Bard WH423 User manual

Manual 2100-487
Page 1 of 23
WALL MOUNTED
PACKAGE HEAT PUMPS
Models:
WH423
WH483
WH604
INSTALLATION INSTRUCTIONS
Manual: 2100-487
Supersedes: NEW
File: Volume III Tab 17
Date: 01-04-08
Bard Manufacturing Company, Inc.
Bryan, Ohio 43506
Since 1914...Moving ahead, just as planned.

Manual 2100-487
Page 2 of 23
CONTENTS
Getting Other Information and Publications
For more information, contact these publishers:...... 3
Wall Mount General Information
Heat Pump Wall Mount Model Nomenclature.......... 4
Shipping Damage .................................................... 7
General ............................................................... 7
Duct Work ............................................................... 7
Filters ............................................................... 7
Fresh Air Intake ....................................................... 8
Condensate Drain.................................................... 8
Installation Instructions
Wall Mounting Information....................................... 9
Mounting the Unit .................................................... 9
Typical Installations ................................................. 9
Wiring – Main Power ........................................... 13
Wiring – Low Voltage Wiring ............................... 13
Optional Outdoor Thermostat Applications ............ 14
Electric Heat Hold-Off............................................ 15
Start Up
Important Installer Note ......................................... 16
Crankcase Heaters................................................ 16
High Pressure Switch ............................................ 16
Three Phase Scroll Compressor Start Up
Information............................................................. 16
Phase Monitor ....................................................... 17
Service Hints ......................................................... 17
Sequence of Operation.......................................... 17
Pressure Service Ports.......................................... 17
Defrost Cycle .................................................... 17-18
Troubleshooting
Solid State Heat Pump Control
Troubleshooting Procedure ................................... 19
Checking Temperature Sensor Outdoor
Unit Circuit ............................................................. 20
Fan Blade Setting Dimensions .............................. 21
Removal of Fan Shroud......................................... 21
Refrigerant Charge ................................................ 21
Pressure Chart ................................................. 22-23
Optional Accessories ............................................. 23
Figures
Figure 1 Unit Dimensions..................................... 5
Figure 2 Blower Damper Assembly...................... 8
Figure 3 Mounting Instructions........................... 10
Figure 3A Electric Heat Clearance ....................... 10
Figure 4 Wall-Mounting Instructions ...................11
Figure 5 Wall-Mounting Instructions ...................11
Figure 6 Common Wall-Mounting Instructions... 12
Figure 7 Unit 24V Terminal Board ...................... 13
Figure 8 Compressor Cutoff Thermostat
Wiring .................................................. 14
Figure 9 Compressor Cutoff Thermostat
Wiring .................................................. 14
Figure 10 Electric Heat Hold-Off Wiring............... 15
Figure 11 Electric Heat Hold-Off Wiring............... 15
Figure 12 Start-Up Label...................................... 16
Figure 13 Defrost Control Board .......................... 18
Figure 14 Fan Blade Setting ................................ 21
Tables
Table 1 Electric Heat Table................................. 4
Table 2 Electrical Specifications ......................... 6
Table 3 Thermostat Wire Size .......................... 14
Table 4 Wall Thermostat................................... 15
Table 5 Troubleshooting ................................... 19
Table 6 Fan Blade Dimensions......................... 21
Table 7 Suction Line Temperatures .................. 21
Table 8 Recommended Operating Ranges ...... 21
Table 9 Indoor Blower Performance ................. 21
Table 10 Maximum ESP of Operation ................ 22
Table 11 Cooling Pressures ............................... 22
Table 12 Heating Pressures ............................... 23
Table 13 Optional Accessories ........................... 23

Manual 2100-487
Page 3 of 23
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/NFPA70
Standard for the Installation ............... ANSI/NFPA 90A
of Air Conditioning and Ventilating Systems
Standard for Warm Air ........................ANSI/NFPA90B
Heating and Air Conditioning Systems
Load Calculation for .........................ACCA Manual J or
Residential Winter and Summer Air Manual N
Conditioning
Low Pressure, Low Velocity .......... ACCA Manual D or
Duct System Design for Winter Manual Q
and Summer Air Conditioning
FOR MORE INFORMATION, CONTACT
THESE PUBLISHERS:
ACCA Air Conditioning Contractors of America
1712 New Hampshire Ave. N.W.
Washington, DC 20009
Telephone: [phone]
Fax: [phone]
ANSI American National Standards Institute
11 West Street, 13th Floor
New York, NY 10036
Telephone: [phone]
Fax: [phone]
ASHRAE American Society of Heating Refrigerating
and Air Conditioning Engineers, Inc.
1791 Tullie Circle, N.E.
Atlanta, GA 30329-2305
Telephone: [phone]
Fax: [phone]
NFPA National Fire Protection Association
Batterymarch Park
P.O. Box 9101
Quincy, MA 02269-9901
Telephone: [phone]
Fax: [phone]

Manual 2100-487
Page 4 of 23
WALL MOUNT GENERAL INFORMATION
HEAT PUMP WALL MOUNT MODEL NOMENCLATURE
WH 48 1 – A 10 X X X X X B
TABLE 1
ELECTRIC HEAT TABLE
sledoM
WK
A-324HW B-324HW B-384HW C-324HW A-384HW A-406HW B-384HW B-406HW C-384HW C-406HW
1-0421-8023-0423-8023-0641-0421-8023-0423-8023-064
AUTBAUTBAUTBAUTBAUTBAUTBAUTBAUTBAUTBAUTB
4 7.61056314.4104201
58.02560711.81008218.02560711.8100821
64.41005025.21063512.708402
97.12006037.81030328.01007037.12006037.81030328.0100703
016.14031432.63006526.14031432.6300652
515.26002151.45004832.63002152.13004830.81002155.26002151.45004832.63002152.13004830.8100215
81 3.34004165.7305064
02 2.38052861.2700215
VENTILATION OPTIONS
X –Barometric FreshAir Damper (Standard)
B – Blank-off Plate
M – Motorized Fresh Air Damper
V – Commercial Room Ventilator - Motorized
withExhaust
E – Economizer (Internal) - Fully Modulating
withExhaust
R – Energy Recovery Ventilator - Motorized
withExhaust
COILOPTIONS
X – Standard
1 – Phenolic Coated Evaporator
2 – Phenolic Coated Condenser
3 – Phenolic Coated Evaporator
and Condenser
CONTROLMODULES
(See Spec. Sheet S3210)
NOTE: For 0KW and circuit breakers (230/208V) or pull disconnects (460V) applications, insert 0Z in the KW field of model number.
MODEL
NUMBER
CAPACITY
42 – 3½ Ton
48 – 4 Ton
60 – 5 Ton
KW
00 – No KW
05 – 5 KW
06 – 6 KW
09 – 9 KW
10 – 10 KW
15 – 15 KW
18 – 18 KW
20 – 20 KW
FILTER OPTIONS
X – 1-Inch Throwaway (Standard)
W – 1-Inch Washable
P – 2-Inch Pleated
VOLTS & PHASE
A – 230/208/60-1
B – 230/208/60-3
C – 460/60-3
REVISION
COLOROPTIONS
X –Beige (Standard)
1 –White
2 –Mesa Tan
4 –Buckeye Gray
OUTLETOPTIONS
X – Front (Standard)

Manual 2100-487
Page 5 of 23
FIGURE 1
UNITDIMENSIONS

Manual 2100-487
Page 6 of 23
TABLE 2
ELECTRICALSPECIFICATIONS
ledoM
TIUCRICELGNIS TIUCRICLAUD
detaR stloV esahP&
.oN dleiF rewoP .stkC
4
muminiM tiucriC yticapmA
1
mumixaM lanretxE roesuF tiucriC rekaerB
2
dleiF rewoP eriW eziS
2
dnuorG eriW eziS
4
muminiM tiucriC yticapmA
1
mumixaM lanretxE roesuF rekaerB.tkC
2
rewoPdleiF eziSeriW
2
eriWdnuorG eziS
AtkCBtkCAtkCBtkCAtkCBtkCAtkCBtkC
Z0A,00A-324HW 50A
301A 51A
1-802/032
12ro1 2ro1 2ro1 43066868 05070909 8
6
3
3
01
8
8
8
A/N434343 A/N622525 A/N050505 A/N030606 A/N8
8
8
A/N01
6
6
A/N010101 A/N010101
Z0B,00B-324HW 60B
390B 51B
3-802/032
1
1
1
1
62443535 53050606 8
8
6
6
01010101 A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N
Z0C,00C-324HW 60C
390C 51C
3-064
1
1
1
1
31327272 02520303 21010101 21010101 A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N
Z0A,00A-384HW 40A 50A
301A 51A 02A
1-802/032
1
12ro1 1ro1 2ro1 2ro1
6375268888 011 050607 001 001 011 8
6
6
3
3
2
01
8
8
8
8
6
A/N A/N63636395 A/N A/N62252525 A/N A/N05050506 A/N A/N03060606 A/N A/N8
8
8
6
A/N A/N01
6
6
6
A/N A/N01010101 A/N A/N01010101
Z0B,00B-384HW 60B
390B 51B 81B 3-802/032
1
1
1
1
1
5234252506 5305060606 8
8
6
6
6
0101010101 A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N
Z0C,00C-384HW
390C 51C 3-064 1 1
1
316272 510303 4101
8
410101 A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N
Z0A,00A-406HW 50A
301A 51A 02A 1-802/032
12ro1 1ro1 2ro1 2ro1 54177979 011 0609 011 011 011 8
4
3
3
2
01
8
6
6
6
A/N54545495 A/N62252525 A/N06060606 A/N06060606 A/N8
8
8
6
A/N01
6
6
6
A/N01010101 A/N01010101
Z0B,00B-406HW
390B 51B 81B
3-802/032
1
1
1
1
33060606 54060606 8
6
6
6
01010101 A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N
Z0C,00C-406HW
390C 51C 3-064 1 1
1
619292 025353 21
8
8
210101 A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N A/N
1Maximum size of the time delay fuse or HACR type circuit breaker for protection of field wiring conductors.
2Based on 75°C copper wire. All wiring must conform to NEC and all local codes.
3Maximum KW that can operate with heat pump on.
4These “Minimum Circuit Ampacity” values are to be used for sizing the field power conductors. Refer to the National Electrical
Code (latest version), article 310 for power conductor sizing.
CAUTION: When more than one field power conductor circuit is run through one conduit, the conductors must be
derated. Pay special attention to note 8 of table 310 regarding Ampacity Adjustment Factors when more than 3
conductors are in a raceway.

Manual 2100-487
Page 7 of 23
SHIPPING DAMAGE
Upon receipt of equipment, the carton should be checked
for external signs of shipping damage. If damage is
found, the receiving party must contact the last carrier
immediately, preferably in writing, requesting inspection
by the carrier’s agent.
GENERAL
The equipment covered in this manual is to be installed
by trained, experienced service and installation
technicians.
The refrigerant system is completely assembled and
charged. All internal wiring is complete.
The unit is designed for use with or without duct work.
Flanges are provided for attaching the supply and return
ducts.
These instructions and any instructions packaged with
any separate equipment required to make up the entire
heat pump system should be carefully read before
beginning the installation. Note particularly “Starting
Procedure” and any tags and/or labels attached to the
equipment.
While these instructions are intended as a general
recommended guide, they do not supersede any national
and/or local codes in any way. Authorities having
jurisdiction should be consulted before the installation is
made. See Page 3 for information on codes and
standards.
Size of unit for a proposed installation should be based
on heat loss calculation made according to methods of
Air Conditioning Contractors of America (ACCA). The
air duct should be installed in accordance with the
Standards of the National Fire Protection Association for
the Installation of Air Conditioning and Ventilating
Systems of Other Than Residence Type, NFPA No.
90A, and Residence Type Warm Air Heating and Air
Conditioning Systems, NFPA No. 90B. Where local
regulations are at a variance with instructions, installer
should adhere to local codes.
DUCT WORK
Any heat pump is more critical of proper operating
charge and an adequate duct system than a straight air
conditioning unit. All duct work, supply and return,
must be properly sized for the design 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.
Any grille that meets the 5/8 inch louver criteria, may be
used. It is recommended that Bard Return Air Grille Kit
RG-2 through RG-5 or RFG-2 through RFG-5 be
installed when no return duct is used. Contact
distributor or factory for ordering information. If using
a return air filter grille, filters must be of sufficient size
to allow a maximum velocity of 400 fpm.
NOTE: If no return air duct is used, applicable
installation codes may limit this cabinet to
installation only in a single story structure.
FILTERS
A 1-inch throwaway filter is supplied with each unit.
The filter slides into position making it easy to service.
This filter can be serviced from the outside by removing
the service door. A 1-inch washable filter and 2-inch
pleated filter are also available as optional accessories.
The internal filter brackets are adjustable to
accommodate the 2-inch filter by bending down the tabs
to allow spacing for the 2-inch filters.
Refer to Table 10 for maximum static pressure available
for duct design.
Design the duct work according to methods given by the
Air Conditioning Contractors of America (ACCA).
When duct runs through unheated spaces, it should be
insulated with a minimum of one inch of insulation. Use
insulation with a vapor barrier on the outside of the
insulation. Flexible joints should be used to connect the
duct work to the equipment in order to keep the noise
transmission to a minimum.
A ¼ inch clearance to combustible material for the first
three feet (3') of duct attached to the outlet air frame is
required. See Wall Mounting Instructions and Figures 3,
4 and 5 for further details.
Ducts through the walls must be insulated and all joints
taped or sealed to prevent air or moisture entering the
wall cavity.
CAUTION
Some installations may not require any return
air duct. Ametallic return air grille is required
with installations not requiring a return air
duct. The spacing between louvers on the
grille shall not be larger than 5/8 inches.

Manual 2100-487
Page 8 of 23
FIGURE 2
BLOWERDAMPERASSEMBLY
FRESH AIR INTAKE
All units are built with fresh air inlet slots punched in
the service panel.
If the unit is equipped with the fresh air damper
assembly, the assembly is shipped already attached to
the unit. The damper blade is locked in the closed
position. To allow the damper to operate, the maximum
and minium blade position stops must be installed. See
Figure 2.
All capacity, efficiency and cost of operation
information as required for Department of Energy
“Energyguide” Fact Sheets is based upon the fresh air
blank-off plate in place and is recommended for
maximum energy efficiency.
The blank-off plate is available upon request from the
factory and is installed in place of the fresh air damper
shipped with each unit.
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 2100-487
Page 9 of 23
INSTALLATION INSTRUCTIONS
WALL MOUNTING INFORMATION
1. Two holes, for the supply and return air openings,
must be cut through the wall as shown in Figure 3.
2. On wood-frame walls, the wall construction must be
strong and rigid enough to carry the weight of the unit
without transmitting any unit vibration. See Figures
4 and 5.
3. Concrete block walls must be thoroughly inspected to
insure that they are capable of carrying the weight of
the installing unit. See Figure 4.
MOUNTING THE UNIT
1. These units are secured by wall mounting brackets,
which secure the unit to the outside wall surface at
both sides. A bottom mounting bracket is provided
for ease of installation, but it is not required.
2. The unit itself is suitable for “0” inch clearance, but
the supply air duct flange and the first 3 feet of supply
air duct require a minimum of ¼ inch clearance to
combustible material. If a combustible wall, use a
minimum of 30½" x 10½" dimensions for sizing.
However, it is generally recommended that a 1-inch
clearance is used for ease of installation and
maintaining the required clearance to combustible
material. The supply air opening would then be
32" x 12". See Figures 3, 3A and 5 for details.
3. Locate and mark lag bolt locations and bottom
mounting bracket location. See Figure 4.
4. Mount bottom mounting bracket.
5. Hook top rain flashing under back bend of top. Top
rain flashing is shipped secured to the right side of
the back.
6. Position unit in opening and secure with 5/16 lag
bolts; use 7/8 inch diameter flat washers on the lag
bolts.
7. Secure rain flashing to wall and caulk across entire
length of top. See Figure 3.
8. For additional mounting rigidity, the return air and
supply air frames or collars can be drilled and
screwed or welded to the structural wall itself
(depending upon wall construction). Be sure to
observe required clearance if combustible wall.
9. On side-by-side installations, maintain a minimum of
20 inches clearance on right side to allow access to
heat strips and control panel, and to allow proper
airflow to the outdoor coil. Additional clearance may
be required to meet local or national codes.
TYPICAL INSTALLATIONS
See Figure 6 for common ways to install the wall-mount
unit.
WARNING
Failure to provide the ¼ inch clearance
between the supply duct and a combustible
surface for the first 3 feet of duct can result in
fire.
WARNING
Fire hazard can result if ¼ inch clearance to
combustible materials for supply air duct is not
maintained. See Figure 3.

Manual 2100-487
Page 10 of 23
FIGURE 3
MOUNTINGINSTRUCTIONS
FIGURE 3A
ELECTRICHEATCLEARANCE
WARNING
• A minimum of ¼ 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 ¼ inch
minimum spacing is maintained at all points.
• Failure to do this could result in overheating
the combustible material and may result in
fire.
6 5/8" 6 5/8"
1 7/8"
21"
21"
16"
16"
16"
DIM. "D"
DIM. "B"
DIM. "E"
16"
DIM. "A"DIM. "C" DIM. "C"
30"
Supply Opening
Return Opening
Wall Bracket
Wall
Mounting
Hole
Pattern
Front view of wall with unit removed
1/4" clearance on
all (4) sides of
supply air duct
is required from
combustible
materials
Supply
Air Duct
Return
Air Opening
Wall
Circuit breaker
access door
Heater access
panel Note: It is recommended
that a bead of silicone
caulking be placed behind
the side mounting flanges
and under top flashing at
time of installation.
MIS-796 A
Top flashing detail view
Attach supplied
rain flashing.
Apply caulk
between flashing
and wall.
Foam air seal
Seal with bead of
caulking along entire
length of top.
Supply flange
Side view of wall with unit installed
DIM. "A" DIM. "B" DIM. "C" DIM. "D" DIM. "E"
Required dimensions to
maintain 1/4" min. clearance
from combustible materials 30 1/2" 10 1/2" 6 1/4" 1 1/4" 29 3/4"
Required dimensions to
maintain 1" clearance from
combustible materials 32" 12" 5 1/2" 2" 29"
DIMENSION CHART
DIM. "A" DIM. "B" DIM. "C" DIM. "D" DIM. "E"
Required dimensions to
maintain 1/4" min. clearance
from combustible materials 30 1/2" 10 1/2" 6 1/4" 1 1/4" 29 3/4"
Required dimensions to
maintain 1" clearance from
combustible materials 32" 12" 5 1/2" 2" 29"
DIMENSION CHART

Manual 2100-487
Page 11 of 23
FIGURE 5
WALL-MOUNTINGINSTRUCTIONS
FIGURE 4
WALL-MOUNTINGINSTRUCTIONS
SEE FIGURE 3 — MOUNTING INSTRUCTIONS
SEE UNIT DIMENSIONS, FIGURE 1,
FOR ACTUAL DIMENSIONS
SEE FIGURE 1 FOR
DUCT DIMENSIONS

Manual 2100-487
Page 12 of 23
FIGURE 6
COMMONWALL-MOUNTINGINSTALLATIONS

Manual 2100-487
Page 13 of 23
If the #8403-058 thermostat is used, nine (9) wires
should be run from the thermostat subbase to the 24V
terminal board in the unit. If the #8403-060
thermostat/humidistat is used, ten (10) wires should be
run from the thermostat subbase to the 24V terminal
board. A nine (9) or ten (10) wire conductor
(depending on thermostat used), 18 gauge copper
color-coded thermostat cable is recommended. The
connection points are shown in Figure 7.
NOTE: The voltage should be measured at the field power
connection point in the unit and while the unit is
operating at full load (maximum amperage
operating condition).
LOW VOLTAGE CONNECTIONS
These units use a grounded 24 volt AC low voltage circuit.
The “R” terminal is the hot terminal and the “C”
terminal is grounded.
“G” terminal is the fan input.
“Y” terminal is the compressor input.
“B” terminal is the reversing valve input. The reversing
valve must be energized for heating mode.
“R” terminal is 24 VAC hot.
“C” terminal is 24 VAC grounded.
“L” terminal is compressor lockout output. This terminal
is activated on a high or low pressure trip by the electronic
heat pump control. This is a 24 VAC output.
“W2” terminal is second stage heat (if equipped).
“O1”terminal is the ventilation input. This terminal
energizes any factory installed ventilation option.
“E” terminal is the emergency heat input. This terminal
energizes the emergency heat relay.
NOTE: For total and proper control using DDC, a total
of 6 controlled outputs are required (5 if no
ventilation system is installed). For proper
system operation under Emergency Heat
conditions where the compressor needs to be
deactivated, the B-W2-E-G outputs need to be
energized. Removing the Y (compressor)
signal alone turns the compressor off, but does
not activate the additional circuitry embedded in
the heat pump for proper and complete operation.
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.
WIRING — LOW VOLTAGE WIRING
The electrical data lists fuse and wire sizes (75ºC copper)
for all models, including the most commonly used heater
sizes. Also shown are the number of field power circuits
required for the various models with heaters.
The unit rating plate lists a “Maximum Time Delay Relay
Fuse” or “HACR” type circuit breaker that is to be used
with the equipment. The correct size must be used for
proper circuit protection and also to assure that there will
be no nuisance tripping due to the momentary high
starting current of the compressor motor.
The disconnect access door on this unit may be locked to
prevent unauthorized access to the disconnect. To convert
for the locking capability, bend the tab located in the
bottom left hand corner of the disconnect opening under
the disconnect access panel straight out. This tab will now
line up with the slot in the door. When shut, a padlock may
be placed through the hole in the tab preventing entry.
See Start-up section for information on three phase scroll
compressor start-ups.
230/208V, 1 phase and 3 phase equipment dual primary
voltage transformers. All equipment leaves the factory
wired on 240V tap. For 208V operation, reconnect from
240V to 208V tap. The acceptable operating voltage
range for the 240 and 208V taps are:
LOWVOLTAGECONNECTIONS
FOR DDC CONTROL
Fan Only Energize G
Cooling Mode Energize Y, G
Heat Pump Heating Energize Y, G, B
2nd Stg Heating Energize G, W2, Y, B
w/Heat Pump (if employed)
Ventilation Energize G, O1
Emergency Heat Energize B, W2, E, G
paTegnaR
042 802 612-352 781-022
FIGURE 7
UNIT 24V TERMINAL BOARD

Manual 2100-487
Page 14 of 23
TABLE 3
THERMOSTAT WIRE SIZE
remrofsnarT AVALFeguaGeriW
mumixaM ecnatsiD teeFnI
553.2
eguag02 eguag81 eguag61 eguag41 eguag21 5406 001 061 052
OPTIONAL OUTDOOR THERMOSTAT
APPLICATIONS
Since most equipment at the time of manufacture is not
designated for any specific destination of the country and
are installed in areas not approaching the lower outdoor
temperature range, outdoor thermostats are not factory
installed as standard equipment, but are offered as an
option. There are also different applications for applying
outdoor thermostats. The set point of either type of
outdoor thermostat application is variable with
geographic region and sizing of the heating equipment to
the individual structure. Utilization of the heating
Application Data, and the heat loss calculation of the
building are useful in determining the correct set points.
NOTE: The additional LAB (low ambient bypass) relay
is required to prevent heater operation during low
temperature cooling operation. FIGURE 8
COMPRESSORCUTOFFTHERMOSTATWIRING
4 - 10KW 1PH --- 6 & 9KW 3-PH
FIGURE 9
COMPRESSORCUTOFFTHERMOSTATWIRING
15 - 20KW 1-PH & 3-PH
Temperature and Humidity Controller #8403-060, along
with the Outdoor Sensor option Part #8403-061, can be
used to:
•Limit minimum outdoor temperature for cooling option.
•Limit minimumoutdoortemperatureforheatpump option.
•Inhibit electric heat operation for heat pumps above
selectedoutdoortemperature.
Thus, not requiring the optional compressor cut-off
thermostat or the electric heat cut-off thermostat option.
OPTIONALCOMPRESSORCUTOFF
THERMOSTAT (See Figures 8 and 9)
Heat pump compressor operation at outdoor
temperatures below 0°F are neither desirable nor
advantageous in term of efficiency. An outdoor
thermostat can be applied to take the mechanical
heating (compressor) off line, and send the
(compressor) signal to energize electric heat in its place
(to make electric heat first stage heating). This can also
be applied to bank the quantity of available electric
heat. For example: A heat pump operates with 10KW
second stage heat – once the outdoor thermostat has
switched then operates 15KW without the compressor
as first stage heat.

Manual 2100-487
Page 15 of 23
FIGURE 10
ELECTRIC HEAT HOLD-OFF WIRING
4 – 10KW 1 PH — 6 & 9KW 3 PH
FIGURE 11
ELECTRIC HEAT HOLD-OFF WIRING
15 – 20KW 1 PH & 3 PH
TABLE 4
WALLTHERMOSTAT
tatsomrehTserutaeFtnanimoderP
850-3048 )1511D0225HT(
taeHegats2;looCegats2 elbammargorP-noNcinortcelE revoegnahclaunaMrootuA
060-3048 )544-0211(
taeHegats3;looCegats3 cinortcelEelbammargorP-noN/elbammargorP lanoitnevnoCroPH revoegnahclaunaMrootuA
ELECTRICHEAT HOLD-OFF
(SEE FIGURES 10 AND 11)
In other applications, it is desirable to disable the operation
of the electric heat until outdoor temperatures have reached
a certain design point. This won't allow the electric heat to
come on as second stage heating unless the outdoor
temperature is below the set point of the outdoor thermostat.
This is done to maximize efficiency by utilizing the heat
pump to bring the conditioned space temperature up, rather
than cycling on the electric heat due a second stage call for
heat from the thermostat on start-up coming off a night set-
back condition or someone increasing the thermostat set
point. (NOTE: Some programmable thermostats do have a
built-in time delay for pulling in second stage heat when
coming off set-back conditions.)

Manual 2100-487
Page 16 of 23
START UP
IMPORTANT INSTALLER NOTE
For improved start-up performance, wash the indoor coil
with a dishwashing detergent.
CRANKCASE HEATERS
WH423 units are provided with compressor crankcase
heat. WH604 and WH483 units are not provided with
crankcase heat. These units utilize scroll compressors
which do not require crankcase heat in this application.
The WH423 models have an insertion well-type heater
located in the lower section of the compressor housing.
This is a self-regulating type heater that draws only
enough power to maintain the compressor at a safe
temperature on these units.
Some form of crankcase heat is essential to prevent
liquid refrigerant from migrating to the compressor,
causing oil pump out on compressor start-up and
possible valve failure due to compressing a liquid.
The decal in Figure 12 is affixed to all WH423 units
detailing start-up procedure. This is very important.
Please read carefully.
HIGH PRESSURE SWITCH
The WH483 and WH604 models are supplied with a
remote reset high pressure switch. If tripped, this
pressure switch may be reset by turning the thermostat
off then back on again.
THREE PHASE SCROLL COMPRESSOR
START UP INFORMATION
Scroll compressors, like several other types of
compressors, will only compress in one rotational
direction. Direction of rotation is not an issue with
single phase compressors since they will always start
and run in the proper direction.
However, three phase compressors will rotate in either
direction depending upon phasing of the power. Since
there is a 50-50 chance of connecting power in such a
way as to cause rotation in the reverse direction,
verification of proper rotation must be made. All three
phase units incorporate a phase monitor to ensure proper
field wiring. See the Phase Monitor later in this manual.
Verification of proper rotation must be made any time a
compressor is change or rewired. If improper rotation is
corrected at this time there will be no negative impact on
the durability of the compressor. However, reverse
operation for over one hour may have a negative impact
on the bearing due to oil pump out.
NOTE:If compressor is allowed to run in reverse
rotation for several minutes, the compressor's
internal protector will trip.
All three phase ZR3 compressors are wired identical
internally. As a result, once the correct phasing is
determined for a specific system or installation,
connecting properly phased power leads to the same
Fusite terminal should maintain proper rotation
direction.
Verification of proper rotation direction is made by
observing that suction pressure drops and discharge
pressure rises when the compressor is energized.
Reverse rotation also results in an elevated sound level
over that with correct rotations, as well as, substantially
reduced current draw compared to tabulated values.
The direction of rotation of the compressor may be
changed by reversing any two line connections to the
unit.
FIGURE 12
START UP LABEL
IMPORTANT
THESE PROCEDURES MUST BE
FOLLOWED AT INITIAL START UP
AND AT ANY TIME POWER HAS
BEEN REMOVED FOR 12 HOURS
OR LONGER.
TO PREVENT COMPRESSOR DAMAGE
WHICH MAY RESULT FROM THE PRESENCE
OF LIQUID REFRIGERANT IN THE
COMPRESSOR CRANKCASE:
1. MAKE CERTAIN THE ROOM THERMOSTAT
IS IN THE “OFF” POSITION. (THE
COMPRESSOR IS NOT TO OPERATE.)
2. APPLY POWER BY CLOSING THE SYSTEM
DISCONNECT SWITCH. THIS ENERGIZES
THE COMPRESSOR HEATER WHICH
EVAPORATES THE LIQUID REFRIGERANT
IN THE CRANKCASE.
3. ALLOW 4 HOURS OR 60 MINUTES PER
POUND OF REFRIGERANT IN THE
SYSTEMAS NOTED ON THE UNIT RATING
PLATE, WHICHEVER IS GREATER.
4. AFTER PROPER ELAPSED TIME THE
THERMOSTAT MAY BE SET TO OPERATE
THE COMPRESSOR.
5. EXCEPT AS REQUIRED FOR SAFETY
WHILE SERVICING, DO NOT OPEN
SYSTEM DISCONNECT SWITCH.
7961-411

Manual 2100-487
Page 17 of 23
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.
SERVICE HINTS
1. Caution owner/operator to maintain clean air filters at
all times. Also, not to needlessly close off supply and
return air registers. This reduces airflow through the
system, which shortens equipment service life as well
as increasing operating costs
2. Switching to heating cycle at 75°F or higher outside
temperature may cause a nuisance trip of the remote
reset high pressure switch. Turn thermostat off, then
on to reset the high pressure switch.
3. The heat pump wall thermostats perform multiple
functions. Be sure that all function switches are
correctly set for the desired operating mode before
trying to diagnose any reported service problems.
4. Check all power fuses or circuit breakers to be sure
they are the correct rating.
5. Periodic cleaning of the outdoor coil to permit full
and unrestricted airflow circulation is essential.
SEQUENCE OF OPERATION
COOLING – Circuit R-Y makes at thermostat pulling in
compressor contactor, starting the compressor and
outdoor motor. The G (indoor motor) circuit is
automatically completed on any call for cooling
operation or can be energized by manual fan switch on
subbase for constant air circulation.
HEATING – A 24V solenoid coil on reversing valve
controls heating cycle operation. Two thermostat
options, one allowing “Auto” changeover from cycle to
cycle and the other constantly energizing solenoid coil
during heating season, and thus eliminating pressure
equalization noise except during defrost, are to be used.
On “Auto” option a circuit is completed from R-W1 and
R-Y on each heating “on” cycle, energizing reversing
valve solenoid and pulling in compressor contactor
starting compressor and outdoor motor. R-G also make
starting indoor blower motor. Heat pump heating cycle
now in operation. The second option has no “Auto”
changeover position, but instead energizes the reversing
valve solenoid constantly whenever the system switch
on subbase is placed in “Heat” position, the “B”
terminal being constantly energized from R. A
Thermostat demand for heat completes R-Y circuit,
pulling in compressor contactor starting compressor and
outdoor motor. R-G also make starting indoor blower
motor.
PRESSURE SERVICE PORTS
High and low pressure service ports are installed on all
units so that the system operating pressures can be
observed. Pressure tables can be found later in the
manual covering all models on both cooling and heating
cycles. It is imperative to match the correct pressure
curve to the unit by model number.
DEFROST CYCLE
The defrost cycle is controlled by temperature and time
on the solid state heat pump control. See Figure 13.
When the outdoor temperature is in the lower 40°F
temperature range or colder, the outdoor coil
temperature is 32°F or below. This coil temperature is
sensed by the coil temperature sensor mounted near the
bottom of the outdoor coil. Once coil temperature
reaches 30°F or below, the coil temperature sensor
sends a signal to the control logic of the heat pump
control and the defrost timer will start.
After 60 minutes at 30°F or below, the heat pump
control will place the system in the defrost mode.
During the defrost mode, the refrigerant cycle switches
back to the cooling cycle, the outdoor motor stops,
electric heaters are energized, and hot gas passing
through the outdoor coil melts any accumulated frost.
When the temperature rises to approximately 57°F, the
coil temperature sensor will send a signal to the heat
pump control which will return the system to heating
operations automatically.
If some abnormal or temporary condition such as a high
wind causes the heat pump to have a prolonged defrost
cycle, the heat pump control will restore the system to
heating operation automatically after 10 minutes.
The heat pump defrost control board has an option of
30, 60 or 90-minute setting. All models are shipped
from the factory on the 60-minute pin. If special
circumstances require a change to another time, remove
the wire from the 60-minute terminal and reconnect to
the desired terminal. The manufacturer’s
recommendation is for 60-minute defrost cycles. Refer
to Figure 13.

Manual 2100-487
Page 18 of 23
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 10 seconds with the SPEEDUP
terminals shorted for the speedup to be completed and
the defrost cycle to start.
As soon as the defrost cycle kicks in remove the
shorting instrument from the SPEEDUP terminals.
Otherwise the timing will remain accelerated and run
through the 1-minute minimum defrost length sequence
in a matter of seconds and will automatically terminate
the defrost sequence.
There is an initiate defrost jumper (sen jump) on the
control that can be used at any outdoor ambient during
the heating cycle to simulate a 0° coil temperature.
FIGURE 13
DEFROSTCONTROL BOARD
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
builtinto the HPC. This is to protect the compressor from
shortcyclingconditions. Insomeinstances,itishelpfulto
the service technician to override or speed up this timing
period,andshortingouttheSPEEDUPterminalsforafew
seconds can do this.

Manual 2100-487
Page 19 of 23
TROUBLESHOOTING
SOLID STATE HEAT PUMP CONTROL
TROUBLESHOOTINGPROCEDURE
1. 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
1-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.
TABLE 5
TROUBLESHOOTING
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lliwrosserpmoC gnitaeh(tratston )gniloocro CotRmorfV42rofkcehC lortnocpmuptaehehtno tupniremrofsnartkcehcdnaremrofsnartotdraobmorfgniriwkcehc,RtatneserptonsiV42fI ecalperdnaesuacenimreted,tuptuoV42onsahremrofsnartfI.egatlovtuptuodna .remrofsnart
CotYmorfV42rofkcehC pirtslanimretegatlovwolno )deppiuqefi(tatsomrehtroodtuo,gniriwtatsomrehtdnatatsomrehtkcehc,tneserptonsiV42fI oteunitnoctneserpsiV42fI.)sledomesahp-3emosnodesu,deppiuqefi(rotinomesahp .petstxen
otCmorfV42rofkcehC lortnocpmuptaehnoCC ehtpmuj,tneserptonsiV42fI.rotcatnocrosserpmocecalperro/dnakcehc,tneserpsiV42fI 1LotCmorfV42rofkcehctratstonseodrosserpmocfI.sdnoces01roflanimretpudeeps .lortnocpmuptaehehtno
tuokcolrosserpmoC woldnahctiwserusserphgihehtkcehc,lortnocpmuptaehehtfo1LtatneserptonsiV42fI tiucricytefasehT.slanimretdnagniriwdetaicossalladna)deppiuqefi(yalerssapyberusserp eht,nepoerayalerssapyberusserpwolrohctiwserusserphgihehtfI.tiucricdesolcasi otnodnafforewopelcyC.tnenopmocevitcefedecalpeR.rosserpmocehttuokcollliwlortnoc .yaledemitetunim-5edirrevootsdnoces01rofslanimretpudeepspmuJ.tuokcolteser
lortnocpmuptaehevitcefeD neebsahyaledemiteht,lortnocpmuptaehehtno1LotCdna,YotCmorftneserpsiV42fI .lortnocpmuptaehehtecalper,CCtatneserpsiV42ondnaderipxeroneddirrevo
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evitcefedrotoM .rotomecalpeR.gnidniwrotomdetrohsroneporofkcehC
evitcefedroticapacrotoM .roticapacecalpeR.roticapacdetrohsroneporofkcehC.gnitarroticapackcehC
evlavgnisreveR ezigrenetonseod )ylnognitaeh( evitcefedlortnocpmuptaeH.C-BdnaC-VRneewtebV42rofkcehC .gniriwtiucriclortnockcehC.1 lortnocpmuptaehecalpeR.2
dionelosevlavgnisreveR evitcefedlioc .liocdetrohsroneporofkcehC .liocdionelosecalpeR
ogtonlliwtinU tsorfedotni )ylnognitaeh( taehrorosneserutarepmeT evitcefedlortnocpmup NES"dnaslanimret"PUDEEPS"ssorcarepmujdnadraobmorfrosneserutarepmettcennocsiD .etunimenonihtiwelcyctsorfedahguorhtogottinuehtesuacdluohssihT.slanimret"PMJ .rosneserutarepmetecalper,elcyctsorfedhguorhtseogtinufI.1 .lortnocpmuptaehecalper,elcyctsorfedhguorhtogtonseodtinufI.2
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Manual 2100-487
Page 20 of 23
CHECKING TEMPERATURE SENSOR
OUTSIDE UNIT CIRCUIT
1. Disconnect temperature sensor from board and from
outdoor coil.
2. Use an ohmmeter and measure the resistance of the
sensor. Also use ohmmeter to check for short or
open.
3. Check resistance reading to chart of resistance. Use
sensor ambient temperature. (Tolerance of part is
± 10%.)
4. If sensor resistance reads very low, then sensor is
shorted and will not allow proper operation of the
heat pump control.
5. If sensor is out of tolerance, shorted, open or reads
very low ohms then it should be replaced.
FR FR FR FR
0.52- 0.42- 0.32- 0.22- 0.12- 0.02- 0.91- 0.81- 0.71- 0.61- 0.51- 0.41- 0.31- 0.21- 0.11- 0.01- 0.9- 0.8- 0.7- 0.6- 0.5- 0.4- 0.3- 0.2- 0.1- 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 0.01 0.11 0.21 178691 990091 585381 813771 982171 784561 409951 925451 553941 473441 675931 659431 605031 912621 980221 801811 272411 575011 010701 475301 062001 46079 18939 80019 93188 17358 99628 12108 23677 03257 01927 07607 70586 81466 99346 94426 56506 54785 0.31 0.41 0.51 0.61 0.71 0.81 0.91 0.02 0.12 0.22 0.32 0.42 0.52 0.62 0.72 0.82 0.92 0.03 0.13 0.23 0.33 0.43 0.53 0.63 0.73 0.83 0.93 0.04 0.14 0.24 0.34 0.44 0.54 0.64 0.74 0.84 0.94 0.05 58965 48255 04635 15025 41505 82094 09574 00264 55844 45534 59224 77014 89893 75783 25673 38563 84553 54543 47533 43623 32713 04803 68992 75192 55382 77572 32862 29062 38352 69642 03042 48332 85722 05122 16512 98902 53402 69891 0.35 0.25 0.35 0.45 0.55 0.65 0.75 0.85 0.95 0.06 0.16 0.26 0.36 0.46 0.56 0.66 0.76 0.86 0.96 0.07 0.17 0.27 0.37 0.47 0.57 0.67 0.77 0.87 0.97 0.08 0.18 0.28 0.38 0.48 0.58 0.68 0.78 0.88 47391 76881 57381 98971 43471 48961 74561 22161 01751 01351 12941 44541 77141 02831 47431 73131 01821 29421 38121 38811 19511 70311 13011 26701 10501 74201 00001 0679 6259 9929 7709 2688 3568 9448 0528 7508 9687 6867 0.98 0.09 0.19 0.29 0.39 0.49 0.59 0.69 0.79 0.89 0.99 0.001 0.101 0.201 0.301 0.401 0.501 0.601 0.701 0.801 0.901 0.011 0.111 0.211 0.311 0.411 0.511 0.611 0.711 0.811 0.911 0.021 0.121 0.221 0.321 0.421 7057 4337 5617 0007 0486 3866 1356 3836 9326 8906 1695 7285 7965 0755 6445 6235 8025 4905 2894 3784 7674 3664 2654 4644 7634 4724 2814 3904 6004 1293 8383 7573 8763 1063 6253 2543
TEMPERATURE F VS. RESISTANCE R OF TEMPERATURE SENSOR