WALL MOUNTED PACKAGED AIR CONDITIONER …E).pdf · air conditioner installation instructions note...

Manual 2100-451E of 24

Manual No.: 2100-451ESupersedes: 2100-451DFile: Volume III, Tab 16Date: 09-02-08

Bard Manufacturing Company, Inc.Bryan, Ohio 43506

Since 1914...Moving ahead, just as planned.

Models: WA3S1WA4S1WA5S1

WALL MOUNTED PACKAGEDAIR CONDITIONER

INSTALLATIONINSTRUCTIONS

NOTETHIS IS AN R-410A

HIGH PRESSURE

REFRIGERANT SYSTEM


CONTENTS

Figures

Figure 1 Unit Dimensions ..................................... 5Figure 2 Mounting Instructions ............................. 9Figure 3 Wall-Mounting Instructions .................. 10Figure 4 Wall-Mounting Instructions .................. 10Figure 5 Common Wall-Mounting Instructions ....11Figure 6 Electric Heat Clearance ....................... 12Figure 7 Low Voltage Wiring .............................. 13Figure 8 Start-Up Label ...................................... 15Figure 9 Fan Blade Setting ................................ 18Figure 10 Control Disassembly ............................ 22Figure 11 Winding Test ........................................ 22Figure 12 Drip Loop ............................................. 22

Getting Other Information and PublicationsFor more information contact these publishers ........ 3

Wall Mount General InformationAir Conditioner Wall Mount Model Nomenclature .... 4Shipping Damage .................................................... 7General ............................................................... 7Duct Work ............................................................... 7Filters ............................................................... 7Condensate Drain .................................................... 7

Installation InstructionsWall Mounting Information ....................................... 8Mounting the Unit .................................................... 8Typical Installations ................................................. 8Wiring – Main Power ....................................... 8 & 9Wiring – Low Voltage Wiring ............................... 12

Start UpGeneral ............................................................. 14Topping Off System Charge................................... 14Safety Practices ..................................................... 14Important Installer Note ......................................... 15Crankcase Heaters ................................................ 15High & Low Pressure Switch ................................. 15Three Phase Scroll Compressor Start UpInformation ............................................................. 15Service Hints ......................................................... 16Sequence of Operation .......................................... 16Blower Time Delay Disable .................................... 16Compressor Control Module .................................. 16Adjustments ........................................................... 17Phase Monitor ....................................................... 17Motor Start Device ................................................. 17Pressure Service Ports .......................................... 17

TroubleshootingCompressor Solenoid ............................................ 18Fan Blade Setting Dimensions .............................. 18Removal of Fan Shroud ......................................... 18R-410A Refrigerant Charge ................................... 19Pressure Chart ...................................................... 22GE ECM™Motors ................................................... 21GE ECM™Motors ................................................... 22Optional Accessories ............................................. 24

TablesTable 1 Electric Heat Table ................................. 4Table 2 Dimensions of Basic Unit ....................... 5Table 3 Electrical Specifications ......................... 6Table 4 Operating Voltage Range .................... 12Table 5 Thermostat Wire Size .......................... 12Table 6 Wall Thermostats ................................. 12

Thermostatic Control - Dual Unit .......... 12Table 7 Fan Blade Dimensions ......................... 18Table 8 Liquid Line Temperatures .................... 19Table 9 Cooling Pressure ................................. 20Table 10 Indoor Blower Performance ................. 23Table 11 Maximum ESP of Operation

Electric Heat Only ................................ 23Table 12 Optional Accessories ........................... 24


Getting Other Information and Publications

These publications can help you install the air conditioneror heat pump. You can usually find these at your locallibrary or purchase them directly from the publisher. Besure to consult current edition of each standard.

National Electrical Code ...................... ANSI/NFPA 70

Standard for the Installation ............... ANSI/NFPA 90Aof Air Conditioning andVentilating Systems

Standard for Warm Air ...................... ANSI/NFPA 90BHeating and AirConditioning Systems

Load Calculation for ....................... ACCA Manual J orResidential Winter and Manual NSummer Air Conditioning

Low Pressure, Low Velocity .......... ACCA Manual D orDuct System Design for Winter Manual Qand Summer Air Conditioning

FOR MORE INFORMATION, CONTACTTHESE PUBLISHERS:

ACCA Air Conditioning Contractors of America1712 New Hampshire Ave. N.W.Washington, DC 20009Telephone: (202) 483-9370Fax: (202) 234-4721

ANSI American National Standards Institute11 West Street, 13th FloorNew York, NY 10036Telephone: (212) 642-4900Fax: (212) 302-1286

ASHRAE American Society of Heating Refrigerating,and Air Conditioning Engineers, Inc.1791 Tullie Circle, N.E.Atlanta, GA 30329-2305Telephone: (404) 636-8400Fax: (404) 321-5478

NFPA National Fire Protection AssociationBatterymarch ParkP.O. Box 9101Quincy, MA 02269-9901Telephone: (800) 344-3555Fax: (617) 984-7057


WALL MOUNT GENERAL INFORMATIONAIR CONDITIONER WALL MOUNT MODEL NOMENCLATURE

WA 4S 1 – B 09 B P X X X X

TABLE 1ELECTRIC HEAT TABLE

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)1(V042tA )1(V802tA )2(V084tA )2(V064tA

wK spmAhP-1 spmAhP-3 hutB wK spmAhP-1 spmAhP-3 hutB wK spmAhP-3 hutB wK spmAhP-3 hutB

0.5 0.5 8.02 560,71 57.3 0.81 997,210.6 0.6 4.41 874,02 05.4 5.21 953,51 0.6 2.7 874,02 25.5 9.6 048,810.8 0.8 3.33 403,72 00.6 8.82 874,020.9 0.9 7.12 717,03 57.6 7.81 830,32 0.9 8.01 717,03 82.8 4.01 062,820.01 0.01 7.14 031,43 05.7 1.63 895,520.51 0.51 5.26 1.63 591,15 52.11 1.45 2.13 693,83 0.51 0.81 591,15 8.31 3.71 990,740.02 0.02 3.38 062,86 00.51 1.27 591,15

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See Table 3 for Heater Availability by Model

VOLTS & PHASEA – 230/208-1B – 230/208/60-3C – 460/60-3

KW0Z – No KW

w/Circuit Breakeror Pull Disconnect

05 – 5 KW06 – 6 KW08 – 8 KW09 – 9 KW10 – 10 KW15 – 15 KW20 – 20 KW

VENTILATION OPTIONSB – Blank-off Plate (Standard)V – Commercial Room Ventilator -

Motorized with Exhaust(3-Position)

E – Economizer (Internal) - FullyModulating with Exhaust

R – Energy Recovery Ventilator -with Exhaust

COLOR OPTIONSX – Beige

(Standard)4 – Buckeye Gray5 – Desert Brown8 – Dark Bronze

OUTLET OPTIONSX – Front (Standard)

COIL OPTIONSX – Standard

CONTROL MODULES

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

MODEL NUMBER

CAPACITY3S – 3 Ton4S – 4 Ton5S – 5 Ton

REVISION

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SHIPPING DAMAGEUpon receipt of equipment, the carton should be checkedfor external signs of shipping damage. If damage isfound, the receiving party must contact the last carrierimmediately, preferably in writing, requesting inspectionby the carrier’s agent.

GENERALThe equipment covered in this manual is to be installedby trained, experienced service and installationtechnicians.

The refrigerant system is completely assembled andcharged. All internal wiring is complete.

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

These instructions explain the recommended method toinstall the air cooled self-contained unit and theelectrical wiring connections to the unit.

These instructions and any instructions packaged withany separate equipment required to make up the entireair conditioning system should be carefully read beforebeginning the installation. Note particularly “StartingProcedure” and any tags and/or labels attached to theequipment.

While these instructions are intended as a generalrecommended guide, they do not supersede any nationaland/or local codes in any way. Authorities havingjurisdiction should be consulted before the installation ismade. See Page 3 for information on codes andstandards.

Size of unit for a proposed installation should be basedon heat loss calculation made according to methods ofAir Conditioning Contractors of America (ACCA). Theair duct should be installed in accordance with theStandards of the National Fire Protection Association forthe Installation of Air Conditioning and VentilatingSystems of Other Than Residence Type, NFPA No.90A, and Residence Type Warm Air Heating and AirConditioning Systems, NFPA No. 90B. Where localregulations are at a variance with instructions, installershould adhere to local codes.

DUCT WORK

All duct work, supply and return, must be properly sizedfor the design air flow requirement of the equipment.Air Conditioning Contractors of America (ACCA) is anexcellent guide to proper sizing. All duct work orportions thereof not in the conditioned space should beproperly insulated in order to both conserve energy andprevent condensation or moisture damage.

Refer to Table 9 for maximum static pressure availablefor duct design.

Design the duct work according to methods given by theAir Conditioning Contractors of America (ACCA).When duct runs through unheated spaces, it should beinsulated with a minimum of 1-inch of insulation. Useinsulation with a vapor barrier on the outside of theinsulation. Flexible joints should be used to connect theduct work to the equipment in order to keep the noisetransmission to a minimum.

A 1/4 inch clearance to combustible material for the firstthree feet of duct attached to the outlet air frame isrequired. See Wall Mounting Instructions and Figures 3and 4 for further details.

Ducts through the walls must be insulated and all jointstaped or sealed to prevent air or moisture entering thewall cavity.

Any grille that meets the 5/8 inch louver criteria, may beused. It is recommended that Bard Return Air Grille KitRG-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 ofsufficient size to allow a maximum velocity of 400 fpm.

NOTE: If no return air duct is used, applicableinstallation codes may limit this cabinet toinstallation only in a single story structure.

FILTERSA 2-inch pleated filter is supplied with each unit. Thefilter slides into position making it easy to service. Thisfilter can be serviced from the outside by removing theservice door. The internal filter brackets are adjustableto accommodate the 1-inch filter by bending up the tabsto allow spacing for the 1-inch filters.

CONDENSATE DRAINA plastic drain hose extends from the drain pan at the topof the unit down to the unit base. There are openings inthe unit base for the drain hose to pass through. In theevent the drain hose is connected to a drain system ofsome type, it must be an open or vented type system toassure proper drainage.

CAUTIONSome installations may not require any returnair duct. A return air grille is required withinstallations not requiring a return air duct.The spacing between louvers on the grilleshall not be larger than 5/8 inches.


WALL MOUNTING INFORMATION1. 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 mustbe strong and rigid enough to carry the weight of theunit without transmitting any unit vibration. SeeFigures 4 and 5.

INSTALLATION INSTRUCTIONS

3. Concrete block walls must be thoroughly inspectedto insure that they are capable of carrying the weightof the installing unit. See Figure 4.

MOUNTING THE UNIT1. These units are secured by wall mounting brackets

which secure the unit to the outside wall surface atboth sides. A bottom mounting bracket is providedfor ease of installation.

2. The unit itself is suitable for “0” inch clearance, butthe supply air duct flange and the first 3 feet ofsupply air duct require a minimum of 1/4 inchclearance to combustible material. If a combustiblewall, use a minimum of 30-1/2" x 10-1/2"dimensions for sizing. However, it is generallyrecommended that a 1-inch clearance is used for easeof installation and maintaining the requiredclearance to combustible material. The supply airopening would then be 32" x 12". See Figures 2, 3and 6 for details.

3. Locate and mark lag bolt locations and bottommounting bracket location. See Figure 4.

4. Mount bottom mounting bracket.

5. Hook top rain flashing under back bend of top. Toprain flashing is shipped secured to the right side ofthe back.

6. Position unit in opening and secure with 5/16 lagbolts; use 7/8 inch diameter flat washers on the lagbolts.

7. Secure rain flashing to wall and caulk across entirelength of top. See Figure 2.

8. For additional mounting rigidity, the return air andsupply air frames or collars can be drilled andscrewed or welded to the structural wall itself(depending upon wall construction). Be sure toobserve required clearance if combustible wall.

9. On side-by-side installations, maintain a minimumof 20 inches clearance on right side to allow accessto heat strips and control panel and to allow properairflow to the outdoor coil. Additional clearancemay be required to meet local or national codes.

TYPICAL INSTALLATIONSSee Figure 5 for common ways to install the wall mountunit.

WIRING — MAIN POWERRefer to the unit rating plate for wire sizing informationand maximum fuse or “HACR” type circuit breaker size.Each outdoor unit is marked with a “Minimum CircuitAmpacity”. This means that the field wiring used mustbe sized to carry that amount of current. Depending onthe installed KW of electric heat, there may be two fieldpower circuits required. If this is the case, the unit serialplate will so indicate. All models are suitable only forconnection with copper wire. Each unit and/or wiringdiagram will be marked “Use Copper Conductors Only”.These instructions must be adhered to. Refer to theNational Electrical Code (NEC) for complete currentcarrying capacity data on the various insulation gradesof wiring material. All wiring must conform to NECand all local codes.

The electrical data lists fuse and wire sizes (75ºCcopper) for all models, including the most commonlyused heater sizes. Also shown are the number of fieldpower circuits required for the various models withheaters.

WARNINGFire hazard can result if 1/4 inch clearance tocombustible materials for supply air duct isnot maintained. See Figure 3.

WARNINGFailure to provide the 1/4 inch clearancebetween the supply duct and a combustiblesurface for the first 3 feet of duct can result infire.


FIGURE 2MOUNTING INSTRUCTIONS

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

The disconnect access door on this unit may be locked toprevent unauthorized access to the disconnect.

To convert for the locking capability, bend the tablocated in the bottom left hand corner of the disconnectopening 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 inthe tab preventing entry.

See Start-up section for information on three phasescroll compressor start-ups.

NOTE: It is recommended that a bead of siliconecaulking be placed behind the side mountingflanges and under the top flashing at thetime of installation.


FIGURE 4WALL-MOUNTING INSTRUCTIONS

FIGURE 3WALL-MOUNTING INSTRUCTIONS

SEE FIGURE 3 — MOUNTING INSTRUCTIONS

SEE UNIT DIMENSIONS, FIGURE 1,FOR ACTUAL DIMENSIONS

SEE FIGURE 1 FORDUCT DIMENSIONS


FIGURE 5COMMON WALL-MOUNTING INSTALLATIONS


NOTE:The voltage should be measured at the fieldpower 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 the24V terminal board in the unit. An eight conductor, 18 gaugecopper, color-coded thermostat cable is recommended. Theconnection points are shown in Figure 7.

WIRING — LOW VOLTAGE WIRING230/208V, 1 phase and 3 phase equipment dual primaryvoltage transformers. All equipment leaves the factorywired on 240V tap. For 208V operation, reconnect from240V to 208V tap. The acceptable operating voltage rangefor the 240 and 208V taps are shown in Table 4 below.

TABLE 6WALL THERMOSTATS

TABLE 5THERMOSTAT WIRE SIZE

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060-3048)544-0211(

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TABLE 4OPERATING VOLTAGE RANGE

PAT EGNAR

V042 612-352

V802 781-022

FIGURE 6ELECTRIC HEAT CLEARANCE

Side section view of supply air duct forwall mounted unit showing 1/4 inchclearance to combustible surfaces.

WARNING• A minimum of 1/4 inch clearance must be

maintained between the supply air duct andcombustible materials. This is required for thefirst 3 feet of ducting.

• It is important to insure that the 1/4 inchminimum spacing is maintained at all points.

• Failure to do this could result in overheating thecombustible material and may result in fire.


FIGURE 7LOW VOLTAGE WIRING


START UPThese units require R-410A refrigerant and polyolesteroil.

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 withliquid refrigerant.

6. R-410A operates at 40-70% higher pressure thanR-22, and systems designed for R-22 cannotwithstand this higher pressure.

7. R-410A has an ozone depletion potential of zero,but must be reclaimed due to its global warmingpotential.

8. R-410A compressors use polyolester oil.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.11. Limit atmospheric exposure to 15 minutes.12. If compressor removal is necessary, always plugcompressor immediately after removal. Purge withsmall amount of nitrogen when inserting plugs.

TOPPING OFF SYSTEM CHARGEIf a leak has occurred in the system, Bard Manufacturingrecommends reclaiming, evacuating (see criteria above),and charging to the nameplate charge. Topping off thesystem charge can be done without problems.With R-410A, there are no significant changes in therefrigerant composition during multiple leaks andrecharges. R-410A refrigerant is close to being anazeotropic blend (it behaves like a pure compound orsingle component refrigerant). The remaining refrigerantcharge, in the system, may be used after leaks haveoccurred and then “top-off” the charge by utilizing thecharging charts on the inner control panel cover as aguideline.REMEMBER: When adding R-410A refrigerant, it mustcome out of the charging cylinder/tank as a liquid toavoid any fractionation, and to insure optimal systemperformance. Refer to instructions for the cylinder thatis being utilized for proper method of liquid extraction.

SAFETY PRACTICES:1. Never mix R-410A with other refrigerants.2. Use gloves and safety glasses, polyolester oils can

be irritating to the skin, and liquid refrigerant willfreeze the skin.

3. Never use air and R-410A to leak check; themixture may become flammable.

4. Do not inhale R-410A – the vapor attacks thenervous system, creating dizziness, loss ofcoordination and slurred speech. Cardiacirregularities, unconsciousness and ultimate deathcan result from breathing this concentration.

5. Do not burn R-410A. This decompositionproduces hazardous vapors. Evacuate the area ifexposed.

6. Use only cylinders rated DOT4BA/4BW 400.7. Never fill cylinders over 80% of total capacity.8. Store cylinders in a cool area, out of direct

sunlight.9. Never heat cylinders above 125°F.10. Never trap liquid R-410A in manifold sets, gauge

lines or cylinders. R-410A expands significantlyat warmer temperatures. Once a cylinder or line isfull of liquid, any further rise in temperature willcause it to burst.


START UP CONTINUED

IMPORTANT INSTALLER NOTEFor improved start-up performance, wash the indoor coilwith a dishwasher detergent.

CRANKCASE HEATERSAll units covered in this manual are provided withcompressor crankcase heat.

This crankcase heater is a band type heater locatedaround the bottom of the compressor. This heater iscontrolled by the crankcase heater relay. The heater isonly energized when the compressor is not running.

Crankcase heat is essential to prevent liquid refrigerantfrom migrating to the compressor, preventing oil pumpout on compressor start-up and possible bearing or scrollvane failure due to compressing a liquid.

The decal in Figure 8 is affixed to all model unitsdetailing start-up procedure. This is very important.Please read carefully.

HIGH & LOW PRESSURE SWITCHAll models covered by this Manual are supplied with aremote reset high pressure switch and low pressureswitch. If tripped, this pressure switch may be reset byturning the thermostat off then back on again.

THREE PHASE SCROLL COMPRESSORSTART UP INFORMATIONScroll compressors, like several other types ofcompressors, will only compress in one rotationaldirection. Direction of rotation is not an issue withsingle phase compressors since they will always startand run in the proper direction.

However, three phase compressors will rotate in eitherdirection depending upon phasing of the power. Sincethere is a 50-50 chance of connecting power in such away as to cause rotation in the reverse direction,verification of proper rotation must be made. All threephase units incorporate a phase monitor to ensure properfield wiring. See the “Phase Monitor” section later inthis manual.

Verification of proper rotation must be made any time acompressor is change or rewired. If improper rotation iscorrected at this time there will be no negative impact onthe durability of the compressor. However, reverseoperation for over one hour may have a negative impacton the bearing due to oil pump out.

NOTE:If compressor is allowed to run in reverserotation for several minutes, thecompressor's internal protector will trip.

All three phase ZPS compressors are wired identicallyinternally. As a result, once the correct phasing isdetermined for a specific system or installation,connecting properly phased power leads to the sameFusite terminal should maintain proper rotationdirection.

Verification of proper rotation direction is made byobserving that suction pressure drops and dischargepressure rises when the compressor is energized.Reverse rotation also results in an elevated sound levelover that with correct rotations, as well as, substantiallyreduced current draw compared to tabulated values.

The direction of rotation of the compressor may bechanged by reversing any two line connections to theunit.

IMPORTANTThese procedures must be followed atinitial start-up and at any time powerhas been removed for 12 hours orlonger.To prevent compressor damage which mayresult from the presence of liquidrefrigerant in the compressor crankcase.

1. Make certain the room thermostat is inthe "off" position (the compressor isnot to operate).

2. Apply power by closing the systemdisconnect switch. This energizes thecompressor heater which evaporatesthe liquid refrigerant in the crankcase.

3. Allow 4 hours or 60 minutes per poundof refrigerant in the system as notedon the unit rating plate, whichever isgreater.

4. After properly elapsed time, thethermostat may be set to operate thecompressor.

5. Except as required for safety whileservicing – Do not open systemdisconnect switch.

7961-061

See “Phase Monitor”, Page 17.

FIGURE 8START-UP LABEL


COMPRESSOR CONTROL MODULEThe compressor control module is standard on the modelscovered by this manual. The compressor control is ananti-short cycle/lockout timer with high and low pressureswitch monitoring and alarm relay output.

Adjustable Delay On Make And Break TimerOn initial power up or anytime power is interrupted to theunit, the delay on make period begins, which will be 2minutes plus 10% of the delay on break setting. Whenthe delay on make is complete and the high pressure andlow pressure switches are closed, the compressorcontactor is energized. Upon shutdown the delay orbreak timer starts and prevents restart until the delay onbreak and delay on make periods have expired.During routine operation of the unit with no powerinterruptions, the compressor will operate on demandwith no delay.

High Pressure Switch and Lockout SequenceIf the high pressure switch opens, the compressorcontactor will de-energize immediately. The lockouttimer will go into a soft lockout and stay in soft lockoutuntil the high pressure switch closes and the delay onbreak time has expired. If the high pressure switchopens again in this same operating cycle, the unit will gointo manual lockout condition and the alarm relay circuitwill energize. Recycling the wall thermostat resets themanual lockout.

Low Pressure Switch, Bypass and Lockout SequenceIf the low pressure switch opens for more than 120seconds, the compressor contactor will de-energize andgo into a soft lockout. Regardless the state of the lowpressure switch, the contactor will reenergize after thedelay on make time delay has expired. If the lowpressure switch remains open, or opens again for longerthan 120 seconds the unit will go into manual lockoutcondition and the alarm relay circuit will energize.Recycling the wall thermostat resets the manual lockout.

Optional Low Ambient ControlAn optional low ambient control is available for bothfactory and field installed options. The low ambientcontrol is to be applied to the WA3S/WA4S/WA5Smodels when operation below 50°outdoor conditions areanticipated. Without this device, the evaporating pressurewould fall off, and the indoor coil would ice over.The fan cycling control cycles the fan motor on, once theliquid refrigerant pressure reaches 350 psig, and off, onceit has dropped to 225 psig. It will continue to cyclebetween these parameters depending on outdoortemperatures and the load/stage of the system.This cycling maintains a minimum liquid pressureaffecting the minimum suction pressure. This effectinsures an evaporating temperature that is slightly abovethe point of ice formation on the evaporator.

SERVICE HINTS1. Maintain clean air filters at all times. Also, do not close

off or block supply and return air registers. This reducesair flow through the system, which shortens equipmentservice life as well as increasing operating costs.

2. Check all power fuses or circuit breakers to be sure theyare the correct rating.

3. Periodic cleaning of the outdoor coil to permit full andunrestricted airflow circulation is essential.Frequency of coil cleaning will depend on duty cycle ofequipment, type of use and installation site variables.Telecommunication type installations in high trafficareas or in areas none too frequent to airborne debris,will require more frequent coil maintenance than thosein areas not subject to those conditions.

SEQUENCE OF OPERATIONNON-ECONOMIZERStage 1 (Y1) cooling call activates Step 1 (partialcapacity, 66%) of compressor capacity.Stage 2 (Y2) cooling call activates Step 2 (full capacity,100%) of compressor capacity.

WITH ECONOMIZERStage 1 (Y1) cooling call goes to economizer controls fordecision:

- If Enthalpy Control decides outdoor conditionsare suitable for free cooling, the economizer willoperate.

• If Stage 2 cooling call is issued duringeconomizer operation, the economizer willclose and the compressor will go straight toStep 2 full capacity operation.

- If Enthalpy Control decides outdoor conditionsare not suitable for free cooling, the economizerwill not operate (or close) and Step 1 of thecompressor will operate.

• If Stage 2 cooling call is issued, thecompressor will shift to Step 2 full coolingcapacity operation.

BLOWER TIME DELAY DISABLEIn certain applications, there is a requirement/desire todisable the blower one-minute delay (where blower runsfor 1 minute after thermostat has satisfied). This could bein a situation that has requirements for fire dampers, orjust otherwise desirable.To disable the blower time delay on the WA*S models, itcan be done by simply disconnecting a single wire at theCompressor Control Module (CCM). Disconnect powerto the unit, remove both the inner and outer control panelcovers, locate the CCM (left side of control panel abovelow voltage box). Next, locate the “gray” wire attached tothe “R” terminal of the CCM. Remove the “gray” wireand tape the end off.Reverse the steps installing the inner and outer controlpanel covers, and turn the power back on.


PHASE MONITORAll units with three phase scroll compressors areequipped with a 3-phase line monitor to preventcompressor damage due to phase reversal.

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

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

If a fault condition occurs, reverse two of the supplyleads to the unit. Do not reverse any of the unit factorywires as damage may occur.

MOTOR START DEVICESingle Phase (-A) model compressor circuits areequipped with a 25 ohm PTCR (Positive TemperatureCoefficient Resistor) motor starting device as standardequipment.

The PTCR is wired in parallel with the run capacitor.When voltage is applied, and device is cool, its lowresistance permits a large current to flow in the auxiliarywindings - increasing the motors available startingtorque. The device then rapidly heats up, and the currentlevels drop to a few milliamperes. The PTCR thenbecomes self-regulating, passing just enough current tomaintain its temperature to remain in the high resistancestate. Once the voltage source is removed, the devicethen cools down and the resistance drops, and is thenready for the next compressor start cycle.

PRESSURE SERVICE PORTSHigh and low pressure service ports are installed on allunits so that the system operating pressures can beobserved. Pressure tables can be found later in themanual covering all models. It is imperative to matchthe correct pressure table to the unit by model number.

Be careful to observe whether unit is operating in highcool or low cool when utilizing the charts.

Alarm Relay Output

Alarm terminal is output connection for applicationswhere alarm relay is employed. This terminal ispowered whenever compressor is locked out due to HPCor LPC sequences as described.

NOTE: Both high and low pressure switch controlsare inherently automatic reset devices. Thehigh pressure switch and low pressureswitch cut out and cut in settings are fixed byspecific air conditioner or heat pump unitmodel. The lockout features, both soft andmanual, are a function of the CompressorControl Module.

ADJUSTMENTS

Adjustable Delay on Make and Delay on BreakTimer

The potentiometer is used to select Delay on Break timefrom 30 seconds to 5 minutes. Delay on Make (DOM)timing on power-up and after power interruptions isequal to 2 minutes plus 10% of Delay on Break (DOB)setting:

0.5 minute (30 seconds) DOB =123 second DOM1.0 minute (60 seconds) DOB =126 second DOM2.0 minute (120 seconds) DOB =132 second DOM3.0 minute (180 seconds) DOB =138 second DOM4.0 minute (240 seconds) DOB =144 second DOM5.0 minute (300 seconds) DOB =150 second DOM

During routine operation of the unit with no powerinterruptions the compressor will operate on demandwith 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


FAN BLADE SETTING DIMENSIONSShown in the drawing below are the correct fan bladesetting dimensions for proper air delivery across theoutdoor coil. See Figure 9

Any service work requiring removal or adjustment in thefan and/or motor area will require that the dimensionsbelow be checked and blade adjusted in or out on themotor shaft accordingly. See Table 7.

TROUBLESHOOTINGCOMPRESSOR SOLENOID(See Sequence of Operation on Page 16 for function.) Anominal 24-volt direct current coil activates the internalcompressor solenoid. The input control circuit voltagemust be 18 to 28 volt ac. The coil power requirement is20 VA. The external electrical connection is made witha molded plug assembly. This plug contains a full waverectifier to supply direct current to the unloader coil.

Compressor Solenoid Test Procedure If it issuspected that the unloader is not working, the followingmethods may be used to verify operation.

1. Operate the system and measure compressoramperage. Cycle the compressor solenoid on and offat ten-second intervals. The compressor amperageshould go up or down at least 25 percent.

2. If step one does not give the expected results, shutunit off. Apply 18 to 28 volt ac to the solenoidmolded plug leads and listen for a click as thesolenoid pulls in. Remove power and listen foranother click as the solenoid returns to its originalposition.

3. If clicks can’t be heard, shut off power and removethe control circuit molded plug from the compressorand measure the solenoid coil resistance. Theresistance should be 32 to 60 ohms depending oncompressor temperature.

4. Next, check the molded plug.

Voltage check: Apply control voltage to the plug wires (18to 28 volt ac). The measured dc voltage at the femaleconnectors in the plug should be around 15 to 27 vdc.

Resistance check: Measure the resistance from the end ofone molded plug lead to either of the two female connectorsin the plug. One of the connectors should read close to zeroohms, while the other should read infinity. Repeat withother wire. The same female connector as before shouldread zero, while the other connector again reads infinity.Reverse polarity on the ohmmeter leads and repeat. Thefemale connector that read infinity previously should nowread close to zero ohms.

Replace plug if either of these test methods does notshow the desired results.

FIGURE 9FAN BLADE SETTING

REMOVAL OF FAN SHROUD1. 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.

TABLE 7FAN BLADE DIMENSIONS

ledoM AnoisnemiD

1S3AW1S4AW1S5AW

"57.1

"A"

AIRFLOW

MIS-1724


TROUBLESHOOTING CONT’D.

R-410AREFRIGERANT CHARGEThe correct system R-410A charge is shown on the unitrating plate. Optimum unit performance will occur witha refrigerant charge resulting in a liquid line temperature(the cooling expansion device) as shown in Table 8 orby pressures as shown in Table 9 (Page 22).

The liquid line temperatures in Table 8 are based upon80ºF dry bulb / 67ºF wet bulb (50 percent R.H.)temperature and rated airflow across the evaporatorduring cooling cycle running in Stage 2 cooling.

TABLE 8LIQUID LINE TEMPERATURE

sledoMdetaRwolfriA

F°59.pmeTDO

F°28.pmeTDO

1S3AW 001,1 79-59 58-38

1S4AW 005,1 79-59 48-28

1S5AW 007,1 99-79 78-58


TABLE 9COOLING PRESSURE – (ALL TEMPERATURES °F)

Low side pressure ± 2 psigHigh side pressure ± 5 psig

GNILOOCYTICAPACHGIH FEERGEDLIOCROODTUOGNIRETNEERUTAREPMETRIA

LEDOM RIANRUTERERUTAREPMET ERUSSERP 05 oF 55 oF 06 oF 56 oF 07 oF 57 oF 08 oF 58 oF 09 oF 59 oF 001 oF 501 oF 011 oF 511 oF

1S3AW

BD°57BW°26

EDISWOLEDISHGIH

211591

511412

911332

221352

621272

921192

131413

231733

431063

531383

631904

831534

931164

041784

BD°08BW°76

EDISWOLEDISHGIH

421102

721022

131932

431952

831872

141792

241913

441143

541363

641583

841314

941044

151864

251594

BD°58BW°27

EDISWOLEDISHGIH

531502

831422

241342

541362

941282

251103

451623

651053

751573

951993

161524

261154

461674

561205

1S4AW

BD°57BW°26

EDISWOLEDISHGIH

711791

911612

121532

321552

521472

721392

821613

031933

131163

231383

331014

531834

631664

731494

BD°08BW°76

EDISWOLEDISHGIH

721102

921022

131932

431952

631872

831892

831813

931143

931463

041883

241514

441344

641174

941005

BD°58BW°27

EDISWOLEDISHGIH

141302

341322

541342

841362

051382

251303

251623

351943

351273

451693

651224

851944

061874

261805

1S5AW

BD°57BW°26

EDISWOLEDISHGIH

811991

911712

021632

221062

321582

521903

621333

821753

921183

031504

231234

331064

531784

631415

BD°08BW°76

EDISWOLEDISHGIH

921502

031422

131742

131072

231292

231513

431933

731363

931783

141114

341834

541564

641294

841915

BD°58BW°27

EDISWOLEDISHGIH

731612

931732

041852

141972

241003

341123

641643

841073

151593

351914

551744

751474

851205

061925

GNILOOCYTICAPACWOL FEERGEDLIOCROODTUOGNIRETNEERUTAREPMETRIA

LEDOMRIANRUTER

ERUTAREPMET ERUSSERP 05 oF 55 oF 06 oF 56 oF 07 oF 57 oF 08 oF 58 oF 09 oF 59 oF 001 oF 501 oF 011 oF 511 oF

1S3AW

BD°57BW°26

EDISWOLEDISHGIH

621181

721891

921512

031332

231052

331762

531982

631013

831233

931353

141873

441404

641924

841454

BD°08BW°76

EDISWOLEDISHGIH

731481

831102

931812

141632

241352

341072

541192

741213

941333

151453

351083

551604

651234

851854

BD°58BW°27

EDISWOLEDISHGIH

351091

451702

551422

651142

751852

851572

061792

261813

361043

561163

761783

861314

071834

171464

1S4AW

BD°57BW°26

EDISWOLEDISHGIH

221481

421102

521812

721632

921452

131272

131192

231213

331533

431953

531183

731704

931534

141364

BD°08BW°76

EDISWOLEDISHGIH

231581

431302

631122

831932

041752

241572

541892

641713

741933

841263

941483

051014

151834

251764

BD°58BW°27

EDISWOLEDISHGIH

541781

741502

941322

251142

451952

651872

651793

751913

851343

951963

161093

361514

461344

561274

1S5AW

BD°57BW°26

EDISWOLEDISHGIH

321781

521702

721622

921542

131362

331282

431503

531823

631053

731373

931993

141524

341154

541774

BD°08BW°76

EDISWOLEDISHGIH

431291

631112

831032

931842

141762

341682

541803

741133

941353

151573

351204

551924

651654

851384

BD°58BW°27

EDISWOLEDISHGIH

641002

841712

941532

151252

251072

451782

651113

951533

161853

361283

561804

661434

861064

961684


TROUBLESHOOTING GE ECM™ MOTORSCAUTION:Disconnect power from unit before removing or replacingconnectors, or servicing motor. To avoid electric shockfrom the motor’s capacitors, disconnect power and wait atleast 5 minutes before opening motor.Symptom Cause/ProcedureMotor rocks slightly • This is normal start-up for ECMwhen starting

Motor won’t start • Check blower turns by hand• No movement • 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, • Check for loose or compliant motor mount but won’t start • Make sure blower wheel is tight on shaft

• Perform motor/control replacement check

Motor oscillates up • It is normal for motor to oscillate with no load& down while being on shafttested off of blower

Motor starts, butruns erratically• Varies up and down • Check line voltage for variation or “sag” or intermittent • 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

• “Hunts” or “puffs” at • Does removing panel or filter reduce high CFM (speed) “puffing”?

- Reduce restriction - Reduce max airflow

• Stays at low CFM • Check low voltage (Thermostat) wires and despite system call connections for cool or heat CFM • 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

• Blower won’t shut off • Current leakage from controls into G, Y or W? Check for Triac switched thermostat or solid- state relay

Excessive noise • Determine if it’s air noise, cabinet, duct or motor noise; interview customer, if necessary

• Air noise • 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

Symptom Cause/Procedure• 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

• “Hunts” or “puffs” at • Does removing panel or filter reduce high CFM (speed) “puffing”?

- Reduce restriction - Reduce max. airflow

Evidence of Moisture• Motor failure or • Replace motor and Perform Moisture Check malfunction has occurred and moisture is present

• Evidence of moisture • Perform Moisture Check present inside air mover

Do Don’t• Check out motor, controls, • Automatically assume the motor is bad. wiring and connections thoroughly before replacing motor• Orient connectors down so • Locate connectors above 7 and 4 o’clock water can’t get in positions - Install “drip loops”• Use authorized motor and • Replace one motor or control model # with model #’s for replacement another (unless an authorized replacement)• Keep static pressure to a • Use high pressure drop filters some have ½" minimum: H20 drop! - Recommend high • Use restricted returns efficiency, low static filters - Recommend keeping filters clean. - Design ductwork for min. static, max. comfort - Look for and recommend ductwork improvement, where necessary

• Size the equipment wisely • Oversize system, then compensate with low airflow

• Check orientation before • Plug in power connector backwards inserting motor connectors • Force plugs

Moisture Check• 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.

Motor

Motor OK whenR > 100k ohm

ECM 2.0

Only removeHex Head Bolts

Connector OrientationBetween 4 and 8 o'clock

Drip Loop

Back ofControl

Figure 5

Winding TestFigure 4

Note: Use the shorter bolts and alignment pin supplied when replacing an ECM 2.0 control.

Figure 3

ECM 2.3/2.5

Power Connector(5-pin)

Control Connector(16-pin)

Hex-head Screws

Motor Connector(3-pin)

Motor Connector(3-pin)

Control Disassembly

Drip Loop

Push untilLatch SeatsOver Ramp

From Motor

CircuitBoard

Replacing ECM Control ModuleTo replace the control module for the GE variable-speed indoor blower motoryou need to take the following steps:

1. You MUST have the correct replacement module. The controls arefactory programmed for specific operating modes. Even though they lookalike, different modules may have completely different functionality.USING THE WRONG CONTROL MODULE VOIDS ALL PRODUCTWARRANTIES AND MAY PRODUCE UNEXPECTED RESULTS.

2. Begin by removing AC power from the furnace or air handler beingserviced. DO NOT WORK ON THE MOTOR WITH AC POWERAPPLIED. To avoid electric shock from the motor’s capacitors, disconnectpower and wait at least 5 minutes before opening motor.

3. It is usually not necessary to remove the motor from the blowerassembly. However, it is recommended that the whole blower assembly, withthe motor, be removed from the furnace/air handler. (Follow themanufacturer’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 controlhousing (at the back end of the control opposite the shaft end). Refer toFigure 10. Remove these two bolts from the motor and control assemblywhile holding the motor in a way that will prevent the motor or controlfrom falling when the bolts are removed. If an ECM2.0 control is beingreplaced (recognized by an aluminum casting rather that a deep-drawnblack 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 themotor endshield but is still connected by a plug and three wires inside thecontrol. Carefully rotate the control to gain access to the plug at thecontrol end of the wires. With thumb and forefinger, reach the latchholding the plug to the control and release it by squeezing the latch taband the opposite side of the connector plug and gently pulling the plug outof the connector socket in the control. DO NOT PULL ON THEWIRES. 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. Referto Figure 11. (Measure to unpainted motor end plate.) If any motor leadfails this test, do not proceed to install the control module. THE MOTORIS DEFECTIVE AND MUST BE REPLACED. Installing the newcontrol 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 THEWRONG CONTROL WILL RESULT IN IMPROPER OR NOBLOWER OPERATION. Orient the control module so that the 3-wiremotor plug can be inserted into the socket in the control. Carefully insertthe plug and press it into the socket until it latches. A SLIGHT CLICKWILL BE HEARD WHEN PROPERLY INSERTED. Finish installingthe replacement control per one of the three following paragraphs, 8a, 8b or 8c.

8a. IF REPLACING AN ECM 2.0 CONTROL (control in castaluminum can with air vents on the back of the can) WITH AN ECM 2.3CONTROL (control containing black potting for water protection inblack deep-drawn steel case with no vents in the bottom of the can), locatethe two through-bolts and plastic tab that are packed with the replacementcontrol. Insert the plastic tab into the slot at the perimeter of the open endof the can so that the pin is located on the inside of the perimeter of thecan. Rotate the can so that the tab inserts into the tab locater hole in theendshield of the motor. Using the two through-bolts provided with thereplacement control, reattach the can to the motor.THE TWO THROUGH-BOLTS PROVIDED WITH THEREPLACEMENT ECM 2.3 CONTROL ARE SHORTER THAN THEBOLTS ORIGINALLY REMOVED FROM THE ECM 2.0CONTROL AND MUST BE USED IF SECURE ATTACHMENT OFTHE CONTROL TO THE MOTOR IS TO BE ACHIEVED.DO NOT OVERTIGHTEN THE BOLTS.

8b. IF REPLACING AN ECM 2.3 CONTROL WITH AN ECM 2.3CONTROL, the plastic tab and shorter through-bolts are not needed. Thecontrol can be oriented in two positions 180° apart. MAKE SURE THEORIENTATION YOU SELECT FOR REPLACING THE CONTROLASSURES THE CONTROL'S CABLE CONNECTORS WILL BELOCATED DOWNWARD IN THE APPLICATION SO THATWATER CANNOT RUN DOWN THE CABLES AND INTO THECONTROL. 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 2.0CONTROL (It is recommended that ECM 2.3 controls be used for allreplacements), the new control must be attached to the motor usingthrough bolts identical to those removed with the original control. DONOT 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 theplug is keyed, OBSERVE THE PROPER ORIENTATION. DO NOTFORCE THE CONNECTOR. It plugs in very easily when properlyoriented. REVERSING THIS PLUG WILL CAUSE IMMEDIATEFAILURE 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 finallocation and orientation.

d.Add a drip loop to the cables so that water cannot enter the motorby draining down the cables. Refer to Figure 12.

The installation is now complete. Reapply the AC power to the HVACequipment and verify that the new motor control module is workingproperly. Follow the manufacturer's procedures for disposition of the oldcontrol module.

Figure 11Figure 10

Figure 12


TABLE 11MAXIMUM ESP OF OPERATION

ELECTRIC HEAT ONLY

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 10INDOOR BLOWER PERFORMANCE 1

ledoM PSEdetaR PSEXAM

2

suounitnoCMFC

3

ts1detaRMFCegatS

4

dn2detaRMFCegatS

5

WK01-5MFC

6

WK02-51MFC

1S3AW 51.0 08.0 008 008 0011 0011 0041

1S4AW 02.0 08.0 528 0011 0051 0011 0051

1S5AW 02.0 08.0 058 0031 0071 0011 0051

taeH-WK 1S3AW 1S4AW 1S5AW

50A-80A-01A-51A-02A-

08.08.08.08.08.

08.08.08.08.08.

08.08.08.08.08.

60B-90B-21B-51B-81B-

08.08.08.08.08.

08.08.08.08.08.

08.08.08.08.08.

60C-90C-21C-51C-81C-

08.08.08.08.08.

08.08.08.08.08.

08.08.08.08.08.


TABLE 12OPTIONAL ACCESSORIES

WA

3S1-

A

WA

3S1-

B

WA

3S1-

C

WA

4S1-

A

WA

4S1-

B

WA

4S1-

C

WA

5S1-

A

WA

5S1-

B

WA

5S1-

C

LEDOM NOITPIRCSED

50A-S4AWHE egakcaPretaeH X X




50A-S5AWHE egakcaPretaeH X




60B-S3AWHE egakcaPretaeH X

60C-S3AWHE egakcaPretaeH X



60B-S5AWHE egakcaPretaeH X X

90B-S5AWHE egakcaPretaeH X X X

51B-S5AWHE egakcaPretaeH X X X


90C-S5AWHE egakcaPretaeH X X

51C-S5AWHE egakcaPretaeH X X X

5-POB )dradnatS(etalPffOknalB X X X X X X X X X

5-PMVRC tsuahxEhtiwrotalitneVmoorssalC )noitisoP-3( X X X X X X X X X

C5-MFIE tsuahxEhtiwrezimonocE X X X X X X X X X

B5A-VREW rotalitneVyrevoceRygrenE X X X X X X

B5C-VREW rotalitneVyrevoceRygrenE X X X

WALL MOUNTED PACKAGED AIR CONDITIONER …E).pdf · air conditioner installation instructions note...

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