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Inspect the unit for damage during shipment and verify it is correct for the intended application.
Ensure adequate power supply for the unit and any supplementary heaters, matching unit nameplate requirements.
Check handling facilities and use proper methods with straps/spreader bars for safe lifting of the unit.
Considerations for unit placement, including clearances, snow drift, water runoff, and noise for optimal installation.
Guidelines for rooftop installations, including structural support, clearances, and ductwork insulation.
Instructions for connecting and pitching the condensate drain line, requiring a trap and 3/4" pipe.
Procedures for outdoor ground-level installations, focusing on pad placement, isolation, and ductwork.
Ensure electrical wiring and grounding comply with local codes and the National Electrical Code.
Provide an approved weather-proof disconnect switch visible from the unit for servicing.
The branch circuit feeding the unit must be protected as indicated on the unit's rating plate.
Run power supply lines in weathertight conduit, ensuring tight connections and strain relief.
The unit must be electrically grounded in accordance with local codes or the National Electrical Code.
All electrical accessories must be installed and wired according to their specific instructions.
Route low-voltage control wiring separately from power wiring, ensuring proper connections.
Units require filters in the return air duct; refer to filter data table for size and specifications.
Perform a thorough pre-start check of unit placement, ductwork, wiring, and clearances.
Initiate cooling by setting the thermostat to COOL, ensuring proper crankcase heat operation.
Check discharge and suction line pressures against normal operating pressures for proper function.
Verify line voltage is within the range shown on the unit nameplate; check supply line size if low.
Shut down cooling by setting the system selector to OFF or thermostat above room temperature.
Initiate heating by setting the thermostat to HEAT, ensuring all access doors are closed.
Shut down heating by setting the system selector to OFF or heating selector below room temperature.
Describes automatic operation for HEAT and COOL cycles and fan switch modes (ON/AUTO).
Details the cooling cycle initiation, including compressor crankcase heat and thermostat control.
Explains the heating cycle, compressor operation, and thermostat control for heating.
Describes how supplementary electric heat engages when indoor temperature drops below thermostat setting.
Explains how the demand defrost control activates cooling to clear outdoor coil frost.
Information on adjusting blower speed using dip switches on the ICM Fan Control.
Periodic tasks for owners, including filter replacement, cabinet cleaning, and coil inspection.
Instructions for cleaning or replacing central duct system air filters monthly for optimal performance.
Guidance on cleaning the outdoor coil by brushing vertically and keeping vegetation clear.
Recommended annual checks by a qualified serviceman for filters, motors, safety controls, and components.
Measures outdoor ambient and coil temperatures to determine defrost needs based on delta-T.
Identifies fault conditions via the defrost control's flashing light indicator.
Details the function of various pins on the defrost control board for testing.
Procedures for checking the defrost control's operation and diagnosing potential issues.
Instructions for measuring sensor resistance at different temperatures to verify functionality.
Interprets LED flash rates to diagnose normal operation or specific fault conditions.
Troubleshooting steps when the defrost control LED is off.
Diagnosing issues when the LED flashes rapidly or continuously.
Checks for conditions preventing normal defrost initiation, including sensor readings.
Troubleshooting steps when forced defrost does not initiate.
Diagnosing manual defrost termination in less than 10 seconds.
Troubleshooting manual defrost termination based on timed intervals.
Checks for defrost initiation at specific intervals, related to sensor accuracy and fan operation.
Diagnosing defrost initiation at longer intervals, checking sensors and system charge.
Troubleshooting when the outdoor fan motor runs during the defrost cycle.
Checks for the correct delay of the switchover valve upon defrost termination.
Diagnosing issues related to a burned-out ODS-A sensor.
Troubleshooting compressor non-operation on SCROLL bearing units.
Diagnosing the absence of a 30-second off delay at defrost initiation on SCROLL units.
Details the limited warranty for Packaged Air Conditioners and Heat Pumps for residential use.
Details the limited warranty for High Efficiency Heat Pumps for commercial use.
Guidance on calling a dealer, including pre-call checks for unit operability.
This document provides comprehensive instructions for the installation, operation, and maintenance of single-packaged heat pump units, specifically the WCH series, available in 2, 2-1/2, 3, 3-1/2, 4, and 5-ton capacities. It is crucial for this document to remain with the unit as customer property and to be returned to the service information pack upon completion of work. A prominent warning highlights the hazardous voltage and the necessity to disconnect power before servicing to prevent injury or death due to electrical shock or contact with moving parts. All installation phases must adhere to national, state, and local codes.
The manual emphasizes that these instructions do not cover all system variations or every possible contingency during installation. For additional information or specific problems not addressed, users are advised to consult the manufacturer. A warning is also issued regarding the use of this information by individuals with adequate electrical and mechanical experience, stating that any attempt to repair a central air conditioning product without proper expertise may result in personal injury and/or property damage. The manufacturer or seller disclaims responsibility for the interpretation of this information or any liability arising from its use.
A critical safety caution advises reconnecting all grounding devices. It explains that all conductive parts of the product are grounded, and any grounding wires, screws, straps, clips, nuts, or washers removed for service must be returned to their original position and properly fastened. Another caution warns that the system contains refrigerant, oil, and refrigerant under high pressure. It is imperative to recover refrigerant to relieve pressure before opening the system, as failure to follow proper procedures can lead to personal illness, injury, or severe equipment damage. The manufacturer maintains a policy of continuous product and product data improvement, reserving the right to change design and specifications without notice.
The general information section covers installation, operation, and maintenance for all single-package WCH air conditioning units. It stresses the importance of following the outlined sequence for an easy and orderly installation, as improper installation can lead to unsatisfactory operation, dangerous conditions, and may void the warranty. The manual must be read carefully before installing, operating, or performing maintenance, and all such tasks should be performed by qualified service technicians. Units must be located according to local codes or the National Electrical Code, and each unit is shipped with an operating charge of HCFC-22.
Upon receipt, users are instructed to inspect the exterior carton for signs of rough handling and check the unit nameplate to confirm it matches the intended application. After moving the equipment, it should be unpacked carefully. Any damage must be reported immediately to the delivery agency, and it should be verified that the refrigerant charge has been retained.
Regarding the power supply, it must be adequate for the unit and any supplementary electric heaters. The power supply must match the requirements on the unit nameplate, and separate branch circuits are needed for supplementary electric heaters. For rigging, it is important to ensure handling facilities are safe for personnel and the unit, using proper rigging methods with straps or slings and spreader bars. A safety warning explicitly states not to lift the unit without testing for balance and rigging, in windy conditions, above personnel, or by attaching to the unit casing, hardware, corner lugs, angles, tabs, or flanges, as this can cause equipment damage.
The "Locations and Recommendations" section details optimal placement for the unit. It notes that the unit is designed for multiple applications, including rooftop and outdoor ground level. Installation should conform to local building codes or the National Electrical Code, with Canadian installations adhering to CSA and local codes. A key recommendation is to select a location that allows unobstructed airflow into the outdoor coil and away from the fan discharge, with discharge air unrestricted for at least three feet above the unit. Reduced clearances can lead to condenser coil starvation or recirculation of warm condenser air. If located under an overhang, provisions must be made to deflect warm discharge air. The unit must also be accessible for service. Installing internal accessories at the shop is practical, and the unit should be positioned to avoid roof-runoff water pouring directly onto it.
A general caution advises avoiding personal injuries and equipment damage. In areas with deep snow, the unit should be raised at least 12 inches off the deck, slab, or pad to prevent coil blockage and allow defrost water to drain. Avoiding locations prone to snow drifts will reduce the need for snow removal. A snow drift barrier can be installed, ensuring it is far enough from the unit to prevent airflow restriction. The unit should be located so that water vapor from defrost cycles discharges upward, preventing condensation on windows or icicle formation on roof overhangs. Minimum elevations must be observed for the drain line trap and ventilation. All ductwork inside the structure should be adequately insulated, and outdoor ductwork must be insulated and weatherproofed according to local codes. If supplementary heat is added, duct connectors should be flame retardant. Access and service clearances are crucial when locating duct entrance openings. Outdoor ducts should be as short as possible, and structure holes must accommodate ducts and insulation. For ground-level applications, the unit needs a solid, level foundation not adjoined to the structure to prevent sound and vibration transmission. Field-supplied mounting pads should be used to prevent vibration transmission. The location should minimize supply and return duct lengths and prevent external water drainage around the unit. Consideration should also be given to shade, appearance, and noise.
The "Installation Applications" section further elaborates on rooftop and ground-level installations. For rooftops, the structure must support the unit's load, with FHA-approved construction and local codes typically adequate for proportionally distributed loads. The unit should be positioned according to recommended clearances. If duct hoods or supply/return ducts are fabricated, the outdoor portions should be as short as possible, insulated with 2 inches of insulation, and weatherproofed. Openings in the structure must accommodate ducts and insulation. Turning vanes are recommended inside supply and return ducts when using square elbow take-offs. Vibration isolators are recommended to prevent transmission to the structure, with at least four isolators providing a minimum 1/4 inch clearance beneath the unit for air circulation.
Condensate drain piping requires a 3/4-inch female NPT connection on the evaporator end. A trap must be provided and filled with water before starting to prevent air from being drawn through. The drain line should be pitched downward, avoiding long horizontal runs, and must be 3/4-inch pipe, pitched 1/4 inch per foot, trapped, and not connected to a closed drain system. Reducing fittings should not be used. If an external drain pan is installed, its pipe should not be connected to the unit's drain pipes or trapped.
For ground-level installations, the unit must be placed on a pad at least two inches larger than the unit on all sides, level, and not in contact with the structure. Outdoor portions of supply and return air ducts should be as short as possible, insulated with at least two inches of insulation, and weatherproofed. The unit must be isolated with mounting pads providing a minimum 1/4 inch clearance for air circulation and corrosion prevention.
The "Electrical Wiring" section provides critical instructions. A warning reiterates the need to lock the unit disconnect switch in the open position before servicing to prevent injury or death from electrical shock or moving parts. All electrical wiring and grounding must comply with local codes or the National Electrical Code ANSI/NFPA 70. An approved weatherproof disconnect must be provided on the side of the unit or within close proximity and sight. The branch circuit feeding the unit must be protected as indicated on the unit rating plate. Power supply lines must be run in weathertight conduit to the disconnect and into the control box, with strain relief for all connectors. Flexible conduit supports are recommended to prevent vibration noise. All connections must be tight.
Notes for electrical wiring specify that branch circuit wiring size should be determined by the unit nameplate ampacity and the N.E.C. For more than three conductors in a raceway or cable, N.E.C. derating ampacity rules apply. Wire size is based on 75 degrees C rated wire insulation. The unit must be electrically grounded according to local codes or the National Electrical Code. All electrical accessories must be installed and wired per their instructions. Low voltage control wiring (Class II) should not be run in the same conduit as power wiring unless Class I wire of proper voltage rating is used. Thermostat cable (No. 18 AWG colored wire) should be routed through the rubber grommet on the unit.
It is important not to short thermostat wires, as this will damage the control transformer. Recommended wire sizes and lengths for the unit thermostat are provided, with total resistance not exceeding one ohm to prevent control malfunction due to excessive voltage drop. Upon completion of wiring, all electrical connections, including factory wiring, must be checked for tightness. Electrical box covers and access doors must be replaced and secured before leaving the unit or turning on power. After wiring, the thermostat system switch should be set to OFF, and power applied by closing the main disconnect switch to activate the compressor sump heat. The sump heat should be energized for a minimum of eight hours before starting the unit to evaporate any liquid HCFC-22 in the compressor.
Air filters are required with adequate filter area in the return air duct. Filter data, including nominal CFM, filter size (Sq Ft), and resistance, are provided for various models. The specific location of filters depends on the installation type and duct system layout. Owners should be aware of filter location and the need for regular changes. If permanent filters are used, they should be sized per manufacturer recommendations with a clean resistance of 0.05" WC.
The "Start-Up" section includes a pre-start quick check list covering unit location, ductwork, condensate line, filters, wiring, power supply, thermostat, fan operation, indoor blower speed, code compliance, cover/panel placement, and tool removal.
For starting the unit in cooling mode, the thermostat switch must first be turned to "OFF," and the unit disconnect switch closed. This energizes the compressor crankcase heat (if equipped), vaporizing liquid HCFC-22 to prevent foaming and compressor damage. This heat should operate for at least eight hours. WCH048-060F units do not have sump heat as shipped, and crankcase heaters are a field-installed option on some models. After this, the system switch is set to "COOL," and the COOL indicator set below room temperature. The outdoor fan motor, compressor, and evaporator fan motor will operate automatically.
Operating pressures should be checked after the unit runs for a short time in cooling mode, comparing suction and discharge pressures to the normal operating pressures in the unit's SERVICE FACTS. Line voltage at the unit must be within the range on the nameplate; low voltage may indicate an undersized supply line. To shut down cooling, the system selector switch is placed in "OFF" or the thermostat reset above room temperature. The main power disconnect should not be de-energized unless servicing, as power is needed for compressor crankcase heat.
For starting in heating mode, all grilles and registers must be open, and access doors closed. The thermostat system switch is set to "HEAT," and the HEAT indicator set above room temperature. The fan switch is set to "AUTO" or "ON," and the indoor fan motor operates automatically. The thermostat must provide a "G" signal for fan operation. For auto changeover thermostats, appropriate connections are detailed. Heating shut-down involves placing the system selector switch to "OFF" or the heating selector lever below room temperature. A warning regarding fiberglass wool insulation and its potential health hazards (cancer, respiratory, skin, or eye irritation) is included, complying with California Proposition 65.
The "Sequence of Operation" section details the automatic heating and cooling cycles. For HEAT and COOL functions, operation is automatic. An optional automatic changeover thermostat in AUTO position switches between heat and cool based on room temperature. The fan switch can be ON for continuous evaporator fan operation or AUTO to coincide with heating or cooling cycles. Continuous fan mode during cooling may not be appropriate in humid climates; if indoor air exceeds 60% relative humidity, AUTO mode is recommended.
In cooling mode, with the disconnect switch ON, current supplies the compressor crankcase heater and control transformer. The outdoor fan relay (ODF) is energized through normally closed contacts on the defrost timer control (DFC) on 460V and 600V units only. Cooling is enabled via low voltage to the "R" terminal on the indoor thermostat. With the system switch in AUTO and TSC-1 contacts closed, power goes to the "O" terminal on the indoor thermostat to the switchover valve coil (SOV), energizing it to the cooling position (it is in heating when de-energized). When indoor temperature rises 1-1/2 degrees, TSC-2 contacts close, powering the "Y" terminal on the indoor thermostat and the compressor contactor (CC), starting the outdoor fan motor and compressor. TSC-2 also powers the "G" terminal, starting the indoor fan motor.
In heating mode, with the disconnect switch ON, current supplies the compressor crankcase heater and control transformer. The outdoor fan relay (ODF) is energized through normally closed contacts on the defrost timer control (DFC) on 460V and 600V units. From the "R" terminal on the indoor thermostat, current goes through the system switch (in AUTO) to TSH-1 contacts. When closed, these contacts power the "Y" terminal on the indoor thermostat and the heating anticipator. The switch-over valve does not energize due to the heating anticipator's high resistance. Power from "Y" goes to the compressor contactor (CC), starting the outdoor fan motor and compressor. TSH-1 also powers the "G" terminal, starting the indoor fan motor.
Supplementary electric heat activates when indoor temperature drops 1-1/2 degrees below the thermostat setting. TSH-2 contacts close, powering the "W" terminal on the indoor thermostat and the supplementary heater control circuit. The fan relay (F) must be energized. An outdoor thermostat may be added to disallow the second stage of electric heat above a selected outdoor temperature. If the outdoor temperature falls below this setting, the additional heater stage comes on. When indoor ambient is satisfied, TSH-2 contacts open, and the unit reverts to compressor-only heating, then off. For emergency heat, an EMERGENCY heat switch disables the compressor, bypasses outdoor thermostats, and engages supplementary electric heaters and indoor fan.
Demand defrost operation occurs during the heating cycle when the outdoor coil requires defrosting, determined by the demand defrost control (DFC). This control continuously measures outdoor coil temperature (CBS) and outdoor ambient temperature (ODS-B) to calculate the delta-T. When the calculated delta-T is met, the DFC opens the circuit to the outdoor fan motor (ODM) and energizes the switch-over valve (SOV), placing the unit in cooling mode to defrost the outdoor coil. On SCROLL bearing units, the control stops the compressor for a minimum of 30 seconds. The outdoor coil temperature sensor (CBS) terminates the defrost cycle, or times off after 12 minutes. The DFC then energizes the outdoor fan motor (ODM), and 15 seconds later de-energizes the (SOV), returning the unit to heating mode. Supplementary electric heat, if provided, controls indoor temperature during defrost.
ICM fan motor adjustments (WCH048, 060F ONLY) are made on the ICM Fan Control in the control box to increase or decrease airflow. A bank of 8 dip switches on the board matches cooling/heat airflow (CFM/TON), fan off-delay options, and electric heat airflow adjustment.
The "Routine Maintenance by Owner" section outlines periodic tasks. Owners can replace disposable air filters, clean permanent filters, clean the unit's cabinet, clean the condenser coil, and conduct general inspections. A warning emphasizes locking the unit disconnect switch in the open position before servicing. Air filters are crucial; they should be inspected monthly during constant operation and weekly for the first four weeks in new construction. Disposable filters should be replaced with the same type and size, not cleaned. Permanent filters should be washed with mild detergent and water, ensuring they are thoroughly dry before reinstallation. If washing fails or deterioration occurs, permanent filters should be replaced annually with the same type and size. The outdoor coil can become clogged with dust and dirt; it should be cleaned by stroking the coil surface vertically with a soft-bristled brush. All vegetation must be kept away from the outdoor coil area.
"Maintenance Performed by Serviceman" recommends an annual check by a qualified serviceman. This includes inspecting filters, motors and drive system components, condenser coils, safety controls, electrical components and wiring, condensate drain, unit duct connections, mounting support, and overall unit deterioration.
The "Demand Defrost System" section describes the defrost control, which measures outdoor ambient and coil temperatures to determine the delta-T and the need for defrost. The coil sensor also terminates the defrost cycle. Fault detection is indicated by a flashing light on the defrost control. Normal operation shows the LED flashing once per second. If flashing rapidly or not at all, refer to the service manual. Pin identification for TEST_COMMON, TST (test), and FRC_DFT (forced defrost) is provided. A warning states not to connect 24 VAC to the ODS-A terminal, as it will blow the thermistor.
A procedure for testing sensors involves measuring the resistance of the sensor while exposed to its subject temperature, comparing it to a chart of temperature vs. resistance values. Flash rate indications help diagnose faults: one flash/second is normal, two flashes/second indicates Fault A (low DT), three flashes/second indicates Fault B (20 defrosts terminated on time) or Fault C (high DT), and four flashes/second indicates Fault A & C or A & B.
The "Demand Defrost Control Checkout" provides a troubleshooting table with symptoms, checks, and actions. This table helps diagnose issues such as LED off, rapid LED flashing, control not initiating normal or forced defrost, defrost terminating too quickly, incorrect defrost intervals, OD fan running during defrost, no SOV delay, ODS-A burned out, compressor not operating on SCROLL bearing units, and no 30-second off delay at defrost initiation.
The "Base Limited Warranty" section details the warranty for packaged air conditioners and heat pumps (TCK, TCH, WCK, WCH models less than 20 tons) for residential use in the U.S.A. and Canada. It applies to products purchased and retained for use with real property. The warranty period begins upon installation completion and proper start-up, verified by an installer's invoice or similar document, or six months after manufacture if verification is unavailable. If the sealed motor compressor or any functional part fails due to a manufacturing defect within five years, the warrantor will furnish the required replacement part without charge, excluding transportation, service labor, diagnosis calls, refrigerant, and related items. The warranty does not apply to units purchased direct (e.g., from internet websites or auctions) on an uninstalled basis, or if not installed by a licensed HVAC technician, not installed according to manufacturer recommendations, or not compliant with industry standards and codes. It also excludes damage from unreasonable use, improper maintenance, non-manufacturing defects (acts of God, fire, water, storms, etc.), or performance problems due to improper selection/installation. This warranty applies to products installed on or after May 1, 2009. The limited warranty and liability are in lieu of all other warranties, express or implied, and the warrantor is not liable for incidental or consequential damages. Some states/provinces may not allow these limitations. Parts are provided through an authorized service organization. Contact Residential Systems for further assistance. This warranty is for residential usage only.
The "Limited Warranty High Efficiency Heat Pump" section covers 4WCZ6, 4WCY4, 2/4WCC3, 2/4WCX3, WCZ, WCD, WCH, WCK, WSC models (parts only) less than 20 tons for commercial use. This warranty is extended to the original purchaser and succeeding owners of the real property to which the Heat Pump is affixed in the U.S.A. and Canada. There is no warranty against corrosion, erosion, or deterioration. The warranty period begins upon installation completion and proper start-up, verified by an installer's invoice or similar document, or six months after manufacture if verification is unavailable. If any part fails due to a manufacturing defect within one year, the warrantor will furnish the replacement part without charge. If the sealed motor-compressor fails within the second through fifth year, the warrantor will furnish the replacement compressor without charge. Warrantor's obligations are limited to furnishing F.O.B. factory or warehouse replacement parts and do not cover lost refrigerant. Liability is limited to the purchase price of the equipment. This warranty does not apply to units purchased direct (e.g., from internet websites or auctions) on an uninstalled basis, or if not installed by a licensed HVAC technician, not installed according to manufacturer recommendations, or not compliant with industry standards and codes. It also excludes damage from unreasonable use, improper maintenance, non-manufacturing defects (acts of God, fire, water, storms, etc.), or performance problems due to improper selection/installation. The warranty and liability are in lieu of all other warranties, express or implied, and the warrantor is not liable for incidental or consequential damages. Some states/provinces may not allow these limitations. Contact Residential Systems for further assistance. This warranty is for commercial usage only.
The "Important Product Information" section encourages product registration to ensure the strongest manufacturer limited warranties. Users need the serial number, model number, and installation date, which can be found on the invoice or provided by the dealer. A space is provided to record this information. For service, users are advised to call their installing dealer if the unit is inoperative, but first check that the main switch is ON, burned-out fuses are replaced or circuit breakers reset, and the thermostat is properly set. A space for the service phone number is provided. The manufacturer reserves the right to change specifications and design without notice.
General| Cooling Capacity | 24, 000 BTU/h |
|---|---|
| EER | 12.0 |
| HSPF | 8.5 |
| Refrigerant Type | R-410A |
| Voltage | 208/230V |
| Phase | 1 |
| Compressor Type | Scroll |
| Sound Level (Outdoor Unit) | 72 dB |
| Heating Capacity | 24000 BTU/h |
