Bard WL702-A, WL701-C, WL701-B User Manual

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WALL MOUNTED PACKAGED INSTALLATION AIR CONDITIONER INSTRUCTIONS Model: WL701-B, WL701-C,

WL702-A

MIS-861

 

 

 

 

 

 

 

 

 

 

Bard Manufacturing Company

Manual No.:

2100-426

Bryan, Ohio 43506

Supersedes:

 

Since 1914...Moving ahead just as planned.

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 ....................................................

4

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

4

Duct Work ...............................................................

4

Filters ...............................................................

5

Fresh Air Intake ........................................................

5

Condensate Drain ....................................................

5

Installation Instructions

 

Wall Mounting Information .......................................

6

Mounting the Unit .....................................................

6

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

6

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

6

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

7

Figures

 

 

Figure 1

Unit Dimensions .....................................

3

Figure 2

Blower Damper Assembly ......................

5

Figure 3

Mounting Instructions .............................

7

Figure 4 Electric Heat Clearances .......................

8

Figure 5

Wall-Mounting Instructions ....................

9

Figure 6

Wall-Mounting Instructions ....................

9

Figure 7

Common Wall-Mounting Instructions ...

10

Figure 8

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

11

Figure 9

Start-Up Label ......................................

12

Figure 10 Fan Blade Setting ................................

15

Start Up

 

Important Installer Note .........................................

12

Crankcase Heaters ................................................

12

High Pressure Switch .............................................

12

Three Phase Scroll Compressor Start Up

 

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

12

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

13

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

13

Compressor Control Module ..................................

13

Adjustments ...........................................................

14

Phase Monitor .......................................................

14

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

14

Troubleshooting

 

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

15

Removal of Fan Shroud .........................................

15

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

15

Pressure Chart ......................................................

16

Optional Accessories .............................................

16

Tables

 

 

 

Table

1

Electrical Specifications .........................

2

Table 2

Dimensions of Basic Unit .......................

3

Table 3

Electric Heat Table .................................

3

Table 4

Operating Voltage Range .......................

7

Table 5

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

8

Table 6

Wall Thermostat and

 

 

 

Subbase Combinations ..........................

8

Table

7

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

15

Table

8

Suction Line Temperatures ..................

15

Table

9

Indoor Blower Performance .................

15

Table

10

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

15

Table

11

Maximum ESP of Operation

 

 

 

Electric Heat Only ................................

15

Table

12

Cooling Pressure .................................

16

Table

13

Optional Accessories ...........................

16

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 Duct . ACCA Manual D or

System Design for Winter and

Manual

Q

 

Summer Air Conditioning

 

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; 5,301,744; 5,002,116; 4,924,934; 4,875,520; 4,825,936

Manual 2100-426

Page 1

WALL MOUNT GENERAL INFORMATION

AIR CONDITIONER WALL MOUNT MODEL NOMENCLATURE

MODEL NUMBER

 

 

 

 

CONTROL MODULES

 

WL 70 1 B 09 X

X X X X J

J - Standard on all

CAPACITY

Models

 

 

 

 

 

70 - 6 Ton

 

 

 

COIL OPTIONS

 

 

 

 

 

 

 

 

X - Standard

REVISION

 

VENTILATION OPTIONS

 

1 - Phenolic Coated Evaporator

 

 

X - Barometric Fresh Air Damper

 

2 - Phenolic Coated Condenser

VOLTS & PHASE

 

(Standard)

 

3 - Phenolic Coated Evaporator

A - 230/208-1

KW

B - Blank-off Plate

COLOR OPTIONS

and Condenser

 

 

 

B - 230/208/60-3 00 - No KW

M - Motorized Fresh Air Damper

 

C - 460/60-3

0Z - No KW

V - Commercial Room Ventilator -

X - Beige

 

 

 

Motorized with Exhaust

(Standard)

 

 

 

w/Circuit Breaker

OUTLET OPTIONS

 

E - Economizer (Internal) - Fully

1 - White

 

or Pull

X - Front (Standard)

 

Modulating with Exhaust

 

 

Disconnect

 

 

 

 

R - Energy Recovery Ventilator -

 

 

 

 

05 - 5 KW

 

 

 

 

with Exhaust

FILTER OPTIONS

 

 

 

09 - 9 KW

 

 

 

10 - 10 KW

 

X - One Inch Throwaway

 

 

15 - 15 KW

 

(Standard)

 

 

 

18 - 18 KW

 

W - One Inch Washable

 

 

 

 

 

P - Two Inch Pleated

 

 

NOTE: For 0KW and circuit breakers (230/208 V) or pull disconnects (460 V) applications, insert 0Z in the KW field of model number.

TABLE 1

ELECTRICAL SPECIFICATIONS

Single Circuit

Dual Circuit

 

 

 

3

1

2

2

 

3

 

1

 

2

2

 

 

 

 

 

 

 

 

 

 

 

 

 

Field Wire

Ground

 

 

No. of

 

 

Field

Ground

 

MCA

MOP

Size

Wire Size

 

 

 

 

Wire

Wire

 

 

 

 

 

 

 

 

 

 

 

 

 

Power

 

 

CKT

CKT

CKT

 

CKT

CKT

 

CKT

CKT

CKT

 

 

MCA

MOP

Size

Size

 

 

Models

Rated

Circuits

A

 

B

A

 

B

A

 

B

A

B

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WL702-A00,A0Z

203/208-1

1

48

60

8

10

NA

 

NA

NA

 

NA

NA

 

NA

NA

NA

-A05

230/208-1

1

48

60

8

10

NA

 

NA

NA

 

NA

NA

 

NA

NA

NA

-A10

230/208-1

1

59

60

6

10

NA

 

NA

NA

 

NA

NA

 

NA

NA

NA

-A15 230/208-1

1 or 2

85

90

4

8

59

 

26

60

 

30

6

 

10

10

10

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WL701-B00,B0Z

 

1

36

50

8

10

NA

 

NA

NA

 

NA

NA

 

NA

NA

NA

-B09

230/208-3

1

36

50

8

10

NA

 

NA

NA

 

NA

NA

 

NA

NA

NA

-B15

1

52

60

6

10

NA

 

NA

NA

 

NA

NA

 

NA

NA

NA

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WL701-C00,C0Z

 

1

17

25

12

12

NA

 

NA

NA

 

NA

NA

 

NA

NA

NA

-C09

460-3

1

17

25

12

12

NA

 

NA

NA

 

NA

NA

 

NA

NA

NA

-C15

 

1

26

30

10

10

NA

 

NA

NA

 

NA

NA

 

NA

NA

NA

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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.

lThese "Minimum Circuit Ampacity" values are to be used for sizing the field power conductors. Refer to the

National Electric Code (latest version), Article 310 for power conductor sizing. CAUTION: When more than one filed power conductor circuit is run through one 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.

Manual 2100-426

Page 2

TABLE 2

DIMENSION OF BASIC UNIT FOR ARCHITECTURAL AND

INSTALLATION REQUIREMENTS (NOMINAL)

Unit

Width

Depth

Height

Supply

Return

E

F

G

I

J

K

L

M

N

O

P

Q

W

D

H

A

B

C

B

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WL70

42

22-1/4

94-7/8

9-7/8

29-7/8

15-7/8

29-7/8

43-7/8

19

41-5/8

30

42-11/16

37

44-3/4

42-1/2

3-1/4

43

33-7/8

10

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

All dimensions in inches.

FIGURE 1

UNIT DIMENSIONS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BACK VIEW

 

 

 

 

 

 

SIDE VIEW

 

FRONT VIEW

MIS-1416

TABLE 3

ELECTRIC HEAT TABLE

Models

 

WL702-A

 

 

WL701-B

 

WL701-C

 

 

 

 

 

 

 

 

 

 

 

 

240V-1

208V-1

240V-3

208V-3

460V-3

 

 

 

 

 

 

 

 

 

 

 

KW

AMPS

BTUH

AMPS

BTUH

AMPS

BTUH

AMPS

BTUH

AMPS

BTUH

 

 

 

 

 

 

 

 

 

 

 

5.0

20.8

17,050

18.1

12,800

---

---

---

---

---

---

 

 

 

 

 

 

 

 

 

 

 

9.0

---

---

---

---

21.7

30,600

18.7

23,030

10.8

30,700

 

 

 

 

 

 

 

 

 

 

 

10.0

41.6

34,130

36.2

25,600

---

---

---

---

---

---

 

 

 

 

 

 

 

 

 

 

 

15.0

62.5

51,200

54.1

38,400

36.2

51,200

31.2

38,400

17.3

47,000

 

 

 

 

 

 

 

 

 

 

 

Manual 2100-426

Page 3

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 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.

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 2100-426

Page 4

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.

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

BLOWER DAMPER ASSEMBLY

BLADE IS LOCKED

CLOSED FOR

SHIPPING

MIS-938

Manual 2100-426

Page 5

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. See Figures 5 and 6.

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 5.

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 5 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 5.

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 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 wall-mount 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.

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.

Manual 2100-426

Page 6

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 information on three phase scroll compressor start-ups.

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:

TABLE 4

OPERATING VOLTAGE RANGE

TAP

RANGE

 

 

 

 

240V

253

-

216

 

 

 

 

208V

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.

FIGURE 3

MOUNTING INSTRUCTIONS

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.

MIS-1430

Manual 2100-426

Page 7

TABLE 5

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 gauge

160

 

 

12 gauge

250

TABLE 6

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

8403-035

---

2 stage cool, 2 stage heat

1F95-80

 

Electronic 7 day programming

8403-043

---

1 stage heat, 1 stage cool

CM-200

System: heat-off-cool Fan: auto-on

 

 

 

 

FIGURE 4

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.

MIS-277

Manual 2100-426

Page 8

FIGURE 5

WALL-MOUNTING INSTRUCTIONS

SEE FIGURE 3 — MOUNTING INSTRUCTIONS

MIS-948

FIGURE 6

WALL-MOUNTING INSTRUCTIONS

SEE UNIT DIMENSIONS, FIGURE 1,

FOR ACTUAL DIMENSIONS

SEE FIGURE 1 FOR

DUCT DIMENSIONS

MIS-1051

Manual 2100-426

Page 9

FIGURE 7

COMMON WALL-MOUNTING INSTALLATIONS

MIS-1050

Manual 2100-426

Page 10

FIGURE 8

LOW VOLTAGE WIRING

 

MIS-1373C

Manual

2100-426

Page

11

START UP

IMPORTANT INSTALLER NOTE

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

CRANKCASE HEATERS

WL701 units are provided with compressor crankcase heat.

The WL701 model has 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 WL701 unit 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 WA701 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 identical 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 2100-426

Page 12

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

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.

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.

Manual 2100-426

Page 13

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

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.

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 2100-426

Page 14

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

Model

Dimension A

 

 

WL70

1.25

 

 

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

INDOOR BLOWER PERFORMANCE

CFM AT 230 V

 

 

WL70

 

 

 

 

 

 

E.S.P.

High Speed

Low Speed

 

 

 

 

In H2O

Dry Coil

Wet Coil

Dry Coil

Wet Coil

.0

2,200

2,000

1,600

1,450

 

 

 

 

 

.1

2,100

1,900

1,525

1,375

 

 

 

 

 

.2

2,000

1,800

---

---

 

 

 

 

 

.3

1,875

1,700

---

---

 

 

 

 

 

.4

1,775

1,600

---

---

.5

1,650

1,475

---

---

 

 

 

 

 

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 the following table:

TABLE 8

SUCTION LINE TEMPERATURES

1

Rated

95° F

82° F

Models

Airflow

OD Temp.

OD Temp.

 

 

 

 

WL70

1,800

58 - 60

56 - 58

 

 

 

 

TABLE 10

CFM AND ESP

Rated

Rated

Recommended

Air Flow

Model

CFM

ESP

Range

 

 

 

 

WL70

1,800

.20

2,000 -- 1,375

j Rated CFM and ESP on high speed tap.

TABLE 11

MAXIMUM ESP OF OPERATION

ELECTRIC HEAT ONLY

Model

WL70

 

 

 

Speed

Low

High

KW

Speed

Speed

-A00

.50

.50

-A05

.50

.50

-A10

.50

 

 

 

 

-B00

.50

.50

-B09

.50

.50

-B15

.50

.50

-C09

.50

.50

-C15

.50

.50

 

 

 

Manual 2100-426

Page 15

TABLE 12

COOLING PRESSURE – (ALL TEMPERATURES °F)

 

Return

 

 

 

 

 

 

 

 

 

 

 

Air

 

 

 

 

 

 

 

 

 

 

Model

Temp.

Pressure

75

80

85

90

95

100

105

110

115

 

75 DB

Low Side

68

68

69

70

71

72

73

74

75

 

62 WB

High Side

215

228

242

256

272

289

305

324

343

WL702-A

80 DB

Low Side

73

73

74

75

76

77

78

79

80

67 WB

High Side

220

234

248

263

279

296

313

332

352

 

 

85 DB

Low Side

76

76

77

78

79

80

81

82

83

 

72 WB

High Side

228

242

257

272

289

306

324

344

364

 

75 DB

Low Side

62

63

64

65

66

67

68

69

70

 

62 WB

High Side

214

230

247

265

280

299

316

333

351

 

80 DB

Low Side

67

68

69

70

71

72

73

74

75

WL701-B,-C

67 WB

High Side

220

236

254

271

287

306

324

342

360

 

85 DB

Low Side

72

73

74

75

76

77

78

79

80

 

72 WB

High Side

225

243

261

279

297

316

335

353

372

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.

TABLE 13

OPTIONAL ACCESSORIES

MODEL DESCRIPTION

WL702-A

WL701-B

WL701-C

EHWA05-A05L

Heater Package

X

 

 

 

 

 

 

 

EHWA10-A10L

Heater Package

X

 

 

 

 

 

 

 

EHWA15-A15L

Heater Package

X

 

 

 

 

 

 

 

EHWA05-B09L

Heater Package

 

X

 

 

 

 

 

 

EHWA05-B15L

Heater Package

 

X

 

 

 

 

 

 

EHWA05A-C09L

Heater Package

 

 

X

 

 

 

 

 

EHWA05A-C15L

Heater Package

 

 

X

 

 

 

 

 

BOP-5

Blank Off Plate

X

X

X

 

 

 

 

 

BFAD-5

Barometric Fresh Air Damper

X

X

X

MFAD-5

Motorized Fresh Air Damper

X

X

X

 

 

 

 

 

CRV-5

Classroom Ventilator with Exhaust

X

X

X

EIFM-5

Economizer with Exhaust

X

X

X

 

 

 

 

 

WERV-A5A

Energy Recovery Ventilator

X

X

 

WERV-C5A

Energy Recovery Ventilator

 

 

X

 

 

 

 

 

WMPD-01C

Pull Disconnect Kit

 

 

X

Manual 2100-426

Page 16