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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 -4 w Rd =1 I �@ I I =1 I I I I I I Rd I Rd I vveF seats 17 Wig. IF= sovi tell. cost lots fig.. 11F. IVF to.. IIs-VVTWw-- pfulvVIIII.- 1112 gig Vs— to.. I of .... vy. ATIF . . . . � so. lose . . . svp . . . . Vs . . . . joi . . . . . . so. 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M .88 . . . 18 ZZ . . . . . . 18 zn . . . . ..8n 8 r. 8 8 c; 8 8 8 9;3 n 8 Z; 8 -888 Z;i= IS88 .888 8ni: 888 -888 88�: 888 -888 8n� 88n -8888 82 6888 888in Is 0 > 0 Iml JE UK IOZ L j v ED rl m ul 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