INSTALLATION, OPERATION

&

MAINTENANCE MANUAL

WALL MOUNT

AIR CONDITONERS
HEAT PUMPS WCBX-
WHBX SERIES
 INSTALLATION, OPERATION & MAINTENANCE MANUAL
FOR MARC WALL MOUNT AIR CONDITIONERS & HEAT PUMPS
WCBX-WHBX SERIES

GENERAL:

1) IMPORTANT: Check the unit’s nameplate for the hazardous location rating and operating
temperature code. Be sure your location falls within the limits of this rating. Do not install this unit in
a hazardous location not shown on the unit’s nameplate. Do not install this unit in atmospheres
where gases have ignition temperatures lower than that shown on the unit’s nameplate (see
operating temperature code on nameplate).
2) The equipment covered in this manual is to be installed by trained, experienced service and installation
technicians.
3) These units are secured by wall mounting brackets which secure the unit to the outside wall surface at
both sides and at the bottom.
4) On wood frame or steel walls, the wall construction must be strong and rigid enough to carry the weight
of the unit without transmitting any unit vibration. Concrete block walls must be thoroughly inspected to
insure that they are capable of carrying the weight of the installed unit. If the walls are not strong
enough to support the unit, an elevated concrete foundation or steel frame extended from the base of
the building may be used to support the vertical weight of the unit in lieu of the bottom mounting
bracket. The side mounting brackets must still be used and the evaporator drain may need to be re-
routed.
5) All ductwork, supply and return, must be properly sized for the design air flow requirements of the
equipment. All ductwork or portions thereof not in the conditioned space should be properly insulated in
order to both conserve energy and prevent condensation or moisture damage.
6) Some installations may not require return air duct. On this type of installation a filter grille is to be
located in the wall. A duct sleeve should be used as building construction requires.
NOTE: If no return air duct is used, applicable installation codes may limit this unit to installation
only in a single story structure.
7) Most installations, for conditioning one room only, may not require supply air duct. In this case, a supply
air register may be installed over the supply air cut-out in the building wall. A duct sleeve should be
used as building construction requires.
8) WARNING: If the unit is equipped with finned-tubular electric heating elements, do not install air duct to
the unit without first consulting Marc Climatic Controls, Inc.

INSTALLING THE UNIT:

9) Two holes for the supply and return air openings must be cut through the wall. The unit itself is suitable
for “0” inch clearance, however, in units with electric heat the supply air duct flange and the first three
(3) feet of supply air duct require 1 inch clearance to combustible materials.
10) After the wall opening positions have been selected, lay out the position for the bottom and side
brackets. Fasten the brackets securely to the wall (type of fasteners will depend on wall construction).
Note that on some units there are holes provided in the cabinet for location of the
side brackets. Make sure that no screws are driven into the unit sides where they may damage internal
parts. No. 10 x 1/2” sheet metal screws are recommended for sizes 1 through 5 ton. For sizes 7
through 10 ton use No. 14 x 3/4” sheet metal screws.

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11) 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 wall is made of combustible material.
12) Attach the optional fresh air damper assembly (if supplied) to the front lower service panel (cut-out is
provided). Some units may have this damper mounted internally.
13) Install a supply air duct sleeve and register, or ductwork, as required. (See #8 WARNING above.)
14) Install a return air duct sleeve and grille, or ductwork, as required. (See #8 WARNING above.)
15) Ducts through the walls must be sealed to prevent air or moisture from entering the wall cavity.

WIRING THE UNIT:

16) Division 2 units: Most units for Division 2 locations have the controls located inside the cabinet. Power
and low voltage wiring can be run through either side or rear wall of the unit and to terminals located
inside the sheetmetal enclosure. Conduit hubs are provided and can be found inside the controls
compartment. Explosion proof conduit seals are required to be installed at the entrance to the unit when
changing area classifications indoors to outdoors (i.e., Division 2 to general purpose, Division 1 to
Division 2, Group B to Group C, etc.).
17) Division 1 units: Most units for Division 1 locations have the controls in a NEMA 7 enclosure mounted
on an exterior side wall of the unit. Conduit entries are provided in the bottom of this enclosure for
power and control (thermostat) wiring.
Warning: A conduit seal must be installed in each conduit and within 18” (or closer - refer to
enclosure nameplate) of the NEMA 7 controls enclosure. For Group B areas, the seal must be
installed immediately adjacent to the NEMA 7 controls enclosure and with 7 threads engaged.
Conduit seals must be installed in accordance with the seal manufacturer’s instructions and the
National Electrical Code, NFPA 70, article 501, section 501-5.
18) Thermostat: Mount the thermostat on a wall inside the space to be conditioned. Be sure to locate it
near the return air grille and about 5 feet above the floor. Some units are provided with the thermostat
factory installed on the return air grille. Wiring is made easy by a simple plug connector. Open the
return air filter grille and remove the filter. Locate the wiring harness inside the air conditioner return air
plenum and the wiring harness extending from the rear of the grille. Plug the male/female connector
together and lay the excess harness inside the return air plenum. Replace the filter and close the grille.
19) Fuse or Circuit Breaker: Due to momentary high current demand when the air conditioner is started,
the power circuit must be protected with “time delay” type fuses or an “HACR” (for U.S. installations)
type circuit breaker. Refer to the unit nameplate for circuit breaker size.
20) Make “power” and “ground” connections with copper conductors only. Wire in accordance with the
National Electrical Code. Refer to the unit nameplate for the minimum circuit capacity (MCA) for power
wire sizing.
21) NOTE: Some units may have electric heat and there may be two field power circuits required. Refer to
the units nameplate. Some units may be provided with steam heating coils. These are normally factory
installed in the supply air discharge just inside the air conditioner. “Steam in” and “Condensate out”
connections are provided through the side of the unit. A valve and trap must be installed. Other steam
specialties may be required to complete the installation.

OPERATING THE UNIT:

22) Turn the humidistat to the “off” position (if supplied).

24) WARNING: Many units contain a three phase scroll compressor which is designed to operate in one
direction only. If on start-up the compressor makes a lot of noise, it is running backwards. To change
rotation switch any two leads supplying power to the compressor. NOTE: The compressor

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 will fail if allowed to run backwards for an extended period of time. Some units with a scroll
compressor are supplied with a phase reversal monitor. If the outdoor (condenser) fan motor runs
but the compressor does not, stop the unit, switch two leads supplying power to the compressor,
and restart the unit.
25) Make sure the blades of the supply air grille are directed to give even distribution of air throughout the
room. Do not close blade on supply air grille as this will result in reduced air flow and cause icing of the
indoor (evaporator) coil. If finned-tubular electric heating elements are supplied, reduced air flow could
cause nuisance tripping of high limit controls and the possibility of a hazardous condition due to over-
temperature of the elements.
26) WARNING: When using electric finned-tubular heating elements, the room temperature must not
o o
exceed 75 F (24 C)
27) Some units are designed to provide forced ventilation and/or positive pressure to the room. These units
may be provided with adjustable or weighted dampers behind the return air grille. Adjust the damper to
bring in more (or less) outdoor air.
28) WARNING: Do not operate the unit without the top service panel in place as this will reduce the amount
of air needed by the evaporator coil and may cause a hazardous condition if electric heat elements are
provided in the unit.

START-UP / MAINTENANCE CHECK LIST:

29) Won’t Run: If the unit fails to operate: Check to see if the unit is getting power. Turn the unit off at the
disconnect and check the control circuit fuses (see important note below). Check the wiring from the
unit to the controls or thermostat. Check for short circuits. Check for a tripped circuit breaker. Also
check the overload relays (if used).
30) Won’t Cool: If the unit operates, but won’t cool: Check to see if the controls are properly set. Check the
filter and replace if needed. Check the overload relays (if provided) and for loose wires. Check the
fuses. The main disconnect switch, circuit breaker, or switch (if provided) must be switched off before
removing fuses. Important Note: On units rated for a Division 2 hazardous location it is extremely
important to replace blown fuses only with Gould #ATQR, #ATDR, #AJT or Bussmann #LP-CC (1/2
Amp min.). NO OTHER FUSES ARE ALLOWED. These fuses are nonindicating, filled, current-limiting
type. (See fuses in the replacements section.) Also check for refrigerant leaks. Although great care has
been exercised in packaging, occasionally rough handling in shipment can cause a refrigerant line to
break or crack.
31) Won’t Heat: Make checks as above (in Won’t Cool). If unit is furnished with finned-tubular electric
heating elements, reset the manual high limit control.
32) Frosting of Indoor Coil: A dirty filter, or restricted air distribution, in combination with cool, damp
weather could cause frosting of the indoor coil. If the return air filter is clean and the indoor coil frosts
over while cooling, set the thermostat to a higher setting such that the compressor cycles off and only
the indoor blower runs. Keep it running until the ice on the coil is gone. Setting the thermostat to a
slightly warmer position will probably keep it from frosting over again. If the coil still frosts, check for a
low refrigerant charge and refrigerant leaks.
33) Blocked Condenser: Keep weeds, snow, sand, etc. from blocking the air supply and discharge of the
condenser section.

MAINTENANCE INSTRUCTIONS:
34) Cleaning the Cabinet: The complete cabinet, may be cleaned with warm water and mild detergent
only. Check surfaces for signs of corrosion or wear both internally and externally.
35) Lubrication: Some motors require oiling annually. To lubricate, remove the oil plugs on each end of the
motor and put 3 drops of SAE 20 grade non-detergent oil into each hole, then replace the oil plugs. For
those motors with grease fittings, or are permanently lubricated, be sure to follow the motor
manufacturer’s instructions.

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36) Keep Filters Clean: A clogged, dirty filter will reduce the operating efficiency of the unit and contribute
to frosting over of the indoor coil. Replace the filter at the beginning of each season and thereafter as
needed. Inspect the filter at least once a month when the system is in constant operation. Some units
have a filter in the return air grille, some have a filter inside the unit behind the service door, and some
have a filter in the fresh air inlet (if supplied).
37) Fresh Air Inlet Filter: Some units have outdoor air inlets as required for ventilation of the room. Keep
the inlet filter clean and unobstructed so that free ventilation can take place. A dirty filter could reduce
the amount of ventilation in the room and allow toxic or hazardous fumes to accumulate. Inspect and
clean the inlet filter at regular intervals.
38) Keep Coils Clean: Check evaporator and condenser coils for signs of dirt built-up. Coils must be kept
clean to ensure operating efficiency and long unit life. Periodic inspection is a must. Be sure to clean
the evaporator drain pan as well.
39) Keep Evaporator Condensate Drain Clean: Periodically check the condensate drain line to make
sure it is clear of obstructions and is carrying off water.
40) Finned-Tubular Electric Heating Elements: (When supplied) Inspect and clean finned-tubular heating
elements on a regular basis and before each heating season. Some applications such as when a
humidistat is used will require the heating elements to operate in hotter months and regular inspections
are a must.
41) Air Flow Switch: (When supplied) Inspect and test the air flow switch for proper operation on a regular
basis. If electric finned-tubular heating elements are supplied, the air flow switch is used as a safety
device and, upon loss of air flow, will interrupt power to the heating elements. Other applications may
require an air flow switch for alarm on loss of ventilation to the room.
42) Belt Drive Assemblies: (When supplied) Check belts at regular intervals and replace with a “static
conducting” type only. Check alignment of motor and pulleys and tension of belt after initial
thirty (30) minutes of running and thereafter at regular maintenance intervals. Grease ball bearings
at regular intervals (refer to ball bearing lubrication section).
43) Ball Bearing Lubrication: (When supplied) Bearings are factory lubricated, ready for use. Relubricate
(grease) ball bearings at regular intervals. The guide shown herein is a general rule for relubrication.
When relubricating, use a #2 consistency lithium base grease formulated from high quality mineral oil
with rust and oxidation inhibitors. Examples: Shell Alvania #2, Mobil Mobilus #2, Texaco Multifak #2.
When lubricating bearings, add grease slowly while shaft is rotating. When grease appears at the seal
area, the bearing contains the correct amount of lubricant. Bearings should operate at temperatures
less than 93C (200F) and should not exceed 107C (225F) for intermittent operation. (See FIG. 3,
Ball Bearing Lubrication Guide.)
44) Miscellaneous: Check all fittings, screws, nuts, bolts, etc. to make sure they are tight or secure (e.g.,
blower and fan set screws and motor mounts, panel and unit mounting screws, screw covers for
conduit bodies, etc.).
45) NOTE: In some units the outdoor service panels have been weather stripped for purposes of isolation
of interior to exterior. When servicing be sure to inspect the weatherstrip on the panels and repair or
replace as necessary making sure the corners come together to form an air tight seal.

REPLACEMENTS:

46) Motor: A failed motor must be replaced with an identical one from Marc Climatic Controls, Inc. If the air
conditioner or heat pump is designed for a Class I, Division 2 location, the motor is for use in the
Division 2 location and is not a general purpose motor. In some cases, a special thermal cut-out, or
TCO, has been added to the motor windings to insure against over-heating.
47) Compressor: It is important to replace a failed compressor with an identical one from Marc Climatic
Controls, Inc.
48) Compressor Discharge Line Temperature Sensor (CTCO or DLT): (If supplied) If necessary
to remove or replace this device, be sure to replace it in the exact location on the compressor
discharge line and secure with the stainless worm gear clamps.

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49) Selector Switch Contact Block: (If supplied) These contact blocks are rated for use in the hazardous
location and exact replacements are required. DO NOT, under any circumstances, replace them with
general purpose contact blocks.
50) Intrinsically-Safe Relays: (If supplied) These relays are approved for installation in a weatherproof,
Class I, Division 2 location and exact replacements are required. DO NOT substitute for any other
brand or part number unless authorized by Marc Climatic Controls, Inc. Other intrinsically-safe relays
must be placed out of the hazardous location in a safe area, and only the conductors from the
intrinsically-safe side are allowed into the hazardous location. Make sure the intrinsically-safe wires
remain routed away from all other wires. Be sure to replace any partitions which have been installed to
assure this separation.
51) Fuses: The fuses used in units rated for Class I, Division 2 hazardous locations are the non-indicating,
filled, current-limiting type and are allowed for use in Class I, Division 2 hazardous locations. Be sure to
replace blown fuses only with Gould #ATQR, #ATDR, #AJT, or Bussmann #LP-CC (1/2 Amp min.). NO
OTHER FUSES ARE ALLOWED. (For fuse models and sizes, refer to the label inside the controls
compartment.) Do not attempt to by-pass or wire around these fuses as they are required for the safe
operation of the intrinsically-safe relay(s) and other components.

52) Finned-Tubular Electric Heating Element: (When supplied) A failed element must be
replaced with an identical one (or suitable replacement) from Marc Climatic Controls, Inc. DO
NOT Replace with any other substitute. DO NOT add additional heating elements to the unit. A
hazardous condition may result.
53) High Limit Control: (When finned-tubular heating elements are supplied) This item must be replaced
with an identical one from Marc Climatic Controls, Inc. The high limit control must be factory set for the
proper high temperature cut-out so as to maintain safety. Upon installation of the replacement, be sure
to re-install the sensor or bulb in the same exact location as the original. If applicable, check to make
sure the pre-set temperature on the new control is the same as on the original.
54) Air Flow Switch and/or Solid State Relay: (When supplied) For a Division 2 unit, most air flow
switch housings are polypropylene and contain a hermetically-sealed micro switch. This micro
switch is not rated to carry the load to switch a standard relay or contactor and must be used with
a solid state “arc-suppressing” relay. Do not attempt to wire around or use the air flow switch
without this relay. If replacement should become necessary either or both of these items must be
furnished by Marc Climatic Controls, Inc.
55) Grounding It is imperative to assure proper grounding of all components inside the air
conditioner or heat pump. If ground wires are removed during service, they must be reinstalled in
exactly the same manner as originally furnished. Grounding fasteners must be stainless steel
and lockwashers must be of the external tooth type. Typically, ground wires are run to the
intrinsically-safe relay mounting panel, compressor, fan motors, explosion proof enclosure,
chassis wall, and terminal block in controls compartment. To maintain integrity, proper mounting
and grounding of the intrinsically-safe relay(s) is required. The intrinsically-safe relay mounting
plate must be grounded in two places. (See figures 1 and 2.)

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