Bard P1148A1, P1142A3, P1060A1 User Manual

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INSTALLATION INSTRUCTIONS

SINGLE PACKAGE

AIR CONDITIONERS

MODELS

P1142A3

P1148A1

P1060A1

Bard Manufacturing Company

Manual :

2100-324B

Bryan, Ohio 43506

Supersedes:

2100-324A

Since 1914 . . . Moving ahead, just as planned

File:

Volume II Tab 10

Date:

04-01-02

© Copyright 2002

Contents

Getting Other Informations and Publications

........ 1

General Instructions

 

Important ................................................................

4

Shipping Damage ....................................................

4

General ................................................................

4

Field-Installed Heater Packages (Optional) .............

4

Installation

 

Location ................................................................

6

Typical Installations ..................................................

6

Condensate Drain Trap ............................................

9

Air Filters ................................................................

9

Wiring – Main Power ..............................................

10

Wiring – 24V Low Voltage Control Circuit ..............

10

Transformer Taps ...................................................

10

Thermostats ...........................................................

10

Start Up and Operation

 

Three Phase Scroll Compressor Start Up

 

Information ..............................................................

11

Sequence of Operation ...........................................

11

Start Up Notes ........................................................

11

High Pressure Switch and Lockout Relay ...............

11

Service and Troubleshooting

 

Service Hints .........................................................

12

Pressure Service Ports ..........................................

12

Refrigerant Charge ................................................

12

Fan Blade Settings .................................................

12

Suction and Discharge Tube Brazing .....................

12

Pressure Table .......................................................

13

Figures

 

 

Figure 1

Prefabricated Rood Curb

 

 

Specifications ..........................................

5

Figure 2

Field Fabricated Curbing .........................

5

Figure3

Elevated Mounting Platforms ..................

7

Figure 4

Airflow and Service Access

 

 

Clearances ..............................................

7

Figure 5

Roof Top Application ...............................

8

Figure 6

Slab Mounting at Ground Level ...............

8

Figure 7

Condensate Drain Trap ...........................

9

Figure 8

Low Voltage Wiring ...............................

10

Figure 9

Fan Blade Setting Dimensions ..............

12

Figure 10

Brazing Diagram ...................................

13

Tables

 

 

Table 1

Electrical Data .........................................

2

Table 2

Optional Field Installed Heater

 

 

Packages ................................................

2

Table 3

Optional Field Installed Heater Table .......

3

Table 4

Maximum ESP of Operation ...................

4

Table 5

Rated CFM and Rated ESP ....................

6

Table 5A

ESP in Inches H2O ..................................

6

Table 6

Air Filter Area and Size ...........................

9

Table 7

Thermostat Wire Size ...........................

10

Table 8

Wall Thermostat and Subbase

 

 

Combinations ........................................

10

Table 9

Refrigerant Charge ...............................

12

Table10

Pressure Table ......................................

13

Getting Other Information and Publications

These publications can help you install the air conditioner or heat pump. You can usually find these at your local library or purchase them directly from the publisher. Be sure to consult current edition of each standard.

National Electrical Code ...........................

ANSI/NFPA 70

Standard for the Installation ..................

ANSI/NFPA 90A

of Air Conditioning and

 

Ventilating Systems

 

Standard for Warm Air ..........................

ANSI/NFPA 90B

Heating and Air

 

Conditioning Systems

 

Load Calculation for ................................

ACCA Manual J

Residential Winter and

 

Summer Air Conditioning

 

Duct Design for Residential ....................

ACCA Manual D

Winter and Summer Air Conditioning

 

and Equipment Selection

 

For more information, contact these publishers:

ACCA

Air Conditioning Contractors of America

 

1712 New Hampshire Ave. N.W.

 

Washington, DC 20009

 

Telephone: (202) 483-9370

 

Fax: (202) 234-4721

ANSI

American National Standards Institute

 

11 West Street, 13th Floor

 

New York, NY 10036

 

Telephone: (212) 642-4900

 

Fax: (212) 302-1286

ASHRAE American Society of Heating, Refrigerating,

and Air Conditioning Engineers, Inc.

1791 Tullie Circle, N.E.

Atlanta, GA 30329-2305

Telephone: (404) 636-8400

Fax: (404) 321-5478

NFPA

National Fire Protection Association

 

Batterymarch Park

 

P.O. Box 9101

 

Quincy, MA 02269-9901

 

Telephone: (800) 344-3555

 

Fax: (617) 984-7057

Manual 2100-324

Page 1

TABLE 1

ELECTRICAL DATA

 

 

 

 

Q

 

R

 

 

 

 

 

Maximum

 

 

 

 

 

 

 

 

R

 

 

 

 

External

Minimum

Field

 

 

 

 

 

 

Rated

Operating

 

Fuses or

Circuit

Power

Ground

 

 

Ckt. Brk.

Ampacity

Wiring

Wire Size

 

Volts &

Voltage

Maximum

 

 

 

 

 

 

 

 

 

 

Model

Phases

Range

Unit Amps

Ckt. A

Ckt. A

Ckt. A

Ckt. A

 

 

 

 

 

 

 

 

P1142A3

230/208-1

197 - 253

24.2

45

29

8

10

 

 

 

 

 

 

 

 

P1148A1

240/208-1

197 - 253

26.1

50

36

8

10

 

 

 

 

 

 

 

 

P1148A1-B

230/208-3

187-253

18.8

35

23

8

10

 

 

 

 

 

 

 

 

P1148A1-C

460-3

414-506

8.5

20

13

12

12

 

 

 

 

 

 

 

 

P1060A1

230/208-1

197 - 253

33.9

60

42

8

10

 

 

 

 

 

 

 

 

P1060A1-B

230/208-3

187 - 253

23.7

45

28

8

10

 

 

 

 

 

 

 

 

P1060A1-C

460-3

414 - 506

11.2

20

14

12

12

 

 

 

 

 

 

 

 

Q Maximum time delay fuse or HACR type circuit breaker.

R 75 degree C cooper wire size, basic unit only.

TABLE 2

OPTIONAL FIELD INSTALLED HEATER PACKAGES

ONLY TO BE USED WITH THE AIR CONDITIONING MODELS INDICATED

Heater Package

Volts and

 

 

 

 

 

 

 

 

Model No.

Phase

 

P1142A3

P1148A1

P1148A1-B

P1148A1-C

P1160A1

 

P1160A1-B

P1160A1-C

 

 

 

 

 

 

 

 

 

 

 

EH5PB-A05

 

 

S

S

A

A

S

 

A

A

EH5PB-A10

240/1

 

S

S

A

A

S

 

A

A

EH5PB-A15

 

S

S

A

A

S

 

A

A

 

 

 

EH5PB-A20

 

 

S

S

A

A

S

 

A

A

 

 

 

 

 

 

 

 

 

 

 

EH5PB-B09

 

 

 

A

S

A

A

 

S

A

EH5PB-B15

240/3

 

 

A

S

A

A

 

S

A

EH5PB-B18

 

 

 

A

S

A

A

 

S

A

 

 

 

 

 

 

 

 

 

 

 

EH5PB-CO9

 

 

 

A

A

S

A

 

A

S

EH5PB-C15

480/3

 

 

A

A

S

A

 

A

S

EH5PB-B18

 

 

 

A

A

S

A

 

A

S

 

 

 

 

 

 

 

 

 

 

 

 

S

– Standard application – Heater volts and phase same as basic unit

 

 

 

A

– Alternate application – Heater volts and phase different from basic unit

 

 

Manual 2100-324

Page 2

TABLE 3

OPTIONAL FIELD-INSTALLED ELECTRIC HEATER TABLE

 

 

Htr. KW &

 

 

 

 

 

 

Circuit B

 

 

 

 

Capacity

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

@ 240V (or

Htr. KW &

@ 240V

 

 

 

 

 

 

 

 

 

 

 

Q

R

S

 

 

480V if

Capacity

 

 

 

Heater

 

or 480V as

Heater

No.

Minimum

Maximum

Field

Ground

 

applicable)

@ 208 Volts

Pkg. Model

Unit Volts

applicable

Internal

Field

Circuit

Overcurrent

Power

Wire

 

 

 

 

No.

Phase

KW

BTUH

KW

BTUH

Htr. Amps

Fuses

Ckts.

Ampacity

Protection

Wiring

Size

 

 

 

 

 

 

 

 

 

 

 

 

 

EH5PB-A05

240/208-1

5

17,100

3.75

12,800

20.8

 

1

26

30

10

10

EH5PB-A10

240/208-1

10

34,100

7.50

26,000

41.7

 

1

53

60

6

10

EH5PB-A15

240/208-1

15

51,200

11.25

38,400

62.5

30/60

1

79

80

4

8

EH5PB-A20

240/208-1

20

68,200

15.00

51,200

83.2

60/60

1

104

110

2

6

 

 

 

 

 

 

 

 

 

 

 

 

 

EH5PB-B09

240/208-3

9

30,700

6.75

23,000

21.7

 

1

28

30

10

10

EH5PB-B15

240/208-3

15

51,200

11.25

38,400

36.2

 

1

46

50

8

10

EH5PB-B18

240/208-3

18

61,400

13.50

46,100

43.4

 

1

55

60

6

10

 

 

 

 

 

 

 

 

 

 

 

 

 

EH5PB-C09

460/3

9

30,700

6.75

23,000

10.8

 

1

15

15

14

14

EH5PB-C15

460/3

15

51,200

11.25

38,400

18.0

 

1

23

25

10

10

EH5PB-C18

460/3

18

61,400

13.50

46,100

21.7

 

1

28

30

10

10

 

 

 

 

 

 

 

 

 

 

 

 

 

QTime delay fuses or “HACR” type circuit breakers must be used for 60 and smaller sizes. Standard fuses or circuit breakers are suitable for sizes 70 and larger.

RBased on wire suitable for 75° C. Other wiring materials must be rated for marked “Minimum Circuit Ampacity” or greater.

SBased upon Table 250-95 of N.E.C. 1993. See electrical data for basic heat pump for Circuit A wiring specification requirements.

IMPORTANT: While this electrical data is presented as a guide, it is important to electrically connect properly size fuses and conductor wires in accordance with the National Electrical Code and all existing local codes.

Manual 2100-324

Page 3

GENERAL INSTRUCTIONS

IMPORTANT

The equipment covered in this manual is to be installed by trained, experienced service and installation technicians. All duct work, supply and return ducts, must be properly sized for the design air flow requirement of the equipment. 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.

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 refrigerant system is completely assembled and charged. All internal wiring is complete.

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

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

These instructions and any instructions packaged with any separate equipment required to make up the entire 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.

FIELD INSTALLED HEATER PACKAGES (OPTIONAL)

These packaged heat pumps are manufactured without supplementary electric heaters. Supplementary heaters EH5PB series (to fit P1142A3, P1148A1, and P1160A1) are available for simple, fast, field installation.

A separate field power circuit is required for the supplementary heaters.

IMPORTANT: Refer to Table 4 and 5 when designing duct work for maximum available

static pressure with heater installed.

Refer to the electrical data shown on pages 2 and 3 for proper application information on all available heater combinations and what units they can be used with. It also shows the applicable circuit ampacities, fuse size, and wire size for each heater combination.

Refer to the installation instructions packed with the heater for details on how to insert it into the basic unit.

TABLE 4

MAXIMUM ESP OF OPERATION

 

P1142A3

P1148A1

P1060A1

 

 

 

 

A00

.50

.50

.50

A05

.50

.50

.50

A10

.50

.50

.50

A15

.40

.50

.50

A20

.40

.50

.50

 

 

 

 

B00

---

.50

.50

B09

---

.50

.50

B15

---

.50

.50

B18

---

.50

.50

 

 

 

 

C00

---

.50

.50

C09

---

.50

.50

C15

---

.50

.50

C18

---

.50

.50

 

 

 

 

Manual 2100-324

Page 4

FIGURE 1

PREFABRICATED ROOF CURB SPECIFICATIONS

HEAVY GAUGE GALVANIZED WITH WOOD NAILING STRIP, WELDED/LEAKPROOF

ONE PIECE CONSTRUCTION – READY TO INSTALL

MIS-1177

CURB AND ROOF DETAILS

Roof

 

 

 

 

 

 

 

 

 

Roof Hood

Air Conditioning

Curb

A

B

C*

 

D

E

F

J*

H*

Model

Units

 

 

 

 

 

 

 

 

 

 

 

 

 

9042-004

82-3/8

44-1/8

41-1/8

 

38-3/8

35-3/8

44

14-3/4

19-1/8

RHE60

P1142A3,

P1148A1,

 

P1060A1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

*Duct Sizing Information

 

 

 

 

 

 

 

 

 

 

Return Air Dimension “C” is length

 

 

Supply Air Dimension “C” is length

 

 

Return Air Dimension “H” is width

 

 

Supply Sir Dimension “J” is width

 

 

FIGURE 2

FIELD FABRICATED CURBING

Roof Hood

Unit

E

Model

Model

 

 

P1142A3

 

RHE60

P1148A1

44-7/8

 

P1060A1

 

MIS-1178

Manual 2100-324

Page 5

INSTALLATION

LOCATION

GENERAL

The unit must be located outside, or in a well ventilated area. It must not be in the space being heated or cooled. A sound absorbing material should be considered if the unit is to be installed in such a position or location that might cause transmission of sound or vibration to the living area or adjacent buildings.

SLAB MOUNTING

In areas where winter temperatures DO NOT go below 32° F for periods over twelve hours, the unit may be slab mounted at grade level. When installing unit at grade level, install on a concrete slab at least four inches above finished grade level. Slab should have a slope tolerance away from the building structure of at lease 1/4 inch per foot, while being level from side to side. Place slab in a location where runoff water from higher ground will not collect around unit. See Figure 3.

A minimum of 18 inches should be provided between the coil inlet and any building surfaces. Provide at least four feet between coil outlet and any building wall, fences or other vertical structures. Provide a minimum of three feet clearance on the service access side of the unit. See Figure 4

ROOF MOUNTING

When a unit is installed in areas where low ambient temperatures or strong winter winds exist, it should be placed for prevailing winter winds are not in direct line with the outdoor coil. If this is not possible, a wind barrier should be constructed. Place barrier 24 inches from the coil inlet side of the unit and in the direction of prevailing winds. Size barrier at least the same height and width as the unit. This may be necessary on ground level installations, also. See Figure 5.

WINTER INSTALLATION BELOW 32°F

In areas where winter conditions go below 32°F for extended periods, the unit must be elevated above the mounting surface to prevent snowfall or ice accumulation from interfering with the operation of the unit. A minimum of twelve inch elevation is recommended, while greater elevation may be required for areas of high snow accumulation. Poured concrete, steel framework, brick, cement block, etc., can be utilized to construct a suitable raised mounting platform. See Figure 6.

DUCT WORK

Refer to Tables 4, 5 and 5A when designing duct work for maximum static pressure available with the specific model and heater package being installed.

TABLE 5

RATED CFM AND

EXTERNAL STATIC PRESSURE (ESP)

WET COIL (COOLING)

 

Rated

Rated

Recommended

Model

CFM

ESP

Air Flow Range

 

 

 

 

P1142A3

1400

.20

1260 - 1540 CFM

 

 

 

 

P1148A1

1550

.40

1400 - 1700 CFM

 

 

 

 

P1060A1

1700

.20

1530 - 1870 CFM

 

 

 

 

TABLE 5A

ESP

P1142A3

P1148A1

P1060A1

Inches

PH11421

PH1048

PH1060

H2O

Dry / Wet

Dry / Wet

Dry / Wet

0

1650 / 1625

1950 / 1920

1850 / 1850

.1

1550 / 1525

1860 / 1830

1800 / 1780

.2

1435 / 1400

1780 / 1750

1725 / 1700

.3

1340 / 1310

1680 / 1660

1660 / 1625

.4

1230 / 1210

1580 / 1550

1580 / 1540

.5

1120 / 1100

1500 / 1480

1500 / 1475

 

 

 

 

TYPICAL INSTALLATIONS

1.ROOF MOUNTED – The unit is mounted on a sturdy base on the roof of the building. Return air to the unit is brought through a single return grille (grilles with built-in filters are best since they enable easy access for filter changing). Return air ducts are attached to the lower section of the front panel.

Supply air is brought from the unit to attic duct work or to a furred down hall. Supply air duct is attached to the top of the front panel.

CAUTION: All outdoor duct work must be thoroughly insulated and weatherproofed. All attic duct work must be thoroughly insulated. Two inch thick insulation with suitable vapor barrier is recommended for both outdoor and attic runs.

In roof top installation, as in all installations, the air conditioner must be level from side to side. However, the unit should have a pitch along the length to assure complete external drainage of precipitation and of defrost condensate.

2.CRAWL SPACE – Duct work installed in crawl space must be well insulated and provided with a vapor barrier. In addition, the crawl space must be thoroughly ventilated and provided with a good vapor barrier as a ground cover. It is most desirable to install the unit will be outdoors rather than inside the crawl space, so that it will be readily accessible for service.

Manual 2100-324

Page 6

FIGURE 3

ELEVATED MOUNTING PLATFORMS

MIS-1183

FIGURE 4

AIRFLOW AND SERVICE ACCESS CLEARANCES

MIS-1185

Manual 2100-324

Page 7

FIGURE 5

ROOF TOP APPLICATION

(MAY ALSO BE REQUIRED FOR GROUND LEVEL INSTALLATIONS.)

MIS-1176

FIGURE 6

SLAB MOUNTING AT GROUND LEVEL (ABOVE 32° F OUTSIDE TEMPERATURE)

MIS-1184

Manual 2100-324

Page 8

3.SLAB MOUNTED AT GROUND LEVEL – This type installation is ideal for homes with a slab floor construction where a roof mounted unit is not desired. The supply and return duct work can be run through a furred closet space.

With a trap installed on a unit located in an unconditioned area, water in the trap may freeze. It is recommended that the trap material be of a type that will allow for expansion of water when it freezes.

4.THROUGH THE WALL – This type installation requires a suitable framework to be fabricated capable of withstanding the unit weight. Normally the unit will be insulated so as to minimize supply and return duct work.

AIR FILTERS

Air filters for the return air side of the system are not provided as part of these models, and must be field supplied and installed as part of the final installation.

5.OTHER INSTALLATIONS – Many other installations are possible with the packaged air conditioner. No matter what the installation, always consider the following facts:

A.Insure that the discharge air is not obstructed inany way so as to cause operation difficulties.

B.The indoor coil drain pan is equipped with a coupling that must be piped through a condensate drain trap to a suitable drain.

C.Always mount the unit is such a position that it may be easily reached for servicing and maintenance.

D.Insure that the unit is clear so that proper air flow over the outdoor coil will be maintained.

If this unit is operated in cooling below a 65° outdoor ambient temperature, the installation of low ambient controls (CMA-6) to unit is required.

CONDENSATE DRAIN TRAP

It is very important to provide a trap in the condensate drain line to allow a positive liquid seal in the line and assure correct drainage from the coil condensate pan.

Install condensate drain trap shown in Figure 7. Use drain connection size or larger. Do not operate unit without trap. Unit must be level or slightly inclined toward drain.

Prior thought should be given to return air location and placement of the air filter(s). The air filter(s) must be of adequate size and readily accessible to the operator of the equipment. Filters must be adequate in size and properly maintained for proper operation. If this is not done, excessive energy use, poor performance, and multiple service problems will result. It is impossible to oversize air filters. Generous sizing will result in cleaner air and coils as well as lower operating costs and extend the time between required changes. Table 6 shows minimum filter areas and recommended filter sizes. Actual filter sizes can vary with the installation due to single or multiple returns utilizing a filter/grille arrangement or being placed immediately ahead of the indoor coil face in the return air duct.

TABLE 6

RECOMMENDED FILTERS

 

Minimum Filter

Recommended

Model

Areas

Size

 

 

 

P1142A3

608 square inches

 

P1148A1

(2) 16 x 20 x 1

(4.62 square feet)

P1060A1

 

 

 

 

 

 

NOTE: If roof hood accessory is to be used, information on air filters may be found under that heading in this manual. Air filters are supplied as part of that package.

FIGURE 7

CONDENSATE DRAIN TRAP

MIS-136

Manual 2100-324

Page 9

WIRING – MAIN POWER

Refer to the unit rating plate for wire sizing information and maximum fuse 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. If field installed heaters are added to the basic unit, a second separate power supply circuit will be required. The heater rating plate located adjacent to the basic unit rating plate will show the appropriate circuit ampacity fuse size, etc. (Also see “Electrical Data” on pages 2 and 3.) All models are suitable for connection with copper wire only.

These instructions must be adhered to. Refer to the National Electrical Code for complete current carrying capacity data on the various insulation grades of wiring material.

The electrical specifications on page 2 and 3 lists fuse and wire sizes (75°F copper) for all models including the most commonly used heater sizes.

The unit rating plate lists a “Maximum Time Delay 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.

TABLE 7

THERMOSTAT WIRE SIZE

 

 

 

Maximum

 

 

 

Distance

Transformer VA

FLA

Wire Gauge

In Feet

 

 

 

 

 

 

20

45

 

 

18

60

55

2.3

16

100

 

 

14

160

 

 

12

250

 

 

 

 

TRANSFORMER TAPS

230/208V, 1 phase and 3 phase equipment employ 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:

TAP

RANGE

240

253 – 216

208

220 – 187

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).

WIRING – 24V LOW VOLTAGE CONTROL

CIRCUIT

Five (5) wires should be run from thermostat subbase to the 24V terminal board in the unit. A five conductor, 18 gauge copper, color-coded thermostat cable is recommended. The connection points are shown in Figure 8.

THERMOSTATS

See specific wiring information for the different models, heater KWs, and voltages on pages 14 through 17.

TABLE 8

WALL THERMOSTAT AND SUBBASE COMBINATIONS

Thermostat

Subbase

 

Predominate Features

8403-002

8404-003

1 stage heat,

1 stage cool,

Mercury

T87F3111

Q539A1220

System:

Heat-off-cool

Fan:

on-auto

8403-041

——

1 stage heat,

1 stage cool,

Mercury

T8034C1499

System:

Heat-off-cool

Fan:

on-auto

 

8403-049

——

2 stage heat,

2 stage cool

 

 

1F93-380

Electronic

Programmable

 

 

 

 

 

8403-043

 

1 stage heat,

1 stage cool,

Mercury

——

System:

Heat-off-cool

Fan:

on-auto

CM200

 

Snap Action

 

 

 

 

 

 

 

 

 

 

 

 

1 stage heat,

1 stage cool,

Mercury

8403-048

——

System:

Heat-off-cool Fan:

on-auto

T8400C1313

 

Electronic

Non-Programmable

 

8403-019

8404-012

2 stage heat, 1 stage cool,

Mercury

T874C1760

Q674A1001

System:

heat-auto-cool

Fan:

on-auto

IMPORTANT NOTE: Only the thermostat and subbase combinations as shown above will work with this equipment. The thermostat and subbase MUST be matched, and correct operation can be assured only by proper selection and application of these parts.

Manual 2100-324

Page 10

FIGURE 8

LOW VOLTAGE WIRING

MIS-1180

Manual 2100-324

Page 11

START UP AND OPERATION

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. Verification of proper rotation direction is made by observing that suction pressure drops and discharge pressure rises when the compressor is energized. Reverse rotation also results in an elevated sound level over that with correct rotation, as well as, substantially reduced current draw compared to tabulated values.

Verification of proper rotation must be made at the time the equipment is put into service. If improper rotation is corrected at this time there will be no negative impact on the durability of the compressor. However, reverse operation for over one hour may have a negative impact on the bearing due to oil pump out.

NOTE: If compressor is allowed to run in reverse rotation for several minutes the compressor’s internal protector will trip.

All three phase ZR*3 compressors are wired identically internally. As a result, once the correct phasing is determined for a specific system or installation, connecting properly phased power leads to the same Fusite terminals should maintain proper rotation direction.

The direction of rotation of the motor may be changed by reversing any two line connections to the unit.

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 circuit R-W1 is completed on each heating cycle energizing electric heat if so equipped.

START UP NOTES

For improved start up performance, wash the indoor coil with dishwasher detergent

COMPRESSOR CONTROL MODULE

The compressor control is an anti-short cycle/lockout timer with high and low pressure switch monitoring and alarm output.

ADJUSTABLE DELAY-ON-MAKE AND BREAK TIMER

On a call for compressor operation the delay-on-make period begins which will be 10% of the delay-on-break setting. When the delay-on-make is complete and the high pressure switch (and low pressure switch if employed) is closed, the compressor contactor is energized. Upon shutdown the delay-on-break timer starts and prevents restart until the delay-on-break and delay-on-make periods have expired.

HIGH PRESSURE SWITCH AND LOCKOUT

SEQUENCE (Standard Feature)

If the high pressure switch opens, the compressor contactor will de-energize immediately. The lockout timer will go into a soft lockout and stay in soft lockout until the high pressure switch closes and the delay-on-make time has expired. If the high pressure switch opens again in this same operating cycle the unit will go into manual lockout condition and the alarm circuit will energize. Recycling the wall thermostat resets the manual lockout.

LOW PRESSURE SWITCH, BYPASS, AND LOCKOUT SEQUENCE

NOTE: The low pressure switch is an optional control and the bypass and lockout sequence are part of the standard compressor control module.

If the low pressure switch opens for more that 120 seconds, the compressor contactor will de-energize and go into a soft lockout. Regardless the state of the low pressure switch, the contactor will reenergize after the delay-on-make time delay has expired. If the low pressure switch remains open or opens again for longer than 120 seconds the unit will go into manual lockout condition and the alarm circuit will energize. Recycling the wall thermostat resets the manual lockout.

Manual 2100-324

Page 12

ALARM OUTPUT

Alarm terminal is output connection for applications where alarm signal is desired. This terminal is powered whenever compressor is locked out due to HPC or LPC sequences as described.

NOTE: Both high and low pressure switch controls are inherently automatic reset devices. The high pressure switch and low pressure switch cut out and cut in settings are fixed by specific air conditioner or heat pump unit model. The lockout features, both soft and manual, are a function of the Compressor Control Module.

ADJUSTMENTS

ADJUSTABLE DELAY-ON-MAKE AND DELAY-ON-BREAK TIMER

The potentiometer is used to select Delay-on-Break time from 30 seconds to 5 minutes. Delay-on-Make (DOM) timing on power-up and after power interruptions is equal to 2 minutes plus 10% of Delay-on-Break (DOB) setting:

0.5 minute

(30 seconds)

DOB

=

123 second DOM

1.0 minute

(60 seconds)

DOB

=

126 second DOM

2.0 minute

(120 seconds)

DOB

=

132 second DOM

3.0 minute

(160 seconds)

DOB

=

138 second DOM

4.0 minute

(240 seconds)

DOB

=

144 second DOM

5.0 minute

(300 seconds)

DOB

=

150 second DOM

Manual 2100-324

Page 13

SERVICE AND TROUBLESHOOTING

SERVICE HINTS

1.Caution homeowner to maintain clean air filters at all times. Also, not to needlessly close off supply and return air registers. This reduces air flow through the system which shortens equipment service life as well as increasing operating costs.

2.Check all power fuses or circuit breakers to be sure that they are the correct rating.

3.Periodic cleaning of the outdoor coil to permit full and unrestricted airflow circulation is essential.

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 in Table 10 in this manual covering all models on cooling cycle. It is imperative to match the correct pressure table to the unit by model number.

FIGURE 9

FAN BLADE SETTING DIMENSIONS

Model

Dimension A

 

 

P1142A3

1.75"

P1148A1

1.75"

P1060A1

1.75"

 

 

REFRIGERANT CHARGE

The correct system R-22 charge is shown on the unit rating plate. Optimum unit performance will occur with a refrigerant charge resulting in a suction line temperature (6” from compressor) as shown in Table 9.

TABLE 9

 

 

95 Degree F

82 Degree F

 

Rated

 

OD

OD

 

Model

Airflow

Temperature

Temperature

 

 

 

 

 

 

 

 

P1142A3

1400

57

-

59

58

-

60

P1148A1

1550

55

-

57

59

-

61

P0160A1

1700

47

-

49

54

-

56

 

 

 

 

 

 

 

 

The above suction line temperatures are based upon

80°F dry bulb/67°F wet bulb (50% RH) temperature and rated airflow across the evaporator during cooling cycle.

FAN BLADE SETTINGS

Shown in Figure 9 are the correct fan blade setting dimensions for proper air delivery across the outdoor coil.

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

SUCTION AND DISCHARGE TUBE BRAZING

Compliant Scroll compressors have copper plated steel suction and discharge tubes. These tubes are far more rugged and less prone to leaks than copper tubes used on other compressors. Due to different thermal properties of steel and copper, brazing procedures may have to be changed from those commonly used.

To disconnect: heat joint Areas 2 and 3 slowly and uniformly until braze material softens and the tube can be pulled out of suction fitting. (See Figure 10.)

To connect:

Recommended brazing materials: silfos with minimum 5% silver or silver braze material with flux.

Reinsert tube into fitting.

Heat tube uniformly in Area 1 moving slowly to Area 2. When joint reaches brazing temperature, apply brazing material. (See Figure 10.)

Heat joint uniformly around the circumference to flow braze material completely around the joint.

Slowly move torch into Area 3 to draw braze material into joint. (See Figure 10.)

Do not overheat joint.

Manual 2100-324

Page 14

FIGURE 10

BRAZING DIAGRAM

MIS-1179

TABLE 10

PRESSURE TABLE

COOLING

Air Temperature Entering Outdoor Coil Degrees F

 

Return Air

Pressure

75

80

85

90

95

100

105

110

115

Model

Temperature

 

 

 

 

 

 

 

 

 

 

 

 

 

75 deg. DB

Low Side

70

72

75

77

78

79

80

81

82

 

62 deg. WB

High Side

208

223

239

254

271

288

305

324

342

 

 

 

 

 

 

 

 

 

 

 

 

P1142A3

80 deg. DB

Low Side

75

77

80

82

84

85

96

87

88

67 deg. WB

High Side

213

229

245

261

278

295

313

332

351

 

 

 

 

 

 

 

 

 

 

 

 

 

 

85 deg. DB

Low Side

81

83

86

88

90

91

92

94

95

 

72 deg. WB

High Side

220

237

254

270

288

305

324

344

363

 

 

 

 

 

 

 

 

 

 

 

 

 

75 deg. DB

Low Side

73

74

75

76

78

79

80

81

82

 

62 deg. WB

High Side

203

217

231

246

264

278

294

312

330

 

 

 

 

 

 

 

 

 

 

 

 

P1148A1

80 deg. DB

Low Side

78

79

81

82

83

84

86

87

88

67 deg. WB

High Side

208

222

237

252

268

285

302

320

338

 

 

 

 

 

 

 

 

 

 

 

 

 

 

85 deg. DB

Low Side

83

85

87

88

87

91

92

93

94

 

72 deg. WB

High Side

215

230

245

261

273

295

313

331

350

 

 

 

 

 

 

 

 

 

 

 

 

 

75 deg. DB

Low Side

65

66

68

69

70

72

74

75

76

 

62 deg. WB

High Side

214

230

247

264

284

299

318

336

355

 

 

 

 

 

 

 

 

 

 

 

 

P1060A1

80 deg. DB

Low Side

69

71

72

74

76

77

79

80

82

67 deg. WB

High Side

219

236

253

271

289

307

326

345

364

 

 

 

 

 

 

 

 

 

 

 

 

 

 

85 deg. DB

Low Side

74

76

78

79

81

83

85

86

88

 

72 deg. WB

High Side

227

244

262

280

296

318

337

357

377

 

 

 

 

 

 

 

 

 

 

 

 

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