WALL MOUNTED
PACKAGED
AIR CONDITIONER
INSTALLATION
INSTRUCTIONS
Models:
WA3S3
WA4S3
WA5S3
WL3S2
WL4S2
WL5S2
NOTE
THIS IS AN R-410A
HIGH PRESSURE
REFRIGERANT SYSTEM
0,6
Bard Manufacturing Company, Inc.
Bryan, Ohio 43506
Since 1914...Moving ahead just as planned.
Manual :
Supersedes:
File:
Date:
2100-526E
2100-526D
Volume III Tab 16
07-16-12
Manual
Page
2100-526E
1 of 24
CONTENTS
Getting Other Information and Publications
For more information contact these publishers ........ 3
Wall Mount General Information
Air Conditioner Wall Mount Model Nomenclature ....
Shipping Damage ....................................................
General
...............................................................
Duct Work ...............................................................
Filters
...............................................................
Condensate Drain ....................................................
4
7
7
7
7
7
Installation Instructions
Wall Mounting Information ....................................... 8
Mounting the Unit .................................................... 8
Typical Installations ................................................. 8
Wiring – Main Power ....................................... 8 & 9
Wiring – Low Voltage Wiring ............................... 12
Figures
Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10
Figure 11
Unit Dimensions ..................................... 5
Mounting Instructions ............................. 9
Wall-Mounting Instructions .................. 10
Wall-Mounting Instructions .................. 10
Common Wall-Mounting Instructions .... 11
Electric Heat Clearance ....................... 12
Start-Up Label ...................................... 14
Fan Blade Setting ................................ 17
Control Disassembly ............................ 21
Winding Test ........................................ 21
Drip Loop ............................................. 21
Manual 2100-526E
Page
2 of 24
Start Up
General
.............................................................
Topping Off System Charge ...................................
Safety Practices .....................................................
Important Installer Note .........................................
Crankcase Heaters ................................................
High & Low Pressure Switch .................................
Three Phase Scroll Compressor Start Up
Information .............................................................
Service Hints .........................................................
Sequence of Operation ..........................................
Compressor Control Module ..................................
Adjustments ...........................................................
Phase Monitor .......................................................
Motor Start Device .................................................
Pressure Service Ports ..........................................
14
15
15
15
16
16
16
16
Troubleshooting
Compressor Solenoid ............................................
Fan Blade Setting Dimensions ..............................
Removal of Fan Shroud .........................................
R-410A Refrigerant Charge ...................................
Pressure Chart ......................................................
GE ECM™Motors ...................................................
GE ECM™Motors ...................................................
Optional Accessories .............................................
17
17
17
18
19
20
21
23
Tables
Table 1
Table 2
Table 3
Table 4
Table 5
Table 6
Table 7
Table 8
Table 9
Table 10
Table 11
Table 12
13
13
13
14
14
14
Electric Heat Table ................................. 4
Dimensions of Basic Unit ....................... 5
Electrical Specifications ......................... 6
Operating Voltage Range .................... 12
Thermostat Wire Size .......................... 12
Wall Thermostats ................................. 12
Thermostatic Control - Dual Unit .......... 12
Fan Blade Dimensions ......................... 17
Cooling Pressure ................................. 19
Indoor Blower Performance ................. 22
Maximum ESP of Operation
Electric Heat Only ................................ 22
Opt. Accessories (WA) ......................... 23
Opt. Accessories (WL) ......................... 24
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.
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
National Electrical Code ...................... ANSI/NFPA 70
Standard for the Installation ............... ANSI/NFPA 90A
of Air Conditioning and
Ventilating Systems
Standard for Warm Air ...................... ANSI/NFPA 90B
Heating and Air
Conditioning Systems
Load Calculation for ....................... ACCA Manual J or
Residential Winter and
Manual N
Summer Air Conditioning
Low Pressure, Low Velocity .......... ACCA Manual D or
Duct System Design for Winter
Manual Q
and Summer Air Conditioning
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
Manual
Page
2100-526E
3 of 24
WALL MOUNT GENERAL INFORMATION
AIR CONDITIONER WALL MOUNT MODEL NOMENCLATURE
WA
4S
3
MODEL
NUMBER
WA – Right Hand
WL – Left Hand
–
B
09
B
P
X
X
X
X
CONTROL MODULES
REVISION
COIL OPTIONS
X – Standard
VOLTS & PHASE
A – 230/208-1
B – 230/208/60-3
C – 460/60-3
CAPACITY
3S – 3 Ton
4S – 4 Ton
5S – 5 Ton
KW
0Z – No KW
w/Circuit Breaker
or Pull Disconnect
05
06
08
09
10
15
20
– 5 KW
– 6 KW
– 8 KW
– 9 KW
– 10 KW
– 15 KW
– 20 KW
OUTLET OPTIONS
X – Front (Standard)
VENTILATION OPTIONS
B – Blank-off Plate (Standard)
V – Commercial Room Ventilator Motorized w/Exhaust (3-Position)
E – Economizer (Internal) - Fully
Modulating w/Exhaust
R – Energy Recovery Ventilator - w/Exhaust
COLOR OPTIONS
X – Beige (Standard)
4 – Buckeye Gray
5 – Desert Brown
8 – Dark Bronze
FILTER OPTIONS
P – Two Inch Pleated
NOTE: For 0KW and circuit breakers (230/208 V) or rotary disconnects (460 V) applications, insert 0Z in the KW field of model number.
TABLE 1
ELECTRIC HEAT TABLE
At 240V (1)
Nominal
KW
Kw
5.0
6.0
8.0
9.0
10.0
15.0
20.0
5.0
6.0
8.0
9.0
10.0
15.0
20.0
1-Ph Amps 3-Ph Amps
20.8
14.4
33.3
21.7
41.7
62.5
83.3
36.1
At 208V (1)
Btuh
Kw
17,065
20,478
27,304
30,717
34,130
51,195
68,260
3.75
4.50
6.00
6.75
7.50
11.25
15.00
1-Ph Amps 3-Ph Amps
18.0
12.5
28.8
18.7
36.1
54.1
72.1
31.2
At 480V (2)
Btuh
12,799
15,359
20,478
23,038
25,598
38,396
51,195
3-Ph Amps
Btuh
Kw
3-Ph Amps
Btuh
6.0
7.2
20,478
5.52
6.9
18,840
9.0
10.8
30,717
8.28
10.4
28,260
15.0
18.0
51,195
13.8
17.3
47,099
(1) These electric heaters are available in 230/208V units only.
(2) These electric heaters are available in 480V units only.
See Table 3 for Heater Availability by Model
Manual 2100-526E
Page
4 of 24
At 460V (2)
Kw
TABLE 2
DIMENSIONS OF BASIC UNIT FOR ARCHITECTURAL & INSTALLATION REQUIREMENTS (NOMINAL)
Supply
Unit
Width
W
Depth
D
42.075
22.432
WA/L3S
WA/L4S
Height
H
Return
A
B
C
B
E
F
G
9.88
29.88
15.88
29.88
43.88
19.10
84.875
I
31.66
94.875
J
K
L
M
32.68
26.94
34.69
32.43
30.00
41.66
42.68
36.94
44.69
N
O
3.37
42.88
P
Q
R
S
T
10.00
1.44
16.00
1.88
23.88
42.43
33.88
WA/L5S
All dimensions in inches. Dimensional Drawings are not to scale.
FIGURE 1
UNIT DIMENSIONS
WA*S*
RIGHT
UNIT
E
O
D
Built In
Rain Hood
4° Pitch
W
7.88
2
1.00
Heater
Access
Panel
31.88
2
.44
2.13
R
Side Wall
Mounting
Brackets
(Built In)
A
Electric
Heat
Supply Air Opening
S
B
C. Breaker/
Disconnect
Access Panel
(Lockable)
I
Top Rain
Flashing
Shipping
Location
Filter Access
Panel
5.75
2
Vent Option
Door
C H
S
Optional
Electrical
Entrances
Return Air Opening
S
Ventilation
Air
F
S
Low Voltage
Electrical
Entrance
G
K
Cond.
Air
Inlet
High Voltage
Electrical
Entrance
Condenser
Air Outlet
1
J
L
M
S
P
1
T
Front View
Drain
Side View
N
Back View
Q
1
Bottom Installation
Bracket
MIS-2487 B
Dimension is 21.00 inches on WA/L4S2 & WA/L5S2 models.
WL*S*
LEFT
UNIT
E
O
.44
R
D
Side Wall
Mounting
Brackets
(Built In)
Supply Air Opening
S
S
S
Optional
Electrical
Entrances
Return Air Opening
S
1
Electric
Heat
A
Heater
Access
Panel
M
1
P
W
C. Breaker/
Disconnect
Access Panel
(Lockable)
Filter Access
Panel
Ventilation
Air
Vent Option
Door
C
H
L
S
2.13
I
Top Rain
Flashing
Shipping
Location
Built In
Rain Hood
4° Pitch
5.75
F
Low Voltage
Electrical
Entrance
K
J
Cond.
Air
Inlet
High Voltage
Electrical
Entrance
Condenser
Air Outlet
G
T
Drain
Bottom
Installation
Bracket
2.63
Back View
Side View
Front View
MIS-2488 B
9.06
Manual
Page
2100-526E
5 of 24
Manual 2100-526E
Page
6 of 24
- B 0Z
- B 06
- B 09
- B 15
- C 0Z
- C 06
- C 09
- C 15
- A 0Z
- A 05
- A 08
- A 10
- A 15
- A 20
- B 0Z
- B 06
- B 09
- B 15
- C 0Z
- C 06
- C 09
- C 15
- A 0Z
- A 05
- A 08
- A 10
- A 15
- A 20
- B 0Z
- B 06
- B 09
- B 15
- C 0Z
- C 06
- C 09
- C 15
WA/L3S
WA/L3S
WA/L4S
WA/L4S
WA/L4S
WA/L5S
WA/L5S
WA/L5S
460-3
230/208-3
230/208-1
460-3
230/208-3
230/208-1
460-3
230/208-3
230/208-1
1
1
1
1
1
1
1
1
1
1
1
1 or 2
1 or 2
1 or 3
1
1
1
1
1
1
1
1
17
17
21
30
34
34
38
56
44
44
53
63
89
115
15
16
21
30
25
25
25
30
40
40
40
60
50
50
60
70
90
120
20
20
25
30
40
40
40
60
45
45
60
70
90
120
38
38
53
63
89
115
1
1
1
1 or 2
1 or 2
1 or 3
28
29
38
56
15
15
20
30
12
13.5
19
28
1
1
1
1
30
30
40
60
23
27
36
55
1
1
1
1
45
45
60
70
90
115
1 Maximum
External Fuse
or Ckt. Brkr.
31
35
51
61
87
113
3 Minimum
Circuit
Ampacity
10
10
10
10
8
8
8
6
8
8
6
6
3
2
10
10
10
10
10
10
10
10
10
10
10
8
8
6
12
12
10
10
10
10
10
10
10
10
8
6
12
12
10
10
10
10
10
8
8
6
8
8
6
4
3
2
14
14
12
10
10
10
10
10
10
10
8
6
14
14
12
10
10
10
10
8
8
6
2 Ground
Wire
8
8
6
6
3
2
2 Field
Power
Wire Size
Single Circuit
1
1
1
1 or 2
1 or 2
1 or 3
No. Field
Power
Circuits
44
44
44
37
37
37
35
35
35
Ckt. A
26
52
52
26
52
52
26
52
52
Ckt. B
3 Minimum
Circuit
Ampacity
26
26
26
Ckt. C
50
50
50
45
45
45
45
45
45
Ckt. A
30
60
60
30
60
60
30
60
60
Ckt. B
1 Maximum
External Fuse
or Ckt. Brkr.
30
30
30
Ckt. C
8
8
8
8
8
8
8
8
8
Ckt. A
Multiple Circuit
10
6
6
10
6
6
10
6
6
Ckt. B
2 Field
Power
Wire Size
10
10
10
Ckt. C
10
10
10
10
10
10
10
10
10
Ckt. A
10
10
10
10
10
10
10
10
10
Ckt. B
2 Ground
Wire
1 Maximum size of the time delay fuse or HACR type circuit breaker for protection of field wiring conductors.
2 Based on 75°C copper wire. All wiring must conform to the National Electric Code (NEC) and all local codes.
3 These “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.
- A 0Z
- A 05
- A 08
- A 10
- A 15
- A 20
WA/L3S
Model
Rated
Volts
and Phase
TABLE 3
ELECTRICAL SPECIFICATIONS
10
10
10
Ckt. C
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.
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.
The refrigerant system is completely assembled and
charged. All internal wiring is complete.
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.
The unit is designed for use with or without duct work.
Flanges are provided for attaching the supply and return
ducts.
Ducts through the walls must be insulated and all joints
taped or sealed to prevent air or moisture entering the
wall cavity.
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 3 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 airflow 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.
CAUTION
Some installations may not require any return
air duct. A 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-5 or 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.
FILTERS
A 2-inch pleated 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
filter access panel. The internal filter brackets are
adjustable to accommodate the 1-inch filter by bending
up the tabs to allow spacing for the 1-inch filters.
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.
Manual
Page
2100-526E
7 of 24
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 4 and 5.
WARNING
3. Locate and mark lag bolt locations and bottom
mounting bracket location. See Figure 4.
4. Mount bottom mounting bracket.
5. Hook top rain flashing under back bend of top. Top
rain flashing is shipped secured to the right side of
the back.
6. Position unit in opening and secure with 5/16 lag
bolts; use 7/8 inch diameter flat washers on the lag
bolts.
7. Secure rain flashing to wall and caulk across entire
length of top. See Figure 2.
Fire hazard can result if 1/4 inch clearance to
combustible materials for supply air duct is
not maintained. 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.
3. Concrete block walls must be thoroughly inspected
to insure that they are capable of carrying the weight
of the installing unit. See Figure 4.
9. On side-by-side installations, maintain a minimum
of 20 inches clearance on right side to allow access
to heat strips and control panel and to allow proper
airflow to the outdoor coil. Additional clearance
may be required to meet local or national codes.
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 2, 3
and 6 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.
Manual 2100-526E
Page
8 of 24
TYPICAL INSTALLATIONS
See Figure 5 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.
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.
The disconnect access door on this unit may be locked to
prevent unauthorized access to the disconnect.
See Start-up section for information on three phase
scroll compressor start-ups.
FIGURE 2
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.
A
B
C
D
E
REQUIRED DIMENSIONS TO MAINTAIN
1/4" MIN. CLEARANCE FROM
COMBUSTIBLE MATERIALS
30 1/2
10 1/2
6 1/4
1 1/4
29 3/4
REQUIRED DIMENSIONS TO MAINTAIN
RECOMMENDED 1" CLEARANCE FROM
COMBUSTIBLE MATERIALS
32
12
5 1/2
2
29
SEAL WITH BEAD
OF CAULKING ALONG
ENTIRE LENGTH OF
TOP.
RAIN FLASHING
SUPPLIED
FOAM AIR SEAL
TOP
WALL STRUCTURE
1/4" CLEARANCE ON ALL
FOUR SIDES OF SUPPLY
AIR DUCT IS REQUIRED
FROM COMBUSTABLE
MATERIALS
WALL
C
D
A
C
HEATER ACCESS
PANEL
SUPPLY AIR
DUCT
B
Supply Opening
16"
16"
E
16"
Return Opening
16"
16"
RETURN AIR
OPENING
16"
1
1
62"
30"
3"
1
1"
7
18"
1
38"
4"
Typ.
62"
1
NOTES:
1
4"
Typ.
IT IS RECOMMENDED THAT A BEAD OF
SILICONE CAULKING BE PLACED BEHIND
THE SIDE MOUNTING FLANGES AND UNDER
TOP FLASHING AT TIME OF INSTALLATION.
7
8"
W**A UNIT SHOWN, W**L UNIT
CONTROLS AND HEATER ACCESS
IS ON OPPOSITE (LEFT) SIDE.
1
1
28"
62"
Dimension is 21" on 95" tall Units.
Wall Opening and Hole Location View
Right Side View
MIS-416 D
Manual
Page
2100-526E
9 of 24
FIGURE 3
WALL-MOUNTING INSTRUCTIONS
SEE FIGURE 3 — MOUNTING INSTRUCTIONS
WALL STRUCTURE
FACTORY SUPPLIED
RAIN FLASHING.
MOUNT ON UNIT
BEFORE INSTALLATION
SUPPLY AIR
OPENING
SUPPLY AIR
OPENING
SUPPLY AIR
DUCT
RETURN AIR
OPENING
RETURN AIR
OPENING
RETURN AIR
OPENING
BOTTOM MOUNTING
BRACKET. MOUNT ON
WALL BEFORE
INSTALLING UNIT.
WOOD OR STEEL SIDING
CONCRETE BLOCK WALL INSTALLATION
WOOD FRAME WALL INSTALLATION
MIS-548 A
SIDE VIEW
FIGURE 4
WALL-MOUNTING INSTRUCTIONS
SEE UNIT DIMENSIONS, FIGURE 1,
FOR ACTUAL DIMENSIONS
SEE UNIT DIMENSIONS, FIGURE 2,
FOR ACTUAL DIMENSIONS.
E + 1.000
ATTACH TO TOP
PLATE OF WALL
B
1.000
1.000" CLEARANCE
ALL AROUND DUCT
INTERIOR FINISHED WALL
OVER FRAME
SUPPLY DUCT
OPENING
A
I
1.000" CLEARANCE
ALL AROUND DUCT
RETURN DUCT
OPENING
EXTERIOR FINISH WALL
OVER FRAME
MIS-549 B
Manual 2100-526E
Page
10 of 24
ATTACH TO BOTTOM
PLATE OF WALL
C
K
2x6
FRAMING MATERIAL
2 x 4'S, 2 x 6'S &/OR
STRUCTURAL STEEL
SEE FIGURE 1 FOR
DUCT DIMENSIONS
CL
THIS STRUCTURAL MEMBER
LOCATED TO MATCH STUD
SPACING FOR REST OF WALL.
A SECOND MEMBER MAY BE
REQUIRED FOR SOME WALLS.
FIGURE 5
COMMON WALL-MOUNTING INSTALLATIONS
SUPPLY DUCT MAY BE LOCATED IN AN ATTIC
OR BELOW CEILING RAFTERS AS SHOWN
RAIN
FLASHING
RAFTERS
RAIN
FLASHING
FINISHED CEILING SURFACE
SUPPLY AIR DUCT
SUPPLY AIR DUCT
W/ GRILLE
FINISHED CEILING SURFACE
RETURN AIR
OPENING W/ GRILLE
RETURN AIR
OPENING W/ GRILLE
OUTSIDE
WALL
RAFTERS
OUTSIDE
WALL
FREE AIR FLOW
NO DUCT
DUCTED SUPPLY
RETURN AT UNIT
SUPPLY DUCT MAYBE LOCATED IN AN ATTIC
OR BELOW CEILING RAFTERS AS SHOWN
RAIN
FLASHING
RAFTERS
SUPPLY DUCT MAYBE LOCATED IN AN ATTIC
OR BELOW CEILING RAFTERS AS SHOWN
RAIN
FLASHING
SUPPLY AIR DUCT
SUPPLY AIR DUCT
LOWERED
CEILING
FINISHED
CEILING SURFACE
OUTSIDE
WALL
RAFTERS
RETURN AIR
SPACE
WALL SLEEVE
CLOSET WALL
FALSE WALL
WALL
SLEEVE
RETURN AIR GRILLE
FALSE WALL INSTALLATION
OUTSIDE
WALL
SUPPLY AIR
GRILLE
FINISHED CEILING
SURFACE
RETURN AIR
GRILLE
RAISED FLOOR
RETURN AIR
CLOSET INSTALLATION
MIS-550 B
Manual
Page
2100-526E
11 of 24
FIGURE 6
ELECTRIC HEAT CLEARANCE
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.
Side section view of supply air duct for
wall mounted unit showing 1/4 inch
clearance to combustible surfaces.
WIRING — LOW VOLTAGE WIRING
230/208V, 1 phase and 3 phase are equipped with dual
primary voltage transformers. All equipment leaves the
factory wired on 240V tap. For 208V operation,
reconnect from 240V to 208V tap. The acceptable
operating voltage range for the 240 and 208V taps are
shown in Table 4 below.
TABLE 4
OPERATING VOLTAGE RANGE
TAP
RANGE
240V
253 - 216
208V
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).
Eight (8) wires should be run from thermostat subbase to the
24V terminal board in the unit. An eight conductor, 18 gauge
copper, color-coded thermostat cable is recommended. See
Manual 2100-507 (latest revision) for low voltage wiring
options.
TABLE 5
THERMOSTAT WIRE SIZE
Transformer
VA
220 - 187
TABLE 6
WALL THERMOSTATS
50
Thermostat
Predominant Features
8403-060
(1120-445)
3 stage Cool; 3 stage Heat
Programmable/Non-Programmable Electronic
HP or Conventional
Auto or Manual changeover
FLA
Wire
Gauge
Maximum
Distance
in Feet
2.1
20 gauge
18 gauge
16 gauge
14 gauge
12 gauge
45
60
100
160
250
2 stage Cool; 2 stage Heat
8403-058
Electronic Non-Programmable
(TH5220D1151)
Auto or Manual changeover
THERMOSTATIC CONTROL
FOR DUAL UNIT APPLICATION
Thermostat
TEC 40
MC3000
Manual 2100-526E
Page
12 of 24
Predominate Features
Bard Specifications
2-Unit / 2-Stage Heat / 2-Stage Cool
Controller
See Spec. Sheet S3353
2-Unit / 2-Stage Heat / 2-Stage Cool
Controller with Option Alarms
See Spec. Sheet S3379
START UP
These units require R-410A refrigerant and Polyol Ester
oil.
GENERAL:
1. Use separate service equipment to avoid cross
contamination of oil and refrigerants.
2. Use recovery equipment rated for R-410A
refrigerant.
3. Use manifold gauges rated for R-410A (800 psi/250
psi low).
4. R-410A is a binary blend of HFC-32 and HFC-125.
5. R-410A is nearly azeotropic - similar to R-22 and
R-12. Although nearly azeotropic, charge with
liquid refrigerant.
6. R-410A operates at 40-70% higher pressure than
R-22, and systems designed for R-22 cannot
withstand this higher pressure.
SAFETY PRACTICES:
1. Never mix R-410A with other refrigerants.
2. Use gloves and safety glasses, Polyol Ester oils can
be irritating to the skin, and liquid refrigerant will
freeze the skin.
3. Never use air and R-410A to leak check; the
mixture may become flammable.
4. Do not inhale R-410A – the vapor attacks the
nervous system, creating dizziness, loss of
coordination and slurred speech. Cardiac
irregularities, unconsciousness and ultimate death
can result from breathing this concentration.
5. Do not burn R-410A. This decomposition
produces hazardous vapors. Evacuate the area if
exposed.
6. Use only cylinders rated DOT4BA/4BW 400.
7. Never fill cylinders over 80% of total capacity.
7. R-410A has an ozone depletion potential of zero,
but must be reclaimed due to its global warming
potential.
8. Store cylinders in a cool area, out of direct
sunlight.
8. R-410A compressors use Polyol Ester oil.
10. Never trap liquid R-410A in manifold sets, gauge
lines or cylinders. R-410A expands significantly
at warmer temperatures. Once a cylinder or line is
full of liquid, any further rise in temperature will
cause it to burst.
9. Polyolester oil is hygroscopic; it will rapidly absorb
moisture and strongly hold this moisture in the oil.
10. A liquid line dryer must be used - even a deep
vacuum will not separate moisture from the oil.
9. Never heat cylinders above 125°F.
11. Limit atmospheric exposure to 15 minutes.
12. If compressor removal is necessary, always plug
compressor immediately after removal. Purge with
small amount of nitrogen when inserting plugs.
TOPPING OFF SYSTEM CHARGE
If a leak has occurred in the system, Bard Manufacturing
recommends reclaiming, evacuating (see criteria above),
and charging to the nameplate charge. Topping off the
system charge can be done without problems.
With R-410A, there are no significant changes in the
refrigerant composition during multiple leaks and
recharges. R-410A refrigerant is close to being an
azeotropic blend (it behaves like a pure compound or
single component refrigerant). The remaining refrigerant
charge, in the system, may be used after leaks have
occurred and then “top-off” the charge by utilizing the
pressure charts on the inner control panel cover as a
guideline.
REMEMBER: When adding R-410A refrigerant, it must
come out of the charging cylinder/tank as a liquid to
avoid any fractionation, and to insure optimal system
performance. Refer to instructions for the cylinder that
is being utilized for proper method of liquid extraction.
Manual
Page
2100-526E
13 of 24
START UP CONTINUED
IMPORTANT INSTALLER NOTE
HIGH & LOW PRESSURE SWITCH
For improved start-up performance, wash the indoor coil
with a dishwasher detergent.
All models covered by this Manual are supplied with a
remote reset high pressure switch and low pressure
switch. If tripped, this pressure switch may be reset by
turning the thermostat off then back on again.
CRANKCASE HEATERS
All units covered in this manual are provided with
compressor crankcase heat.
This crankcase heater is 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.
Crankcase heat is essential to prevent liquid refrigerant
from migrating to the compressor, preventing oil pump
out on compressor start-up and possible bearing or scroll
vane failure due to compressing a liquid.
The decal in Figure 7 is affixed to all model units
detailing start-up procedure. This is very important.
Please read carefully.
FIGURE 7
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
Manual 2100-526E
Page
14 of 24
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 ZPS compressors are wired identically
internally. As a result, once the correct phasing is
determined for a specific system or installation,
connecting properly phased power leads to the same
Fusite terminal should maintain proper rotation
direction.
Verification of proper rotation direction is made by
observing that suction pressure drops and discharge
pressure rises when the compressor is energized.
Reverse rotation also results in an elevated sound level
over that with correct rotations, as well as, substantially
reduced current draw compared to tabulated values.
The direction of rotation of the compressor may be
changed by reversing any two line connections to the
unit.
See “Phase Monitor”, Page 16.
SERVICE HINTS
Adjustable Delay On Make And Break Timer
1. Maintain clean air filters at all times. Also, do not close
off or block supply and return air registers. This reduces
air flow through the system, which shortens equipment
service life as well as increasing operating costs.
On initial power up or anytime 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 and
low pressure switches are 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.
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.
Frequency of coil cleaning will depend on duty cycle of
equipment, type of use and installation site variables.
Telecommunication type installations in high traffic
areas or in areas none too frequent to airborne debris,
will require more frequent coil maintenance than those
in areas not subject to those conditions.
SEQUENCE OF OPERATION
NON-ECONOMIZER
Stage 1 (Y1) cooling call activates Step 1 (partial
capacity, 66%) of compressor capacity.
Stage 2 (Y2) cooling call activates Step 2 (full capacity,
100%) of compressor capacity.
WITH ECONOMIZER
Stage 1 (Y1) cooling call goes to economizer controls for
decision:
- If Enthalpy Control decides outdoor conditions are
suitable for free cooling, the economizer will operate.
• If Stage 2 cooling call is issued during
economizer operation, the economizer will
close and the compressor will go straight to
Step 2 full capacity operation.
- If Enthalpy Control decides outdoor conditions
are not suitable for free cooling, the economizer
will not operate (or close) and Step 1 of the
compressor will operate.
• If Stage 2 cooling call is issued, the
compressor will shift to Step 2 full cooling
capacity operation.
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.
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.
Optional Low Ambient Control
An optional low ambient control is available for both
factory and field installed options. The low ambient
control is to be applied to the WA3S/WA4S/WA5S
models when operation below 50°outdoor conditions are
anticipated. Without this device, the evaporating pressure
would fall off, and the indoor coil would ice over.
The fan cycling control cycles the fan motor on, once the
liquid refrigerant pressure reaches 350 psig, and off, once
it has dropped to 225 psig. It will continue to cycle
between these parameters depending on outdoor
temperatures and the load/stage of the system.
This cycling maintains a minimum liquid pressure
affecting the minimum suction pressure. This effect
insures an evaporating temperature that is slightly above
the point of ice formation on the evaporator.
Manual
Page
2100-526E
15 of 24
Alarm Relay Output
PHASE MONITOR
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.
All units with three phase scroll compressors are
equipped with a 3-phase line monitor to prevent
compressor damage due to phase reversal.
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.
If phases are reversed, the red fault LED will be lit and
compressor operation is inhibited.
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 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.
ADJUSTMENTS
MOTOR START DEVICE
Adjustable Delay on Make and Delay on Break
Timer
Single Phase (-A) model compressor circuits are
equipped with a 25 ohm PTCR (Positive Temperature
Coefficient Resistor) motor starting device as standard
equipment.
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
1.0 minute
2.0 minute
3.0 minute
4.0 minute
5.0 minute
(30 seconds)
(60 seconds)
(120 seconds)
(180 seconds)
(240 seconds)
(300 seconds)
DOB =123
DOB =126
DOB =132
DOB =138
DOB =144
DOB =150
second DOM
second DOM
second DOM
second DOM
second DOM
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
The PTCR is wired in parallel with the run capacitor.
When voltage is applied, and device is cool, its low
resistance permits a large current to flow in the auxiliary
windings - increasing the motors available starting
torque. The device then rapidly heats up, and the current
levels drop to a few milliamperes. The PTCR then
becomes self-regulating, passing just enough current to
maintain its temperature to remain in the high resistance
state. Once the voltage source is removed, the device
then cools down and the resistance drops, and is then
ready for the next compressor start cycle.
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.
Be careful to observe whether unit is operating in high
cool or low cool when utilizing the charts.
Manual 2100-526E
Page
16 of 24
TROUBLESHOOTING
COMPRESSOR SOLENOID
FAN BLADE SETTING DIMENSIONS
(See Sequence of Operation on Page 15 for function.) A
nominal 24-volt direct current coil activates the internal
compressor solenoid. The input control circuit voltage
must be 18 to 28 volt ac. The coil power requirement is
20 VA. The external electrical connection is made with
a molded plug assembly. This plug contains a full wave
rectifier to supply direct current to the unloader coil.
Shown in the drawing below are the correct fan blade
setting dimensions for proper air delivery across the
outdoor coil. See Figure 8.
Compressor Solenoid Test Procedure If it is
suspected that the unloader is not working, the following
methods may be used to verify operation.
1. Operate the system and measure compressor
amperage. Cycle the compressor solenoid on and off
at ten-second intervals. The compressor amperage
should go up or down at least 25 percent.
2. If step one does not give the expected results, shut
unit off. Apply 18 to 28 volt ac to the solenoid
molded plug leads and listen for a click as the
solenoid pulls in. Remove power and listen for
another click as the solenoid returns to its original
position.
3. If clicks can’t be heard, shut off power and remove
the control circuit molded plug from the compressor
and measure the solenoid coil resistance. The
resistance should be 32 to 60 ohms depending on
compressor temperature.
4. Next, check the molded plug.
Voltage check: Apply control voltage to the plug wires (18
to 28 volt ac). The measured dc voltage at the female
connectors in the plug should be around 15 to 27 vdc.
Resistance check: Measure the resistance from the end of
one molded plug lead to either of the two female connectors
in the plug. One of the connectors should read close to zero
ohms, while the other should read infinity. Repeat with
other wire. The same female connector as before should
read zero, while the other connector again reads infinity.
Reverse polarity on the ohmmeter leads and repeat. The
female connector that read infinity previously should now
read close to zero ohms.
Replace plug if either of these test methods does not
show the desired results.
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. See Table 7.
FIGURE 8
FAN BLADE SETTING
AIRFLOW
"A"
MIS-1724
TABLE 7
FAN BLADE DIMENSIONS
Model
WA/L3S
WA/L4S
WA/L5S
Dimension A
1.75"
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.
Manual
Page
2100-526E
17 of 24
TROUBLESHOOTING CONT’D.
R-410A
REFRIGERANT CHARGE
This unit was charged at the factory with the quantity
of refrigerant listed on the serial plate. AHRI capacity
and efficiency ratings were determined by testing with
this refrigerant charge quantity.
Manual 2100-526E
Page
18 of 24
The following pressure tables show nominal pressures
for the units. Since many installation specific
situations can affect the pressure readings, this
information should only be used by certified
technicians as a guide for evaluating proper system
performance. They shall not be used to adjust charge.
If charge is in doubt, reclaim, evacuate and recharge
the unit to the serial plate charge.
TABLE 8
COOLING PRESSURE – (ALL TEMPERATURES °F)
HIGH CAPACITY COOLING
RETURN AIR
MODEL TEMPERATURE PRESSURE
WA3S
WL3S
WA4S
WL4S
WA5S
WL5S
AIR TEMPERATURE ENTERING OUTDOOR COIL DEGREE F
5 0 oF
5 5 oF
6 0 oF
6 5 oF
7 0 oF
7 5 oF
8 0 oF
8 5 oF
9 0 oF
9 5 oF
WA3S
WL3S
WA4S
WL4S
WA5S
WL5S
110oF
115oF
75° D B
62° WB
LOW SIDE
HIGH SIDE
112
195
115
214
119
233
122
253
126
272
129
291
131
314
132
337
134
360
135
383
136
409
138
435
139
461
140
487
80° D B
67° WB
LOW SIDE
HIGH SIDE
124
201
127
220
131
239
134
259
138
278
141
297
142
319
144
341
145
363
147
390
148
413
149
440
151
468
152
495
85° D B
72° WB
LOW SIDE
HIGH SIDE
135
205
138
224
142
243
145
263
149
282
152
301
154
326
156
350
157
375
159
399
161
425
162
451
164
476
165
502
75° D B
62° WB
LOW SIDE
HIGH SIDE
117
197
119
216
121
235
123
255
125
274
127
293
128
316
130
339
131
361
132
383
133
410
135
438
136
466
137
494
80° D B
67° WB
LOW SIDE
HIGH SIDE
127
201
129
220
131
239
134
259
136
278
138
298
138
318
139
341
139
364
143
400
143
415
144
443
146
471
149
500
85° D B
72° WB
LOW SIDE
HIGH SIDE
141
203
143
223
145
243
148
263
150
283
152
303
152
326
153
349
153
372
154
396
156
422
158
449
160
478
162
508
75° D B
62° WB
LOW SIDE
HIGH SIDE
118
199
119
217
120
236
122
260
123
285
125
309
126
333
128
357
129
381
130
405
132
432
133
460
135
487
136
514
80° D B
67° WB
LOW SIDE
HIGH SIDE
129
205
130
224
131
247
131
270
132
292
132
315
134
339
137
363
139
387
141
425
143
438
145
465
146
492
148
519
85° D B
72° WB
LOW SIDE
HIGH SIDE
137
216
139
237
140
258
141
279
142
300
143
321
146
346
148
370
151
395
153
419
155
447
157
474
158
502
160
529
110oF
115oF
LOW CAPACITY COOLING
MODEL
1 0 0 oF 1 0 5 oF
RETURN AIR
PRESSURE
TEMPERATURE
AIR TEMPERATURE ENTERING OUTDOOR COIL DEGREE F
5 0 oF
5 5 oF
6 0 oF
6 5 oF
7 0 oF
7 5 oF
8 0 oF
8 5 oF
9 0 oF
9 5 oF
1 0 0 oF 1 0 5 oF
75° D B
62° WB
LOW SIDE
HIGH SIDE
126
181
127
198
129
215
130
233
132
250
133
267
135
289
136
310
138
332
139
353
141
378
144
404
146
429
148
454
80° D B
67° WB
LOW SIDE
HIGH SIDE
137
184
138
201
139
218
141
236
142
253
143
270
145
291
147
312
149
333
151
354
153
380
155
406
156
432
158
458
85° D B
72° WB
LOW SIDE
HIGH SIDE
153
190
154
207
155
224
156
241
157
258
158
275
160
297
162
318
163
340
165
361
167
387
168
413
170
438
171
464
75° D B
62° WB
LOW SIDE
HIGH SIDE
122
184
124
201
125
218
127
236
129
254
131
272
131
291
132
312
133
335
134
359
135
381
137
407
139
435
141
463
80° D B
67° WB
LOW SIDE
HIGH SIDE
132
185
134
203
136
221
138
239
140
257
142
275
145
298
146
317
147
339
148
362
149
384
150
410
151
438
152
467
85° D B
72° WB
LOW SIDE
HIGH SIDE
145
187
147
205
149
223
152
241
154
259
156
278
156
397
157
319
158
343
159
369
161
390
163
415
164
443
165
472
75° D B
62° WB
LOW SIDE
HIGH SIDE
123
187
125
207
127
226
129
245
131
263
133
282
134
305
135
328
136
350
137
373
139
399
141
425
143
451
145
477
80° D B
67° WB
LOW SIDE
HIGH SIDE
134
192
136
211
138
230
139
248
141
267
143
286
145
308
147
331
149
353
151
375
153
402
155
429
156
456
158
483
85° D B
72° WB
LOW SIDE
HIGH SIDE
146
200
148
217
149
235
151
252
152
270
154
287
156
311
159
335
161
358
163
382
165
408
166
434
168
460
169
486
Low side pressure ± 4 psig
High side pressure ± 10 psig
Manual
Page
2100-526E
19 of 24
TROUBLESHOOTING GE ECM™ MOTORS
CAUTION:
Symptom
Cause/Procedure
Disconnect power from unit before removing or replacing
connectors, or servicing motor. To avoid electric shock
from the motor’s capacitors, disconnect power and wait at
least 5 minutes before opening motor.
• Noisy blower or cabinet
• Check for loose blower housing, panels, etc.
• High static creating high blower speed?
- Check for air whistling through seams in
ducts, cabinets or panels
- Check for cabinet/duct deformation
Symptom
Cause/Procedure
Motor rocks slightly
when starting
• This is normal start-up for ECM
• “Hunts” or “puffs” at
high CFM (speed)
• Does removing panel or filter reduce
“puffing”?
- Reduce restriction
- Reduce max. airflow
Motor won’t start
• No movement
• Check blower turns by hand
• Check power at motor
• Check low voltage (24 Vac R to C) at motor
• Check low voltage connections
(G, Y, W, R, C) at motor
• Check for unseated pins in connectors on
motor harness
• Test with a temporary jumper between R - G
• Check motor for tight shaft
• Perform motor/control replacement check
• Perform Moisture Check
• Motor rocks,
but won’t start
• Check for loose or compliant motor mount
• Make sure blower wheel is tight on shaft
• Perform motor/control replacement check
Motor oscillates up
& down while being
tested off of blower
• It is normal for motor to oscillate with no load
on shaft
Motor starts, but
runs erratically
• Varies up and down
or intermittent
• Check line voltage for variation or “sag”
• Check low voltage connections
(G, Y, W, R, C) at motor, unseated pins in
motor harness connectors
• Check “Bk” for erratic CFM command (in
variable-speed applications)
• Check out system controls, Thermostat
• Perform Moisture Check
Evidence of Moisture
• Motor failure or
malfunction has occurred
and moisture is present
• Replace motor and Perform Moisture Check
• Evidence of moisture
present inside air mover
• Perform Moisture Check
Do
Don’t
• Check out motor, controls,
wiring and connections
thoroughly before replacing
motor
• Orient connectors down so
water can’t get in
- Install “drip loops”
• Use authorized motor and
model #’s for replacement
• Keep static pressure to a
minimum:
- Recommend high
efficiency, low static filters
- Recommend keeping filters
clean.
- Design ductwork for min.
static, max. comfort
- Look for and recommend
ductwork improvement,
where necessary
• Automatically assume the motor is bad.
• Size the equipment wisely
• “Hunts” or “puffs” at
high CFM (speed)
• Does removing panel or filter reduce
“puffing”?
- Reduce restriction
- Reduce max airflow
• Stays at low CFM
despite system call
for cool or heat CFM
• Check low voltage (Thermostat) wires and
connections
• Verify fan is not in delay mode; wait until
delay complete
• “R” missing/not connected at motor
• Perform motor/control replacement check
• Stays at high CFM
• “R” missing/not connected at motor
• Is fan in delay mode? - wait until delay time
complete
• Perform motor/control replacement check
• Check orientation before
inserting motor connectors
• Locate connectors above 7 and 4 o’clock
positions
• Replace one motor or control model # with
another (unless an authorized replacement)
• Use high pressure drop filters some have ½"
H20 drop!
• Use restricted returns
• Oversize system, then compensate with low
airflow
• Plug in power connector backwards
• Force plugs
Moisture Check
• Blower won’t shut off
• Current leakage from controls into G, Y or W?
Check for Triac switched thermostat or solidstate relay
Excessive noise
• Determine if it’s air noise, cabinet, duct or
motor noise; interview customer, if necessary
• High static creating high blower speed?
- Is airflow set properly?
- Does removing filter cause blower to slow
down? Check filter
- Use low-pressure drop filter
- Check/correct duct restrictions
• Air noise
Manual 2100-526E
Page
20 of 24
• Connectors are oriented “down” (or as recommended by equipment
manufacturer)
• Arrange harness with “drip loop” under motor
• Is condensate drain plugged?
• Check for low airflow (too much latent capacity)
• Check for undercharged condition
• Check and plug leaks in return ducts, cabinet
Comfort Check
• Check proper airflow settings
• Low static pressure for lowest noise
• Set low continuous-fan CFM
• Use humidistat and 2-speed cooling units
• Use zoning controls designed for ECM that regulate CFM
• Thermostat in bad location?
TROUBLESHOOTING GE ECM™ MOTORS CONT’D.
Replacing ECM Control Module
To replace the control module for the GE variable-speed indoor blower
motor you need to take the following steps:
1. You MUST have the correct replacement module. The controls are
factory programmed for specific operating modes. Even though they look
alike, different modules may have completely different functionality.
USING THE WRONG CONTROL MODULE VOIDS ALL PRODUCT
WARRANTIES AND MAY PRODUCE UNEXPECTED RESULTS.
2. Begin by removing AC power from the furnace or air handler being
serviced. DO NOT WORK ON THE MOTOR WITH AC POWER
APPLIED. To avoid electric shock from the motor’s capacitors, disconnect
power and wait at least 5 minutes before opening motor.
3. It is usually not necessary to remove the motor from the blower
assembly. However, it is recommended that the whole blower assembly, with
the motor, be removed from the furnace/air handler. (Follow the
manufacturer’s procedures). Unplug the two cable connectors to the motor.
There are latches on each connector. DO NOT PULL ON THE WIRES.
The plugs remove easily when properly released.
4. Locate the two standard ¼" hex head bolts at the rear of the control
housing (at the back end of the control opposite the shaft end). Refer to
Figure 9. Remove these two bolts from the motor and control
assembly while holding the motor in a way that will prevent the motor
or control from falling when the bolts are removed. If an ECM2.0
control is being replaced (recognized by an aluminum casting rather
that a deep-drawn black steel can housing the electronics), remove
only the hex-head bolts. DO NOT REMOVE THE TORX-HEAD
SCREWS.
5. The control module is now free of mechanical attachment to the
motor endshield but is still connected by a plug and three wires inside the
control. Carefully rotate the control to gain access to the plug at the
control end of the wires. With thumb and forefinger, reach the latch
holding the plug to the control and release it by squeezing the latch tab
and the opposite side of the connector plug and gently pulling the plug out
of the connector socket in the control. DO NOT PULL ON THE
WIRES. GRIP THE PLUG ONLY.
6. The control module is now completely detached from the motor.
Verify with a standard ohmmeter that the resistance from each motor lead
(in the motor plug just removed) to the motor shell is >100K ohms. Refer
to Figure 10. (Measure to unpainted motor end plate.) If any motor
lead fails this test, do not proceed to install the control module. THE
MOTOR IS DEFECTIVE AND MUST BE REPLACED. Installing
the new control module will cause it to fail also.
7. Verify that the replacement control is correct for your
application. Refer to the manufacturer's authorized replacement list.
USING THE WRONG CONTROL WILL RESULT IN
IMPROPER OR NO BLOWER OPERATION. Orient the control
module so that the 3-wire motor plug can be inserted into the socket in
the control. Carefully insert the plug and press it into the socket until
it latches. A SLIGHT CLICK WILL BE HEARD WHEN
PROPERLY INSERTED. Finish installing the replacement control per
one of the three following paragraphs, 8a, 8b or 8c.
8a. IF REPLACING AN ECM 2.0 CONTROL (control in cast
aluminum can with air vents on the back of the can) WITH AN ECM 2.3
CONTROL (control containing black potting for water protection in
black deep-drawn steel case with no vents in the bottom of the can), locate
the two through-bolts and plastic tab that are packed with the replacement
control. Insert the plastic tab into the slot at the perimeter of the open end
of the can so that the pin is located on the inside of the perimeter of the
can. Rotate the can so that the tab inserts into the tab locater hole in the
endshield of the motor. Using the two through-bolts provided with the
replacement control, reattach the can to the motor.
8b. IF REPLACING AN ECM 2.3 CONTROL WITH AN ECM 2.3
CONTROL, the plastic tab and shorter through-bolts are not needed. The
control can be oriented in two positions 180° apart. MAKE SURE THE
ORIENTATION YOU SELECT FOR REPLACING THE CONTROL
ASSURES THE CONTROL'S CABLE CONNECTORS WILL BE
LOCATED DOWNWARD IN THE APPLICATION SO THAT
WATER CANNOT RUN DOWN THE CABLES AND INTO THE
CONTROL. Simply orient the new control to the motor's endshield,
insert bolts, and tighten. DO NOT OVERTIGHTEN THE BOLTS.
8c. IF REPLACING AN ECM 2.0 CONTROL WITH AN ECM
2.0 CONTROL (It is recommended that ECM 2.3 controls be used for
all replacements), the new control must be attached to the motor using
through bolts identical to those removed with the original control. DO
NOT OVERTIGHTEN THE BOLTS.
9. Reinstall the blower/motor assembly into the HVAC equipment.
Follow the manufacturer's suggested procedures.
10. Plug the 16-pin control plug into the motor. The plug is keyed.
Make sure the connector is properly seated and latched.
11. Plug the 5-pin power connector into the motor. Even though the
plug is keyed, OBSERVE THE PROPER ORIENTATION. DO NOT
FORCE THE CONNECTOR. It plugs in very easily when properly
oriented. REVERSING THIS PLUG WILL CAUSE IMMEDIATE
FAILURE OF THE CONTROL MODULE.
12. Final installation check. Make sure the motor is installed as follows:
a. Unit is as far INTO the blower housing as possible.
b. Belly bands are not on the control module or covering vent holes.
c. Motor connectors should be oriented between the 4 o’clock and 8
o’clock positions when the blower is positioned in its final
location and orientation.
d. Add a drip loop to the cables so that water cannot enter the motor
by draining down the cables. Refer to Figure 11.
The installation is now complete. Reapply the AC power to the
HVAC equipment and verify that the new motor control module is
working properly. Follow the manufacturer's procedures for
disposition of the old control module.
Figure 410
Figure
Winding Test
Figure 9
3
Control Disassembly
Motor Connector
(3-pin)
Only remove
From Motor
Hex Head Bolts Push until
Latch Seats
Over Ramp
Circuit
Board
Motor
ECM 2.0
Motor OK when
R > 100k ohm
Note:
Use the shorter
bolts and
alignment pin
supplied when
replacing an
ECM 2.0
control.
Figure
Figure11
5
Drip Loop
ECM
2.3/2.5
Motor Connector
(3-pin)
Back of
Control
Connector Orientation
Between 4 and 8 o'clock
Control Connector
(16-pin)
Power Connector
(5-pin)
Hex-head Screws
Drip Loop
THE TWO THROUGH-BOLTS PROVIDED WITH THE
REPLACEMENT ECM 2.3 CONTROL ARE SHORTER THAN THE
BOLTS ORIGINALLY REMOVED FROM THE ECM 2.0
CONTROL AND MUST BE USED IF SECURE ATTACHMENT OF
THE CONTROL TO THE MOTOR IS TO BE ACHIEVED.
DO NOT OVERTIGHTEN THE BOLTS.
Manual
Page
2100-526E
21 of 24
TABLE 9
INDOOR BLOWER PERFORMANCE 1
Rated ESP
MAX ESP
2
Continuous
C FM
WA/L3S
0.15
0.80
800
800
1100
1100
1400
WA/L4S
0.20
0.80
825
1100
1500
1100
1500
WA/L5S
0.20
0.80
850
1300
1700
1100
1500
Model
3
Rated 1st
Stage CFM
4
Rated 2nd
Stage CFM
5
5-10 KW
C FM
6
15-20 KW
C FM
1 Motor will deliver consistent CFM through voltage supply range with no deterioration.
(197-253V for 230/208V models, 414-506V for 460V models)
2 Continuous CFM is the total air being circulated during continuous (manual) fan mode.
3 Will occur automatically with a call for "Y1" signal from thermostat.
4 Will occur automatically with a call for "Y2" signal from thermostat.
5 Will occur automatically with a call for "W1" signal from thermostat.
6 Will occur automatically with a call for "W2" or "Emergency Heat" signal from thermostat.
TABLE 10
MAXIMUM ESP OF OPERATION
ELECTRIC HEAT ONLY
KW-Heat
Manual 2100-526E
Page
22 of 24
WA/L3S
WA/L4S
WA/L5S
-A05
-A08
-A10
-A15
-A20
.80
.80
.80
.80
.80
.80
.80
.80
.80
.80
.80
.80
.80
.80
.80
-B06
-B09
-B12
-B15
-B18
.80
.80
.80
.80
.80
.80
.80
.80
.80
.80
.80
.80
.80
.80
.80
-C06
-C09
-C12
-C15
-C18
.80
.80
.80
.80
.80
.80
.80
.80
.80
.80
.80
.80
.80
.80
.80
WA5S3-C
WA5S3-B
WA5S3-A
WA4S3-C
WA4S3-B
WA4S3-A
WA3S3-C
WA3S3-B
MODEL
DESCRIPTION
WA3S3-A
TABLE 11
OPTIONAL ACCESSORIES
EHWA4S-A05
Heater Package
X
X
EHWA4S-A10
Heater Package
X
X
EHWA4S-A15
Heater Package
X
X
EHWA4S-A20
Heater Package
X
X
EHWA5S-A05
Heater Package
EHWA5S-A08
Heater Package
EHWA5S-A10
Heater Package
X
EHWA5S-A15
Heater Package
X
EHWA5S-A20
Heater Package
X
EHWA3S-B06
Heater Package
EHWA5S-B06
Heater Package
EHWA5S-B09
Heater Package
EHWA5S-B15
Heater Package
EHWA5S-C06
Heater Package
X
X
X
EHWA5S-C09
Heater Package
X
X
X
EHWA5S-C15
Heater Package
X
X
X
BOP-5
Blank Off Plate (Standard)
X
X
X
X
X
X
X
X
X
CRVMP-5
Classroom Ventilator with Exhaust (3-Position)
X
X
X
X
X
X
X
X
X
EIFM-5C
Economizer with Exhaust
X
X
X
X
X
X
X
X
X
WERV-A5B
Energy Recovery Ventilator
X
X
X
X
X
X
WERV-C5B
Energy Recovery Ventilator
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Manual
Page
X
2100-526E
23 of 24
WL5S2-C
WL5S2-B
WL5S2-A
WL4S2-C
WL4S2-B
WL4S2-A
WL3S2-C
DESCRIPTION
EHWA4S-A05L
Heater Package
X
X
EHWA4S-A10L
Heater Package
X
X
EHWA4S-A15L
Heater Package
X
X
EHWA4S-A20L
Heater Package
X
X
EHWA5S-A05L
Heater Package
EHWA5S-A08L
Heater Package
EHWA5S-A10L
Heater Package
X
EHWA5S-A15L
Heater Package
X
EHWA5S-A20L
Heater Package
X
EHWA3S-B06L
Heater Package
EHWA5S-B06L
Heater Package
EHWA5S-B09L
Heater Package
EHWA5S-B15L
Heater Package
EHWA5S-C06L
Heater Package
X
X
X
EHWA5S-C09L
Heater Package
X
X
X
EHWA5S-C15L
Heater Package
X
X
X
BOP-5
Blank Off Plate (Standard)
X
X
X
X
X
X
X
X
X
CRVMP-5
Classroom Ventilator with Exhaust (3-Position)
X
X
X
X
X
X
X
X
X
EIFM-5C
Economizer with Exhaust
X
X
X
X
X
X
X
X
X
WERV-A5B
Energy Recovery Ventilator
X
X
X
X
X
X
WERV-C5B
Energy Recovery Ventilator
Manual 2100-526E
Page
24 of 24
WL3S2-B
MODEL
WL3S2-A
TABLE 12
OPTIONAL ACCESSORIES
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X