INSTALLATION INSTRUCTIONS
WALL MOUNTED
PACKAGE AIR CONDITIONERS
MODELS
WL423
WL484
WL602
Bard Manufacturing Company
Bryan, Ohio 43506
Since 1914...Moving ahead just as planned.
Manual : 2100-400
Supersedes:
File: Volume III Tab 16
Date: 01-31-02
© Copyright 2002
CONTENTS
Getting Other Information and Publications 1
Wall Mount General Information
Heat Pump 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
Wiring – Main Power.............................................. 12
Wiring – Low Voltage Wiring.................................. 12
Figures
Figure 1 Unit Dimensions ...................................... 3
Figure 2 Fresh Air Damper Assembly ................... 6
Figure 3 Mounting Instructions............................... 8
Figure 4 Electric Heat Clearance .......................... 9
Figure 5 Wall Mounting Instructions..................... 10
Figure 6 Wall Mounting Instructions .................... 10
Figure 7 Common Wall Mounting Installations......11
Figure 8 Unit 24V Terminal Board ....................... 13
Figure 9 Fan Blade Setting ................................. 16
Start Up
Important Installer Note ......................................... 14
High Pressure Switch ............................................ 14
Three Phase Scroll Compressor Start Up ............. 14
Phase Monitor ....................................................... 14
Condenser Fan Operation ..................................... 14
Service Hints ......................................................... 14
Sequence of Operation.......................................... 14
Compressor Control Module.................................. 15
Adjustments........................................................... 15
Pressure Service Ports .......................................... 15
Troubleshooting
Fan Blade Setting Dimensions .............................. 16
Removal of Fan Shroud......................................... 16
Refrigerant Charge ................................................ 16
Pressure Table....................................................... 17
Optional Accessories............................................. 18
Tables
Table 1 Electric Heat Table .................................. 2
Table 2 Electrical Specifications........................... 4
Table 3 Thermostat Wire Size ........................... 12
Table 4 Wall thermostat and Subbase
Combinations ........................................ 12
Table 5 Fan Blade Dimensions.......................... 16
Table 6 Refrigerant Charge ............................... 16
Table 7 Indoor Blower Performance .................. 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: (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; 5,301,777; 5,002,116; 4,924,934; 4,875,520;
4,825,936; 4,432,409
Manual 2100-400
Page 1
W ALL MOUNT GENERAL INFORMA TION
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
NOTE: All vent options are without exhaust capability. May require separate field supplied barometric relief in building.
REVISIONS
WL 42 3 – A 10 X N X X X A
COLOR OPTIONS
X - Beige (Standard)
1 - White
KW
VENTILATION OPTIONS
X - Barometric Fresh Air Damper (Standard)
B - Blank-off Plate
M - Motorized Fresh Air Damper
V - Commercial Ventilator -
Motorized with Exhaust
E - Economizer (Internal) - Fully
Modulating with Exhaust
R - Energy Recovery Ventilator -
Motorized with Exhaust
2 - Mesa Tan
4 - Buckeye Gray
5 - Desert Brown
6 - Dark Bronze
FILTER OPTIONS
X - One Inch Throwaway
(Standard)
W- One Inch Washable
P - Two Inch Pleated
CONTROL
MODULES
(See Chart Below)
COIL OPTIONS
X - Standard
1 - Phenolic Coated Evaporator
2 - Phenolic Coated Condenser
3 - Phenolic Coated Evaporator
and Condenser
OUTLET OPTIONS
X - Front (Standard)
TABLE 1
ELECTRIC HEAT TABLE
A-324LW
sledoM
A-484LW
A-206LW
1-0421-8023-0423-8023-064
WKAUTBAUTBAUTBAUTBAUTB
58.02050711.8100821
97.12006037.81030328.0100703
016.14031432.6300652
515.26002150.45004832.63002152.13004833.7100074
B-324LW
B-484LW
B-206LW
C-324LW
C-484LW
C-206LW
Manual 2100-400
Page 2
FIGURE 1
UNIT DIMENSIONS
-gieH
htdiW
ledoM
)W(
24LW
84LW
06LW
570.24234.22578.4888.988.9288.5188.9288.3401.9166.1300.0386.2349.6296.4334.2373.388.2488.3200.0144.100.6188.1
htpeD
th
)D(
)H(
ylppuSnruteR
EFGI JKLMNOPQRSTABCB
Manual 2100-400
Page 3
BACK VIEW
FRONT VIEWLEFT SIDE VIEW
MIS-1286
TABLE 2
ELECTRICAL SPECIFICATIONS
TIUCRICELGNIS TIUCRICLAUD
3
.oN
detaR
&stloV
ledoM
Z0A,00A-324LW
50A
01A
51A
Z0B,00B-324LW
90B
51B
Z0C,00C-324LW
90C
51C
Z0A,00A-484LW
50A
01A
51A
Z0B,00B-484LW
90B
51B
Z0C,00C-484LW
90C
51C
Z0A,00A-206LW
50A
01A
51A
Z0B,00B-206LW
90B
51B
Z0C,00C-206LW
90C
51C
esahP
3-064
3-064
3-064
dleiF
rewoP
stiucriC
1
1
1-802/032
1
2ro1
1
3-802/032
1
1
1
1
1
1
1
1-802/032
1
2ro1
1
3-802/032
1
1
1
1
1
1
1
1-802/032
1
2ro1
1
3-802/032
1
1
1
1
1
53
53
95
58
42
43
25
31
71
62
63
63
95
58
52
43
25
31
71
62
44
44
55
58
23
43
25
61
71
62
1
muminiM
tiucriC
yticapmA
05
05
06
09
53
53
05
51
02
03
05
05
06
09
53
53
06
51
02
03
06
06
06
09
54
54
06
02
02
03
2
mumixaM
lanretxE
roesuF
tiucriC
rekaerB
8
8
6
4
8
8
6
8
8
6
4
8
8
6
8
8
6
4
8
8
6
2
dleiF
rewoP
eriW
eziS
41
21
01
41
21
01
21
21
01
eriW
eziS
01
01
01
8
01
01
01
41
21
01
01
01
01
8
01
01
01
41
21
01
01
01
01
8
01
01
01
21
21
01
3
muminiM
tiucriC
dnuorG
yticapmA
TKC
A
B
A/N
A/N
A/N
A/N
A/N
A/N
65
62
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
95
62
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
95
62
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
1
mumixaM
lanretxE
esuF
.tkCro
rekaerB
TKC
TKC
A
B
A/N
A/N
A/N
A/N
A/N
A/N
06
03
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
06
03
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
06
03
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
2
dleiF
eziS
TKC
TKC
A
B
A/N
A/N
A/N
A/N
A/N
A/N
6
01
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
6
01
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
6
01
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
2
eriWrewoP
TKC
dnuorG
eziSeriW
TKC
TKC
A
B
A/N
A/N
A/N
A/N
A/N
A/N
01
01
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
01
01
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
01
01
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
A/N
Maximum size of the time delay fuse or HACR type circuit breaker for protection of field wiring conductors.
j
Based on 75° C copper wire. All wiring must conform to NEC and all local codes.
k
These “Minimum Circuit Ampacity” values are to be used for sizing the field power conductors. Refer to the
l
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
WALL MOUNTING INFORMATION
1. Two holes for the supply and return air openings
must be cut through the wall as shown in Figure 3.
INSTALLATION INSTRUCTIONS
WARNING
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.
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
Manual 2100-400
Page 8
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 CLEARANCE TO COMBUSTIBLE SURFACES.
MIS-277
WARNING
A
minimum
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.
of 1/4 inch clearance must be maintained between
Manual 2100-400
Page 9
FIGURE 5
WALL MOUNTING INSTRUCTIONS
WALL STRUCTURE
SUPPLY AIR
DUCT
RETURN AIR
OPENING
MIS-948
FACTORY SUPPLIED RAIN
FLASHING. MOUNT ON UNIT
BEFORE INSTALLATION
BOTTOM MOUNTING
BRACKET. MOUNT ON
WALL BEFORE
INSTALLING UNIT.
SEE FIGURE 3 – MOUNTING INSTRUCTIONS
SUPPLY AIR
OPENING
RETURN AIR
OPENING
SUPPLY AIR
OPENING
RETURN AIR
OPENING
FIGURE 6
WALL MOUNTING INSTRUCTIONS
ATTACH TO TOP
PLATE OF WALL
1.000” CLEARANCE
ALL AROUND
INTERIOR FINISHED
WALL OVER FRAME
1.000” CLEARANCE
ALL AROUND
EXTERIOR FINISHED
WALL OVER FRAME
SEE UNIT DIMENSIONS, FIGURE 1,
FOR ACTUAL DIMENSIONS
SUPPLY DUCT
OPENING
RETURN DUCT
OPENING
MIS-1051
Manual 2100-400
Page 10
FRAMING MATERIAL
2 X 4’S, 2 X 6’S AND/OR
STRUCTURAL STEEL
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.
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.
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.
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:
TABLE 3
THERMOSTAT WIRE SIZE
mumixaM
remrofsnarT
AVALFeguaGeriW
553.2
eguag02
eguag81
eguag61
egaug41
egaug21
ecnatsiD
teeFnI
54
06
001
061
052
See “Start Up” section for important information on
three phase scroll compressor start ups.
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
840-3048
31310048T
Manual 2100-400
Page 12
---loocegats1,taehegats1
---taehegats2,loocegats2
---
---
300-4048
0221A935Q
210-4048
1001A476Q
210-4048
1001A476Q
TABLE 4
loocegats1,taehegats1
looc-ffo-taeh:metsySno-otua:naF
looc-ffo-taeh:metsySno-otua:naF
taehegats2,loocegats1
looc-otua-taeh:metsySno-otua:naF
taehegats2,loocegats2
looc-otua-taeh:metsySno-otua:naF
cinortcelEgnimmargorpyad7
loocegats1,taehegats1
looc-ffo-taeh:metsySno-otua:naF
loocegats1,taehegats1
cinortcelE
FIGURE 8
UNIT 24V TERMINAL BOARD
MIS-1373A
Manual 2100-400
Page 13
ST ART 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.
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.
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.
Manual 2100-400
Page 14
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.
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.
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.
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.
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.
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.
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.
FIGURE 9
FAN BLADE SETTING
TABLE 5
FAN BLADE SETTING
DIMENSION
noisnemiD
ledoM
324LW
484LW
206LW
A
57.1
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.
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
detaR
ledoM
324LW004145-2566-46
484LW055165-4576-56
206LW007155-3526-06
wolfriA
DO59
erutarepmeT
DO28
erutarepmeT
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.
INDOOR BLOWER PERFORMANCE
V032woLV032hgiHV032woLV032hgiH
HnI20
0.
1.
2.
3.
4.
5.
.P.S.E
0561
0551
0541
0531
0031
---
teW
lioCyrD
lioC
0061
0051
0041
0031
5711
---
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
CFM @ 230V
484LW,324LW206LW
lioCyrD
5881
0771
5361
0051
0731
0521
teW
lioC
0081
5661
0451
0041
5821
0511
lioCyrD
0061
5251
---
---
---
---
teW
lioC
0541
5731
---
---
---
---
0022
0012
0002
5781
5771
0561
teW
lioCyrD
lioC
0002
0091
0081
0071
0061
5741
Manual 2100-400
Page 16
TABLE 8
ledoM324LW484LW206LW
WK
hgiH
deepS
woL
deepS
hgiH
deepS
woL
deepS
hgiH
deepS
woL
deepS
50A01A51A-
05.
05.
05.
05.
05.
05.
05.
05.
05.
05.
05.
05.
05.
05.
05.
05.
05.
05.
00B90B51B-
05.
05.
05.
05.
05.
05.
05.
05.
05.
05.
05.
05.
05.
05.
05.
05.
05.
05.
90C51C-
05.
05.
05.
05.
05.
05.
05.
05.
05.
05.
05.
05.
RECOMMENDED AIRFLOW
detaR
ledoM
324LW004103.0511-0061
484LW055102.5821-0571
206LW007103.5731-0591
* Rated CFM and ESP on high speed tap.
*MFC
detaR
*PSE
dednemmoceR
egnaRwolfriA
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
TABLE 9
MAXIMUM ESP OF OPERATION
ELECTRIC HEAT ONLY
COOLING
Air Temperature Entering Outdoor Coil °F
riAnruteR
ledoM
324LW
484LW
206LW
erutarepmeTerusserP5708580959001501011511
BD.ged57
BW.ged26
BD.ged08
BW.ged76
BD.ged58
BW.ged27
BD.ged57
BW.ged26
BD.ged08
BW.ged76
BD.ged58
BW.ged27
BD.ged57
BW.ged26
BD.ged08
BW.ged76
BD.ged58
BW.ged27
ediSwoL
ediShgiH
ediSwoL
ediShgiH
ediSwoL
ediShgiH
ediSwoL
ediShgiH
ediSwoL
ediShgiH
ediSwoL
ediShgiH
ediSwoL
ediShgiH
ediSwoL
ediShgiH
ediSwoL
ediShgiH
07
27
37
57
67
77
87
97
702
022
532
57
77
87
212
622
87
08
912
432
942
37
47
67
402
712
232
87
97
012
322
832
48
58
78
712
132
742
17
27
47
332
742
262
67
87
97
732
352
962
48
58
58
542
162
872
152
662
382
003
813
08
18
28
38
48
142
752
372
092
803
623
18
38
48
58
68
78
662
382
003
913
733
87
97
08
28
38
842
562
482
403
523
18
28
48
68
78
98
452
272
88
09
462
282
57
67
872
592
08
582
303
68
78
692
413
192
213
433
29
39
59
203
323
543
77
87
87
313
133
153
18
28
38
48
123
043
093
88
98
09
333
353
373
97
733
58
643
88
853
48
843
09
753
79
963
97
173
58
183
19
493
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
TABLE 11
OPTIONAL ACCESSORIES
traP
rebmuNnoitpircseD
5-POB
5-DAFB
5-DAFM
5-VRC
5-MFIE
6-AMC
A01-AMC
A31-AMC
51-CMC
61-AMC
81-AMCCAL&CPL XXXXX
B50-BCMW
C10-DCMW
A80-BCMW
A90-BCMW
B70-BCMW
etalPffOknalB
repmaDriAhserFcirtemoraB
repmaDriAhserFdezirotoM
tsuahxEhtiwrotalitneVlaicremmoC
tsuahxEhtiwrezimonocE
)CAL(lortnoCtneibmAwoL
RDT+CPH+CPL
yaleRmralA+RDT+CPH+CPL
tiKtratS
lortnoCeusserPwoL
tiKrekaerBtiucriC
tiKtcennocsiDlluP
rekaerBtiucriC
rekaerBtiucriC
rekaerBtiucriC
WL423-A
WL423-B
WL423-C
WL484-A
WL484-B
WL484-C
WL602-A
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
XXXXXXXXXXXXXXXXX
XXX
XX
XXX
X
X
XX XX
XXXXXX
X
X
X
X
X
WL602-B
X
X
X
X
X
X
X
X
X
WL602-C
Manual 2100-400
Page 18
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