MIS-656

Models: WH301, WH361

WALL MOUNTEDPACKAGED HEAT PUMPINSTALLATION

INSTRUCTIONS

Manual No.: 2100-193MSupersedes: 2100-193LFile: Volume III, Tab 17Date: 05-17-04

Bard Manufacturing CompanyBryan, Ohio 43506

Since 1914. . .Moving ahead just as planned.

© Copyright 2003

CONTENTS

i

Start UpImportant Installer Note ........................................ 18Crankcase Heaters .............................................. 18Service Hints ........................................................ 18Sequence of Operation ........................................ 18Pressure Service Ports ........................................ 19Defrost Cycle ....................................................... 19

TroubleshootingSolid State Heat Pump ControlTroubleshooting Procedures ................................ 20Checking Temperature Sensor OutsideUnit Circuit ........................................................... 21Temperature "A" VS. Resistance "R" ofTemperature Sensor ............................................ 22Fan Blade Setting Dimensions ............................ 22Removal of Fan Shroud ....................................... 22Refrigerant Charge .............................................. 22Pressure Tables ................................................... 23Optional Accessories ........................................... 24

Getting Other Information and PublicationsFor more information,contact these publishers ........................................ 1

Wall Mount General InformationHeat Pump Wall Mount Model Nomenclature ........ 2Shipping Damage .................................................. 2General ............................................................. 2Duct Work ............................................................. 2Filters ............................................................. 6Fresh Air Intake ...................................................... 6Condensate Drain .................................................. 6

Installation InstructionsWall Mounting Information ..................................... 7Mounting the Unit ................................................... 7Top Outlet Only ...................................................... 7Wiring � Main Power .......................................... 13Wiring � Low Voltage Wiring ............................... 13Low Voltage Connections .................................... 13Optional Outdoor Thermostat Applications .......... 15Heat Anticipation .................................................. 17Thermostat Indicator Lamps ................................ 17Emergency Heat Position .................................... 17Compressor Malfunction Light ............................. 17

FiguresFigure 1 Unit Dimensions ................................... 4Figure 2 Fresh Air Damper Assembly ................. 6Figure 3 Mounting Instructions ........................... 8Figure 4 Electric Heat Clearance ........................ 9Figure 5 Attaching Top Outlet to Unit ................ 10Figure 6 Top Outlet Model Mounted ................. 10Figure 7 Wall-Mounting Instructions ................. 11Figure 8 Wall-Mounting Instructions ................. 11Figure 9 Common Wall-Mounting Installations . 12Figure 10 Low Voltage Wiring ............................. 14Figure 11 Compressor Cutoffb

Thermostat Wiring .............................. 15Figure 12 Compressor Cutoff

Thermostat Wiring .............................. 15Figure 13 Electric Heat Hold-Off Wiring .............. 16Figure 14 Electric Heat Hold-Off Wiring .............. 16Figure 15 Start Up Label ..................................... 18Figure 16 Defrost Control Board ......................... 19Figure 17 Fan Blade Setting ............................... 22

TablesTable 1 Electric Heat Table ................................ 3Table 2 Dimensions of Basic Unit ...................... 4Table 3 Electrical Specifications ........................ 5Table 4 Operating Voltage Range ................... 13Table 5 Thermostat Wire Size ......................... 14Table 6 Wall Thermostat and

Subbase Combinations ...................... 17Table 7 Troubleshooting .................................. 20Table 8 Fan Blade Dimensions ....................... 22Table 9 Suction Line Temperatures ................. 22Table 10 Indoor Blower Performance ................ 22Table 11 CFM and ESP..................................... 22Table 12 Maximum ESP of Operation

Electric Heat Only ............................... 22Table 13 Cooling Pressures .............................. 23Table 14 Heating Pressures .............................. 23Table 15 Optional Accessories .......................... 24

Manual 2100-193Page 1

Getting Other Information and Publications

These publications can help you install the airconditioner or heat pump. You can usually find these atyour local library or purchase them directly from thepublisher. Be sure to consult current edition of eachstandard.

National Electrical Code ....................... ANSI/NFPA 70

Standard for the Installation ............... ANSI/NFPA 90Aof Air Conditioning andVentilating Systems

Standard for Warm Air ........................ANSI/NFPA 90BHeating and AirConditioning Systems

Load Calculation for ............................. ACCA Manual JResidential Winter andSummer Air Conditioning

Duct Design for Residential ................ACCA Manual DWinter and Summer AirConditioning and EquipmentSelection

FOR MORE INFORMATION, CONTACTTHESE PUBLISHERS:

ACCA Air Conditioning Contractors of America1712 New Hampshire Avenue NWWashington, DC 20009Telephone: (202) 483-9370Fax: (202) 234-4721

ANSI American National Standards Institute11 West Street, 13th FloorNew York, NY 10036Telephone: (212) 642-4900Fax: (212) 302-1286

ASHRAE American Society of Heating Refrigerating,and Air Conditioning Engineers, Inc.1791 Tullie Circle, N.E.Atlanta, GA 30329-2305Telephone: (404) 636-8400Fax: (404) 321-5478

NFPA National Fire Protection AssociationBatterymarch ParkP.O. Box 9101Quincy, MA 02269-9901Telephone: (800) 344-3555Fax: (617) 984-7057

Manufactured under the following U.S. patent numbers:5,485,878; 5,301,744; 5,002,116; 4,924,934;

4,875,520; 4,825,936

Manual 2100-193Page 2

WALL MOUNT GENERAL INFORMATIONHEAT PUMP WALL MOUNT MODEL NOMENCLATURE

WH 36 1 � A 10 X X X X X A

VOLTS & PHASEA - 230/208/60/1B - 230/208/60/3C - 460/60/3

MODELNUMBER

REVISIONS

CAPACITY30 - 2 1/2 Ton36 - 3 Ton

KW

VENTILATION OPTIONSX - Barometric Fresh AirDamper

(Standard)B - Blank-off PlateM - Motorized Fresh Air DamperV - Commercial Room Ventilator-

Motorized with ExhaustE - Economizer (Internal - Fully

Modulating with ExhaustR - Energy Recovery Ventilator -

with Exhaust

FILTER OPTIONSX - One Inch Throwaway

(Standard)W- One Inch WashableP - Two Inch Pleated

COLOR OPTIONSX - Beige (Standard)1 - White2 - Mesa Brown4 - Buckeye Gray5 - Desert Brown8 - Dark Bronze

CONTROL MODULES

COIL OPTIONS X- Standard 1 - Phenolic Coated Evapora-tor 2 - Phenolic Coated Con-denser 3 - Phenolic Coated Evapora-tor

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

Models

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

SHIPPING DAMAGEUpon receipt of equipment, the carton should be checkedfor external signs of shipping damage. If damage isfound, the receiving party must contact the last carrierimmediately, preferably in writing, requesting inspectionby the carrier�s agent.

GENERALThe equipment covered in this manual is to be installedby trained, experienced service and installationtechnicians.

The refrigerant system is completely assembled andcharged. All internal wiring is complete.

The unit is designed for use with or without duct work.Flanges are provided for attaching the supply and returnducts.

These instructions explain the recommended method toinstall the air cooled self-contained unit and theelectrical wiring connections to the unit.

These instructions and any instructions packaged withany separate equipment required to make up the entireheat pump system should be carefully read beforebeginning the installation. Note particularly �StartingProcedure� and any tags and/or labels attached to theequipment.

While these instructions are intended as a generalrecommended guide, they do not supersede any nationaland/or local codes in any way. Authorities havingjurisdiction should be consulted before the installation ismade. See Page 1 for information on codes andstandards.

Size of unit for a proposed installation should be basedon heat loss calculations made according to methods ofAir Conditioning Contractors of America (ACCA). Theair duct should be installed in accordance with theStandards of the National Fire Protection Association forthe Installation of Air Conditioning and VentilatingSystems of Other Than Residence Type, NFPA No. 90A,and Residence Type Warm Air Heating and AirConditioning Systems, NFPA No. 90B. Where localregulations are at a variance with instructions, installershould adhere to local codes.

DUCT WORKAny heat pump is more critical of proper operatingcharge and an adequate duct system than a straight airconditioning unit. All duct work, supply and return,must be properly sized for the design air flowrequirement of the equipment. Air ConditioningContractors of America (ACCA) is an excellent guide toproper sizing. All duct work or portions thereof not inthe conditioned space should be properly insulated inorder to both conserve energy and prevent condensationor moisture damage.

Manual 2100-193Page 3

TAB

LE 1

ELEC

TRIC

HEA

T TA

BLE

sled

oM

A-103H

WB-103

HW

C-103H

WA-163

HW

B-163H

WC-163

HW

1-0421-802

3-0423-802

3-0641-042

1-8023-042

3-8023-064

WK

AU

TB

AU

TB

AU

TB

AU

TB

AU

TB

AU

TB

AU

TB

AU

TB

AU

TB

AU

TB

58.02

560711.81

008218.02

560711.81

00821

016.14

031432.63

006526.14

031432.63

00652

515.26

002151.45

00483

64.41

005025.21

063512.7

574024.41

005025.21

063512.7

57402

97.12

006037.81

030328.01

007037.12

006037.81

030328.01

00703

510.81

002152.63

002152.13

004830.81

00215

Manual 2100-193Page 4

MIS

-126

2

FIG

UR

E 1

UN

IT D

IMEN

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NS

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NT

VIEW

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CK

VIE

WSI

DE

VIEW

* O

PTI

ON

AL

TOP

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TLE

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AC

TOR

Y IN

STA

LLE

D O

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) FO

R W

H30

AN

DW

H36

MO

DE

LS O

NLY

.

TAB

LE 2

DIM

ENSI

ON

S O

F B

ASI

C U

NIT

(N

OM

INA

L)

led

oM

htdi

W)

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PQ

RS

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03H

W63

HW

002.83521.71

365.0788.7

88.7288.31

88.7200.04

05.8157.52

39.7157.62

57.8252.92

00.7257.2

91.9357.22

41.991.4

00.2100.5

Manual 2100-193Page 5

TAB

LE 3

ELEC

TRIC

AL

SPEC

IFIC

ATI

ON

S

Max

imum

siz

e of

the

time

dela

y fu

se o

r HA

CR

type

circ

uit b

reak

er fo

r pro

tect

ion

of fi

eld

wiri

ng c

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ctor

s.B

ased

on

75°

copp

er w

ire.

All

wiri

ng m

ust c

onfo

rm to

the

Nat

iona

l Ele

ctric

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ode

and

all l

ocal

cod

es.

Max

imum

KW

that

can

ope

rate

with

hea

t pum

p on

Thes

e "M

inim

um C

ircui

t Am

paci

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valu

es a

re to

be

used

for s

izin

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e fie

ld p

ower

con

duct

ors.

Ref

er to

the

Nat

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ctric

Cod

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test

revi

sion

), A

rticl

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0 fo

r pow

er c

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CA

UTI

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: W

hen

mor

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pow

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circ

uit i

sru

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mus

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Pay

spe

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atte

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not

e 8

of ta

ble

310

rega

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city

Adj

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hen

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an th

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AT

KC

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Z0A-,00

A-103H

W50

A-�

01A-

1-802/0321 1 1

42 05 67

53 05 08

8 8 4

01 01 8

--

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01

Z0B-,00

B-103H

W�

60B-

�90

B-3-802/032

1 1 1

91 73 64

52 0405

01 8 8

01 01 01

--

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1 1 1 1

01 91 42 62

51 02 52 03

41 21 01 01

41 21 01 01

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Manual 2100-193Page 6

FRESH AIR INTAKEAll units are built with fresh air inlet slots punched inthe service panel.

If the unit is equipped with a fresh air damper assembly,the assembly is shipped already attached to the unit.The damper blade is locked in the closed position. Toallow the damper to operate, the maximum andminimum blade position stops must be installed. SeeFigure 2.

All capacity, efficiency and cost of operationinformation as required for Department of Energy�Energyguide� Fact Sheets is based upon the fresh airblank-off plate in place and is recommended formaximum energy efficiency.

The blank-off plate is available upon request from thefactory and is installed in place of the fresh air dampershipped with each unit.

Any grille that meets the 5/8 inch louver criteria may beused. It is recommended that Bard Return Air Grille KitRG-2 through RG-5 or RFG-2 through RFG-5 beinstalled when no return duct is used. Contactdistributor or factory for ordering information. If usinga return air filter grille, filters must be of sufficient sizeto allow a maximum velocity of 400 fpm.

NOTE: If no return air duct is used, applicableinstallation codes may limit this cabinet toinstallation only in a single story structure.

FILTERSA one (1) inch throwaway filter is supplied with eachunit. The filter slides into position making it easy toservice. This filter can be serviced from the outside byremoving the service door. A one (1) inch washablefilter and a two (2) inch pleated filter are also availableas optional accessories. The internal filter brackets areadjustable to accommodate the two inch filter byloosening two (2) screws in each bracket assembly andsliding the brackets apart to the required width andretightening the four (4) screws.

Refer to Table 12 for maximum static pressure availablefor duct design.

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

A 1/4 inch clearance to combustible material for thefirst three (3) feet of duct attached to the outlet air frameis required. See Wall Mounting Instructions and Figures3 and 4 for further details.

Ducts through the walls must be insulated and all jointstaped or sealed to prevent air or moisture entering thewall cavity.

CONDENSATE DRAINA plastic drain hose extends from the drain pan at thetop of the unit down to the unit base. There are openingsin the unit base for the drain hose to pass through. In theevent the drain hose is connected to a drain system ofsome type, it must be an open or vented type system toassure proper drainage.

BLADE IS LOCKEDCLOSED FORSHIPPING

FIGURE 2FRESH AIR DAMPER ASSEMBLY

MIS-938

CAUTIONSome installations may not require anyreturn air duct. A metallic return air grille isrequired with installations not requiring areturn air duct. The spacing betweenlouvers on the grille shall not be larger than5/8 inches.

Manual 2100-193Page 7

INSTALLATION INSTRUCTIONS

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

MOUNTING THE UNIT1. These units are secured by wall mounting brackets

which secure the unit to the outside wall surface atboth sides. A bottom mounting bracket is provided forease of installation, but is not required.

2. The unit itself is suitable for �0� inch clearance butthe supply air duct flange and the first 3 feet of supplyair duct require a minimum of 1/4 inch clearance tocombustible material. If a combustible wall, use aminimum of 28-1/2" x 8-1/2" dimensions for sizing.However, it is generally recommended that a 1 inchclearance is used for ease of installation andmaintaining the required clearance to combustiblematerial. The supply air opening would then be 30" x10". See Figures 3, 4, 5 and 6 for details.

WARNINGFire hazard can result if 1/4 inch clearanceto combustible materials for supply air ductis not maintained. See Figure 3.

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

WALL MOUNTING INFORMATION1. Two holes, for the supply and return air openings,

must be cut through the wall as shown in Figure 3.

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

4. Mount bottom mounting bracket, if used.

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

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

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

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

9. On side by side installations, maintain a minimum of20 inches clearance on right side to allow access toheat strips and control panel and to allow properairflow to the outdoor coil. Additional clearance maybe required to meet local or national codes.

TOP OUTLET ONLY1. Remove airframe angles from the back of the unit.

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

3. Secure angles to the top of the unit with 14 screwsprovided. Use prepunched holes provided. Do notrelocate. See Figure 5.

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

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

WARNINGFailure to provide the 1/4 inch clearancebetween the supply duct and a combustiblesurface for the first 3 feet of duct can resultin fire.

Manual 2100-193Page 8

FIG

UR

E 3

MO

UN

TIN

G IN

STR

UC

TIO

NS

MIS

-311

Manual 2100-193Page 9

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

FIGURE 4ELECTRIC HEAT CLEARANCE

WARNINGA minimum of 1/4" clearance must be maintained between thesupply air duct and combustible materials. This is required forthe fist three (3) feet of ducting.

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

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

MIS-277

Manual 2100-193Page 10

FIGURE 5ATTACHING TOP OUTLET AIRFRAMES TO UNIT

MIS-481

FIGURE 6UNIT WITH TOP OUTLET MOUNTED UNDER OVERHANG

MIS-482

Manual 2100-193Page 11

FIGURE 7WALL-MOUNTING INSTRUCTIONS

MIS-549

FIGURE 8WALL-MOUNTING INSTRUCTIONS

MIS-548

SEE FIGURE 3 � MOUNTING INSTRUCTIONS

SEE UNIT DIMENSIONS, FIGURE 1,FOR ACTUAL DIMENSIONS

SEE FIGURE 1 FORDUCT DIMENSIONS

Manual 2100-193Page 12

MIS-550

FIGURE 9COMMON WALL-MOUNTING INSTALLATIONS

Manual 2100-193Page 13

WIRING � MAIN POWERRefer to the unit rating plate for wire sizing informationand maximum fuse or �HACR Type� circuit breakersize. Each outdoor unit is marked with a �MinimumCircuit Ampacity�. This means that the field wiring usedmust be sized to carry that amount of current. Dependingon the installed KW of electric heat, there may be twofield power circuits required. If this is the case, the unitserial plate will so indicate. All models are suitable onlyfor connection with copper wire. Each unit and/or wiringdiagram will be marked �Use Copper Conductors Only�.These instructions must be adhered to. Refer to theNational Electrical Code (NEC) for complete currentcarrying capacity data on the various insulation gradesof wiring material. All wiring must conform to NEC andall local codes.

The electrical data lists fuse and wire sizes (75ºCcopper) for all models, including the most commonlyused heater sizes. Also shown are the number of fieldpower circuits required for the various models withheaters.

The unit rating plate lists a �Maximum Time DelayRelay Fuse� or �HACR Type� circuit breaker that is tobe used with the equipment. The correct size must beused for proper circuit protection and also to assure thatthere will be no nuisance tripping due to the momentaryhigh starting current of the compressor motor.

The disconnect access door on this unit may be locked toprevent unauthorized access to the disconnect. Toconvert for the locking capability, bend the tab locatedin the bottom left hand corner of the disconnect openingunder the disconnect access panel straight out. This tabwill now line up with the slot in the door. When shut, apadlock may be placed through the hole in the tabpreventing entry.

WIRING � LOW VOLTAGE WIRING230/208V, 1 phase and 3 phase equipment dual primaryvoltage transformers. All equipment leaves the factorywired on 240V tap. For 208V operation, reconnect from240V to 208V tap. The acceptable operating voltagerange for the 240 and 208V taps are shown in Table 4:

Nine (9) wires should be run from thermostat subbase tothe 24V terminal board in the unit. A nine conductor, 18gauge copper, color-coded thermostat cable isrecommended. The connection points are shown inFigure 10.

LOW VOLTAGE CONNECTIONSThese units use a grounded 24 volt AC low voltagecircuit.

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

"G" terminal is the fan input.

"Y" terminal is the compressor input for cooling andheat pump.

"B/W1" terminal is the reversing valve input. Thereversing valve must be energized for heating mode.

"R" terminal is 24 VAC hot.

"C" terminal is 24 VAC grounded.

"L" terminal is compressor lockout output. Thisterminal is activated on a high or low pressure trip by theelectronic heat pump control. This is a 24 VAC output.

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

"01" terminal is the ventilation input. This terminalenergizes any factory installed ventilation option.

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

TABLE 4OPERATING VOLTAGE RANGE

NOTE: The voltage should be measured at thefield power connection point in theunit and while the unit is operating atfull load (maximum amperageoperating condition.)

PAT EGNAR

V042 612-352

V802 781-022

LOW VOLTAGE CONNECTIONSFOR DDC CONTROL

Fan Only Energize G

Cooling Mode Energize Y, G

Heat Pump Heating Energize Y, G, B

2nd Stage Heating Energize G, W2, Y, B/W1 (if employed)

Ventilation Energize G, O1

Emergency Heat Energize B, W2, E, G

Manual 2100-193Page 14

FIGURE 10LOW VOLTAGE WIRING

TABLE 5THERMOSTAT WIRE SIZE

remrofsnarTAV ALF eguaGeriW

mumixaMecnatsiDteeFnI

55 3.2

eguag02eguag81eguag61eguag41eguag21

5406001061052

Manual 2100-193Page 15

OPTIONAL OUTDOOR THERMOSTATAPPLICATIONSSince most equipment at the time of manufacture is notdesignated for any specific destination of the countryand are installed in areas not approaching the loweroutdoor temperature range, outdoor thermostats are notfactory installed as standard equipment, but are offeredas an option. There are also different applications forapplying outdoor thermostats. The set point of eithertype of outdoor thermostat application is variable withgeographic region and sizing of the heating equipment tothe individual structure. Utilization of the heatingApplication Data, and the heat loss calculation of thebuilding are useful in determining the correct set points.

OPTIONAL COMPRESSOR CUTOFFTHERMOSTAT (See Figures 11 and 12)Heat pump compressor operation at outdoortemperatures below 0°F are neither desirable noradvantageous in term of efficiency. An outdoorthermostat can be applied to take the mechanical heating(compressor) off line, and send the (compressor) signalto energize electric heat in its place (to make electricheat first stage heating). This can also be applied tobank the quantity of available electric heat. Forexample: A heat pump operates with 10KW secondstage heat � once the outdoor thermostat has switchedthen operates 15KW without the compressor as firststage heat.

FIGURE 11COMPRESSOR CUTOFF THERMOSTAT WIRING

4 & 10KW 1 PH � 6 & 9KW 3 PH

FIGURE 12COMPRESSOR CUTOFF THERMOSTAT WIRING

15KW 1 PH & 3 PH

MIS-409

MIS-409

Manual 2100-193Page 16

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

In other applications, it is desirable to disable theoperation of the electric heat until outdoor temperatureshave reached a certain design point. This won't allowthe electric heat to come on as second stage heatingunless the outdoor temperature is below the set point ofthe outdoor thermostat. This is done to maximize

efficiency by utilizing the heat pump to bring theconditioned space temperature up, rather than cycling onthe electric heat due a second stage call for heat from thethermostat on start-up coming off a night set-backcondition or someone increasing the thermostat setpoint. (NOTE: Some programmable thermostats dohave a built-in time delay for pulling in second stageheat when coming off set-back conditions.)

FIGURE 13ELECTRIC HEAT HOLD-OFF WIRING

4 & 10KW 1 PH � 6 & 9KW 3 PH

FIGURE 14ELECTRIC HEAT HOLD-OFF WIRING

15KW 1 PH & 3 PH

MIS-1858

MIS-1858

Manual 2100-193Page 17

HEAT ANTICIPATIONThe thermostats shown below have a fixed heatanticipator for stage 1 with no adjustment required.Stage 2 has an adjustable anticipator for the W2connection and fixed for the W3 connection. Both theW2 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 bythe W2 circuit. The normal factory wiring provides foronly one electric heat contactor to be controlled by W2,and the anticipator should be set at .40A. If special fieldwiring is done, it is best to actually measure the load buta good rule is .40A for EACH heat contactor controlledby W2.

THERMOSTAT INDICATOR LAMPSThe red lamp marked "Em. Ht." comes on and stays onwhenever the system switch is placed in emergency heatposition. The green lamp marked "check" will come onif there is any problem that prevents the compressorfrom running when it is supposed to.

EMERGENCY HEAT POSITIONThe operator of the equipment must manually place thesystem switch in this position. This is done when thereis a known problem with the unit, or when the green"check" lamp comes on indicating a problem.

COMPRESSOR MALFUNCTION LIGHTActuation of the green "check" lamp is accomplished bya relay output from the heat pump control board which isfactory installed. Any condition such as loss of charge,high head pressure, etc., that will prevent compressorfrom operating will cause green lamp to activate. This isa signal to the operator of the equipment to place systemin emergency heat position.

1 No automatic changeover position - must manually place in heat or cool. Reversingvalve remains energized at all times system switch is in heat position (except duringdefrost cycle). No pressure equalization noise when thermostat is satisfied on eitherheating 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.

IMPORTANT NOTE: Both thermostat and subbase combinations shown aboveincorporate the following features: Man-Auto fan switch, Off-Heat-Cool-EM.Heat Switch, and two (2) indicator lamps - one for emergency heat and one forcompressor malfunction.

TABLE 6WALL THERMOSTAT AND SUBBASE COMBINATIONS

puorG tatsomrehT esabbuS serutaeFetanimoderP

A 710-3048)9211R478T(

900-4048)1811L476Q(

looCrotaeH 1otuAoN

B 810-3048)4201N478T(

101-4048)1621F476Q(

looC�taeHcitamotuA 2noitisoPrevoegnahC

940-3048083-39F1

taehegats3,loocegats2elbammargorP cinortcelE

revoegnahclaunaMrootuA

240-3048)0701G1158T(

taehegats2,loocegats1revoegnahCcitamotuAcinortcelE

540-3048)1671A148T(

taehegats2,loocegats1launaM

Manual 2100-193Page 18

IMPORTANT INSTALLER NOTEFor improved start-up performance, wash the indoorcoil with a dishwashing detergent.

CRANKCASE HEATERSAll units are provided with some form of compressorcrankcase heat.

All single and three phase models have an insertionwell-type heater located in the lower section of thecompressor housing. This is a self-regulating typeheater that draws only enough power to maintain thecompressor at a safe temperature.

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

The decal in Figure 15 is affixed to all outdoor unitsdetailing start up procedure. This is very important.Please read carefully.

SERVICE HINTS1. Caution homeowner to maintain clean air filters at all

times. Also, not to needlessly close off supply andreturn air registers. This reduces air flow through thesystem which shortens equipment service life as wellas increasing operating costs.

2. Switching to heating cycle at 75°F or higher outsidetemperature may cause a nuisance trip of the remotereset high pressure switch. Turn thermostat off thenon to reset the high pressure switch.

3. The heat pump wall thermostats perform multiplefunctions. Be sure that all function switches arecorrectly set for the desired operating mode beforetrying to diagnose any reported service problems.

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

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

SEQUENCE OF OPERATIONCOOLING � Circuit R-Y makes at thermostat pullingin compressor contactor, starting the compressor andoutdoor motor. The G (indoor motor) circuit isautomatically completed on any call for coolingoperation or can be energized by manual fan switch onsubbase for constant air circulation.

START UP

HEATING � A 24V solenoid coil on reversing valvecontrols heating cycle operation. Two thermostatoptions, one allowing "Auto" changeover from cycle tocycle and the other constantly energizing solenoid coilduring heating season and thus eliminating pressureequalization noise except during defrost, are to be used.On "Auto" option, a circuit is completed from R-W1and R-Y on each heating "on" cycle, energizingreversing valve solenoid and pulling in compressorcontactor starting compressor and outdoor motor. R-Galso make starting indoor blower motor. Heat pumpheating cycle now in operation. The second option hasno "Auto" changeover position, but instead energizesthe reversing valve solenoid constantly whenever thesystem switch on subbase is placed in "Heat" position,the "B" terminal being constantly energized from R. Athermostat demand for heat completes R-Y circuitpulling in compressor contactor starting compressor andoutdoor motor.R-G make starting indoor blower motor.

FIGURE 15START UP LABEL

IMPORTANTTHESE PROCEDURES MUST BEFOLLOWED AT INITIAL START UPAND AT ANY TIME POWER HASBEEN REMOVED FOR 12 HOURSOR LONGER.TO PREVENT COMPRESSOR DAMAGEWHICH MAY RESULT FROM THE PRESENCEOF LIQUID REFRIGERANT IN THECOMPRESSOR CRANKCASE:

1. Make certain the room thermostat is in the"off" position (the compressor is not tooperate).

2. Apply power by closing the systemdisconnect switch. This energizes thecompressor heater which evaporates theliquid refrigerant in the crankcase.

3. Allow 4 hours or 60 minutes per poind ofrefrigerant in the system as noted on theunit rating plate, whichever is greater.

4. After properly elapsed time, the thermostatmay be set to operate the compressor.

5. Except as required for safety whileservicing. Do not open systemdisconnect switch. 7961-061

Manual 2100-193Page 19

PRESSURE SERVICE PORTSHigh and low pressure service ports are installed on allunits so that the system operating pressures can beobserved. Pressure tables can be found on Page 22covering all models. It is imperative to match the correctpressure table to the unit by model number.

DEFROST CYCLEThe defrost cycle is controlled by temperature and timeon the solid state heat pump control. See Figure 16.

When the outdoor temperature is in the lower 40° Ftemperature range or colder, the outdoor coiltemperature is 32° F or below. This coil temperature issensed by the coil temperature sensor mounted near thebottom of the outdoor coil. Once coil temperaturereaches 30° F or below, the coil temperature sensorsends a signal to the control logic of the heat pumpcontrol and the defrost timer will start.

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

During the defrost mode, the refrigerant cycle switchesback to the cooling cycle, the outdoor motor stops,electric heaters are energized, and hot gas passingthrough the outdoor coil melts any accumulated frost.When the temperature rises to approximately 57° F, thecoil temperature sensor will send a signal to the heatpump control which will return the system to heatingoperations automatically.

If some abnormal or temporary condition such as a highwind causes the heat pump to have a prolonged defrostcycle, the heat pump control will restore the system toheating operation automatically after 10 minutes.

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

circumstances require a change to another time, removethe wire from the 60 minute terminal and reconnect tothe desired terminal. The manufacturer'srecommendation is for 60 minute defrost cycles. Referto Figure 16.

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

Use a small screwdriver or other metallic object, oranother 1/4 inch QC, to short between the SPEEDUPterminals to accelerate the HPC timer and initiatedefrost.

Be careful not to touch any other terminals with theinstrument used to short the SPEEDUP terminals. Itmay take up to 10 seconds with the SPEEDUPterminals shorted for the speedup to be completed andthe defrost cycle to start.

As soon as the defrost cycle kicks in remove theshorting instrument from the SPEEDUP terminals.Otherwise the timing will remain accelerated and runthrough the 1 minute minimum defrost length sequencein a matter of seconds and will automatically terminatethe defrost sequence.

There is an initiate defrost jumper (sen jump) on thecontrol that can be used at any outdoor ambient duringthe heating cycle to simulate a 0° coil temperature.This can be used to check defrost operation of the unitwithout waiting for the outdoor ambient to fall into thedefrost region.

By placing a jumper across the SEN JMP terminals (a 1/4 inch QC terminal works best) the defrost sensormounted on the outdoor coil is shunted out and willactivate the timing circuit. This permits the defrostcycle to be checked out in warmer weather conditionswithout the outdoor temperature having to fall into thedefrost region.

In order to terminate the defrost testthe SEN JMP jumper must beremoved. If left in place too long thecompressor could stop due to the highpressure control opening because ofhigh pressure condition created byoperating in the cooling mode withoutdoor fan off. Pressure will risefairly fast as there is likely no actualfrost on the outdoor coil in thisartificial test condition.

There is also a 5 minute compressor timedelay function built into the HPC. Thisis to protect the compressor from shortcycling conditions. In some instances itis helpful to the service technician tooverride or speed up this timing period,and shorting out the SPEEDUP terminalsfor a few seconds can do this.

MIS-1528

FIGURE 16DEFROST CONTROL BOARD

Manual 2100-193Page 20

TROUBLESHOOTING

SOLID STATE HEAT PUMP CONTROLTROUBLESHOOTING PROCEDURE1. Turn on AC power supply to indoor and outdoor

units.

2. Turn thermostat blower switch to "Fan On" � theindoor blower should start. (If it doesn't, troubleshootindoor unit and correct problem).

3. Turn thermostat blower switch to "Auto" position.Indoor blower should stop.

4. Set system switch to heat or cool. Adjust thermostatto call for "Heat" or "Cool" � the indoor blower,compressor and outdoor fan should start.

NOTE: If there was no power to 24 volt transformer, thecompressor and outdoor fan motor will not startfor 5 minutes. This is because of the compressorshort cycle protection.

TABLE 7TROUBLESHOOTING

MOTPMYS SESUACELBISSOP KCEHCOTTAHW RIAPERROKCEHCOTWOH

rotcatnocrosserpmoCezigrenetonseod

)gnitaehrognilooc(

gniriwtiucriclortnoC ,tinutanoitcennocRrofkcehCC-RneewtebV42dna

rewopottinuroodtuootnoitcennocRnuRlortnocpmuptaeh

tuokcolrosserpmoC .1

.2

neewtebV42rofkcehClortnocpmuptaehnoC-1L

hgihssorcakcehC.hctiwserusserp

.1

.2

tatsomrehtnrutC-LneewtebegatlovonfIerusserphgihteserotniaganodnaffo

.hctiwstonlliwdnaneposihctiwserusserphgihfI

.hctiwsersserphgihecalper,teser

trohsrosserpmoCnoitcetorpelcyc

C-CCneewtebV42rofkcehClortnocpmuptaehnoC-Ydna

pudeepsrepmuj,C-CCneewtebegatlovonfIdluohsrewopsdnoces01nihtiwdnalanimret

pudeepsevomeR.C-CCneewtebraeppasdnoces01retfarepmuj

lortnocpmuptaeHevitcefed

elbissoprehtollakcehC560-0012launaM.sesuac

lortnocpmuptaehecalpeR

evitcefedrotcatnoC liocdetrohsroneporofkcehCgnidniw

rotcatnocecalpeR

tongnisahprewoP.tcerroc

esahpnoDELderrofkcehC).ylnostinuesahp3(.rotinom

.tinuehtotsdaelrewopowthctiwS

rotomroodtuonaFnurtonseod

gnitaehrognilooc()tsorfedgnirudtpecxe

evitcefedrotoM detrohsroneporofkcehCgnidniwrotom

rotomecalpeR

roticapacrotoMevitcefed

kcehC.gnitarroticapackcehC.roticapacdetrohsroneporof

roticapacecalpeR

lortnocpmuptaeHevitcefed

taehnoyalernafssorcakcehC)CN-moC(lortnocpmup

lortnocpmuptaehecalpeR

seodevlavgnisreveRezigreneton

)ylnognitaeh(

evlavgnisreveRevitcefedliocdionelos

liocdetrohsroneporofkcehC liocdionelosecalpeR

lortnocpmuptaeHevitcefed

C-VRneewtebV42rofkcehCC-Bdna

.1

.2gniriwtiucriclortnockcehClortnocpmuptaehecalpeR

otniogtonlliwtinUtsorfed

)ylnognitaeh(

rosneserutarepmeTlortnocpmuptaehro

evitcefed

rosneserutarepmettcennocsiDssorcarepmujdnadraobmorf

nesdnaslanimretpudeepsdluohssihT.slanimretpmuj

ahguorhtogottinuehtesuac.etunimenonihtiwelcyctsorfed

.1

.2

ecalper,elcyctsorfedhguorhtseogtinufIrosneserutarepmet

,elcyctsorfedhguorhtogtonseodtinufI.lortnocpmuptaehecalper

tuoemoctonlliwtinUtsorfedfo

)ylnognitaeh(

rosneserutarepmeTlortnocpmuptaehro

evitcefed

pudeepsssorcarepmuJesuacdluohssihT.slanimret

tsorfedfotuoemocottinueht.etunimenonihtiw

.1

.2

ecalper,elcyctsorfedfotuosemoctinufI.rosneserutarepmret

,elcyctsorfedfotuoemoctonseodtinufI.lortnocpmuptaehecalper

Manual 2100-193Page 21

CHECKING TEMPERATURE SENSOROUTSIDE UNIT CIRCUIT1. Disconnect temperature sensor from board and from

outdoor coil.

2. Use an ohmmeter and measure the resistance of thesensor. Also use ohmmeter to check for short oropen.

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

4. If sensor resistance reads very low, then sensor isshorted and will not allow proper operation of theheat pump control.

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

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

F R F R F R F R

0.52-0.42-0.32-0.22-0.12-0.02-0.91-0.81-0.71-0.61-0.51-0.41-0.31-0.21-0.11-0.01-0.9-0.8-0.7-0.6-0.5-0.4-0.3-0.2-0.1-0.00.10.20.30.40.50.60.70.80.90.010.110.21

1786919900915853818137719821717845614099519254515539414734416759316594316050319126219802218018112724115750110107014753010620014607918939800199318817358996281210823677032570192707607705868146699346944265650654785

0.310.410.510.610.710.810.910.020.120.220.320.420.520.620.720.820.920.030.130.230.330.430.530.630.730.830.930.040.140.240.340.440.540.640.740.840.940.05

5896548255046351502541505820940957400264558444553459224770148989375783256733856384553545434753343623327130480368992751925538277572328622906238352696420304248332857220512216512989025340269891

0.350.250.350.450.550.650.750.850.950.060.160.260.360.460.560.660.760.860.960.070.170.270.370.470.570.670.770.870.970.080.180.280.380.480.580.680.780.88

47391768815738198971434714896174561221610175101351129414454177141028314743173131018212942138121388111951170311130112670110501742010000106796259992977092688356894480528750896876867

0.980.090.190.290.390.490.590.690.790.890.990.0010.1010.2010.3010.4010.5010.6010.7010.8010.9010.0110.1110.2110.3110.4110.5110.6110.7110.8110.9110.0210.1210.2210.3210.421

705743375617000704863866135638369326890616957285796507556445623580254905289437847674366426544644763447242814390460041293838375738763106362532543

Manual 2100-193Page 22

REFRIGERANT CHARGEThe correct system R-22 charge is shown on the unitrating plate. Optimum unit performance will occur witha refrigerant charge resulting in a suction linetemperature (6 inches from compressor) as shown inTable 9.

TABLE 10INDOOR BLOWER PERFORMANCE

CFM AT 230 VOLTS

.P.S.EHnI 2O

163HW,103HW

deepSwoL deepShgiH

/lioCyrD lioCteW /lioCyrD lioCteW

0. /059 539 /593,1 513,1

1. /039 519 /043,1 072,1

2. /019 588 /582,1 091,1

3. /558 038 /502,1 001,1

4. /008 557 /011,1 000,1

5. /--- --- /500,1 078

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

TABLE 12MAXIMUM ESP OF OPERATION

ELECTRIC HEAT ONLY

ledoM

teltuOtnorF teltuOpoT

woLdeepS

hgiHdeepS

woLdeepS

hgiHdeepS

103HW163HW

00A50A01A51A

05.04.53.53.

05.05.04.04.

05.04.52.AN

05.05.04.AN

103HW163HW

00B60B90B51B

05.04.53.53.

05.05.54.54.

05.AN03.AN

05.AN04.AN

103HW163HW

00C60C90C51C

05.05.03.03.

05.05.04.04.

05.AN53.AN

05.AN54.AN

Values shown are for units equipped withstandard 1" throwaway filter or 1" washablefilter. Derate ESP by .15 for 2" pleated filter.

REMOVAL OF FAN SHROUD1. Disconnect all power to unit.2. Remove the screws holding both grilles, one on each

side of unit, and remove grilles.3. Remove screws holding fan shroud to condenser and

bottom � nine (9) screws.4. Unwire condenser fan motor.5. Slide complete motor, fan blade, and shroud assembly

out the left side of the unit.6. Service motor/fan as needed.7. Reverse steps to reinstall.

FAN BLADE SETTING DIMENSIONSShown in Figure 17 are the correct fan blade settingdimensions for proper air delivery across the outdoorcoil.

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

The suction line temperatures in Table 9 are based upon80ºF dry bulb/67ºF wet bulb (50 percent R.H.)temperature and rated airflow across the evaporatorduring cooling cycle.

FIGURE 17FAN BLADE SETTING

TABLE 9SUCTION LINE TEMPERATURES

ledoMdetaRwolfriA

DOF59erutarepmeT

DOF28erutarepmeT

103HW 001,1 85-65 56-36

163HW 001,1 15-94 86-66

TABLE 11CFM AND ESP

! Rated CFM and ESP on high speed tap

ledoM

�

detaRMFC

�

detaRPSE

dednemmoceRegnaRwolfriA

103HW163HW

000,1001,1

03.03.

003,1-039053,1-039

TABLE 8FAN BLADE DIMENSION

ledoM AnoisnemiD

103HW163HW

52.1

Manual 2100-193Page 23

Low side pressure ± 2 psigHigh side pressure ± 5 psigTables are based upon rated CFM (airflow) across the evaporator coil andshould be found under section titled "Refrigerant Charge" on Page 21 inmanual. If there is any doubt as to correct charge being in the system, thecharge should be removed, system evacuated and recharged to serial plateinstructions.

TABLE 13COOLING PRESSURE (PSI) � OUTDOOR TEMPERATURE °F

ledoMriAnruteRerutarepmeT erusserP 57 08 58 09 59 001 501 011 511

103HW

BDged57BWged26

ediSwoLediShgiH

67532

87942

08362

18772

38192

48503

58913

78333

88743

BDged08BWged76

ediSwoLediShgiH

18142

38552

58962

78482

88892

09213

19723

39143

49653

BDged58BWged27

ediSwoLediShgiH

88052

09462

29972

39492

59803

79323

89833

001353

101863

163HW

BDged57BWged26

ediSwoLediShgiH

96012

17622

37242

57752

67372

87092

08603

28323

38933

BDged08BWged76

ediSwoLediShgiH

37612

67232

87842

08462

28182

48792

58413

78133

98843

BDged58BWged27

ediSwoLediShgiH

97322

18042

48652

68372

88092

09803

29523

49243

59063

AIR TEMPERATURE ENTERING OUTDOOR COIL °F

TABLE 14HEATING PRESSURE (PSI) � OUTDOOR TEMPERATURE °F

AIR TEMPERATURE ENTERING OUTDOOR COIL °F

ledoMriAnruteRerutarepmeT erusserP 0 5 01 51 02 52 03 53 04 54 05 55 06

103HW 07 o ediSwoLediShgiH

12341

52841

82351

23951

63561

93271

34081

74881

15791

55702

95712

36822

76932

163HW 07 o ediSwoLediShgiH

22541

52251

82951

13761

43771

83681

24791

64802

05022

55332

06642

56062

07572

Manual 2100-193Page 24

WH

301-

A

WH

301-

B

WH

301-

C

WH

361-

A

WH

361-

B

WH

361-

C

TABLE 15OPTIONAL ACCESSORIES

LEDOM NOITPIRCSED

50A-03HWHE segakcaPretaeH ➀ X

01A-03HWHE segakcaPretaeH ➀ X

50A-63HWHE segakcaPretaeH ➀ X

01A-63HWHE segakcaPretaeH ➀ X

51A-63HWHE segakcaPretaeH ➀ X

60B-30HWHE segakcaPretaeH ➀ X X

90B-30HWHE segakcaPretaeH ➀ X X

51B-30HWHE segakcaPretaeH ➀ X

60C-30HWHE segakcaPretaeH ➀ X X

90C-30HWHE segakcaPretaeH ➀ X X

51C-30HWHE segakcaPretaeH ➀ X X

3-POB etalPffOknalB X X X X X X

3-DAFB repmaDriAhserFcirtemoraB X X X X X X

3-DAFM repmaDriAhserFdezirotoM X X X X X X

3-VRC tsuahxEhtiwrotalitneVlaicremmoC X X X X X X

3-MFIE tsuahxEhtiwrezimonocE X X X X X X

A3A-VREW rotalitneVyrevoceRygrenE X X X X

A3C-VREW rotalitneVyrevoceRygrenE X X

3-HMC )CPL(lortnoCerusserPwoL X X X X X X

7-HMC )CAL(lortnoCtneibmAwoL X X X X

9-HMC CPL+CAL X X X X

41-HMC )TDO(tatsomrehTroodtuO X X

51-CMC )KS(tiKtratS X X

A50-BCMW tiKrekaerBtiucriC X

B30-BCMW tiKrekaerBtiucriC X X

10-DPMW tiKrekaerBtiucriC X X

A60-BCMW tiKrekaerBtiucriC X