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
SIO
NS
FRO
NT
VIEW
BA
CK
VIE
WSI
DE
VIEW
* O
PTI
ON
AL
TOP
OU
TLE
T (F
AC
TOR
Y IN
STA
LLE
D O
NLY
) 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)
W(ht
peD
)D(
th
gieH
)H(
ylp
pu
Snr
uteR
EF
GI
JK
LM
NO
PQ
RS
TA
BC
B
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
ondu
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
al C
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
ty"
valu
es a
re to
be
used
for s
izin
g th
e fie
ld p
ower
con
duct
ors.
Ref
er to
the
Nat
iona
l Ele
ctric
Cod
e (la
test
revi
sion
), A
rticl
e 31
0 fo
r pow
er c
ondu
ctor
siz
ing.
CA
UTI
ON
: W
hen
mor
e th
an o
ne fi
eld
pow
er c
ondu
ctor
circ
uit i
sru
n th
roug
h on
e co
ndui
t, th
e co
nduc
tors
mus
t be
dera
ted.
Pay
spe
cial
atte
ntio
n to
not
e 8
of ta
ble
310
rega
rdin
g A
mpa
city
Adj
ustm
ent F
acto
rs w
hen
mor
e th
an th
ree
cond
ucto
rs a
re in
a r
acew
ay.
Not
ava
ilabl
e in
top
outle
t ver
sion
5431 2
led
oM
detaR
dn
Astl
oV
esah
P
.o
Ndlei
Fre
wo
Psti
ucriC
�
mu
mini
Mti
ucriC
yticap
mA
�
mu
mixaM
lanretx
Er
oes
uF
tiucri
Crekaer
B
�
dleiF
rew
oP
eriW
eziS
�
dn
uor
Geri
Wezi
S
�
mu
mini
Mti
ucriC
yticap
mA
�
mu
mixaM
esu
Flanretx
Eti
ucriC
ro
rekaerB
�
rew
oP
dleiF
eziS
eriW
�
dn
uor
Gezi
Seri
W
AT
KC
BT
KC
AT
KC
BT
KC
AT
KC
BT
KC
AT
KC
BT
KC
Z0A-,00
A-103H
W50
A-�
01A-
1-802/0321 1 1
42 05 67
53 05 08
8 8 4
01 01 8
--
--
--
05
--
--
--
62
--
--
--
05
--
--
--
03
--
--
-- 8
--
--
--
01
--
--
--
01
--
--
--
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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-
--
--
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-
--
--
--
--
-
Z0C-,00
C-103H
W�
60C-
�90
C-�
51C-
3-064
1 1 1 1
01 91 42 62
51 02 52 03
41 21 01 01
41 21 01 01
--
--
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--
--
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Z0A-,00
A-163H
W50
A-�
01A-
�51
A-
1-802/032
1 12ro
12
ro1
72 35 97 38
0406 08 09
01 6 4 4
01 01 8 8
--
--
--
35 35
--
--
--
62 25
--
--
--
06 06
--
--
--
03 06
--
--
-- 6 6
--
--
--
01 6
--
--
--
01 01
--
--
--
01 01
Z0B-,00
B-163H
W�
60B-
�90
B-�
51B-
3-802/032
1 1 1 1
02 83 7405
52 0405 05
01 8 8 8
01 01 01 01
--
--
--
--
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--
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--
Z0C-,00
C-163H
W�
60C-
�90
C-�
51C-
3-064
1 1 1 1
11 02 52 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