Bard WL423, WL602, WL484 User Manual

INSTALLATION INSTRUCTIONS

WALL MOUNTED

PACKAGE AIR CONDITIONERS

MODELS

WL423

WL484

WL602

	Bard Manufacturing Company	Manual :	2100-400
	Bryan, Ohio 43506	Supersedes:
	Since 1914...Moving ahead just as planned.	File:	Volume III Tab 16
		Date:	01-31-02

© Copyright 2002

CONTENTS

Getting Other Information and Publications	1	Start Up
		Important Installer Note .........................................	14
Wall Mount General Information		High Pressure Switch ............................................	14
Heat Pump Wall Mount Model Nomenclature ..........	2	Three Phase Scroll Compressor Start Up .............	14
Shipping Damage ....................................................	5	Phase Monitor .......................................................	14
General ................................................................	5	Condenser Fan Operation .....................................	14
Duct Work ................................................................	5	Service Hints .........................................................	14
Filters ................................................................	6	Sequence of Operation ..........................................	14
Fresh Air Intake ........................................................	6	Compressor Control Module ..................................	15
Condensate Drain ....................................................	6	Adjustments ...........................................................	15
		Pressure Service Ports ..........................................	15

Installation Instructions		Troubleshooting
Wall Mounting Information .......................................	7	Fan Blade Setting Dimensions ..............................	16
Mounting the Unit .....................................................	7	Removal of Fan Shroud .........................................	16
Wiring – Main Power ..............................................	12	Refrigerant Charge ................................................	16
Wiring – Low Voltage Wiring ..................................	12	Pressure Table .......................................................	17
		Optional Accessories .............................................	18

Figures			Tables
Figure 1	Unit Dimensions ......................................	3	Table 1	Electric Heat Table ..................................	2
Figure 2 Fresh Air Damper Assembly ...................		6	Table 2	Electrical Specifications ...........................	4
Figure 3	Mounting Instructions ...............................	8	Table 3	Thermostat Wire Size ...........................	12
Figure 4	Electric Heat Clearance ..........................	9	Table 4	Wall thermostat and Subbase
Figure 5 Wall Mounting Instructions .....................		10		Combinations ........................................	12
Figure 6	Wall Mounting Instructions ....................	10	Table 5	Fan Blade Dimensions ..........................	16
Figure 7 Common Wall Mounting Installations ......		11	Table 6	Refrigerant Charge ...............................	16
Figure 8 Unit 24V Terminal Board .......................		13	Table 7	Indoor Blower Performance ..................	16
Figure 9 Fan Blade Setting .................................		16	Table 8	Recommended Air Flow ........................	17
			Table 9	Maximum EXP Electric Heat Only ........	17
			Table 10	Pressure Table ......................................	17
			Table 11	Optional Accessories ............................	18

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: [phone]

Fax: [phone]

ANSI	American National Standards Institute
	11 West Street, 13th Floor
	New York, NY 10036
	Telephone: [phone]
	Fax: [phone]

ASHRAE American Society of Heating Refrigerating,

and Air Conditioning Engineers, Inc.

1791 Tullie Circle, N.E.

Atlanta, GA 30329-2305

Telephone: [phone]

Fax: [phone]

NFPA	National Fire Protection Association
	Batterymarch Park
	P.O. Box 9101
	Quincy, MA 02269-9901
	Telephone: [phone]
	Fax: [phone]

Manufactured under the following U.S. Patent numbers: 5,485,878; 5,301,777; 5,002,116; 4,924,934; 4,875,520; 4,825,936; 4,432,409

Manual 2100-400

Page 1

WALL MOUNT GENERAL INFORMATION

HEAT PUMP WALL MOUNT MODEL NOMENCLATURE

MODEL NUMBER

CAPACITY

42 - 3 1/2 Ton

48 - 4 Ton

60 - 5 Ton

VOLTS & PHASE

A - 230/208/60/1 B - 230/208/60/3 C - 460/60/3

	WL 42 3 – A 10 X N X X X A							CONTROL
								MODULES
								(See Chart Below)
								COIL OPTIONS
	REVISIONS							X - Standard
								1 - Phenolic Coated Evaporator
						COLOR OPTIONS
								2 - Phenolic Coated Condenser
						X - Beige (Standard)		3 - Phenolic Coated Evaporator
	KW					1	- White	and Condenser
						2	- Mesa Tan
	VENTILATION OPTIONS					4	- Buckeye Gray	OUTLET OPTIONS
	X - Barometric Fresh Air Damper (Standard)					5	- Desert Brown	X - Front (Standard)
	B - Blank-off Plate					6	- Dark Bronze

M - Motorized Fresh Air Damper

V - Commercial Ventilator -

Motorized with Exhaust

E - Economizer (Internal) - Fully

FILTER OPTIONS

Modulating with Exhaust

X - One Inch Throwaway

R - Energy Recovery Ventilator -

(Standard)

Motorized with Exhaust

W - One Inch Washable

P - Two Inch Pleated

NOTE: All vent options are without exhaust capability. May require separate field supplied barometric relief in building.

TABLE 1

ELECTRIC HEAT TABLE

		WL423-A				WL423-B			WL423-C
Models		WL484-A				WL484-B			WL484-C
		WL602-A				WL602-B			WL602-C
	240-1		208-1		240-3		208-3		460-3
KW	A	BTU	A	BTU	A	BTU	A	BTU	A	BTU
5	20.8	17050	18.1	12800
9					21.7	30600	18.7	23030	10.8	30700
10	41.6	34130	36.2	25600
15	62.5	51200	54.0	38400	36.2	51200	31.2	38400	17.3	47000

Manual 2100-400

Page 2

Page	Manual
3	400-2100

FIGURE 1

UNIT DIMENSIONS

					Heig-												Supply						Return
	Width	Depth			ht
Model	(W)	(D)			(H)											A						B	C						B						E			F	G	I	J	K			L					M							N			O	P	Q		R	S	T
WL42
WL48	42.075	22.432	84.875										9.88						29.88				15.88	29.88										43.88		19.10			31.66	30.00	32.68	26.94	34.69					32.43							3.37					42.88	23.88	10.00		1.44	16.00	1.88
WL60

BACK VIEW

LEFT SIDE VIEW

FRONT VIEW

MIS-1286

TABLE 2

ELECTRICAL SPECIFICATIONS

SINGLE CIRCUIT

DUAL CIRCUIT

3

1

2

2

3

1

2

2

Maximum

External

No.

Maximum

Minimum

Fuse

Field

External

Field

Circuit

or Ckt.

Power Wire

Ground

Rated

Field

Minimum

Fuse or

Power

Ground

Ampacity

Breaker

Size

Wire Size

Volts &

Power

Circuit

Circuit

Wire

Wire

CKT

CKT

CKT

CKT

CKT

CKT

CKT

CKT

Model

Phase

Circuits

Ampacity

Breaker

Size

Size

A

B

A

B

A

B

A

B

WL423-A00, A0Z

1

35

50

8

10

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

A05

230/208-1

1

35

50

8

10

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

A10

1

59

60

6

10

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

A15

1 or 2

85

90

4

8

56

26

60

30

6

10

10

10

WL423-B00, B0Z

1

24

35

8

10

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

B09

230/208-3

1

34

35

8

10

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

B15

1

52

50

6

10

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

WL423-C00, C0Z

1

13

15

14

14

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

C09

460-3

1

17

20

12

12

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

C15

1

26

30

10

10

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

WL484-A00, A0Z

1

36

50

8

10

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

A05

230/208-1

1

36

50

8

10

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

A10

1

59

60

6

10

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

A15

1 or 2

85

90

4

8

59

26

60

30

6

10

10

10

WL484-B00, B0Z

1

25

35

8

10

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

B09

230/208-3

1

34

35

8

10

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

B15

1

52

60

6

10

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

WL484-C00, C0Z

1

13

15

14

14

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

C09

460-3

1

17

20

12

12

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

C15

1

26

30

10

10

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

WL602-A00, A0Z

1

44

60

8

10

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

A05

230/208-1

1

44

60

8

10

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

A10

1

55

60

6

10

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

A15

1 or 2

85

90

4

8

59

26

60

30

6

10

10

10

WL602-B00, B0Z

1

32

45

8

10

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

B09

230/208-3

1

34

45

8

10

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

B15

1

52

60

6

10

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

WL602-C00, C0Z

1

16

20

12

12

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

C09

460-3

1

17

20

12

12

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

C15

1

26

30

10

10

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

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 NEC and all local codes.

lThese “Minimum Circuit Ampacity” values are to be used for sizing the field power conductors. Refer to the National Electric Code (latest revision), article 310 for power conductor sizing. CAUTION: When more than one field power conductor circuit is run through one conduit, the conductors must be derated. Pay special attention to note 8 of table 310 regarding Ampacity Adjustment Factors when more than 3 conductors are in a raceway.

Manual 2100-400

Page 4

SHIPPING DAMAGE

Upon receipt of equipment, the carton should be checked for external signs of shipping damage. If damage is found, the receiving party must contact the last carrier immediately, preferably in writing, requesting inspection by the carrier’s agent.

GENERAL

The equipment covered in this manual is to be installed by trained, experienced service and installation technicians.

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

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

These instructions 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.

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.

DUCT WORK

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 10 for maximum static pressure available for duct design.

Design the duct work according to methods given by the Air Conditioning Contractors of America (ACCA). When duct runs through unheated spaces, it should be insulated with a minimum of one inch of insulation. Use insulation with a vapor barrier on the outside of the insulation. Flexible joints should be used to connect the duct work to the equipment in order to keep the noise transmission to a minimum.

A 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 3 and 4 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.

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 inch.

Any grille that meets with 5/8 inch louver criteria may be used. It is recommended that Bard Return Air Grille Kit RG2 through RG5 or RFG2 through RFG5 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 2100-400

Page 5

FILTERS

A one 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 one inch washable filter and two inch pleated filter are also available as optional accessories. The internal filter brackets are adjustable to accommodate the two inch filter by loosening two (2) screws on each bracket assembly and sliding the brackets apart to the required width and retightening the four (4) screws.

FRESH AIR INTAKE

All units are built with fresh air inlet slots punched in the 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. To allow the damper to operate, the maximum and minimum blade position stops must be installed. See Figure 2.

All capacity, efficiency and cost of operation information as required for Department of Energy “Energyguide” Fact Sheets is based upon the fresh air blank-off plate in place and is recommended for maximum energy efficiency.

The blank-off plate is available upon request from the factory and is installed in place of the fresh air damper shipped with each unit.

CONDENSATE DRAIN

A plastic drain hose extends from the drain pan at the top of the unit down to the unit base. There are openings in the unit base for the drain hose to pass through. In the event the drain hose is connected to a drain system of some type, it must be an open or vented type system to assure proper drainage.

FIGURE 2

FRESH AIR DAMPER

BLADE IS LOCKED

CLOSED FOR

SHIPPING.

MIS-938

Manual 2100-400

Page 6

INSTALLATION INSTRUCTIONS

WALL MOUNTING INFORMATION

1.Two holes for the supply and return air openings must be cut through the wall as shown in Figure 3.

2.On wood frame walls, the wall construction must be strong and rigid enough to carry the weight of the unit without transmitting any unit vibration.

3.Concrete block walls must be thoroughly inspected to insure that they are capable of carrying the weight of the installed unit.

MOUNTING THE UNIT

1.These units are secured by wall mounting brackets which secure the unit to the outside wall surface at both sides. A bottom mounting bracket is provided for ease of installation, but is not required.

2.The unit itself is suitable for 0 inch clearance, but the supply air duct flange and the first 3 feet of supply air duct require a minimum of 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 and 4 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 causing damage, injury or death.

3.Locate and mark lag bolt locations and bottom mounting bracket location. See Figure 3.

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 left side to allow access to control panel and heat strips, and to allow proper airflow to the outdoor coil. Additional clearance may be required to meet local or national codes.

Manual 2100-400

Page 7

400-2100 Manual

8 Page

FIGURE 3

MOUNTING INSTRUCTIONS

MIS-947

FIGURE 4

ELECTRIC HEAT CLEARANCE

SIDE SECTION VIEW OF SUPPLY AIR DUCT FOR

WALL MOUNTED UNIT SHOWING 1/4 INCH CLEAR-

ANCE TO COMBUSTIBLE SURFACES.

MIS-277

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 a fire causing damage, injury or death.

Manual 2100-400

Page 9

FIGURE 5

WALL MOUNTING INSTRUCTIONS

WALL STRUCTURE

SEE FIGURE 3 – MOUNTING INSTRUCTIONS

FACTORY SUPPLIED RAIN

FLASHING. MOUNTON UNIT

BEFOREINSTALLATION

SUPPLYAIR

DUCT

RETURN AIR

OPENING

BOTTOM MOUNTING

BRACKET. MOUNT ON

WALL BEFORE

INSTALLING UNIT.

MIS-948

SUPPLY AIR	SUPPLY AIR
OPENING	OPENING

RETURN AIR	RETURN AIR
OPENING	OPENING

FIGURE 6

WALL MOUNTING INSTRUCTIONS

SEE UNIT DIMENSIONS, FIGURE 1, FOR ACTUAL DIMENSIONS

ATTACH TO TOP

PLATE OF WALL

1.000” CLEARANCE ALL AROUND

SUPPLY DUCT

OPENING

INTERIOR FINISHED

WALLOVER FRAME

1.000” CLEARANCE ALL AROUND

EXTERIOR FINISHED WALLOVER FRAME

RETURN DUCT

OPENING

FRAMING MATERIAL

2 X 4’S, 2X 6’SAND/OR

STRUCTURAL STEEL

MIS-1051

ATTACH TO BOTTOM

PLATE OF WALL THIS STRUCTURAL MEMBER LOCATED TO MATCH STUD SPACING FOR REST OF WALL. A SECOND MEMBER MAY BE REQUIRED FOR SOME WALLS.

Manual 2100-400

Page 10

FIGURE 7

COMMON WALL MOUNTING INSTALLATIONS

FREE AIR FLOW NO DUCT	DUCTED SUPPLY RETURN AT UNIT
FALSE WALL INSTALLATION	CLOSET INSTALLATION
		MIS-1050
	Manual	2100-400
	Page	11

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 muse conform to NEC and all local codes.

The electrical data lists fuse and wire sizes (75° C 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.

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:

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).

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:

The unit rating plate lists a “Maximum Time Delay Relay Fuse” or “HACR” type circuit breaker that is to be used with the equipment. The correct size must be used for proper circuit protection and also to assure that there will be no nuisance tripping due to the momentary high starting current of the compressor motor.

The disconnect access door on this unit may be locked to prevent unauthorized access to the disconnect. To convert for the locking capability bend the tab located in the bottom left hand corner of the disconnect opening under the disconnect access panel straight out. This tab will now line up with the slot in the door. When shut a padlock may be placed through the hole in the tab preventing entry.

See “Start Up” section for important information on three phase scroll compressor start ups.

TABLE 3

THERMOSTAT WIRE SIZE

			Maximum
Transformer			Distance
VA	FLA	Wire Gauge	In Feet
		20 gauge	45
		18 gauge	60
55	2.3	16 gauge	100
		14 guage	160
		12 guage	250

TABLE 4

WALL THERMOSTAT AND SUBBASE COMBINATIONS

	Thermostat	Subbase	Predominate Features
	8403-002	8404-003	1 stage heat, 1 stage cool
	T87F3111	Q539A1220	System: heat-off-cool		Fan: auto-on
	8403-041	---	1 stage heat, 1 stage cool
	T8034C		System: heat-off-cool		Fan: auto-on
	8403-019	8404-012	1 stage cool, 2 stage heat
	T874C1760	Q674A1001	System: heat-auto-cool		Fan: auto-on
	8403-021	8404-012	2 stage cool, 2 stage heat
	T874D1934	Q674A1001	System: heat-auto-cool		Fan: auto-on
	8403-049	---	2 stage cool, 2 stage heat
	1F93-380		Electronic	7 day programming
	8403-043	---	1 stage heat, 1 stage cool
	CM-200		System: heat-off-cool		Fan: auto-on
	8403-048	---	1 stage heat, 1 stage cool
	T84001313		Electronic

Manual 2100-400

Page 12

FIGURE 8

UNIT 24V TERMINAL BOARD

	MIS-1373A
Manual	2100-400
Page	13

START UP

IMPORTANT INSTALLER NOTE

For improved start up performance wash the indoor coil with a dish washing detergent.

HIGH PRESSURE SWITCH

The WL484 and WL602 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. 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 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.

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

PHASE MONITOR

All units with three phase scroll compressors are equipped with a 3 phase line monitor to prevent compressor damage due to phase reversal.

The phase monitor in this unit is equipped with two LEDs. If the Y signal is present at the phase monitor and phases are correct the green LED will light.

If phases are reversed, the red fault LED will be lit and compressor operation is inhibited.

If a fault condition occurs, reverse two of the supply leads to the unit. Do not reverse any of the unit factory wires as damage may occur.

CONDENSER FAN OPERATION

The condenser fan motor on 230/208 volt, one and three phase, 60 HZ units is a two speed motor that comes factory wired on high speed for peak performance. If ambient conditions permit, it can be reconnected to low speed (red wire) for lower sound level. See wiring diagram.

50 HZ models must have fan wired on low speed. These models are factory wired on low speed.

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.Switching to heating cycle at 75° F or higher outside temperature may cause a nuisance trip of the remote reset high pressure switch. Turn thermostat off then on to reset the high pressure switch.

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

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

SEQUENCE OF OPERATION

COOLING – Circuit R-Y makes at thermostat pulling in compressor contactor, starting the compressor and outdoor motor. The G (indoor motor) circuit is automatically completed on any call for cooling operation or can be energized by manual fan switch on subbase of constant air circulation. On all 230 volt units there is a one minute off delay on the blower motor. 460 volt models do not have an off delay. 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.

Manual 2100-400

Page 14

COMPRESSOR CONTROL MODULE

The compressor control module is standard on the WL484 and WL602 models covered by this manual and is optional on the WL423 model. 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.

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.

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.

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 (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

PRESSURE SERVICE PORTS

High and low pressure service ports are installed on all units so that the system operating pressures can be observed. A pressure table 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 2100-400

Page 15

TROUBLESHOOTING

FAN BLADE SETTING DIMENSIONS

Shown in Figure 10 is the correct fan blade setting dimension 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.

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.

FIGURE 9

FAN BLADE SETTING

TABLE 5

FAN BLADE SETTING

DIMENSION

	Dimension
Model	A
WL423
WL484	1.75
WL602

REMOVAL OF FAN SHROUD

1.Disconnect all power to the unit.

2.Remove the screws holding both grilles, one on each side of unit, and remove grilles.

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 6.

TABLE 6

REFRIGERANT CHARGE

	Rated	95 OD	82 OD
Model	Airflow	Temperature	Temperature
WL423	1400	52 - 54	64 - 66
WL484	1550	54 - 56	65 - 67
WL602	1700	53 - 55	60 - 62

The suction line temperatures in table above are based upon 80° F dry bulb / 67° F wet bulb (50% R.H.) temperature and rated airflow across the evaporator during cooling cycle.

TABLE 7

INDOOR BLOWER PERFORMANCE

CFM @ 230V

			WL423, WL484				WL602
		Low 230V		High 230V		Low 230V		High 230V
	E.S.P.
		Dry Coil	Wet	Dry Coil	Wet	Dry Coil	Wet	Dry Coil	Wet
	In H20		Coil		Coil		Coil		Coil
	.0	1650	1600	1885	1800	1600	1450	2200	2000
	.1	1550	1500	1770	1665	1525	1375	2100	1900
	.2	1450	1400	1635	1540	- - -	- - -	2000	1800
	.3	1350	1300	1500	1400	- - -	- - -	1875	1700
	.4	1300	1175	1370	1285	- - -	- - -	1775	1600
	.5	- - -	- - -	1250	1150	- - -	- - -	1650	1475

Manual 2100-400

Page 16

TABLE 8

RECOMMENDED AIRFLOW

	Rated	Rated	Recommended
Model	CFM *	ESP *	Airflow Range
WL423	1400	.30	1600 - 1150
WL484	1550	.20	1750 - 1285
WL602	1700	.30	1950 - 1375

* Rated CFM and ESP on high speed tap.

TABLE 9

MAXIMUM ESP OF OPERATION

ELECTRIC HEAT ONLY

Model	WL423		WL484		WL602
	High	Low	High	Low	High	Low
KW	Speed	Speed	Speed	Speed	Speed	Speed
-A05	.50	.50	.50	.50	.50	.50
-A10	.50	.50	.50	.50	.50	.50
-A15	.50	.50	.50	.50	.50	.50
-B00	.50	.50	.50	.50	.50	.50
-B09	.50	.50	.50	.50	.50	.50
-B15	.50	.50	.50	.50	.50	.50
-C09	.50	.50	.50	.50	.50	.50
-C15	.50	.50	.50	.50	.50	.50

Values shown are for units equipped with standard 1 inch throwaway filter or 1 inch washable filter. Derate ESP by .15 for 2 inch pleated filters.

TABLE 10

PRESSURE TABLE

COOLING					Air Temperature Entering Outdoor Coil °F
		Return Air
	Model	Temperature	Pressure	75	80	85	90	95	100	105	110	115
		75 deg. DB	Low Side	70	72	73	75	76	77	78	79	79
		62 deg. WB	High Side	207	220	235	251	266	283	300	318	337
	WL423	80 deg. DB	Low Side	75	77	78	80	81	82	83	84	85
		67 deg. WB	High Side	212	226	241	257	273	290	308	326	346
		85 deg. DB	Low Side	78	80	81	83	84	85	86	87	88
		72 deg. WB	High Side	219	234	249	266	283	300	319	337	358
		75 deg. DB	Low Side	73	74	76	78	79	80	82	83	84
		62 deg. WB	High Side	204	217	232	248	265	284	304	325	348
	WL484	80 deg. DB	Low Side	78	79	81	82	84	86	87	89	90
		67 deg. WB	High Side	210	223	238	254	272	291	312	334	357
		85 deg. DB	Low Side	84	85	87	88	90	92	93	95	97
		72 deg. WB	High Side	217	231	247	264	282	302	323	345	369
		75 deg. DB	Low Side	71	72	74	75	76	77	78	78	79
		62 deg. WB	High Side	233	247	262	278	295	313	331	351	371
	WL602	80 deg. DB	Low Side	76	78	79	80	81	82	83	84	85
		67 deg. WB	High Side	237	253	269	285	303	321	340	390	381
		85 deg. DB	Low Side	84	85	85	86	87	88	89	90	91
		72 deg. WB	High Side	245	261	278	296	314	333	353	373	394

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 instructions.

NOTE: Pressure table based on high speed condenser fan operation. If condensing pressures appear elevated check condenser fan wiring. See “Condenser Fan Operation” on Page 14.

Manual 2100-400

Page 17

Part

Number Description

TABLE 11

OPTIONAL ACCESSORIES

WL423-A

WL423-B

WL423-C

WL484-A

WL484-B

WL484-C

WL602-A

WL602-B

WL602-C

BOP-5	Blank Off Plate	X	X	X	X	X	X	X	X	X
BFAD-5	Barometric Fresh Air Damper	X	X	X	X	X	X	X	X	X
MFAD-5	Motorized Fresh Air Damper	X	X	X	X	X	X	X	X	X
CRV-5	Commercial Ventilator with Exhaust	X	X	X	X	X	X	X	X	X
EIFM-5	Economizer with Exhaust	X	X	X	X	X	X	X	X	X
CMA-6	Low Ambient Control (LAC)	X	X		X	X		X	X
CMA-10A	LPC + HPC + TDR	X	X	X
CMA-13A	LPC + HPC + TDR + Alarm Relay	X	X
CMC-15	Start Kit	X
CMA-16	Low Pressue Control				X	X	X	X	X	X
CMA-18	LPC & LAC				X	X	X	X	X
WMCB-05B	Circuit Breaker Kit		X			X
WMCD-01C	Pull Disconnect Kit			X			X			X
WMCB-08A	Circuit Breaker	X			X
WMCB-09A	Circuit Breaker							X
WMCB-07B	Circuit Breaker								X

Manual 2100-400

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