HomeMy WebLinkAboutINSTALLATION INSTRUCTIONSI
INSTALLATION INSTRUCTIONS
WALL MOUNTED
PACKAGE AIR CONDITIONERS
MODELS
W18AI W181-1
W24A1
W30AI
W36A1
W42AI
W48AI
W60AI
W70A1
W24LI
W301-1
W36LI
W42LI
W48LI
W60LI
W70LI
A,
Bard Manufacturing Company, Inc. Manual: 2100-508A
Bryan, Ohio 43506 Supersedes: 2100-508
Since 1914 ... Moving aheadjust as planned. File: Volume III Tab 16
CLIMATE CONTROL SOL UTIONS Date: 02-10-09
Contents
Getting Other Information and Publications 3
Wall Mount General Information
Wall Mount Model Nomenclature ............................ 4
ShippingDamage .................................................... 4
General................................................................ 4
DuctWork ................................................................ 5
Filters................................................................ 5
Fresh Air Intake . ...................................................... 5
Condensate Drain .................................................... 5
Installation Instructions
Wall Mounting Information .......................................
6
Mounting the Unit ....................................................
6
Clearances Required ...............................................
6
Minimum Clearances ...............................................
6
Wiring — Main Power .............................................
14
Wiring — Low Voltage Wiring .................................
14
Figures
Figure 1
FreshAir DamperAssembly ...................
5
Figure 2
Unit Dimensions ............................. ........
7
Figure 3A
Mounting Instructions ..............................
8
Figure 3B
Mounting Instructions - W1 8, 24, 30, 36 ....
9
Figure 3C
Mounting Instructions - W42, 48, 60, 70 ...
10
Figure 4
Electric Heat Clearance .................. ......
11
Figure 5
Wall Mounting Instructions ....................
12
Figure 6
Wall Mounting Instructions ....................
12
Figure 7
Common Wall Mounting Installations ....
13
Figure 8
Fan Blade Setting .................................
18
Manual 2100-508A
Page 2 of 25
Start Up
General..............................................................
Topping Off System Charge ...................................
Safety Practices .....................................................
Important Installer Note .........................................
High Pressure Switch ............................................
Three Phase Scroll Compressor ............................
Phase Monitor .......................................................
Condenser Fan Operation .....................................
Service Hints .........................................................
Sequence of Operation ..........................................
Compressor Control Module ..................................
Adjustments...........................................................
Pressure Service Ports ..........................................
15
15
15
16
16
16
16
16
16
17
17
17
17
Troubleshooting
Fan Blade Setting Dimensions .............................. 18
Removal of Fan Shroud ......................................... 18
Refrigerant Charge ....................... ........................ 18
Tables
Table 1
Fan Blade Dimensions ..........................
18
Table 2A
Refrigerant Charge ............... ...............
18
Table 2B
Refrigerant Charge ...............................
18
Table 3
Cooling Pressure ..................................
19
Table 4
Electrical Specifications W**A ..............
20
Table 5
Electrical Specifications W**L ...............
21
Table 6
Recommended Airflow ..........................
22
Table 7
Indoor Blower Performance ..................
22
Table 8
Maximum ESP Electric Heat Only ........
22
Table 9
Electric Heat .........................................
23
Table 10
Optional Accessories ............................
24
Table 11
Vent & Control Options .........................
25
GETTING OTHER INFORMATION AND PUBLICATIONS
These publications can help you install the air
conditioner or heat pump. You can usually find these at
your local library or purchase them directly from the
publisher. Be sure to consult current edition of each
standard.
National Electrical Code ...................... ANSVNFPA 70
Standard for the Installation .............. ANSI/NFPA 90A
of Air Conditioning and Ventilating Systems
Standard for Warm Air ...................... ANSM*TA90B
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
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 1003 6
Telephone: (212) 642-4900
Fax: (212) 302-1286
ASHRA.E 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
Manual 2100-508A
Page 3 of 25
WALL MOUNT GENERAL INFORMATION
AIR CONDITIONER WALL MOUNT MODEL NOMENCLATURE
W 42 .1 - A 10
I I IMODELNUMSER REVISIONS
KW
CAPACITY
18 - 1%Tc
24 - 2Ton VOLTS & PHASE
30 - 21ATon A - 230/208/6011
36 - 3Ton B - 230/208/60/3
42 - 3%Ton C - 460/60/3
48 - 4Ton
60 - 5Ton A - Right Hand AirConditioner
70 - 6Ton L - Left Hand AlrConclifioner
VENTILATION OPTIONS
* - Barometric Fresh AirDamper (Standard/
* - Blank -off Plate
* - Motorized Fresh Air Damper
* - Commercial Ventilator - M otorized with Exhaust
E - Economizer (internal) - Fully Modulating with Exhaust
R - Energy Recovery Ventilator - Motorized with Exhaust
(See Spec. SheetS3397)
X A
I
CONTROLMODULES
(See Spec. SheetS3397)
COILOPTIONS
COLORO 'IONS
X - Standard
X - Beige(Standard)
I - PhenolicCoated Evaporator
1 - White
2 - PhenolicCoated Condenser
2 - MesaTan
3 - PhenolicCoated Evaporator
4 - Buckeye Gray
andCondenser
5 - Desert Brown
6 - Dark Bronze
OLITILETOPTIONS
A - Aluminum
X -Front (Standard)
S - StainlessSteel T -Top Outlet (W30A, W36A Only)
FILTEROPTIONS
X -One Inch Throwaway (Standard)
W- OneinchWashable
P -TwolnchPleated
NOTE: Vent options X, B and M am without exhaust capability. May require separate field supplied barometric refief in building.
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 intemal 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.
Manual 2100-508A
Page 4 of 25
These instructions and any instructions packaged with
any separate equipment required to make up the entire
air conditioning system should be carefully read before
beginning the installation. Note particularly "Starting
Procedure" and any tags and/or labels attached to the
equipment.
While these instructions are intended as a general
recommended guide, they do not supersede any national
and/or local codes in any way. Authorities having
jurisdiction should be consulted before the installation is
made. See Page 3 for information on codes and
standards.
Size of unit for a proposed installation should be based
on heat loss calculation made according to methods of
Air Conditioning Contractors of America (ACCA). The
air duct should be installed in accordance with the
Standards of the National Fire Protection Association
for the Installation of Air Conditioning and Ventilating
Systems of Other Than Residence Type, NFPA No.
90A, and Residence Type Warm Air Heating and Air
Conditioning Systems, NFPA No. 90B. Where local
regulations are at a variance with instructions, installer
should adhere to local codes.
DUCT WORK
All duct work, supply and return, must be properly sized
for the design airflow requirement of the equipment. Air
Conditioning Contractors of America (ACCA) is an
excellent guide to proper sizing. All duct work or portions
thereof not in the conditioned space should be properly
insulated in order to both conserve energy and prevent
condensation or moisture damage.
Refer to Maximum ESP of operation Electric Heat Table 6.
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.
Models W18 & W24 as approved for zero inch clearance to
the supply duct. For model series W30, W36, W42, W48,
W60 and W70 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 fiarther details.
Ducts through the walls must be insulated and all joints
taped or scaled to prevent air or moisture entering the wall
cavity.
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.
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: Ifno return air duct is used, applicable installation
codes may limit this cabinet to installation only in a
single story structure.
FILTERS
A 1 -inch throwaway filter is standard with each unit.
The filter slides into position making it easy to service.
This filter can be serviced from the outside by removing
the filter access panel. A 1 -inch washable filter and 2-
inch pleated filter are also available as optional
accessories. The internal filter brackets are adjustable
to accommodate the 2-inch filter by bending two (2)
tabs down on each side of the filter support bracket.
FRESH AIR INTAKE
All units are built with fresh air inlet slots punched in
the service door.
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 1.
All capacity, efficiency and cost of operation
information is based upon the fresh air blank -off plate in
place and is recommended for maximum energy
efficiency.
The blank -off plate is available upon request from the
factory and is installed in place of the fresh air damper
shipped with each unit.
CONDENSATE DRAIN
A plastic drain hose extends from the drain pan at the
top of the unit down to the unit base. There are
openings in the unit base for the drain hose to pass
through. In the event the drain hose is connected to a
drain system of some type, it must be an open or vented
type system to assure proper drainage.
FIGURE 1
FRESH AIR DAMPER
Page 5of25
I
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.
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, attached to
skid for shipping, 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 for model series
W30, W36, W42, W48, W60 and W70. However, it
is generally recommended that a 1 -inch clearance is
used for case of installation and maintaining the
required clearance to combustible material. See
Figure 3 for details on opening sizes.
3. Locate and mark lag bolt locations and bottom
mounting bracket location. See Figure 3.
4. Mount bottom mounting bracket.
5. Hook top rain flashing, attached to front - right of
supply flange for shipping, under back bend of top.
Clearances Required for Service Access
and Adequate Condenser Airflow
MODELS LEFT SIDE RIGHT TIDE
W1 8A, W24A, W30A, W36A 15" 20"
W1 8L, W24L. W30L. W36L 20" 15..
W42A, W48A, W60A, W70A 20' 20"
W42L, W48L, W60L, W70L 20" 20"
NOTE: For side by side installation of two (2) W**A models there
must be 20" between units. This can be reduced to 15" by using
a W**L model (left side compressor and controls) for the left unit
and WA (right side compressor and controls) for right unit.
See W**A SpecifiGation S3397 & W**L Specificallion S3400
WARNING
Failure to provide the 114 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.
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.
Minimum Clearances Required to
Combustible Materials
MODELS SUPPLY AIR DUCT CABINET
FIRST THREE FEET
W1 8A, L / W24A, L 01. T
W30A, L / W36A. L 1/4" T
VV4ZA, L / W48A L 1/4" 0.
W60A, L / W70A: L
Manual 2100-508A
Page 6 of 25
FIGURE 2
Dimensions of Bask Unit for Architectural and Installation Rectuirements (Nominal)
MODEL
WIDTH
DEPTH
HEIGHT
SU PLY
RETURN
A
B
I C
I B
E
F
G
I
I J
I K
L
M
N
1 0
P
Q
R
S
W
(D)
(H)
W18A L
33.300
17.125
70.563
7.88
19.88
11.88
19.88
35.00
11.00
25.75
20.56
26.75
I
28.06
I
29.25
27.00
2.63
34.13
I
22.06
1
4.19
12.0
5.00
W24A: L
.5
W30A L
38.200
17.125
70.563
7.88
27.88
13.88
27.88
40.00
11.00
25.75
17.93
26.75
28.75
29.25
W36A: L
W42A, L
W48A, L
42.075
22.432
84.875
9.88
29.88
15.88
29.88
43.88
13.62
31.66
30.00
32.68
26.94
34.69
W60A, L
1
W70A, 1-142.075122.432194.875
9.88
29.88
15.88
29.88
43.88
13.63
41.66
30.00142.68136.94
44.69
ensions are in inches.
Dimensional drawings are not to scale.
VV`A
RIGHT
Builtin 7.11
Rain 11=1
IN 4* Pitch
UNIT
HeaterL
5
1.000
Fmflt l4lich, Slide rjew �Draln N
Q) Dimension is 21.00 inches on W70A & W70L models.
0 Optional top outlet (factory installed only) for W30A and W36A models only.
W. L
LEFT
UNIT
0 0-
T. . .. . . .
ln�i./- R.ff-/ Rat*KeW
.44
--i
1R
SuPPYAirOP017il7g iq�
T
83Ck K16W \Bottom-Installatio
n
Bracket
�VB
Side Kew Fmnt View
Manual 2100-508A
Page 7 of 25
-u
CD
r7
0
3 13
16
Wall Openh7gandHoloLocallon View
FIGURE 3A
Wl8Al,Wl8Ll,W24Al,W24Ll
MOUNTING INSTRUCTIONS
SEAL WITH BEAD
OF CAULKING ALONG
ENTIRE LENGTH OF TOP.
SUPPLIED
AIR SEAL
STRUCTURE
FOUR SIDES OF SUPPLY
AIR DUCT IS REQUIRED
FROM COMBUSTABLE
MATERIALS
HEATERACCESS I I I I -n SUPPLY AIR
RETURN AIR
OPENING
Right Side View
NOTES
IT IS RECOMMENDED THAT A BEAD OF
SILICONE CAULKING BE PLACED BEHIND
THE SIDE MOUNTING FLANGES AND UNDER
TOP FLASHING AT TIME OF INSTALLATION.
W-A UNIT SHOWN, W"L UNIT
CONTROLS AND HEATER ACCESS
IS ON OPPOSITE (LEFT) SIDE.
MIS-353 C
FIGURE 313
Wl W30L1, W36A1, W36L1
MOUNTING INSTRUCTIONS
A
B
C
D
E
REQUIRED DIMENSIONS TO MAINTAIN
1/4' M1N. CLEARANCE FROM
28112
81/2
51/4
313/16
175/8
COMBUSTIBLE MATERIALS
REQUIRED DIMENSIONS TO INTAIN
RECOMMENDED 1"CLEA E FROM
30
10
41/2
I
4 9116
16 7/8
COMBUSTIBLE MATERIALS
C r— A ----I C
2' Rdil OP6679 14"
2' 28'
4' 3T'
2' 7. 1
P
m P
Wall0ponIngandHole Locatlon Vlow
EW
0 C
C
SEALWITHBEAD
OF CAULKING ALONG
ENTIRE LENGTH OF TOP RAIN FLASHING
�J�SUPPUED
AIRSEAL
-WALL STRUCTURE
114" CLEARANCE ON ALL
FOUR SIDES OF SUPPLY
AIR DUCT IS REQUIRED
FROM COMBUSTABLE
MATERIALS
HEATER ACCESS J'fl IUPPLYAIR
DA11.1 I I I DUCT
RETURN AIR
OPENING
oiNOTES:
IT IS RECOMMENDED THAT A BEAD OF
SILICONE CAULKING BE PLACED BEHIND
THE SIDE MOUNTING FLANGES AND UNDER
TOP FLASHING AT TIME OF INSTALLATION.
W**A UNIT SHOWN, W*'L UN IT
CONTROLS AND H EATER ACCESS
l IS ON OPPOSITE (LEFT) SIDE.
Right Side View
MIS-3`11 C
CD
0
A
B
C
I D
E _
REQUIRED DIMENSIONS TO MAINTAIN
30V2
101/2
29 3/4
1/4" MIN. CLEARANCE FROM
COMBUSTIBLE MATERIALS
+1/412114
REQUIRED DIMENSIONS TO MAINTAIN
32
12
5112
29
RECOMMENDED l"CLEARANCE FROM
COMBUSTIBLE MATERIALS
D C r-- A ---I C
sum), opening F
Relum Opening
FIGURE 3C
W42AI, W421-1, W48AI, W481-1, W60Al, W601-1, W70Al, W70LI
MOUNTING INSTRUCTIONS
SEAL WITH BEAD
OF CAULKING ALONG
ENTIRE LENGTH OF RAIN FLASHING
TOP.7<��SIJPPLIED
HEATER ACCESS
PANEL
SUPPLYAIR
DUCT
RETURN AIR
OPENING
Emil
AIR DUCT IS REQUIRED
FROM COMBUSTABLE
MATERIALS
6-j" 30" NOTES:
3- IT IS RECOMMENDED THAT A BEAD OF
4- SILICONE CAULKING BE PLACED BEHIND
THE SIDE MOUNTING FLANGES AND UNDER
--�Ypr TOP FLASHING AT TIME OF INSTALLATION.
W"A UNIT SHOWN, W-L UNIT
2"1 CONTROLS AND HEATER ACCESS
8 -2 6 " IS ON OPPOSITE (LEFT) SIDE.
6 1 f
Y'lp�
(D Dimenslon is 21"onW7OAand VV70L Units.
watf OpenIng anoHole Location View R1917t Side Vlew MIS416 C
i
FIGURE 4
ELECTRIC HEAT CLEARANCE
W30AI, W301-11, W36AI, 1111361-11, W42AI, W421-1, W48AI, W481-1, W60A1, W601-11, W70A1, 11111701-11
TYPICAL BUILDING ---\ N
OUTSIDE SHEETING 0 /— WALL FRAME
INSIDE SHEETING
SUPPLY
AIR DUCT
1/40 MIN.
SUPPLY AIR DUCT SEE NOTE
FLAKE OF WALL
MOUNTED UNIT
MIS-277 A
SIDE SECTION VIEW OF SUPPLYAIR DUCT FOR
WALL MOUNTED UNIT SHOWING 1/4 INCH
CLEARANCE TO COMBUSTIBLE SURFACES.
AI
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 2100-508A
Page 11 of25
FIGURE 5
WALL MOUNTING INSTRUCTIONS
SEE FIGURE 3 —MOUNTING INSTRUCTIONS
RETURNAIR
OPENING
—
JF§R'E_��AIR
OPEN
G
RETURN
0
ENING
MR
WOOD
OR STEEL SIDING
I I I
I
FACTORY SUPPLIED
RAIN FLASHING.
MOUNT ON UNIT
BEFORE INSTALLATION
WALL
CONCRETEBLOCK WALL INSMLLABON WOOD FR4ME WALL &STALIABON SIDE VIEW MIS-548A
FIGURE 6
WALL MOUNTING INSTRUCTIONS
SEE UNIT DIMENSIONS, FIGURE 2,
FOR ACTUAL DIMENSIONS.
E + 1000
ATTACH TO TOP
PLATE OF WALL--�F_r_�: !L71
INTERIOR FINISHED WALL
OVER FRAME
1.000* CLEARANCE
FINISH WALL
1.000
�UerLyUuw A
OPENING
RETURN DUCT
OPENING
FRAMING MATERIAL
2 x 4S, 2 x 9S WOR
ATTACH TO BOTTOM�'�
THIS STRUCTURAL MEMBER
LOCATED TO MATCH STUD
STRUCTURAL STEEL
PLATE OF WALL
SPACING FOR REST OF WALL
MIS-549A
A SECOND MEMBER MAY BE
REQUIRED FOR SOME WALLS.
Manual 2100-508A
Page 12 of 25
WALL
FIGURE 7
COMMON WALL MOUNTING INSTALLATIONS
RAFTERS
FINISHED Cl
SUPPLY AIR DUCT
W/ GRILLE
RETURN AIR
OPENING W/ GRILLE
FREEAN FL OW
NO DUCT
SURFACEI
SUPPLY DUCT MAYBE LOCATED IN AN ATTIC
OR BELOW CEILING RAFTERS AS SHOWN
I RAFTERS
CEILING SURFACE
RETURNAIR
WALL SLEEVE SPACE
FALSE WALL
RETURN AIR GRILLE
WALL I I
FALSE WALL INSTALLA TION
WALL
SUPPLY DUCT MAY BE LOCATED IN AN ATTIC
OR BELOW CEILING RAFTERS AS SHOWN
RAFTERS
(AIR DUCT—
N,
FINISHED CEILING SURFACE
RETURN AIR
OPENING W/ GRILLE
DUCTED SUPPL Y
RETURNATUNIT
SUPPLY DUCT MAYBE LOCATED IN AN ATTIC
RAIN*
FLASHING
OR BELOW CEILING RAFTERS AS SHOWN
0/
RAFTERS
Ll
SUPPLY AIR DUCL---)
LOWERED
PLY AIR
CEILING SUPPLY AIR
GRILLE
FINISHED CEILIN(
SURFACE
CLOSET WALL
WALL
SLEEVE
IS L AIR
'=� AISED
OUTSIDE/4'
�FLOORETURN
= GRILLE
LRETURN
WALL
AIROO
T I
CLOSETINSTALLATION
MIS-550 B
Manual 2100-508A
Page 13 of 25
WIRING - MAIN POWER
Refer to the unit rating plate for wire sizing information
and maximum fuse or "HACW' type circuit breaker
size. Each outdoor unit is marked with a "Minimum
Circuit Ampacity". This means that the field wiring
used must be sized to carry that amount of current.
Depending on the installed KW of electric heat, there
may be two field power circuits required. If this is the
case, the unit serial plate will so indicate. All models
are suitable only for connection with copper wire. Each
unit and/or wiring diagram will be marked "Use Copper
Conductors Only". These instructions must be adhered
to. Refer to the National Electrical Code (NEC) for
complete current carrying capacity data on the various
insulation grades of wiring material. All wiring must
conform to NEC and all local codes.
The electrical data lists fuse and wire sizes (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 "HACT' 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 comer of the disconnect opening
under the disconnect access panel straight out. This tab
will now line up with the slot in the door. When shut, a
padlock may be placed through the hole in the tab
preventing entry.
See "Start Up" section for important information on
three phase scroll compressor start ups.
See Tables 4 & 5 for Electrical Specifications.
WIRING - LOW VOLTAGE WIRING
230/208V, I 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:
TAP RANGE
240 253-216
208 220-187
NOTE: The voltage should be measured at thefieldpower
connection point in the unit and while the unit is
operating atfull load (maximum amperage
operating condition).
For wiring size and connections, refer to Wiring Manual
2100-507.
Manual 2100-508A
Page 14 of 25
START UP
THESE UNITS REQUIRE R-410A
REFRIGERANT AND POLYOL
ESTER OIL.
GENERAL:
1. Use separate service equipment to avoid cross
contamination of oil and refrigerants.
2. Use recovery equipment rated for R4 1 OA
refrigerant.
3. Use manifold gauges rated for R-410A (800 psi/250
psi low).
4. R-4 I OA is a binary blend of BFC-32 and HFC- 125.
5. R-410A is nearly azeotropic - similar to R-22 and
R- 12. Although nearly azeotropic, charge with
liquid refrigerant.
6. R-4 I OA operates at 40-70% higher pressure than
R-22, and systems designed for R-22 cannot
withstand this higher pressure.
7. R-4 I OA has an ozone depletion potential of zero,
but must be reclaimed due to its global warming
potential.
8. R-41 OA compressors use polyolester oil.
9. Polyol Ester 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 plug
compressor immediately after removal. Purge with
small amount of nitrogen when inserting plugs.
TOPPING OFF SYSTEM CHARGE
If a leak has occurred in the system, Bard Manufacturing
recommends reclaiming, evacuating (see criteria above)
and charging to the nameplate charge. If done correctly:
topping off the system charge can be done without
problems.
With R-410A, there are no significant changes in the
refrigerant composition during multiple leaks and
recharges. R-410A refrigerant is close to being an
azeotropic blend (it behaves like a pure compound or
single component refrigerant). The remaining
reftigerant charge, in the system, may be used after
leaks have occurred and then "top-off'the charge by
utilizing the charging charts on the inner control panel
cover as a guideline.
WARNING
Failure to conform to these practices
could lead to damage, injury or death.
SAFETY PRACTICES:
1. Never mix R-410A with other refrigerants.
2. Use gloves and safety glasses, Polyol Ester oils can
be irritating to the skin, and liquid refrigerant will
freeze the skin.
3, Never use air and R-41 OA to leak check; the
mixture may become flammable.
4. Do not inhale R-41 OA — the vapor attacks the
nervous system, creating dizziness, loss of
coordination and slurred speech. Cardiac
irregularities, unconsciousness and ultimate death
can result from breathing this concentration.
5. Do not bum R-41 OA. This decomposition
produces hazardous vapors. Evacuate the area if
exposed.
6. Use only cylinders rated DOT4BA/4BW 400.
7. Never fill cylinders over 80% of total capacity.
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 exparids significantly
at warmer temperatures. Once a c / ylinder or line is
full of liquid, any further rise in temperature will
cause it to burst.
Manual 2100-508A
Page 15 of 25
,qTART UP (Continued)
IMPORTANT INSTALLER NOTE
For improved start up performance wash the indoor coil
with a dish washing detergent.
HIGH PRESSURE SWITCH
All W**A/W**L wall mounted air conditioner series
models are supplied with a remote reset for the high and
low 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 ofproper 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.
NOTE: lfcompressor is allowed to run in reverse rotation
for several minutes, the compressor's internal
protector will trip.
All three phase 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. I
PHASE MONITOR
All units with three phase scroll compressors are
equipped with a 3 phase line monitor to prevent
compressor damage due to phase reversal.
The phase monitor in this unit is equipped with two
LEDs. If the Y signal is present at the phase monitor
and phases are correct the green LED will light.
If phases are reversed, the red fault LED will be lit and
compressor operation is inhibited.
If a fault condition occurs, reverse two of the supply
leads to the unit. Do not reverse any of the unitfactory
wires as damage may occur.
CONDENSER FAN OPERATION
Apolies to W42, W48, W60 and W70 models only 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 owner/operator to maintain clean air filters
at all times. Also, not to needlessly close off supply
and return air registers. This reduces airflow
through the system, which shortens equipment
service life as well as increasing operating costs.
2. Check all power fuses or circuit breakers to be sure
they are the correct rating.
3. Periodic cleaning of the outdoor coil to permit full
and unrestricted airflow circulation is essential.
Manual 2100-508A
Page 16 of 25
SEQUENCE OF OPERATION
COOLING — Circuit R-Y makes at thermostat pulling
in compressor contactor, starting the compressor and
outdoor motor. The G (indoor motor) circuit is
automatically completed on any call for cooling
operation or can be energized by manual fan switch on
subbase for constant air circulation. On a call for
heating, circuit R-WI 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 all
models covered by this manual. The compressor control
module 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 anytime power is interrupted to
the unit, the delay on make period begins, which will be
2 minutes plus 10% of the delay on break setting. When
the delay on make is complete and the high pressure
switch and low pressure switch is closed, the compressor
contactor is energized. Upon shutdown, the delay on
break timer starts and prevents restart until the delay on
break and delay on make periods have expired.
During routine operation of the unit with no power
interruptions, the compressor will operate on demand
with no delay.
High Pressure Switch and Lockout Sequence
If the high pressure switch opens, the compressor
contactor will de -energize immediately. The lockout
timer will go into a soft lockout and stay in soft lockout
until the high pressure switch closes and the delay on
break time has expired. If the high pressure switch
opens again in this same operating cycle, the unit will go
into manual lockout condition and the alarm relay circuit
will energize. Recycling the wall thermostat resets the
manual lockout.
Low Pressure Switch, Bypass, and Lockout
Sequence
If the low pressure switch opens for more than 120
seconds, the compressor contactor will de -energize and
go into a soft lockout. Regardless the state of the low
pressure switch, the contactor will reenergize after the
delay on make time delay has expired. If the low
pressure switch remains open, or opens again for longer
than 120 seconds, the unit will go into manual lockout
condition and the alarm relay circuit will energize.
Recycling the wall thermostat resets the manual lockout.
Alarm Relay Output
Alarm terminal is output connection for applications
where alarm relay is employed. This terminal is
powered whenever the 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 arefixed by specific air
conditioner unit model. The lockoutfeatures,
both soft and manual, are afunction 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 (30 seconds)
DOB = 123 secondDOM
1.0 minute (60 seconds)
DOB = 126 second DOM
2.0 minute (120 seconds)
DOB = 132 second DOM
3.0 minute (180 seconds)
DOB = 138 second DOM
4.0 minute (240 seconds)
DOB = 144 second DOM
5.0 minute (300 seconds)
DOB = 150 second DOM
During routine operation of the unit with no power
interruptions the compressor will operate on demand
with no delay.
Typical Settings for Dual Unit Installation:
Unit 1: DOB set at 2 minutes, and DOM is 132 seconds
Unit 2: DOB set at 4 minutes, and DOM is 144 seconds
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.
See Table 3.
Manual 2100-508A
Page 17 of 25
TROUBLESHOOTING
FAN BLADE SETTING DIMENSIONS
Shown in Figure 8 is the correct fan blade setting for
proper air delivery across the outdoor coil. Refer to
Table I for unit specific dimension.
Any service work requiring removal or adjustment in
the fan and/or motor area will require that the
dimensions below be checked and blade adjusted in or
out on the motor shaft accordingly.
FIGURE 8
FAN BLADE SETTING
TABLE I MIS-1724
FAN BLADE DIMENSION
Model
Dimension
A
W18A1 /W18L1
W24A1 I W24LI
1.001,
W30A1 / W301-i
W36A1 / W36L1
1.25"
W42AI /W421-1
W48AI /W481-1
1.75"
W60A1 / W60L1
W70A1 / W701-1
.75"
REMOVAL OF FAN SHROUD
1. Disconnect all power to the unit.
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.
4. Ufiwire condenser fan motor.
5. Slide complete motor, fan blade, and shroud
assembly out the left side of the unit.
6. Service motor/fan as Deeded.
7. Reverse steps to reinstall.
REFRIGERANT CHARGE
The correct system R-41 OA 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
2A. If charge quantity is in doubt, reclaim unit and
recharge to factory nameplate quantity.
TABLE 2A
REFRIGERANT CHARGE
Model
Rated
Airflow
95OF OD
Temperature
820F OD
Temperature
W18AI /W18L1
600
61 -65
62-66
W24A1 / W241-1
800
56-60
56-60
W30A1 I W30LI
1000
57-61
57-61
W36A1 /W36L1
1 1100
1 56-60
1 5 -
W42AI /W421-1
1400
58-62
W48AI / W481-1
1550
63-67
W60A1 / W601-1
1650
63-67
The suction line temperatures in Table 2 above are
based upon 80'F dry bulb / 670F wet bulb (50% R.H.)
temperature and rated airflow across the evaporator
during cooling cycle.
TABLE 2B
REFRIGERANT CHARGE
Mod�l
kW70A1
Rated
Airflow
95-F
ubcooling
82-F
Subcooling
I OLJ
1800
15-18-
16-19-
The correct system R-4 1 OA charge is shown on the unit
nameplate. Optimum unit performance will occur with
a refrigerant charge resulting in a liquid subcooling as
shown in Table 2B. If charge is in doubt, reclaim and
recharge to factory nameplate charge.
Manual 2100-508A
Page 18 of 25
TABLE 3
COOLING PRESSURE TABLE
Air Temperature Entering Outdoor Coil 'F
Return Air
Model
Temperature
Pressure
75
80
85
90
95
100
105
110
115
120
75 deg. DB
LowSide
127
129
131
133
135
137
138
140
141
143
62 deg. WS
High Side
295
316
337
360
383
407
432
457
484
511
W18A1/1-1
80 deg. DB
Low Side
136
138
140
142
144
146
148
150
151
153
67 deg. WB
High Side
303
324
346
369
393
417
443
469
496
524
85 deg. DB
Low Side
141
143
145
147
149
151
153
155
156
158
72 deg. WB
High Side 1
314
335,
358,
382
407,
432,
459
485,
513,
542
75 deg. D13
Low Side
121
123
125
127
130
132
134
135
137
138
62 deg. WB
High Side
326
350
375
401
426
450,
477
502
527
553
80 deg' IDS
LowSide
129
132
134
136
139
141
143
144
146
148
W24A1/1-1
67 deg. WB
High Side
334
359
385
411
437
462
489
515,
541
567
85 deg. DB
Low Side
134
137
139
141
144
146
148
149
151
153
72 deg. WB
High Side
346
372
398
425
452
478
506
533
560 1
587
75 deg. DB
Low Side
121
122
125
127
130
132
134
136
137
138
62 deg. WB
HighSide
3351
357
380
404
429
454
481
509
537
566
W30A1/L1
80 deg. DB
Low Side
129
131
134
136
139
141
143
145
146
148
67 deg. WB
High Side
344
366
390
414
440
4661
493
522
551
581
85 deg. D13
Low Side
134
136
139
141
144
146
148
150
151
153
72 deg. WB
High Side
366
379
404
428
455
482
510
640
570
601
75 deg. DB
Low Side
123
125
127
129
131
133
136
138
140
143
62 deg. WB
High Side
350
372
396
420
445
470
496
524
552
581
W36A11L1
80 deg ' IDS
Low Side
132
134
136
138
140
142
145
148
150
153
67 deg. WB
High Side
359.
382
406.
431.
456
482
509
537
566
596
85 deg. DB
Low Side
137
139
141
143
145
147
150
153
155
158
72 deg. WB
High Side
372
395
420
'446
472
499.
527
556
586
617
75 deg. IDS
LowSlde
128
130
132
133
135
137
138
140
142
144
62 deg. WB
High Side
341
362
383
406
429
453
480
506
534
564
W42AUl
80 deg' DB
Low Side
137
139
141
142
144
146
148
150
152
154
67 deg. WB
High Side
350
371
393
416
440
465
492
519
548
578
85 deg. D13
Low Side
142
144
146
147
149
151
153
155
157
159
72 deg. W13
High Side
362.
384
407.
431.
455
481
509
537
567
598
75 deg. DB
Low Side
125
127
129
131
133
136
137
140
143
146
62 deg. WS
High Side
349
370
391
415
440
467,
495
526
557
590
W48A111-1
80 deg. DB
Low Side
134
136
138
140
142
145
147
150
153
156
67 deg. VVB
High Side
358
379
401
426
451
479
508
539
571
605
85 deg. DB
Low Side
139
141
143
145
147
150
152
155
158
161
72 deg. WB
High Side
371
392
415
441
467
496
526
568.
591.
626
75 deg. DB
Low Side
126
128
130
132
133
135
137
137
139
141
62 deg. WB
High Side
1 3521
373
3961
4181
442
466
491
517
544
571
W60A111-1
80 deg. DB
Low Side
135
137
139
141
142
144
146
147
149
151
67 deg. V1B
High Side
361
383
406
429
453
478
1 504
530
558
586
85 deg. DB
Low Side
140
142
144
146
147
149
151
152
154
156
72 deg. WB
High Side
374
396
420
444
469
495
522
549
578
607
75 deg. DB
Low Side
118
119
121
122
123
126
127
130
132
135
62 deg. WB
High Side
326
347
370
392
416
440
465
4891
5161
542
W70A111-1
80 deg' DB
Low Side
126
127
129
131
132
134
136
1391
1411
144
67 deg. WB
High Side
334,
356,
3791
402
427
451
477
502
529
556
85 deg. DB
Low Side
130
1311
1341
136
137
139
141
1441
1461
149
72 deg. W13
High Side
346
368
392
416
4421
4671
494
520
648
575
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 charge weight.
N07E., Pressure table based on high speed condenser fan operation. If condensing pressures appear elevated check
condenserfan wiring. See "CondenserFan Operation".
Manual 2100-508A
Page 19 of 25
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TABLE 6
RECOMMENDEDAIRFLOW
Model
Rated
CFM
Rated
ESP
Recommended
Airflow Range
Factory Speed
Connection
W1 8A, W11 8L
550
.40
575-726
High
W24A, W24L
800
.20
700-950
High
W30A, W30L
1000
.40
930-1300
High
W36A, W36L,
1100
.30
930-1350
High
W42A, W42L
1400
.30
1600-1150
High
W48A, W48L
1550
.20
1750-1285
High
W60A, W60L
1650
.30
1950-1376
High
W70A, W70L
1800
.20
2000-1475
High
Rated CFM and ESP on high speed tap.
TABLE 7
INDOOR BLOWER PERFORMANCE
W18AJL,
W30AIL, W36A/L
W42AIL, W48AIL
W60AJL, W70AJL
W24AIL
High Speed
High peed
Low Speed
High peed
Low S eed
High Speed
Low Speed
E.S.P.
In
Dry
Wet
Dry
Wet
Dry
Wet
Dry
Wet
Dry
Wet
Dry
Wet
Dry
Wet
H 2 0
Coll
Coil
Coil
Coll
Coil
Coil
Coil
Coil
Coil
Coll
Coll
Coll
Coll
Coil
.0
1020
975
1395
1315
950
935
1885
1800
1650
1600
2200
2000
1600
1450
.1
960
905
1340
1270
930
915
1770
1665
1550
1500
2100
1900
1525
1375
.2
865
800
1285
1190
910
885
1635
1540
1450
1400
2000
1800
-
-
.3
820
735
1205
1100
855
830
1500
1400
1350
1300
1875
1700
-
-
735
650
1110
1000
800
755
1370
1285
1300
1175
1775
1600
-
-
.5
, 615
535
, 1005,
870
1 -
-
1 1250
1 1150
-
-
1650
1475
-
-
TABLE 8
MAXIMUM ESP OF OPERATION
ELECTRIC HEAT ONLY
Model
W11 8A/L, W24AIL
W30AIL, W36AIL
W42AIL, W48AIL
W60A/L, W70A/L
Outlet
FRONT
FRONT TOP
FRONT
FRONT
Speed
Single
High
Low
High
Low
High
Low
High
Low
-AOZ
.50
.50
.50
.50
.50
.50
.50
.50
.50
-A04
.50
.45
-A05
.50
.50
.50
.50
.50
.50
.50
-AO8
.50
.50
.50
-A10
.50
.45
.50
.35
.50
.50
.50
.50
-At 5
.40
.35
.50
.50
.50
.50
-A20
.50
.45
.50
.40
-BOZ
.50
.50
.50
.50
.50
.50
.50
.50
.50
-B06
.50
.50
.40
-B09
.50
.50
.45
.40
.50
.50
.50
.50
-1315
.45
.30
.50
.50
.50
.50
-1318
.50
.50
.50
.50
-Coz
.50
.50
.50
.50
.50
.50
.50
.50
-006
.50
.50
_C09
.50
AO
.45
.40
.50
.50
.50
1
.50
C15
1
1 .45
.35
1
.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 2100-508A
Page 22 of 25
TABLE 9
ELECTRIC HEAT
Models
240V-1
208V-1
240V-3
208V-3
460V-3
KW
Amps
BTUH
Amps
BTUH
Amps
BTUH
Amps
BTUH
Amps
BTUH
4
16.7
13650
14.4
10240
6
20.8
17065
18.1
12800
6
14.4
20500
12.5
15360
7.2
20500
8
33.3
27300
28.8
20475
9
21.7
30600
18.7
23030
10.8
30700
10
41.6
34130
36.2
25600
12
14.4
40950
15
62.5
51250
54.0
38400
36.2
51200
31.2
38400
18.0
51200
18
43.3
61430
37.5
46100
20
83.2
68260
72.1
51200
1
1
1
Manual 2100-508A
Page 23of25
-u K
G
CIRCUIT BREAKER (WMCB) &
PULL DISCONNECT (WMPD)
HEATER KITS
z
W18AI-A
W24Al-A
W24AI-B
W24Al-C
W30Al-A
W30AI-B
W30Al-C
W36Al-A
W36AI-B
W36Al-C
W42AI-A
W42Al-B
W42Al-C
W48AI-A
W48AI-B
W48AI-C
W60AI-A
W60AI-B
W60Al-C
W70AI-A
W70AI-B
Fn 01-C
0
55
z
>—I
r->
>m
0 r
0 M
M"
co 0
co
0
X
MR
cn
TABLE 11
VENT & CONTROL OPTIONS
to
C6
Gi
C;
OF
Part Number Description
CMC-14
ODT
x
x
x
CMC-16
Start Kit (230V I -Phase)
x
x
x
CMC-23
DDC
x
x
CMC-24
DDC
x
CMC-28
LAC
x
x ,
x
x
BFAD-2
Barometric Fresh Air Damper - Standard
x
BOP-2
Blank Off Plate
x
MFAD-2
Motorized Fresh Air Damper
x
CRV-2
Commercial Ventilator - Spring Return
x
ElFM-2B
Economizer
x
ERVF-2A
Energy Recovery Ventilator - 230 Volt
x
BFAD-3
Barometric Fresh Air Damper - Standard
x
BOP-3
Blank Off Plate
x
MFAD-3
Motorized Fresh Air Damper
x
CRVS-3
Commercial Ventilator - Spring Return
x
CRVP-3
Commercial Ventilator - Power Return
x
ElFM-3C
Economizer
x
ERVF-3A
Energy Recovery Ventilator - 230 Volt
x
ERVF-3C
Energy Recovery Ventilator - 460 Volt
x
BFAD-5
Barometdc Fresh Air Damper - Standard
x
BOP-5
Blank Off Plate
x
MFAD-5
Motorized Fresh Air Damper
x
CRVS-5
Commercial Ventilator - Spring Return
x
CRVP-5
Commercial Vent lator - Power Return
x
E1FM-5C
Economizer
x
5A
Energy Recovery Venfilator - 230 Volt
x
RERVF
4�771
Energy Recovery Ventilator - 460 Volt
x
Manual 2100-508A
Page 25 of 25