WALL MOUNTED P ACKAGED
AIR CONDITIONER
INSTALLATION
INSTRUCTIONS
Models:
WA611
WA701-B
WA701-C
WA702-A
WA721
Bard Manufacturing Company
Bryan, Ohio 43506
Since 1914...Moving ahead, just as planned.
MIS-801
Manual No.: 2100-425
Supersedes:
File: Volume III, Tab 16
Date: 01-01-03
© Copyright 2003
CONTENTS
Getting Other Information and Publications
For more information, contact these publishers: ..... 1
Wall Mount General Information
Air Conditioner Wall Mount Model Nomenclature.... 2
Shipping Damage .................................................... 5
General ............................................................... 5
Duct Work ............................................................... 5
Filters ............................................................... 6
Fresh Air Intake ....................................................... 6
Condensate Drain.................................................... 6
Installation Instructions
Wall Mounting Information....................................... 7
Mounting the Unit .................................................... 7
Typical Installations ................................................. 7
Wiring – Main Power ............................................. 7
Wiring – Low Voltage Wiring ................................. 9
Figures
Start Up
Important Installer Note ......................................... 14
Crankcase Heaters................................................ 14
High Pressure Switch ............................................ 14
Three Phase Scroll Compressor Start Up
Information............................................................. 14
Service Hints ......................................................... 15
Sequence of Operation.......................................... 15
Compressor Control Module.................................. 15
Adjustments........................................................... 16
Phase Monitor ....................................................... 16
Pressure Service Ports .......................................... 16
Troubleshooting
Fan Blade Setting Dimensions .............................. 17
Removal of Fan Shroud......................................... 17
Refrigerant Charge ................................................ 17
Pressure Chart ...................................................... 18
Optional Accessories............................................. 19
Tables
Figure 1 Unit Dimensions..................................... 3
Figure 2 Blower Damper Assembly...................... 6
Figure 3 Mounting Instructions............................. 8
Figure 4 Wall-Mounting Instructions .................. 10
Figure 5 Wall-Mounting Instructions .................. 10
Figure 6 Common Wall-Mounting Instructions ....11
Figure 7 Electric Heat Clearances ..................... 12
Figure 8 Low Voltage Wiring.............................. 13
Figure 9 Start-Up Label...................................... 14
Figure 10 Fan Blade Setting ................................ 17
Table 1 Electric Heat Table................................. 2
T able 2 Dimensions of Basic Unit ....................... 3
Table 3 Electrical Specifications ......................... 4
Table 4 Operating Voltage Range ...................... 9
Table 5 Thermostat Wire Size ............................ 9
Table 6 Wall Thermostat and
Subbase Combinations.......................... 9
Table 7 Fan Blade Dimensions......................... 17
Table 8 Suction Line Temperatures .................. 17
Table 9 CFM and ESP ...................................... 17
Table 10 Indoor Blower Performance ................. 17
Table 11 Maximum ESP of Operation
Electric Heat Only ................................ 18
Table 12 Cooling Pressure ................................. 18
Table 13 Optional Accessories ........................... 19
i
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 or
Residential Winter and Manual N
Summer Air Conditioning
Low Pressure, Low Velocity .......... ACCA Manual D or
Duct System Design for Winter Manual Q
and Summer Air Conditioning
FOR MORE INFORMATION, CONTACT
THESE PUBLISHERS:
ACC A 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
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 2100-425
Page 1
WALL MOUNT GENERAL INFORMA TION
AIR CONDITIONER WALL MOUNT MODEL NOMENCLATURE
MODEL NUMBER
CAPACITY
61 – 5 Ton
70 – 6 Ton
72 – 6 To n
REVISION
VOL TS & PHASE
A – 230/208-1
B – 230/208/60-3
C – 460/60-3
NOTE: For 0KW and circuit breakers (230/208 V) or pull disconnects (460 V) applications, insert 0Z in the KW field of model number.
WA 70 1 – B 09 X X X X X J
VENTILATION OPTIONS
X – Barometric Fresh Air Damper
KW
00 – No KW
0Z – No KW
w/Circuit
Breaker
or Pull
Disconnect
05 – 5 KW
09 – 9 KW
10 – 10 KW
15 – 15 KW
18 – 18 KW
(Standard)
B – Blank-off Plate
M – Motorized Fresh Air Damper
V – Commercial Room V entilator -
Motorized with Exhaust
E – Economizer (Internal) - Fully
Modulating with Exhaust
R – Energy Recovery V entilator -
with Exhaust
FILTER OPTIONS
X – One Inch Throwaway
W – One Inch Washable
P – Two Inch Pleated
COLOR OPTIONS
X – Beige
(Standard)
1 – White
(Standard)
COIL OPTIONS
X – Standard
1 – Phenolic Coated Evaporator
2 – Phenolic Coated Condenser
3 – Phenolic Coated Evaporator
CONTROL MODULES
J – Standard on all
Models
and Condenser
OUTLET OPTIONS
X – Front (Standard)
TABLE 1
ELECTRIC HEAT TABLE
sledoM
1-V0421-V8023-V0423-V8023-V064
WKSPMAHUTBSPMAHUTBSPMAHUTBSPMAHUTBSPMAHUTB
0.5
0.8
0.9
0.01
8.02004,811.81001,41------------------
3.33006,828.82008,12------------------
------------7.12009,137.81053,428.01000,23
6.14054,532.63009,62------------------
A-116AWB-116AWC-116AW
sledoM
1-V0421-V8023-V0423-V8023-V064
WKSPMAHUTBSPMAHUTBSPMAHUTBSPMAHUTBSPMAHUTB
0.5
0.9
0.01
0.51
0.81
0.02
8.02050,711.81008,21------------------
------------7.12006,037.81030,328.01007,03
6.14031,432.63006,52------------------
5.26002,151.45004,832.63002,152.13004,833.71000,74
------------3.34034,165.73001,64------
2.38062,861.27002,15------------------
A-207AW
B-107AW
B-127AW
Manual 2100-425
Page 2
C-107AW
C-127AW
TABLE 2
DIMENSIONS OF BASIC UNIT FOR ARCHITECTURAL AND INSTALLATION REQUIREMENTS (Nominal)
htdiW
tinU
W
116AW
07AW
244/1-228/7-498/7-98/7-928/7-518/7-928/7-34918/5-140361/11-24734/3-442/1-244/1-3348/7-3301
127AW
All dimensions in inches.
htpeD
D
thgieH
H
ylppuSnruteR
EFGI J KL MNOPQABCB
FIGURE 1
UNIT DIMENSIONS
Manual 2100-425
Page 3
MIS-764
Manual 2100-425
Page 4
SLEDOMdetaR
Z0A,00A-116AW
50A80A01A-
Z0B,00B-116AW
90B-
Z0C,00C-116AW
90C-
Z0A,00A-207AW
50A01A51A02A-
Z0B,00B-107AW
90B51B81B-
Z0C,00C-107AW
90C51C-
Z0B,00B-127AW
90B51B81B-
Z0C,00C-127AW
90C51C-
TABLE 3
ELECTRICAL SPECIFICATIONS
TIUCRICELGNIS TIUCRICLAUD
3
fo.oN
rewoP
stiucriC
1
1-802/302
3-802/032
3-064
1-802/302
3-802/032
3-064
3-802/032
3-064
1
1
1
1
1
1
1
1
1
1
2ro1
2ro1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
muminiM
tiucriC
34
34
74
85
92
33
51
71
84
84
95
58
011
63
63
25
06
71
71
62
63
63
25
06
71
71
62
1
revO
yticapmA
05
05
06
06
54
54
02
02
06
06
06
09
011
05
05
06
06
52
52
03
05
05
06
06
52
52
03
2
mumixaM
dleiF
tnerruC
noitcetorP
eriW
eziS
8
8
8
6
8
8
21
21
8
8
6
4
2
8
8
6
6
21
21
01
8
8
6
6
21
21
01
2
3
tiucriCmuminiM
dnuorG
eriW
eziS
01
01
01
01
01
01
21
21
01
01
01
8
6
01
01
01
01
21
21
01
01
01
01
01
21
21
01
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
95
95
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
yticapmA
ATKCBTKCATKCBTKCATKCBTKCATKCBTKC
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
62
25
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
1
revOmumixaM
tnerruC
noitcetorP
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
06
06
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
03
06
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
2
eziSeriWdleiF
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
6
6
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
01
6
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
2
eziSeriWdnuorG
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
01
01
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
01
01
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
AN
j
Maximum size of the time delay fuse or HACR type circuit breaker for protection of field wiring conductors.
k
Based on 75°C copper wire. All wiring must conform to the National Electric Code (NEC) and all local codes.
These "Minimum Circuit Ampacity" values are to be used for sizing the field power conductors. Refer to the National Electric Code (latest
l
version), Article 310 for power conductor sizing.
conduit, the conductors must be derated. Pay special attention to Note * of Table 310 regarding Ampacity Adjustment Factors when
more than 3 conductors are in a raceway.
CAUTION: When more than one filed power conductor circuit is run through one
SHIPPING DAMAGE
DUCT WORK
Upon receipt of equipment, the carton should be
checked for external signs of shipping damage. If
damage is found, the receiving party must contact the
last carrier immediately, preferably in writing,
requesting inspection by the carrier’s agent.
GENERAL
The equipment covered in this manual is to be
installed by trained, experienced service and
installation technicians.
The refrigerant system is completely assembled and
charged. All internal wiring is complete.
The unit is designed for use with or without duct
work. Flanges are provided for attaching the supply
and return ducts.
These instructions 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
air conditioning system should be carefully read
before beginning the installation. Note particularly
“Starting Procedure” and any tags and/or labels
attached to the equipment.
All duct work, supply and return, must be properly
sized for the design air flow requirement of the
equipment. Air Conditioning Contractors of America
(ACCA) is an excellent guide to proper sizing. All
duct work or portions thereof not in the conditioned
space should be properly insulated in order to both
conserve energy and prevent condensation or moisture
damage.
Refer to Table 9 for maximum static pressure available
for duct design.
Design the duct work according to methods given by
the Air Conditioning Contractors of America (ACCA).
When duct runs through unheated spaces, it should be
insulated with a minimum of 1 inch of insulation. Use
insulation with a vapor barrier on the outside of the
insulation. Flexible joints should be used to connect
the duct work to the equipment in order to keep the
noise transmission to a minimum.
A 1/4 inch clearance to combustible material for the
first three feet of duct attached to the outlet air frame is
required. See Wall Mounting Instructions and Figures
4 and 5 for further details.
Ducts through the walls must be insulated and all
joints taped or sealed to prevent air or moisture
entering the wall cavity.
While these instructions are intended as a general
recommended guide, they do not supersede any
national and/or local codes in any way. Authorities
having jurisdiction should be consulted before the
installation is made. See Page 1 for information on
codes and standards.
Size of unit for a proposed installation should be based
on heat loss calculation made according to methods of
Air Conditioning Contractors of America (ACCA).
The air duct should be installed in accordance with the
Standards of the National Fire Protection Association
for the Installation of Air Conditioning and
Ventilating Systems of Other Than Residence Type,
NFPA No. 90A, and Residence Type Warm Air
Heating and Air Conditioning Systems, NFPA No.
90B. Where local regulations are at a variance with
instructions, installer should adhere to local codes.
CAUTION
Some installations may not require any return
air duct. A metallic return air grille is required
with installations not requiring a return air
duct. The spacing between louvers on the
grille shall not be larger than 5/8 inches.
Any grille that meets the 5/8 inch louver criteria, may
be used. It is recommended that Bard Return Air Grille
Kit RG-2 thru RG-5 or RFG-2 thru RFG-5 be installed
when no return duct is used. Contact distributor or
factory for ordering information. If using a return air
filter grille, filters must be of sufficient size to allow a
maximum velocity of 400 fpm.
NOTE: If no return air duct is used, applicable
installation codes may limit this cabinet to
installation only in a single story structure.
Manual 2100-425
Page 5
FILTERS
A 1 inch throwaway filter is supplied with each unit.
The filter slides into position making it easy to service.
This filter can be serviced from the outside by
removing the service door. A 1 inch washable filter
and 2 inch pleated filter are also available as optional
accessories. The internal filter brackets are adjustable
to accommodate the 2 inch filter by bending down the
tabs to allow spacing for the 2 inch filters.
FRESH AIR INTAKE
All units are built with fresh air inlet slots punched in
the service panel.
If the unit is equipped with the fresh air damper
assembly, the assembly is shipped already attached to
the unit. The damper blade is locked in the closed
position to allow the damper to operate, the maximum
and minium blade position stops must be installed.
See Figure 2.
BLOWER DAMPER ASSEMBLY
All capacity, efficiency and cost of operation
information as required for Department of Energy
“Energyguide” Fact Sheets is based upon the fresh air
blank-off plate in place and is recommended for
maximum energy efficiency.
The blank-off plate is available upon request from the
factory and is installed in place of the fresh air damper
shipped with each unit.
CONDENSATE DRAIN
A plastic drain hose extends from the drain pan at the
top of the unit down to the unit base. There are
openings in the unit base for the drain hose to pass
through. In the event the drain hose is connected to a
drain system of some type, it must be an open or
vented type system to assure proper drainage.
FIGURE 2
BLADE IS LOCKED
CLOSED FOR
SHIPPING
MIS-938
Manual 2100-425
Page 6
INST ALLA TION INSTRUCTIONS
WALL MOUNTING INFORMATION
1. Two holes, for the supply and return air openings,
must be cut through the wall as shown in Figure 3.
2. On wood-frame walls, the wall construction must
be strong and rigid enough to carry the weight of
the unit without transmitting any unit vibration.
See Figures 4 and 5.
WARNING
Fire hazard can result if 1/4 inch clearance to
combustible materials for supply air duct is
not maintained. See Figure 3.
3. Concrete block walls must be thoroughly inspected
to insure that they are capable of carrying the
weight of the installing unit. See Figure 4.
MOUNTING THE UNIT
1. These units are secured by wall mounting brackets
which secure the unit to the outside wall surface at
both sides. A bottom mounting bracket is provided
for ease of installation.
2. The unit itself is suitable for “0” inch clearance,
but the supply air duct flange and the first 3 feet of
supply air duct require a minimum of 1/4 inch
clearance to combustible material. If a combustible
wall, use a minimum of 30-1/2" x 10-1/2"
dimensions for sizing. However, it is generally
recommended that a 1 inch clearance is used for
ease of installation and maintaining the required
clearance to combustible material. The supply air
opening would then be 32" x 12". See
Figures 3, 4 and 7 for details.
WARNING
Failure to provide the 1/4 inch clearance
between the supply duct and a combustible
surface for the first 3 feet of duct can result in
fire.
3. Locate and mark lag bolt locations and bottom
mounting bracket location. See Figure 4.
4. Mount bottom mounting bracket.
5. Hook top rain flashing under back bend of top.
Top rain flashing is shipped secured to the right
side of the back.
6. Position unit in opening and secure with 5/16 lag
bolts; use 7/8 inch diameter flat washers on the lag
bolts.
7. Secure rain flashing to wall and caulk across entire
length of top. See Figure 3.
8. For additional mounting rigidity, the return air and
supply air frames or collars can be drilled and
screwed or welded to the structural wall itself
(depending upon wall construction). Be sure to
observe required clearance if combustible wall.
9. On side by side installations, maintain a minimum
of 20 inches clearance on right side to allow access
to heat strips and control panel and to allow proper
airflow to the outdoor coil. Additional clearance
may be required to meet local or national codes.
TYPICAL INSTALLATIONS
See Figure 6 for common ways to install the wallmount unit.
WIRING — MAIN POWER
Refer to the unit rating plate for wire sizing
information and maximum fuse or “HACR" type
circuit breaker size. Each outdoor unit is marked with
a “Minimum Circuit Ampacity”. This means that the
field wiring used must be sized to carry that amount of
current. Depending on the installed KW of electric
heat, there may be two field power circuits required. If
this is the case, the unit serial plate will so indicate. All
models are suitable only for connection with copper
wire. Each unit and/or wiring diagram will be marked
“Use Copper Conductors Only”. These instructions
must be adhered to. Refer to the National Electrical
Code (NEC) for complete current carrying capacity
data on the various insulation grades of wiring
material. All wiring must conform to NEC and all
local codes.
The electrical data lists fuse and wire sizes (75ºC
copper) for all models, including the most commonly
used heater sizes. Also shown are the number of field
power circuits required for the various models with
heaters.
Manual 2100-425
Page 7
The unit rating plate lists a “Maximum Time Delay
Relay Fuse” or “HACR" type circuit breaker that is to
be used with the equipment. The correct size must be
used for proper circuit protection and also to assure
that there will be no nuisance tripping due to the
momentary high starting current of the compressor
motor.
The disconnect access door on this unit may be locked
to prevent unauthorized access to the disconnect. To
MOUNTING INSTRUCTIONS
convert for the locking capability, bend the tab located
in the bottom left hand corner of the disconnect
opening under the disconnect access panel straight
out. This tab will now line up with the slot in the door.
When shut, a padlock may be placed through the hole
in the tab preventing entry.
See Start-up section for information on three phase
scroll compressor start-ups.
FIGURE 3
NOTE: It is recommended that a bead of silicone
caulking be placed behind the side mounting
flanges and under the top flashing at the
time of installation.
Manual 2100-425
Page 8
MIS-796
WIRING — LOW VOLTAGE WIRING
230/208V, 1 phase and 3 phase equipment dual
primary voltage transformers. All equipment leaves
the factory wired on 240V tap. For 208V operation,
reconnect from 240V to 208V tap. The acceptable
operating voltage range for the 240 and 208V taps are
shown in Table 4 below.
TABLE 4
OPERATING VOLTAGE RANGE
PATEGNAR
V042612-352
V802781-022
THERMOSTAT WIRE SIZE
remrofsnarT
AVALFeguaGeriW
553.2
NOTE: The voltage should be measured at the field
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.
TABLE 5
power connection point in the unit and while
the unit is operating at full load (maximum
amperage operating condition).
mumixaM
ecnatsiD
teeFnI
eguag02
eguag81
eguag61
eguag41
eguag21
54
06
001
061
052
TABLE 6
WALL THERMOSTAT AND SUBBASE COMBINATIONS
tatsomrehTesabbuSserutaeFetanimoderP
200-3048
1113F78T
140-3048
C4308T
910-3048
0671C478T
120-3048
4391D478T
940-3048
083-39F1
340-3048
002-MC
300-4048
0221A935Q
---loocegats1,taehegats1
210-4048
1001A476Q
210-4048
1001A476Q
---taehegats2,loocegats2
---
loocegats1,taehegats1
no-otua:naFlooc-ffo-taeh:metsyS
no-otua:naFlooc-ffo-taeh:metsyS
taehegats2,loocegats1
taehegats2,loocegats2
gnimmargorpyad7cinortcelE
loocegats1,taehegats1
no-otua:naFlooc-otua-taeh:metsyS
no-otua:naFlooc-otua-taeh:metsyS
no-otua:naFlooc-ffo-taeh:metsyS
Manual 2100-425
Page 9
FIGURE 4
WALL-MOUNTING INSTRUCTIONS
SEE FIGURE 3 —MOUNTING INSTRUCTIONS
FIGURE 5
WALL-MOUNTING INSTRUCTIONS
SEE UNIT DIMENSIONS, FIGURE 1,
FOR ACTUAL DIMENSIONS
MIS-548
SEE FIGURE 1 FOR
DUCT DIMENSIONS
Manual 2100-425
Page 10
MIS-549
FIGURE 6
COMMON WALL-MOUNTING INSTALLATIONS
MIS-550
Manual 2100-425
Page 11
MIS-277
FIGURE 7
ELECTRIC HEAT CLEARANCE
Side section view of supply air duct for
wall mounted unit showing 1/4 inch
clearance to combustible surfaces.
WARNING
• A minimum of 1/4 inch clearance must be maintained between
the supply air duct and combustible materials. This is required
for the first 3 feet of ducting.
• It is important to insure that the 1/4 inch minimum spacing is
maintained at all points.
• Failure to do this could result in overheating the combustible
material and may result in fire.
Manual 2100-425
Page 12
FIGURE 8
LOW VOLTAGE WIRING
Manual 2100-425
Page 13
START UP
IMPORTANT INSTALLER NOTE
For improved start-up performance, wash the indoor
coil with a dishwasher detergent.
CRANKCASE HEATERS
WA611, WA70 and WA721 units are provided with
compressor crankcase heat.
The WA611, WA70 and WA721 models have a band
type heater located around the bottom of the
compressor. This heater is controlled by the crankcase
heater relay. The heater is only energized when the
compressor is not running.
Some form of crankcase heat is essential to prevent
liquid refrigerant from migrating to the compressor,
casing oil pump out on compressor start-up and
possible valve failure due to compressing a liquid.
The decal in Figure 9 is affixed to all WA611, WA70
and WA721 units detailing start-up procedure. This is
very important. Please read carefully.
FIGURE 9
START-UP LABEL
IMPORTANT
These procedures must be followed at
initial start-up and at any time power
has been removed for 12 hours or
longer.
To prevent compressor damage which may
result from the presence of liquid
refrigerant in the compressor crankcase.
1. Make certain the room thermostat is in
the "off" position (the compressor is
not to operate).
2. Apply power by closing the system
disconnect switch. This energizes the
compressor heater which evaporates
the liquid refrigerant in the crankcase.
3. Allow 4 hours or 60 minutes per pound
of refrigerant in the system as noted
on the unit rating plate, whichever is
greater.
4. After properly elapsed time, the
thermostat may be set to operate the
compressor.
5. Except as required for safety while
servicing – Do not open system
disconnect switch.
7961-061
HIGH PRESSURE SWITCH
The WA611, WA70 and WA721 models are supplied
with a remote reset high pressure switch. If tripped,
this pressure switch may be reset by turning the
thermostat off then back on again.
THREE PHASE SCROLL COMPRESSOR
START UP INFORMATION
Scroll compressors, like several other types of
compressors, will only compress in one rotational
direction. Direction of rotation is not an issue with
single phase compressors since they will always start
and run in the proper direction.
However, three phase compressors will rotate in either
direction depending upon phasing of the power. Since
there is a 50-50 chance of connecting power in such a
way as to cause rotation in the reverse direction,
verification of proper rotation must be made. All three
phase units incorporate a phase monitor to ensure
proper field wiring. See the Phase Monitor" section
later in this manual.
Verification of proper rotation must be made any time
a compressor is change or rewired. If improper
rotation is corrected at this time there will be no
negative impact on the durability of the compressor.
However, reverse operation for over one hour may
have a negative impact on the bearing due to oil pump
out.
NOTE: If compressor is allowed to run in reverse
rotation for several minutes, the
compressor's internal protector will trip.
All three phase ZR3 compressors are wired 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 terminal should maintain proper rotation
direction.
Verification of proper rotation direction is made by
observing that suction pressure drops and discharge
pressure rises when the compressor is energized.
Reverse rotation also results in an elevated sound level
over that with correct rotations, as well as,
substantially reduced current draw compared to
tabulated values.
The direction of rotation of the compressor may be
changed by reversing any two line connections to the
unit.
Manual 2100-425
Page 14
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
they are the correct rating.
3. Periodic cleaning of the outdoor coil to permit full
and unrestricted airflow circulation is essential.
SEQUENCE OF OPERATION
During routine operation of the unit with no power
interruptions the compressor will operate on demand
with no delay.
High Pressure Switch and Lockout Sequence
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 break 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 relay circuit will energize. Recycling the wall
thermostat resets the manual lockout.
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. On all 208/230
volt models, when G circuit is de-energized the indoor
blower motor will continue to run for one minute. On
a call for heating, circuit R-W1 make at the thermostat
pulling in heat contact for the strip heat and blower
operation. On a call for second stage heat, R-W2
makes bringing on second heat contactor, if so
equipped.
COMPRESSOR CONTROL MODULE
The compressor control module is standard on the
models covered by this manual. The compressor
control is an anti-short cycle/lockout timer with high
and low pressure switch monitoring and alarm relay
output.
Adjustable Delay On Make And Break Timer
On initial power up or any time power is interrupted to
the unit the delay on make period begins which will
be 2 minutes plus 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 or break timer starts and
prevents restart until the delay on break and delay on
make periods have expired.
Low Pressure Switch, Bypass, and Lockout
Sequence
If the low pressure switch opens for more than 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 relay circuit will
energize. Recycling the wall thermostat resets the
manual lockout.
Alarm Relay Output
Alarm terminal is output connection for applications
where alarm relay is employed. 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.
Manual 2100-425
Page 15
ADJUSTMENTS
PHASE MONITOR
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) DO B =123 second DOM
1.0 minute (60 seconds) DO B =126 second DOM
2.0 minute (120 seconds)DOB =132 second DOM
3.0 minute (180 seconds)DOB =138 second DOM
4.0 minute (240 seconds)DOB =144 second DOM
5.0 minute (300 seconds)DOB =150 second DOM
During routine operation of the unit with no power
interruptions the compressor will operate on demand
with no delay.
Typical Settings for Dual Unit Installation:
Unit 1: DOB set at 2 minutes, and DOM is 132 seconds
Unit 2: DOB set at 4 minutes, and DOM is 144 seconds
All units with three phase scroll compressors are
equipped with a 3 phase line monitor to prevent
compressor damage due to phase reversal.
The phase monitor in this unit is equipped with two
LEDs. If the Y signal is present at the phase monitor
and phases are correct the green LED will light.
If phases are reversed, the red fault LED will be lit and
compressor operation is inhibited.
If a fault condition occurs, reverse two of the supply
leads to the unit. Do not reverse any of the unit
factory wires as damage may occur.
PRESSURE SERVICE PORTS
High and low pressure service ports are installed on all
units so that the system operating pressures can be
observed. Pressure tables can be found later in the
manual covering all models. It is imperative to match
the correct pressure table to the unit by model number.
Manual 2100-425
Page 16
TROUBLESHOOTING
FAN BLADE SETTING DIMENSIONS
Shown in the drawing below 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.
FIGURE 10
FAN BLADE SETTING
TABLE 7
FAN BLADE DIMENSIONS
ledoMAnoisnemiD
116AW
07AW
127AW
52.1
57.
REMOVAL OF FAN SHROUD
1. Disconnect all power to unit.
2. Remove the screws holding both grills – one on
each side of unit – and remove grills.
3. Remove screws holding fan shroud to condenser
and bottom – (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.
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 inches from compressor) as shown in
Table 8:
TABLE 8
SUCTION LINE TEMPERATURES
sledoM
116AW
07AW
127AW
detaR
wolfriA
053,145-2506-75
008,106-8585-65
008,116-9595-75
The suction line temperatures in Table 8 are based
upon 80ºF dry bulb / 67ºF wet bulb (50 percent R.H.)
temperature and rated airflow across the evaporator
during cooling cycle.
TABLE 9
CFM and ESP
1
detaR
ledoM
116AW053,102.001,1--574,1
07AW008,102.573,1--000,2
127AW008,102.574,1--000,2
detaR
MFC
1
F°59
.pmeTDO
detaR
PSE
F°28
wolFriA
egnaR
.pmeTDO
dednemmoceR
Rated CFM and ESP on high speed tap.
Q
TABLE 10
INDOOR BLOWER PERFORMANCE – CFM AT 230 VOLTS
116AW
.P.S.E
HnI2O
0.007,1575,1524,1573,1002,2000,2006,1054,1
1.055,1574,1573,1052,1001,2009,1525,1573,1
2.004,1053,1052,1001,1000,2008,1------
3.052,1051,1001,1---578,1007,1------
4.------------577,1006,1------
5.------------056,1574,1------
deepShgiHdeepSmuideM
lioCyrDlioCteWlioCyrDlioCteWlioCyrDlioCteWlioCyrDlioCteW
1
deepShgiHdeepSwoL
07AW
127AW
j This model has 3-speed motor, but low speed cannot be used.
Manual 2100-425
Page 17
TABLE 11
MAXIMUM ESP OF OPERATION
ELECTRIC HEAT ONLY
ledoM116AW07AW127AW
deepS
WK
50A80A01A02A-
90B51B81B-
90C51C-
muideM
deepS
03.
03.
03.
03.
03.
---
---
03.
---
hgiH
deepS
03.
03.
03.
03.
03.
---
---
03.
---
woL
deepS
05.
---
05.
04.
05.
05.
05.
05.
05.
hgiH
deepS
05.
---
05.
05.
05.
05.
05.
05.
05.
woL
deepS
---
---
---
---
05.
05.
05.
---
---
hgiH
deepS
---
---
---
---
05.
05.
05.
---
---
TABLE 12
COOLING PRESSURE – (All temperatures °F)
nruteR
riA
ledoM
C-,B-.A-116AW
A-207AW
C-,B-107AW
127AW
.pmeTerusserP5708580959001501011511
BD57
BW26
BD08
BW76
BD58
BW27
BD57
BW26
BD08
BW76
BD58
BW27
BD57
BW26
BD08
BW76
BD58
BW27
BD57
BW26
BD08
BW76
BD58
BW27
ediSwoL
ediShgiH
ediSwoL
ediShgiH
ediSwoL
ediShgiH
ediSwoL
ediShgiH
ediSwoL
ediShgiH
ediSwoL
ediShgiH
ediSwoL
ediShgiH
ediSwoL
ediShgiH
ediSwoL
ediShgiH
ediSwoL
ediShgiH
ediSwoL
ediShgiH
ediSwoL
ediShgiH
27
732
77
342
08
252
86
512
37
022
67
822
26
412
76
022
27
522
36
502
86
112
37
612
27
732
77
342
08
252
86
822
37
432
67
242
36
032
86
632
37
342
46
222
96
722
47
432
37
042
87
642
18
552
96
242
47
842
77
752
46
742
96
452
47
162
56
732
07
442
57
152
47
742
97
352
28
262
07
652
57
362
87
272
56
562
07
172
57
972
66
452
17
162
67
862
57
652
08
362
38
272
17
272
67
972
97
982
66
082
17
782
67
792
76
862
27
572
77
582
67
962
18
672
48
682
27
982
77
692
08
603
76
992
27
603
77
613
86
682
37
492
87
303
77
682
28
392
58
303
37
503
87
313
18
423
86
613
37
423
87
533
96
203
47
013
97
123
97
403
48
213
78
323
47
423
97
233
28
443
96
333
47
243
97
353
07
813
57
723
08
933
97
723
58
533
88
743
57
343
08
253
38
463
07
153
57
063
08
273
17
633
67
543
18
753
Low side pressure ± 2 psig
High side pressure ± 5 psig
Tables are based upon rated CFM (airflow) across the evaporator coil. If there is any doubt as to correct operating
charge being in the system, the charge should be removed, system evacuated and recharged to serial plate instruction.
Manual 2100-425
Page 18
TABLE 13
OPTIONAL ACCESSORIES
WA611-A
WA611-B
WA611-C
WA702-A
WA701-B
WA701-C, WA721-C
LEDOMNOITPIRCSED
50A-50AWHEegakcaPretaeHX
01A-01AWHEegakcaPretaeHX
51A-51AWHEegakcaPretaeHX
02A-02AWHEegakcaPretaeHX
90B-06AWHEegakcaPretaeHXX
51B-50AWHEegakcaPretaeHXX
81B-50AWHEegakcaPretaeHXX
90C-A50AWHEegakcaPretaeHXX
51C-A50AWHEegakcaPretaeH X
50A-16AWHEegakcaPretaeHX
01A-16AWHEegakcaPretaeHX
80A-16AWHEegakcaPretaeHX
90B-16AWHEegakcaPretaeHX
5-POBetalPffOknalB XXXXXXX
5-DAFBrepmaDriAhserFcirtemoraB XXXXXXX
5-DAFMrepmaDriAhserFdezirotoM XXXXXXX
5-VRCtsuahxEhtiwrotalitneVmoorssalC XXXXXXX
5-MFIEtsuahxEhtiwrezimonocE XX XXXX
A5A-VREWrotalitneVyrevoceRygrenEXXX
A5C-VREWrotalitneVyrevoceRygrenEXX
C10-DPMWtiKtcennocsiDlluPXX
WA721-B
Manual 2100-425
Page 19
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