0 0.0.0 2.0 3.0 4.0 5.0.0 7.0.0 9.0.0.0 2.0 3.0 4.0 5.0.0 7.0.0 9.0 20.0 2.0 22.0 23.0 24.0 77 7334 75 7000 40 3 53 33 239 09 59 527 597 5570 544 532 520 94 492 473 477 43 452 444 437 4274 42 4093 400 392 33 3757 37 352 3452 Manual 20-5B Page 20 of 27
TROUBLESHOOTING FAN BLADE SETTING DIMENSIONS Shown in Figure 9 is the correct fan blade setting for proper air delivery across the outdoor coil. Refer to Table 2 for unit specific dimension. 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 9 FAN BLADE SETTING REFRIGERANT CHARGE The correct system R-4A charge is shown on the unit rating plate. Optimum unit performance will occur with a refrigerant charge resulting in a suction line temperature (" from compressor) as shown in Table 3. If charge quantity is in doubt, reclaim unit and recharge to factory nameplate quantity. Model TABLE 3 REFRIGERANT CHARGE Rated Airflow 95 F OD Temperature 2 F OD Temperature WH 00 57-2 - W24H 00 5-2 5-3 WH 00 5-2 2 - W3H 0 5-2 57 - W42H 400-5 5-9 W4H 5 0-4 3-7 W0H 0-4 5-9 TABLE 2 FAN BLADE DIMENSION Model WH W24H WH W3H W42H W4H W0H Dimension A.00".25".75" MIS-724 The suction line temperatures in Table 3 above are based upon 0 F dry bulb / 7 F wet bulb (% R.H.) temperature and rated airflow across the evaporator during cooling cycle. REMOVAL OF FAN SHROUD. Disconnect all power to the 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.. Service motor/fan as needed. 7. Reverse steps to reinstall. Manual 20-5B Page 2 of 27
Model WH W24H WH W3H W42H W4H W0H Return Air Temperature 75 deg. DB 2 deg. WB 0 deg. DB 7 deg. WB 5 deg. DB 72 deg. WB 75 deg. DB 2 deg. WB 0 deg. DB 7 deg. WB 5 deg. DB 72 deg. WB 75 deg. DB 2 deg. WB 0 deg. DB 7 deg. WB 5 deg. DB 72 deg. WB 75 deg. DB 2 deg. WB 0 deg. DB 7 deg. WB 5 deg. DB 72 deg. WB 75 deg. DB 2 deg. WB 0 deg. DB 7 deg. WB 5 deg. DB 72 deg. WB 75 deg. DB 2 deg. WB 0 deg. DB 7 deg. WB 5 deg. DB 72 deg. WB 75 deg. DB 2 deg. WB 0 deg. DB 7 deg. WB 5 deg. DB 72 deg. WB TABLE 4A COOLING PRESSURE TABLE Air Temperature Entering Outdoor F Pressure 75 0 5 90 95 0 5 5 20 32 292 4 299 4 9 24 329 33 337 3 349 25 32 34 334 39 34 22 329 3 337 3 349 27 354 3 33 4 37 29 352 3 3 43 374 2 332 35 34 40 353 34 3 43 39 4 3 2 35 35 40 373 2 3 37 359 42 372 24 35 33 3 373 372 39 32 44 395 32 374 4 34 4 397 2 352 37 3 42 374 37 332 4 340 5 352 2 373 37 33 42 39 3 373 40 33 45 39 2 375 35 35 40 39 32 392 4 402 4 4 34 39 43 40 4 422 3 373 40 33 45 39 Low side pressure ± 4 PSIG side pressure ± PSIG 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 charge weight. NOTE: Pressure table based on high speed condenser fan operation. If condensing pressures appear elevated check condenser fan wiring. See Condenser Fan Operation. 3 353 4 32 53 375 3 39 40 40 45 422 33 39 42 40 47 422 2 399 37 409 42 423 34 43 43 424 4 439 3 422 45 433 44 33 397 42 407 47 42 40 37 3 55 400 33 423 42 434 47 449 3 423 45 434 449 424 39 435 44 4 35 437 44 44 49 44 37 449 47 40 52 47 35 42 44 432 49 447 42 400 52 4 57 424 35 449 44 40 49 47 37 44 47 459 52 475 32 449 4 4 4 477 3 4 45 473 490 39 47 49 4 54 5 37 44 47 459 52 475 44 424 54 435 59 4 37 475 4 47 5 4 39 472 49 44 54 35 47 44 4 49 5 37 4 4 0 5 5 4 5 5 5 5 53 39 47 49 4 54 5 TABLE 4B HEATING PRESSURES (ALL TEMPERATURES F) 4 4 5 42 47 3 3 4 5 53 534 4 49 5 9 5 527 37 3 4 5 5 534 37 5 4 529 5 54 43 535 53 549 5 5 4 5 5 5 5 53 4 477 5 49 4 40 53 545 55 54 43 522 53 535 5 554 3 5 4 544 53 53 37 54 4 5 45 5 55 5 0 0 43 53 53 5 5 59 5 0 5 53 42 5 52 575 57 595 45 547 55 5 0 5 4 559 5 573 5 593 3 57 45 593 4 4 00 5 5 37 45 5 55 53 0 03 Return Air Model Temperature W H 70 deg. W 24H 70 deg. W H 70 deg. W 3H 70 deg. W 42H 70 deg. W 4H 70 deg. W 0H 70 deg. Pressure 0 5 5 20 25 35 40 45 55 0 4 290 57 292 53 254 47 2 299 42 2 39 294 52 25 55 29 53 2 49 22 0 45 270 43 29 5 22 55 55 27 5 23 52 3 49 274 47 0 22 57 7 5 290 55 27 54 54 27 52 5 25 59 34 59 292 5 34 59 24 5 3 72 290 4 323 32 4 0 2 322 4 29 3 39 79 297 70 332 72 322 70 33 70 29 70 32 7 7 77 342 0 332 77 39 75 342 77 7 7 33 95 39 354 342 5 33 4 355 4 37 4 349 4 334 9 37 97 35 93 345 93 370 92 327 92 32 4 352 3 3 4 3 0 339 0 37 24 372 2 395 9 39 3 379 5 404 9 352 9 39 35 394 35 4 32 377 24 39 2 423 3 40 Manual 20-5B Page 22 of 27
Electrical Specifications W**H Series Rated Model Volts and Phase WH- A00, A0Z A04 2/20-3 A0 W24H- A00, A0Z A04 2/20-3 A0 W24H- B00, B0Z 2/20-3 B0 W24H- C00, C0Z 40-3 C0 WH- A00, A0Z* A05* 2/20-3 A* WH- B00, B0Z* B0 2/20-3 3 B09* WH- C00, C0Z* C0 40-3 3 C09* C5 W3H- A00, A0Z* A05 2/20-3 A* 5 A5 W3H- B00, B0Z* B0 2/20-3 3 B09* 5 B5 W3H- C00, C0Z* C0 40-3 3 C09* C5 W42H- A00, A0Z A05 2/20-3 A 5 A5 W42H- B00, B0Z B0 2/20-3 3 B09 5 B5 W42H- C00, C0Z C0 40-3 3 C09 5 C5 W4H- A00, A0Z A04 A05 2/20-3 A 5 A5 5 A20 W4H- B00, B0Z B0 3 B09 2/20-3 5 B5 5 B W4H- C00, C0Z 3 C09 40-3 5 C5 W0H- A00, A0Z A05 3 A 2/20-5 A5 5 A20 W0H- B00, B0Z 3 B09 2/20-3 5 B5 5 B W0H- C00, C0Z 3 C09 40-3 5 C5 No. Field Power Circuits or 2 or 2 or 2 or 2 or 2 or 2 or 2 or 2 or 2 or 2 or 2 or 2 or 2 or 2 4 Minimum Circuit Ampacity 37 5 24 44 5 7 35 2 24 7 3 45 20 25 2 29 55 4 23 4 5 2 2 25 2 3 2 2 44 53 53 3 22 2 2 37 5 3 9 9 29 47 5 5 2 4 27 27 4 7 93 93 2 55 55 2 2 2 TABLE 5 Single Circuit Maximum 2 Field External Fuse Power or Ckt. Brkr. Wire Size 20 40 0 25 70 20 40 5 25 35 0 25 40 45 5 20 25 40 0 90 90 45 0 5 25 25 70 90 90 35 0 0 5 25 0 70 90 90 25 35 0 0 70 20 0 0 0 0 25 40 0 0 70 20 2 2 4 4 4 2 4 4 4 3 3 4 3 3 2 2 4 3 3 2 2 2 Ground Wire Maximum size of the time delay fuse or HACR type circuit breaker for protection of field wiring conductors. 2 Based on 75C copper wire. All wiring must conform to the National Electrical Code and all local codes. 3 These Minimum Circuit Ampacity values are to be used for sizing the field power conductors. Refer to the National Electrical code (latest version), Article 3 for power conductor sizing. Caution: When more than one field power circuit is run through one conduit, the conductors must be derated. Pay special attention to note of Table 3 regarding Ampacity Adjustment Factors when more than three (3) current carrying conductors are in a raceway. * Top outlet supply option is available only factory installed and only on the selected models. Dual Circuit 4 Minimum Maximum 2 Field Circuit External Fuse Power Ampacity or Ckt. Breaker Wire Size Ckt. A Ckt. B Ckt. A Ckt. B Ckt. A Ckt. B 2 Ground Wire Size IMPORTANT: While this electrical data is presented as a guide, it is important to electrically connect properly sized fuses and conductor wires in accordance with the National Electrical Code and all local codes. Manual 20-5B Page 23 of 27 Ckt. A Ckt. B 2 44 2 45 25 2 4 2 4 2 4 4 55 55 3 3 3 37 37 37 59 2 52 2 52 52 2 52 52 52 0 0 0 0 0 0 0 0 0 34 2 40 2 4 2 0 4 52 0 0 4 52 0 0 59 52 0 0 34 2 40 2
Model Rated CFM * TABLE RECOMMENDED AIRFLOW Rated ESP * Recommended Airflow Range Factory Speed Connection WH 00. 575-725 W24H 00. 20 700-9 WH 00. 40 9-0 W3H 0. 9-3 W42H 400. 00 - W4H 5. 20 7-25 W0H. 9-375 * Rated CFM and ESP on high speed tap. Rated CFM and ESP on low speed tap. TABLE 7 INDOOR BLOWER PERFORMANCE WH, W24H WH WH, W3H W42H, W4H W0H E.S.P. In H 2 O Speed Dry Wet Low Speed Dry Wet Speed Dry Wet Low Speed Dry Wet Speed Dry Wet Low Speed Dry Wet Speed Dry Wet Low Speed Dry Wet.0..2.3.4.5 20 90 5 20 735 5 975 905 00 735 535 7 735 7 0 05 540 700 75 00 5 490 395 340 25 205 05 35 270 90 0 00 70 9 9 9 55 00 935 95 5 755 5 770 35 0 370 2 00 5 540 400 25 5 4 3 0 00 0 400 0 75 2200 20 2000 75 775 2000 900 00 700 00 475 00 525 4 375 Manual 20-5B Page 24 of 27
TABLES MAIMUM ESP OF OPERATION ELECTRIC HEAT ONLY Front Outlet Top Outlet Model WH W24H W24H W24H A00 A04 A0 B00 B0 C00 C0 ESP Model WH W3H WH W3H WH W3H A00 A05 A A5 B00 B0 B09 B5 C00 C0 C09 C5 Low Speed.35.35.35.35.. Speed.45.45 Low Speed.25 NA NA. NA NA.35 NA Speed NA NA NA NA.45 NA Model Speed KW -A00 -A04 -A05 -A -A5 -A20 -B00 -B09 -B5 -B -C00 -C09 -C5 W42H W4H W0H Speed ----- ----- ----- Low Speed -----.45.45 -----.45.45 ----- Speed Low Speed.45.45.45.45.45.45 Speed ----- Low Speed -----.25.25.25.25....35.35 TABLE 9 ELECTRIC HEAT Models 240V- 20V- 240V-3 20V-3 40V-3 KW Amps BTUH Amps BTUH Amps BTUH Amps BTUH Amps BTUH 4. 7 3 4. 4 240 5 20. 705. 200 4. 4 200 2. 5 5 7. 2 200 33. 3 270 2. 20475 9 2. 7 00. 7 2. 700 4. 34 3. 2 20 2 4. 4 409 5 2. 5 52 54. 0 3400 3. 2 5200 3. 2 3400. 0 5200 43. 3 4 37. 5 40 20 3. 2 20 72. 5200 Manual 20-5B Page 25 of 27
TABLE OPTIONAL ACCESSORIES Part Number WH-A W24H-A W24H-B W24H-C WH-A WH-B WH-C W3H-A W3H-B W3H-C W42H-A W42H-B W42H-C W4H-A W4H-B W4H-C W0H-A W0H-B W0H-C EHWH02A-A04 EHWH02A-A0 EHW24H-A04 EHW24H-A0 EHW24H-B0 EHWH-A05 EHWH-A EHWH3-A05 EHWH3-A EHWH3-A5 EHWH03-B0 HEATER KITS EHW3H-B0 EHWH03-B09 EHWH-B5 EHWC03A-C0 EHWH42-A05 EHWH42-A EHWH42-A5 EHWH-04-A20 EHWH05-B0 EHWH05-B09 EHWH05-B5 EHWH42-C0 EHWH05A-C09 EHWH05A-C5 EHWH04-A5 EHWH04-A EHW05H-B CIRCUIT BREAKER (WMCB) & PULL DISCONNECT (WMPD) WMCB-02A WMCB-02B WMCB-03A WMCB-03B WMCB-0A WMCB-05B WMCB-07B WMCB-0A WMCB-09A WMPD-0C Manual 20-5B Page 2 of 27
TABLE VENT & CONTROL OPTIONS Part Number CMC-4 MC-5 K CMC-2 BFAD-2 BOP-2 MFAD-2 CRV-2 EIFM-2B ERVF-A2 BFAD-3 BOP-3 MFAD-3 CRVS-3 CRVP-3 EIFM-3C ERVF-A3 ERVF-C3 BFAD-5 BOP-5 MFAD-5 CRVS-5 CRVP-5 EIFM-5C ERVF-A5 ERVF-C5 W, W24 W, W3 W42, W4, W0 Description ODT Start Kit (2V -Phase only Start Kit (2V -Phase only 2 LAC Barometric Fresh Air Damper - Standard Blank Off Plate Motorized Fresh Air Damper Commercial Ventilator - Spring Return Economize r Energy Recovery Ventilator - 2 Volt Barometric Fresh Air Damper - Standard Blank Off Plate Motorized Fresh Air Damper Commercial Ventilator - Spring Return Commercial Ventilator - Power Return Economize r Energy Recovery Ventilator - 2 Volt Energy Recovery Ventilator - 40 Volt Barometric Fresh Air Damper - Standard Blank Off Plate Motorized Fresh Air Damper Commercial Ventilator - Spring Return Commercial Ventilator - Power Return Economize r Energy Recovery Ventilator - 2 Volt Energy Recovery Ventilator - 40 Volt C ) S ) PTCR Start Kit can be used with all -A single phase models. Increases starting torque 2-3x. Not used for -B or -C three phase models. Do not use if SK is used. 2 Start Capacitor and potential relay start kit can be used with all -A single phase models. Increases starting torque 9x. Not used for -B or -C three phase models. Do not use if CMC-5 is used. Manual 20-5B Page 27 of 27