2100-218
INSTALLATION
INSTRUCTIONS
WALL MOUNTED
PACKAGE AIR CONDITIONERS
MODELS
WA381
WA421
WA482
WA491
WA602
Bard Manufacturing Company
Bryan, Ohio 43506
Since 1914...Moving ahead just as planned.
Manual :
Supersedes:
File:
Date:
2100-218K
2100-218J
Volume III Tab 16
09-20-01
© Copyright 2001
Contents
Getting Other Information and Publications
Wall Mount General Information
Heat Pump Wall Mount Model Nomenclature ..........
Shipping Damage ....................................................
General ................................................................
Duct Work ................................................................
Filters
................................................................
Fresh Air Intake .......................................................
Condensate Drain ....................................................
1
2
5
5
6
6
6
6
Installation Instructions
Wall Mounting Information ....................................... 7
Mounting the Unit .................................................... 7
Wiring – Main Power ............................................. 12
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
Unit Dimensions ...................................... 3
Fresh Air Damper Assembly ................... 6
Mounting Instructions .............................. 8
Electric Heat Clearance .......................... 9
Wall Mounting Instructions .................... 10
Wall Mounting Instructions .................... 10
Common Wall Mounting Installations ..... 11
Unit 24V Terminal Board ....................... 13
Starting Procedure ................................ 14
Fan Blade Setting ................................. 17
Start Up
Important Installer Note .........................................
Crankcase Heaters ................................................
High Pressure Switch ............................................
Three Phase Scroll Compressor Start Up .............
Condenser Fan Operation .....................................
Service Hints .........................................................
Sequence of Operation ..........................................
Compressor Control Module ..................................
Adjustments ...........................................................
Phase Monitor .......................................................
Pressure Service Ports ..........................................
14
14
14
14
14
15
15
15
15
16
16
Troubleshooting
Fan Blade Setting Dimensions ..............................
Removal of Fan Shroud .........................................
Refrigerant Charge ................................................
Pressure Table .......................................................
Optional Accessories .............................................
17
17
17
19
20
Tables
Table 1
Table 2
Table 3
Table 4
Table 5
Table 6
Table 7
Table 7A
Table 8
Table 9
Table 9A
Table 10
Table 11
Electric Heat Table .................................. 2
Electrical Specifications ................ 4 and 5
Thermostat Wire Size ........................... 12
Wall thermostat and Subbase
Combinations ........................................ 12
Fan Blade Dimensions .......................... 17
Refrigerant Charge ............................... 17
Indoor Blower Performance .................. 17
Indoor Blower Performance .................. 18
Recommended Air Flow ........................ 18
Maximum EXP Electric Heat Only ........ 18
Maximum EXP Electric Heat Only ........ 18
Pressure Table ...................................... 19
Optional Accessories ............................ 20
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
Residential Winter and
Summer Air Conditioning
Duct Design for Residential .............. ACCA Manual D
Winter and Summer Air Conditioning
and Equipment Selection
ASHRAE American Society of Heating, Refrigeration
and Air Conditioning Engineers, Inc.
1791 Tullie Circle, N.E.
Atlanta, GA 30329-2305
Telephone: (404) 636-8400
Fax: (404) 321-5478
NFPA
National Fire Protection Association
Batterymarch Park
P.O. Box 9101
Quincy, MA 02269-9901
Telephone: (800) 344-3555
Fax: (617) 984-7057
MANUFACTURED UNDER THE FOLLOWING
U.S. PATENT NUMBERS:
5,485,878; 5,301,777; 5,002,116; 4,924,934;
4,875,520; 4,825,936; 4,432,409
Manual 2100-218
Page 1
WALL MOUNT GENERAL INFORMATION
HEAT PUMP WALL MOUNT MODEL NOMENCLATURE
MODEL NUMBER
CAPACITY
38 - 3 Ton
42 - 3 1/2 Ton
48 - 4 Ton
60 - 5 Ton
WA
42
1
–
A
10
X
N
X
X
REVISIONS
COLOR OPTIONS
X - Beige (Standard)
1 - White
2 - Mesa Tan
4 - Buckeye Gray
5 - Desert Brown
6 - Dark Bronze
KW
VOLTS & PHASE
A - 230/208/60/1
B - 230/208/60/3
C - 460/60/3
CONTROL
MODULES
(See Chart Below)
X A
COIL OPTIONS
X - Standard
1 - Phenolic Coated Evaporator
2 - Phenolic Coated Condenser
3 - Phenolic Coated Evaporator
and Condenser
OUTLET OPTIONS
VENTILATION OPTIONS
X - Front (Standard)
X - Barometric Fresh Air Damper (Standard)
B - Blank-off Plate
M - Motorized Fresh Air Damper
V - Commercial Ventilator Motorized with Exhaust
FILTER OPTIONS
E - Economizer (Internal) - Fully
X - One Inch Throwaway (Standard)
Modulating with Exhaust
W - One Inch Washable
R - Energy Recovery Ventilator P - Two Inch Pleated
Motorized with Exhaust
NOTE: All vent options are without exhaust capability. May require separate field supplied barometric relief in building.
TABLE 1
ELECTRIC HEAT TABLE
WA381-A
WA421-A
WA482-A
WA491-A
WA602-A
Models
230-1
WA381-B
WA421-B
WA482-B
WA491-B
WA602-B
208-1
KW
A
B TU
A
B TU
5
20.8
17050
18.1
12800
6
8
33.3
27280
28.8
10
41.6
34130
36.2
25600
15
62.5
51200
54.0
38400
18
Manual 2100-218
Page 2
83.2
68260
72.1
208-3
460-3
A
B TU
A
B TU
A
B TU
14.4
20500
12.5
15360
7.2
20480
21.7
30600
18.7
23030
10.8
30700
36.2
51200
31.2
38400
17.3
47000
43.3
61430
37.5
46100
20450
9
20
230-3
WA381-C
WA421-C
WA482-C
WA491-C
WA602-C
51200
FIGURE 1
UNIT DIMENSIONS
Width
Model
(W)
Depth Height
(D)
(H)
Supply
A
B
Return
C
B
E
F
G
I
J
K
L
M
N
O
P
Q
R
S
T
WA38
WA42
WA48 42.075 22.432 84.875 9.88 29.88 15.88 29.88 43.88 19.10 31.66 30.00 32.68 26.94 34.69 32.43 3.37 42.88 23.88 10.00 1.44 16.00 1.88
WA49
WA60
Manual 2100-218
Page 3
FRONT VIEW
SIDE VIEW
BACK VIEW
MIS-1262
TABLE 2
ELECTRICAL SPECIFICATIONS
SINGLE CIRCUIT
3
Rated
Volts &
P h ase
Model
1
DUAL CIRCUIT
2
2
Maximum
N o.
External
Field
Field
Minimum Fuse or Pow er Ground
P o w er
Circuit
Wire
Circuit
Wire
Circuits Ampacity Breaker
Siz e
Siz e
3
1
2
2
Minimum
Circuit
Ampacity
Maximum
External Fuse
or Circuit
Breaker
Field Pow er
Wire Siz e
Ground
Wire Siz e
CKT A CKT B CKT A CKT B CKT A CKT B CKT A CKT B
WA381-A00, A0Z
A 05
230/208-1
A 08
A 10
1
1
1
1
25
32
47
58
35
35
50
60
8
8
8
6
10
10
10
10
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
WA381-B00, B0Z
B06 230/208-3
B 09
1
1
1
20
24
33
30
30
35
10
10
8
10
10
10
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
WA381-C00, C0Z
C 06
C 09
1
1
1
11
13
17
15
15
20
14
14
12
14
14
12
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
WA421-A00, A0Z
A 05
A10 230/208-1
A 15
A 20
1
1
1
1 or 2
1 or 2
33
33
59
85
110
50
50
60
90
110
8
8
6
4
2
10
10
10
8
6
N/A
N/A
N/A
56
56
N/A
N/A
N/A
26
52
N/A
N/A
N/A
60
60
N/A
N/A
N/A
30
60
N/A
N/A
N/A
6
6
N/A
N/A
N/A
10
6
N/A
N/A
N/A
10
10
N/A
N/A
N/A
10
10
WA421-B00, B0Z
B 09
230/208-3
B 15
B 18
1
1
1
1
24
34
52
60
35
35
50
60
8
8
6
6
10
10
10
10
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
WA421-C00, C0Z
C 09
C 15
1
1
1
12
17
26
15
20
30
14
12
10
14
12
10
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
WA482-A00, A0Z
A 05
A10 230/208-1
A 15
A 20
1
1
1
1 or 2
1 or 2
38
38
59
85
110
50
50
60
90
110
8
8
6
4
2
10
10
10
8
6
N/A
N/A
N/A
59
59
N/A
N/A
N/A
26
52
N/A
N/A
N/A
60
60
N/A
N/A
N/A
30
60
N/A
N/A
N/A
6
6
N/A
N/A
N/A
10
6
N/A
N/A
N/A
10
10
N/A
N/A
N/A
10
10
WA482-B00, B0Z
B 09
230/208-3
B 15
B 18
1
1
1
1
26
34
52
60
35
35
60
60
8
8
6
6
10
10
10
10
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
WA482-C00, C0Z
C 09
C 15
1
1
1
13
17
26
15
20
30
14
12
10
14
12
10
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
WA491-A00, A0Z
A 05
230/208-1
A 08
A 10
1
1
1
1
33
33
47
58
50
50
50
60
8
8
8
6
10
10
10
10
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
WA491-B00, B0Z
B06 230/208-3
B 09
1
1
1
27
27
33
40
40
40
8
8
8
10
10
10
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
WA491-C00, C0Z
C 06
C 10
1
1
1
13
13
17
15
15
20
14
14
12
14
14
12
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
460-3
460-3
460-3
460-3
TABLE CONTINUED ON PAGE 5
j
k
l
Maximum size of the time delay fuse or HACR type circuit breaker for protection of field wiring conductors.
Based on 75° C copper wire. All wiring must conform to NEC and all local codes.
These “Minimum Circuit Ampacity” values are to be used for sizing the field power conductors. Refer to the
National Electric Code (latest revision), article 310 for power conductor sizing. CAUTION: When more than
one field power conductor circuit is run through one conduit, the conductors must be derated. Pay special
attention to note 8 of table 310 regarding Ampacity Adjustment Factors when more than 3 conductors are in
a raceway.
Manual 2100-218
Page 4
TABLE CONTINUED FROM PAGE 4
SINGLE CIRCUIT
3
Rated
Volts &
P h ase
Model
N o.
Minimum
Field
Circuit
P o w er
Circuits Ampacity
1
DUAL CIRCUIT
2
2
3
1
2
2
Maximum
External Fuse
or Circuit
Breaker
Maximum
Minimum
External
Circuit
Field
Field Pow er
Ground
Fuse or Pow er Ground
Ampacity
Wire Siz e
Wire Siz e
Circuit
Wire
Wire
Breaker
Siz e
Siz e
CKT A CKT B CKT A CKT B CKT A CKT B CKT A CKT B
WA602-A00, A0Z
A 05
A10 230/208-1
A 15
A 20
1
1
1
1 or 2
1 or 2
44
44
55
85
110
60
60
60
90
110
8
8
6
4
2
10
10
10
8
6
N/A
N/A
N/A
59
59
N/A
N/A
N/A
26
52
N/A
N/A
N/A
60
60
N/A
N/A
N/A
30
60
N/A
N/A
N/A
6
6
N/A
N/A
N/A
10
6
N/A
N/A
N/A
10
10
N/A
N/A
N/A
10
10
WA602-B00, B0Z
B 09
230/208-3
B 15
B 18
1
1
1
1
32
34
52
60
45
45
60
60
8
8
6
6
10
10
10
10
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
WA602-C00, C0Z
C 09
C 15
1
1
1
16
17
26
20
20
30
12
12
10
12
12
10
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
460-3
j
k
l
Maximum size of the time delay fuse or HACR type circuit breaker for protection of field wiring conductors.
Based on 75° C copper wire. All wiring must conform to NEC and all local codes.
These “Minimum Circuit Ampacity” values are to be used for sizing the field power conductors. Refer to the
National Electric Code (latest revision), article 310 for power conductor sizing. CAUTION: When more than
one field power conductor circuit is run through one conduit, the conductors must be derated. Pay special
attention to note 8 of table 310 regarding Ampacity Adjustment Factors when more than 3 conductors are in
a raceway.
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.
Manual 2100-218
Page 5
DUCT WORK
FILTERS
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.
A one inch throwaway filter is supplied with each unit.
The filter slides into position making it easy to service.
This filter can be serviced from the outside by removing
the service door. A one inch washable filter and two
inch pleated filter are also available as optional
accessories. The internal filter brackets are adjustable
to accommodate the two inch filter by loosening two (2)
screws on each bracket assembly and sliding the
brackets apart to the required width and retightening the
four (4) screws.
Refer to Table 10 for maximum static pressure
available for duct design.
Design the duct work according to methods given by the
Air Conditioning Contractors of America (ACCA).
When duct runs through unheated spaces, it should be
insulated with a minimum of one inch of insulation.
Use insulation with a vapor barrier on the outside of the
insulation. Flexible joints should be used to connect the
duct work to the equipment in order to keep the noise
transmission to a minimum.
A 1/4 inch clearance to combustible material for the
first three feet of duct attached to the outlet air frame is
required. See Wall Mounting Instructions and Figures 3
and 4 for further details.
FRESH AIR INTAKE
All units are built with fresh air inlet slots punched in
the service panel.
If the unit is equipped with a fresh air damper assembly,
the assembly is shipped already attached to the unit.
The damper blade is locked in the closed position. To
allow the damper to operate, the maximum and
minimum blade position stops must be installed. See
Figure 2.
Ducts through the walls must be insulated and all joints
taped or sealed to prevent air or moisture entering the
wall cavity.
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.
Some installations may not require any return air duct.
A metallic return air grille is required with installations
not requiring a return air duct. The spacing between
louvers on the grille shall not be larger than 5/8 inch.
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.
Any grille that meets with 5/8 inch louver criteria may
be used. It is recommended that Bard Return Air Grille
Kit RG2 through RG5 or RFG2 through RFG5 be
installed when no return duct is used. Contact
distributor or factory for ordering information. If using
a return air filter grille, filters must be of sufficient size
to allow a maximum velocity of 400 fpm.
NOTE: If no return air duct is used, applicable
installation codes may limit this cabinet to
installation only in a single story structure.
CONDENSATE DRAIN
A plastic drain hose extends from the drain pan at the
top of the unit down to the unit base. There are
openings in the unit base for the drain hose to pass
through. In the event the drain hose is connected to a
drain system of some type, it must be an open or vented
type system to assure proper drainage.
FIGURE 2
FRESH AIR DAMPER
BLADE IS LOCKED
CLOSED FOR
SHIPPING.
MIS-938
Manual 2100-218
Page 6
INSTALLATION INSTRUCTIONS
WALL MOUNTING INFORMATION
1. Two holes for the supply and return air openings
must be cut through the wall as shown in Figure 3.
2. On wood frame walls, the wall construction must be
strong and rigid enough to carry the weight of the
unit without transmitting any unit vibration.
3. Concrete block walls must be thoroughly inspected
to insure that they are capable of carrying the weight
of the installed unit.
WARNING
Failure to provide the 1/4 inch clearance
between the supply duct and a combustible
surface for the first 3 feet of duct can result in
fire causing damage, injury or death.
4. Mount bottom mounting bracket.
MOUNTING THE UNIT
1. These units are secured by wall mounting brackets
which secure the unit to the outside wall surface at
both sides. A bottom mounting bracket is provided
for ease of installation, but is not required.
2. The unit itself is suitable for 0 inch clearance, but
the supply air duct flange and the first 3 feet of
supply air duct require a minimum of 1/4 inch
clearance to combustible material. If a combustible
wall use a minimum of 30-1/2” x 10-1/2”
dimensions for sizing. However it is generally
recommended that a 1 inch clearance is used for
ease of installation and maintaining the required
clearance to combustible material. The supply air
opening would then be 32” x 12”. See Figures 3 and
4 for details.
3. Locate and mark lag bolt locations and bottom
mounting bracket location. See Figure 3.
5. Hook top rain flashing under back bend of top. Top
rain flashing is shipped secured to the right side of
the back.
6. Position unit in opening and secure with 5/16 lag
bolts; use 7/8 inch diameter flat washers on the lag
bolts.
7. Secure rain flashing to wall and caulk across entire
length of top. See Figure 3.
8. For additional mounting rigidity, the return air and
supply air frames or collars can be drilled and
screwed or welded to the structural wall itself
(depending upon wall construction). Be sure to
observe required clearance if combustible wall.
9. On side by side installations, maintain a minimum
of 20 inches clearance on right side to allow access
to control panel and heat strips, and to allow proper
airflow to the outdoor coil. Additional clearance
may be required to meet local or national codes.
Manual 2100-218
Page 7
Manual 2100-218
Page 8
FIGURE 3
MOUNTING INSTRUCTIONS
MIS-416
FIGURE 4
ELECTRIC HEAT CLEARANCE
SIDE SECTION VIEW OF SUPPLY AIR DUCT FOR
WALL MOUNTED UNIT SHOWING 1/4 INCH
CLEARANCE TO COMBUSTIBLE SURFACES.
MIS-277
WARNING
A minimum of 1/4 inch clearance must be maintained between
the supply air duct and combustible materials. This is required for
the first 3 feet of ducting.
It is important to insure that the 1/4 inch minimum spacing is
maintained at all points.
Failure to do this could result in overheating the combustible
material and may result in a fire causing damage, injury or death.
Manual 2100-218
Page 9
FIGURE 5
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
OPENING
RETURN AIR
OPENING
RETURN
AIR
OPENING
RETURN AIR
OPENING
BOTTOM MOUNTING
BRACKET. MOUNT
ON WALL BEFORE
INSTALLING UNIT.
MIS-548
FIGURE 6
WALL MOUNTING INSTRUCTIONS
SEE UNIT DIMENSIONS, FIGURE 1,
FOR ACTUAL DIMENSIONS
ATTACH TO TOP
PLATE OF WALL
1.000” CLEARANCE
ALL AROUND
INTERIOR FINISHED WALL
OVER FRAME
SUPPLY DUCT
OPENING
1.000” CLEARANCE
ALL AROUND
RETURN DUCT
OPENING
EXTERIOR FINISHED
WALL OVER FRAME
MIS-549
Manual 2100-218
Page 10
FRAMING MATERIAL
2 X 4’S, 2 X 6’S AND/OR
STRUCTURAL STEEL
ATTACH TO BOTTOM
PLATE OF WALL
THIS STRUCTURAL MEMBER LOCATED TO
MATCH STUD SPACING FOR REST OF WALL.
A SECOND MEMBER MAY BE REQUIRED FOR
SOME WALLS.
FIGURE 7
COMMON WALL MOUNTING INSTALLATIONS
FREE AIR FLOW NO DUCT
FALSE WALL INSTALLATION
DUCTED SUPPLY RETURN AT UNIT
CLOSET INSTALLATION
MIS-550
Manual 2100-218
Page 11
WIRING – MAIN POWER
WIRING – LOW VOLTAGE WIRING
Refer to the unit rating plate for wire sizing information
and maximum fuse or “HACR” type circuit breaker
size. Each outdoor unit is marked with a “Minimum
Circuit Ampacity”. This means that the field wiring
used must be sized to carry that amount of current.
Depending on the installed KW of electric heat, there
may be two field power circuits required. If this is the
case, the unit serial plate will so indicate. All models
are suitable only for connection with copper wire. Each
unit and/or wiring diagram will be marked “Use Copper
Conductors Only”. These instructions must be adhered
to. Refer to the National Electrical Code (NEC) for
complete current carrying capacity data on the various
insulation grades of wiring material. All wiring muse
conform to NEC and all local codes.
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:
The electrical data lists fuse and wire sizes (75° C
copper) for all models including the most commonly
used heater sizes. Also shown are the number of field
power circuits required for the various models with
heaters.
The unit rating plate lists a “Maximum Time Delay
Relay Fuse” or “HACR” type circuit breaker that is to
be used with the equipment. The correct size must be
used for proper circuit protection and also to assure that
there will be no nuisance tripping due to the momentary
high starting current of the compressor motor.
The disconnect access door on this unit may be locked
to prevent unauthorized access to the disconnect. To
convert for the locking capability bend the tab located
in the bottom left hand corner of the disconnect
opening under the disconnect access panel straight out.
This tab will now line up with the slot in the door.
When shut a padlock may be placed through the hole in
the tab preventing entry.
TAP
240
208
RANGE
253 – 216
220 – 187
NOTE: The voltage should be measured at the field
power connection point in the unit and while the
unit is operating at full load (maximum
amperage operating condition).
Five (5) wires should be run from thermostat subbase to
the 24V terminal board in the unit. A five conductor, 18
gauge copper, color-coded thermostat cable is
recommended. The connection points are shown in
Figure 8:
TABLE 3
THERMOSTAT WIRE SIZE
Transformer
VA
55
FLA
Wire Gauge
Maximum
Distance
In Feet
2.3
20 gauge
18 gauge
16 gauge
14 guage
12 guage
45
60
100
160
250
See “Start Up” section for important information on
three phase scroll compressor start ups.
TABLE 4
WALL THERMOSTAT AND SUBBASE COMBINATIONS
T hermostat
8403-002
T87F3111
8403-041
T8034C
Subbase
Predominate Features
8404-003 1 stage heat, 1 stage cool
Q539A1220 System: heat-off-cool Fan: auto-on
---
1 stage heat, 1 stage cool
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
1F95-80
8403-043
CM-200
Manual 2100-218
Page 12
---
---
2 stage cool, 2 stage heat
Electronic
7 day programming
1 stage heat, 1 stage cool
System: heat-off-cool Fan: auto-on
FIGURE 8
UNIT 24V TERMINAL BOARD
MIS-1373A
Manual 2100-218
Page 13
START UP
IMPORTANT INSTALLER NOTE
For improved start up performance wash the indoor coil
with a dish washing detergent.
CRANKCASE HEATERS
WA421 units are provided with compressor crankcase
heat. The other units are not provided with crankcase
heat. These units utilize scroll compressors which do
not require crankcase heat in this application.
The WA421 models have an insertion well-type heater
located in the lower section of the compressor housing.
This is a self-regulating type heater that draws only
enough power to maintain the compressor at a safe
temperature on these units.
FIGURE 9
STARTING PROCEDURE
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).
Some form of crankcase heat is essential to prevent
liquid refrigerant from migrating to the compressor
causing oil pump out on compressor start up and
possible valve failure due to compressing a liquid.
2. Apply power by closing the system disconnect
switch. This energizes the compressor heater
which evaporates the liquid refrigerant in the
crankcase.
The decal in Figure 9 is affixed to all WA421 units
detailing start up procedure. This is very important.
Please read carefully.
3. Allow 4 hours or 60 minutes per pound of
refrigerant in the system as noted on the unit
rating plate, which ever is greater.
HIGH PRESSURE SWITCH
4. After properly elapsed time, the thermostat
may be set to operate the compressor.
The WA381, WA482, WA491 and WA602 models are
supplied with a remote reset high pressure switch. If
tripped, this pressure switch may be reset by turning the
thermostat off then back on again.
THREE PHASE SCROLL COMPRESSOR
START UP INFORMATION
Scroll compressors, like several other types of
compressors, will only compress in one rotational
direction. Direction of rotation is not an issue with
single phase compressors since they will always start
and run in the proper direction.
However, three phase compressors will rotate in either
direction depending upon phasing of the power. Since
there is a 50-50 chance of connecting power in such a
way as to cause rotation in the reverse direction,
verification of proper rotation must be made.
Verification of proper rotation direction is made by
observing that suction pressure drops and discharge
pressure rises when the compressor is energized.
Reverse rotation also results in an elevated sound level
over that with correct rotation, as well as, substantially
reduced current draw compared to tabulated values.
Verification of proper rotation must be made at the
time the equipment is put into service. If improper
rotation is corrected at this time there will be no
negative impact on the durability of the compressor.
However, reverse operation for over one hour may have
a negative impact on the bearing due to oil pump out.
Manual 2100-218
Page 14
5. Except as required for safety while servicing,
Do not open system disconnect switch.
7961-061
NOTE: If compressor is allowed to run in reverse
rotation for several minutes, the compressor’s
internal protector will trip.
All three phase ZR compressors are wired identically
internally. As a result, once the correct phasing is
determined for a specific system or installation,
connecting properly phased power leads to the same
Fusite terminal should maintain proper rotation
direction.
The direction of rotation of the compressor may be
changed by reversing any two line connections to the
unit.
CONDENSER FAN OPERATION
The condenser fan motor on 230/208 volt, one and three
phase, 60 HZ units is a two speed motor that comes
factory wired on high speed for peak performance. If
ambient conditions permit, it can be reconnected to low
speed (red wire) for lower sound level. See wiring
diagram.
50 HZ models must have fan wired on low speed.
These models are factory wired on low speed.
SERVICE HINTS
1. Caution homeowner to maintain clean air filters at
all times. Also, not to needlessly close off supply
and return air registers. This reduces air flow
through the system, which shortens equipment
service life as well as increasing operating costs.
2. Switching to heating cycle at 75° F or higher outside
temperature may cause a nuisance trip of the remote
reset high pressure switch. Turn thermostat off then
on to reset the high pressure switch.
3. Check all power fuses or circuit breakers to be sure
they are the correct rating.
4. Periodic cleaning of the outdoor coil to permit full
and unrestricted airflow circulation is essential.
SEQUENCE OF OPERATION
COOLING – Circuit R-Y makes at thermostat pulling
in compressor contactor, starting the compressor and
outdoor motor. The G (indoor motor) circuit is
automatically completed on any call for cooling
operation or can be energized by manual fan switch on
subbase of constant air circulation. On all 230 volt
units there is a one minute off delay on the blower
motor. 460 volt models do not have an off delay. On a
call for heating, circuit R-W1 make at the thermostat
pulling in heat contact for the strip heat and blower
operation. On a call for second stage heat, R-W2 makes
bringing on second heat contactor, if so equipped.
COMPRESSOR CONTROL MODULE
The compressor control module is standard on the
WA391, WA482, WA491and WA602 models covered
by this manual and is optional on the WA421 model.
The compressor control is an anti-short cycle/lockout
timer with high and low pressure switch monitoring and
alarm relay output.
Adjustable Delay On Make And Break Timer
On initial power up or any time power is interrupted to
the unit the delay on make period begins which will be 2
minutes plus 10% of the delay on break setting. When
the delay on make is complete and the high pressure
switch (and low pressure switch if employed) is closed,
the compressor contactor is energized. Upon shutdown
the delay or break timer starts and prevents restart until
the delay on break and delay on make periods have
expired.
break time has expired. If the high pressure switch
opens again in this same operating cycle the unit will go
into manual lockout condition and the alarm relay
circuit will energize. Recycling the wall thermostat
resets the manual lockout.
Low Pressure Switch, Bypass, and Lockout
Sequence
If the low pressure switch opens for more than 120
seconds, the compressor contactor will de-energize and
go into a soft lockout. Regardless the state of the low
pressure switch, the contactor will reenergize after the
delay on make time delay has expired. If the low
pressure switch remains open, or opens again for longer
than 120 seconds the unit will go into manual lockout
condition and the alarm relay circuit will energize.
Recycling the wall thermostat resets the manual
lockout.
Alarm Relay Output
Alarm terminal is output connection for applications
where alarm relay is employed. This terminal is
powered whenever compressor is locked out due to
HPC or LPC sequences as described.
NOTE: Both high and low pressure switch controls are
inherently automatic reset devices. The high
pressure switch and low pressure switch cut out
and cut in settings are fixed by specific air
conditioner or heat pump unit model. The
lockout features, both soft and manual, are a
function of the Compressor Control Module.
ADJUSTMENTS
Adjustable Delay on Make and Delay on Break
Timer
The potentiometer is used to select Delay on Break time
from 30 seconds to 5 minutes. Delay on Make (DOM)
timing on power-up and after power interruptions is
equal to 2 minutes plus 10% of Delay on Break (DOB)
setting:
0.5 minute
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.
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
Typical Settings for Dual Unit Installation:
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
Unit 1: DOB set at 2 minutes, and DOM is 132 seconds
Unit 2: DOB set at 4 minutes, and DOM is 144 seconds
Manual 2100-218
Page 15
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.
Manual 2100-218
Page 16
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. A pressure table can be found later in the
manual covering all models. It is imperative to match
the correct pressure table to the unit by model number.
TROUBLESHOOTING
FAN BLADE SETTING DIMENSIONS
4. Unwire condenser fan motor.
Shown in Figure 10 is the correct fan blade setting
dimension for proper air delivery across the outdoor
coil.
5. Slide complete motor, fan blade, and shroud
assembly out the left side of the unit.
6. Service motor/fan as needed.
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.
7. Reverse steps to reinstall.
REFRIGERANT CHARGE
The correct system R-22 charge is shown on the unit
rating plate. Optimum unit performance will occur with
a refrigerant charge resulting in a suction line
temperature (6” from compressor) as shown in Table 6.
FIGURE 10
FAN BLADE SETTING
TABLE 5
FAN BLADE DIMENSION
Model
WA381
WA421
WA482
WA491
WA602
TABLE 6
REFRIGERANT CHARGE
Dimension
A
1.75
REMOVAL OF FAN SHROUD
Model
Rated
Airflow
95 OD
82 OD
Temperature Temperature
WA381
1100
50 - 48
48 - 46
WA421
1400
52 - 54
64 - 66
WA482
1550
54 - 56
65 - 67
WA491
1250
48 - 46
47 - 45
WA602
1700
53 - 55
60 - 62
1. Disconnect all power to the unit.
The suction line temperatures in table above are based
upon 80° F dry bulb / 67° F wet bulb (50% R.H.)
temperature and rated airflow across the evaporator
during cooling cycle.
2. Remove the screws holding both grilles, one on each
side of unit, and remove grilles.
3. Remove screws holding fan shroud to condenser
and bottom. Nine (9) screws.
TABLE 7
INDOOR BLOWER PERFORMANCE
CFM @ 230V
WA421, WA482
E.S.P.
In H20
.0
.1
.2
.3
.4
.5
Low 230V
WA602
High 230V
Low 230V
High 230V
Dry Coil Wet Coil Dry Coil Wet Coil Dry Coil Wet Coil Dry Coil Wet Coil
1650
1550
1450
1350
1300
---
1600
1500
1400
1300
1175
---
1885
1770
1635
1500
1370
1250
1800
1665
1540
1400
1285
1150
1600
1525
1450
1375
2200
2100
2000
1875
1775
1650
2000
1900
1800
1700
1600
1475
Table 7A on Page 18 for models WA381 and WA491
Manual 2100-218
Page 17
TABLE 7A
INDOOR BLOWER PERFORMANCE
CFM @ 230V / 460V
WA381
High Speed
E.S.P.
In
H 2O
Dry
Coil
.0
.1
.2
.3
Medium Speed
Wet
Coil
1625
1475
1350
1150
WA491
Dry
Coil
1475
1350
1150
825
Wet
Coil
1425
1325
1200
1025
1325
1200
1025
750
L o w S p eed
High Speed
Dry
Coil
Dry
Coil
Wet
Coil
1125
1100
1000
825
1100
1000
850
675
1700
1550
1400
1250
Wet
Coil
1550
1400
1250
1100
Medium Speed
Dry
Coil
1475
1375
1250
1100
Wet
Coil
1375
1250
1100
825
TABLE 8
RECOMMENDED AIRFLOW
Model
Rated
C FM *
Rated
ESP *
Recommended
Airflow Range
Factory Speed
Connection
WA381
1100
.15
1250 - 850
Medium
WA421
1400
.30
1600 - 1150
High
WA482
1550
.20
1750 - 1285
High
WA491
1250
.20
1475 - 1100
High
WA602
1700
.30
1950 - 1375
High
TABLE 9
MAXIMUM ESP OF OPERATION
ELECTRIC HEAT ONLY
Model
KW
WA421
WA482
TABLE 9A
MAXIMUM ESP OF OPERATION
ELECTRIC HEAT ONLY
WA602
High
Low
High
Low
High
Low
Speed Speed Speed Speed Speed Speed
-A05
-A10
-A15
-A20
.50
.50
.50
.50
.50
.50
.50
.45
.50
.50
.50
.50
.50
.50
.50
.45
.50
.50
.50
.50
.50
.50
.50
.40
-B00
-B09
-B15
-B18
.50
.50
.50
.50
.50
.50
.50
.50
.50
.50
.50
.50
.50
.50
.50
.50
.50
.50
.50
.50
.50
.50
.50
.50
-C09
-C15
.50
.50
.50
.50
.50
.50
.50
.50
.50
.50
.50
.50
Values shown are for units equipped with standard
1 inch throwaway filter or 1 inch washable filter.
Derate ESP by .15 for 2 inch pleated filters.
Manual 2100-218
Page 18
Model
KW
WA381
WA491
High
Med
Low
High
Med
S p eed S p eed S p eed S p eed S p eed
-A05
-A08
-A10
.30
.30
.30
.30
.30
.30
.30
.30
.20
.30
.40
.30
.30
.40
.30
-B06
-B09
.40
.40
.30
.30
.30
.30
.30
.30
.30
.30
-C06
-C09
.30
.30
.30
.30
.30
.30
.30
.30
.30
.30
Values shown are for units equipped with
standard 1 inch throwaway filter or 1 inch
washable filter. Derate ESP by .15 for 2 inch
pleated filters.
TABLE 10
PRESSURE TABLE
COOLING
Model
WA381
WA421
WA482
WA491
WA602
AIR TEMPERATURE ENTERING OUTDOOR COIL °F
Return Air
Temperature
Pressure
75
80
85
90
95
75 deg. D B
62 deg. WB
Low S i de
High Side
74
175
74
187
75
202
76
216
78
232
79
249
79
265
80
284
81
302
80 deg. D B
67 deg. WB
Low S i de
High Side
79
179
79
192
80
207
81
222
83
238
84
255
85
272
86
291
87
310
85 deg. D B
72 deg. WB
Low S i de
High Side
82
185
82
199
83
214
84
230
86
246
87
264
88
252
89
301
90
321
75 deg. D B
62 deg. WB
Low S i de
High Side
68
213
71
228
74
243
76
259
78
274
80
290
81
305
83
321
84
337
80 deg. D B
67 deg. WB
Low S i de
High Side
72
218
76
234
79
249
82
265
84
281
86
297
88
313
89
330
90
346
85 deg. D B
72 deg. WB
Low S i de
High Side
78
226
82
242
85
258
88
274
90
290
92
307
94
323
96
341
97
358
75 deg. D B
62 deg. WB
Low S i de
High Side
73
204
74
217
76
232
78
248
79
265
80
284
82
304
83
325
84
348
80 deg. D B
67 deg. WB
Low S i de
High Side
78
210
79
223
81
238
82
254
84
272
86
291
87
312
89
334
90
357
85 deg. D B
72 deg. WB
Low S i de
High Side
84
217
85
231
87
247
88
264
90
282
92
302
93
323
95
345
97
369
75 deg. D B
62 deg. WB
Low S i de
High Side
70
199
71
213
71
227
72
244
73
260
75
279
76
298
77
320
79
341
80 deg. D B
67 deg. WB
Low S i de
High Side
75
204
76
218
76
233
77
250
78
267
80
286
81
306
82
328
84
350
85 deg. D B
72 deg. WB
Low S i de
High Side
78
211
79
226
79
241
80
259
81
276
83
296
84
317
85
339
87
362
75 deg. D B
62 deg. WB
Low S i de
High Side
71
233
72
247
74
262
75
278
76
295
77
313
78
331
78
351
79
371
80 deg. D B
67 deg. WB
Low S i de
High Side
76
237
78
253
79
269
80
285
81
303
82
321
83
340
84
390
85
381
85 deg. D B
72 deg. WB
Low S i de
High Side
84
245
85
261
85
278
86
296
87
314
88
333
89
353
90
373
91
394
100
105
110
115
Low side pressure ± 2 PSIG
High side pressure ± 5 PSIG
Tables are based upon rated CFM (airflow) across the evaporator coil. If there is any doubt as to correct
operating charge being in the system, the charge should be removed, system evacuated and recharged
to serial plate instructions.
NOTE:
Pressure table based on high speed condenser fan operation. If condensing pressures
appear elevated check condenser fan wiring. See “Condenser Fan Operation” on Page 14.
Manual 2100-218
Page 19
WA602-C
WA602-B
WA602-A
WA491-C
WA491-B
WA491-A
WA482-C
WA482-B
WA482-A
WA421-C
WA421-B
WA421-A
WA381-C
WA381-B
WA381-A
TABLE 11
OPTIONAL ACCESSORIES
Part
Number
Description
EHWA05-A05
EHWA05-A08
EHWA05-A10
EHWA05-A15
Heater Packages
Heater Packages
Heater Packages
Heater Packages
EHWA38-A05
EHWA38-A08
EHWA38-A10
EHWA49-A05
Heater Packages
Heater Packages
Heater Packages
Heater Packages
EHWA05-B09
EHWA05-B15
EHWA05-B18
Heater Packages
Heater Packages
Heater Packages
EHWA38-B06
EHWA38-B09
EHWA49-B06
Heater Packages
Heater Packages
Heater Packages
EHWA05-C09A
EHWA05-C15
Heater Packages
Heater Packages
EHWA38-C06
Heater Packages
BOP-5
BFAD-5
MFAD-5
Blank Off Plate
Barometric Fresh Air Damper
Motorized Fresh Air Damper
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
CRV-5
EIFM-5
WERV-A5B
WERV-C5B
Commercial Ventilator with Exhaust
Economizer with Exhaust
Energy Recovery Ventilator
Energy Recovery Ventilator
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
CMA-6
CMA-10
Low Ambient Control (LAC)
LPC + HPC + TDR
X
CMA-13
CMC-15
CMA-16
CMA-18
LPC + HPC + TDR + LAC
Start Kit
Low Pressue Control
LP C + LA C
WMCB-05B
WMCD-01C
WMCB-08A
WMCB-09A
WMCB-07B
WMCB-05A
WMCB-04B
WMCB-06B
Circuit Breaker Kit
Pull Disconnect Kit
Circuit Breaker
Circuit Breaker
Circuit Breaker
Circuit Breaker
Circuit Breaker
Circuit Breaker
Manual 2100-218
Page 20
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X
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X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
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