Installation Guide for Bard models including: HVAC HP and AC Unit for Educational Facilities
Index Wall-Mount Air Conditioners
Literature Assembly 911-0768 Contains the following: 2100-034(G) 2100-479 2100-689(H) 2110-1448(E) 7960-810 7960-420 User's Guide Leak Test, Evacuation, Charging Wall Mount PKG A/C Manual Replacement Parts Manual Supplemental 50HZ Instructions Warranty USER'S APPLICATION GUIDE AND TECHNICAL PRODUCT OVERVIEW Manual: 2100-034G Supersedes: 2100-034F Date: 12-17-20 Bard Manufacturing Company, Inc. Bryan, Ohio 43506 www.bardhvac.com BARDHVAC.COM Climate Control Solutions General Information The User's Application Guide covers a wide range of heating and cooling products manufactured by Bard Manufacturing Company. It is intended to be a general guide for care and operation of typical systems and covers the most important features you should be aware of and are responsible for as the user of the equipment. Because our product offerings are so varied and can be equipped with many features and options, it is not possible to cover all aspects of what your specific system may be configured for. Some systems may be quite simple in features to provide basic cooling and possibly heating, while other systems may also incorporate various ventilation technologies, dehumidification circuits and many different internal controls as well as room temperature controls. Therefore, you should request a detailed operation sequence and explanation of any special features from your installer and/or service company and also have them instruct you as to any routine maintenance procedures you are responsible for. Contents Overview ........................................................................ 3 Documentation .............................................................4 Unit Literature Assembly Documentation Provided with Your Units .....................................................4 Unit Installation ...........................................................5 WALL MOUNT Products Mounting the Product on Wall Surface .........................................................5 WALL MOUNT Products Clearances for Outdoor Condenser Fan Airflow ...........................................6 WALL MOUNT Products Clearances for Indoor Supply and Return Airflow......................................6 WALL MOUNT Products Condensate and Defrost Drainage ..............................................................7 I-TEC and Q-TEC Products Installing the Product Inside a Room ......................................................8 I-TEC and Q-TEC Products Clearances for Outdoor Condenser Fan Airflow ...........................................8 I-TEC and Q-TEC Products Clearances for Indoor Supply and Return Airflow......................................9 I-TEC Air Path................................................9 Q-TEC Air Path...............................................9 I-TEC and Q-TEC Products Condensate Drainage .10 All Products Power Supply Verification................11 Field-Supplied Voltage ..................................11 Single and Three Phase Power .......................11 Hertz (Frequency).........................................11 Unit Maintenance .......................................................12 All Products Filters and Filter Servicing ..............12 Outdoor Unit Wall Mount Room Air Filters.......12 WALL MOUNT Products Filters and Filter Servicing ............................................................13 I-TEC Indoor Products Filters and Filter Servicing ............................................................14 Q-TEC Indoor Products Filters and Filter Servicing ............................................................15 All Products Coil Cleaning .................................16 Equipment Corrosion Protection .....................16 All Products Condenser Airflow ..........................17 Unit Operation ............................................................18 Air-to-Air Cooling Products (Air Conditioners) .........18 Air-to-Air Cooling and Heating Products (Heat Pumps) .....................................................18 Cooling Mode ...............................................18 Heating Mode ..............................................18 Water-to-Air Cooling and Heating Products (Geothermal Heat Pumps)....................................19 Cooling Mode ...............................................19 Heating Mode ..............................................19 Water Supply Systems...................................19 Dehumidification and Ventilation Operation.......20 Dehumidification (Air-to-Air or Water-to-Air Systems) ............................................................20 Ventilation Options (Air-to-Air or Water-to-Air Systems) ............................................................20 Troubleshooting .........................................................21 All Units Troubleshooting ..................................21 Manual 2100-034G Page 2 of 21 Overview The User's Application Guide and Technical Product Overview covers the following products: WALL MOUNT Air Conditioners and Heat Pumps I-TEC® Air Conditioners and Heat Pumps Q-TECTM Air Conditioners and Heat Pumps The User's Application Guide and Technical Product Overview covers the following topics: · Documentation provided by Bard for proper use of your new product. · Unit installation guidelines. · Routine unit maintenance. · Unit operation. · Unit troubleshooting. Please use this guide as a general overview regarding unit application, maintenance and troubleshooting. Refer to product installation instructions and supplemental documentation provided with the unit or go to www.bardhvac.com for detailed individual product information. Overview Manual 2100-034G Page 3 of 21 Documentation There are two sources of valuable information for your new Bard product: · Documentation provided with your unit, normally located inside the unit control panel during shipping. This information should be saved once the unit is installed for future maintenance reference or to answer questions about equipment after installation. · Documentation provided on the internet at www.bardhvac.com. This may be accessed from a desktop computer at the office, a laptop or an internet-capable cell phone at the worksite. Up-to-date documentation is available, along with specification sheets and other valuable resources regarding your new Bard product. Unit Literature Assembly Documentation Provided with Your Unit Bard products are shipped with documentation that when used by a technician with cooling and heating knowledge, can ensure that your product is installed safely, performs optimally and achieves the longest life cycle possible. Shipped literature includes the following: · User Manual (this document) · Installation Instructions · Replacement Parts Manual · Wiring Diagrams · Warranty Information Manual 2100-034G Page 4 of 21 Documentation Unit Installation Installation plays a key part in unit functionality, performance and safety. Product securing and placement, duct design and supply/return location, electrical routing and condensate and defrost drainage all play key roles in making sure a unit will perform per the design specifications. WALL MOUNT Products Mounting the Product on a Wall Surface Outdoor products are normally mounted to an exterior wall surface, including brick, cement block, metal or wood construction. These products are labeled as "WALL MOUNT" units. Before installation begins, the wall surface should be inspected by a construction professional to ensure it will support the weight of the unit and accessory items. Approximate weights are available from the product specification sheet, and a safety factor should be designed into the installation. Typical fasteners to attach the unit to the wall using the integrated mounting flanges on both sides of the unit include tap cons, bolts, studs and other fastening devices. The selection of the fasteners to be used needs to be reviewed by a construction professional and decided upon based on the wall construction and fastener strength required. It is important to follow all guidelines and procedures covered in the installation instructions manual provided for the product. Built-In Mounting Flange Detail: Outdoor WALL MOUNT products include a mounting flange that is part of the cabinet construction. Ø.375" holes are provided for unit mounting unless specified otherwise in installation instructions. Specification Sheets: Unit specification sheets provided at www.bardhvac.com include basic unit weights and dimensions (see example below). Ventilation options and other accessories must be added into the total weight of the unit. Specification Sheet Example Unit Installation Wall Mount Manual 2100-034G Page 5 of 21 WALL MOUNT Products Clearances for Outdoor Condenser Fan Airflow Unit placement and avoidance of obstructions outside the structure are very critical to unit performance. Avoid installing the unit in areas that will obstruct outdoor condenser fan airflow or create "pockets" of heated air being exhausted from the condenser coil. Solid construction fences should not be placed directly in front of the unit without provisions for condenser airflow. Solid exterior walls need to be spaced as far away from units as possible to avoid pockets of heated air causing condenser air recirculation. Solid barriers located too close to the face or side surfaces (condenser fan inlet and outlet) of the WALL MOUNT can both impede airflow and force heated air to short circuit (be returned) from the condenser outlet to the condenser inlet. Either condition will effectively raise the condensing temperature and pressure reducing cooling capacity and efficiency. In extreme cases, the unit may fail to operate due to high refrigerant pressures inside the unit, and compressor and/or fan motor failure may occur. Clearances given in installation instructions ensure components can be serviced and maintenance can be performed when needed. National and local electrical codes must be reviewed before unit installation. Always use common sense when installing products, follow unit clearances given in the installation instructions and contact local Bard distributors when additional knowledge is needed regarding unit clearances for proper unit functionality. WALL MOUNT Products Clearances for Indoor Supply and Return Airflow The Bard unit should be placed in an area where the supply (leaving conditioned air) and return (unit air intake) air paths will be unrestricted. Avoid placing objects in the structure within 24" of the return (unit air intake) grille. Avoid placing objects directly in the path of the supply (conditioned) air grille. This will inhibit the "throw" of the supply air throughout the structure and reduce the cooling and/or heating ability of the unit; in extreme cases, this may cause evaporator coil freezing issues. Supply air must be able to freely circulate conditioned air throughout the structure. Adjustment of supply grille deflectors is often necessary to ensure proper room circulation. Ducted applications should not exceed the rated duct static pressures given in the unit specification sheets. Special requirements for duct construction and distances to combustible materials need to be followed per the installation instructions when electric heating is used. Manual 2100-034G Page 6 of 21 Unit Installation Wall Mount WALL MOUNT Products Condensate and Defrost Drainage Condensate drainage for air conditioning units needs to be planned before installation. Your new Bard WALL MOUNT product includes provisions to allow condensate water to exit the bottom of the unit. If condensate water is to be routed away from the unit, adequate drain sizing needs to be provided to allow proper drainage for condensate water generation. During normal air conditioning operation, large amounts of condensate water is generated inside the unit as moisture is extracted from the supply air. This is collected in an evaporator pan and drained to either a drainage system (indoor products) or outside the unit cabinet (outdoor products). Evaporator drain traps are not necessary for any of our wall mounted outdoor products, and the use of "standing water" U-shaped traps may be prone to freezing in certain climate zones. Condensate Water Drainage: Unit condensate water exits the base of the unit during cooling operation. Defrost water drainage from heat pump units needs to be planned before installation. During seasons requiring heating operation, the unit will need to warm the condenser coil to remove frost build-up (defrost). Outdoor heat pump products include holes in the unit base under the condenser coil for proper water drainage when in the heating defrost cycle. Avoid placing the unit on a pad or blocking the base drainage holes under the condenser coil without proper allowances (6" recommended) for water drainage due to damage caused by freezing conditions. Without proper drainage, defrost water may freeze causing ice build up and damage the lower portion of the condenser coil. Defrost Water Drainage: Holes are provided in the front of the unit base for heat pump condensate water drainage. Defrost Water Drainage: 6" clearance is recommended under WALL MOUNT Heat Pump products to allow proper defrost water drainage. Unit Installation Wall Mount Manual 2100-034G Page 7 of 21 I-TEC and Q-TEC Products Installing the Product Inside a Room Indoor products are normally supported by the floor surface and are adjacent to an interior wall surface, including brick, cement block, metal or wood construction. These products are normally labeled as "I-TEC" or "Q-TEC" units. Before installation begins, the floor surface should be inspected by a construction professional to ensure it will support the weight of the unit and accessory items. Approximate weights are available from the product specification sheet, and a safety factor should be designed into the installation. I-TEC A sheet metal sleeve is normally installed in the wall allowing vent and condenser fan air to enter and exit the unit. Different sleeve depths are available for installation into various wall depths. Typical fasteners to attach the sleeve to the outside surface of the wall include tap cons and other fastening devices. The I-TEC or Q-TEC unit is then slid up to the wall surface and connected to the sleeve using screws. Trim kits are available to enclose gaps between the wall surface and the unit. A louver grille is used to cover the external wall opening and fasteners used during sleeve installation. Q-TEC Wall Sleeve: Wall sleeves allow for outdoor air to enter and exit the unit inside the room. Air Paths: Air paths through the unit allow for cooling operation and fresh air to enter the structure (I-TEC shown). Louver Installation: Outdoor louvers provide an esthetically pleasing look to the installation and cover the unit opening (I-TEC shown). I-TEC and Q-TEC Products Clearances for Outdoor Condenser Fan Airflow Solid barriers located too close to the face of the outdoor louver of the I-TEC or Q-TEC can both impede airflow and force heated air to short circuit (be returned) from the condenser outlet to the condenser inlet. Either condition will effectively raise the condensing temperature and pressure reducing cooling capacity and efficiency. In extreme cases, the unit may fail to operate due to high refrigerant pressures inside the unit, and compressor and/or fan motor failure may occur. It is recommended to allow 15' (457.2 cm) in front of unit louver for proper condenser airflow. Always use common sense when installing products, follow unit clearances given in the installation instructions and contact local Bard distributors when additional knowledge is needed regarding unit clearances for proper unit functionality. Manual 2100-034G Page 8 of 21 Unit Installation I-TEC and Q-TEC I-TEC and Q-TEC Products Clearances for Indoor Supply and Return Airflow The Bard unit should be placed in an area where the supply (leaving conditioned air) and return (unit air intake) air paths will be unrestricted. Avoid placing objects inside the room within 24" of the return (unit air intake) louvers or grille. Avoid placing objects directly in the path of the supply (conditioned) air grilles. This will inhibit the "throw" of the supply air throughout the structure and reduce the cooling and/or heating ability of the unit and in extreme cases may cause evaporator coil freezing issues. Ducted applications should not exceed the rated duct static pressures given in the unit specification sheets. Special requirements for duct construction and distances to combustible materials need to be followed per the unit installation instructions when electric heating is used. I-TEC Air Path The I-TEC product has been engineered for extremely quiet unit operation and has multiple air paths for air entering and exiting the unit. Room air enters the upper sides to be conditioned (cooled) inside the unit and exits the unit top. The unit will either be ducted to supply registers or have a supply air plenum box installed. A supply air plenum box allows quiet operation without ducting the air leaving the unit. Room air also enters the bottom of both front doors during ventilation operation. Typical I-TEC Installation Q-TEC Air Path The Q-TEC product has been engineered for efficient, economical unit operation and has a mid-mounted front grille for air entering the unit. The unit will either be ducted to supply registers or have a supply air plenum box installed. A supply air plenum box allows quiet operation without ducting the air leaving the unit. Cool conditioned air exits unit Room air enters unit Typical Q-TEC Installation The I-TEC and Q-TEC product installation instructions contain additional information regarding unit air paths and required clearances. This information may be accessed at www.bardhvac.com. Unit Installation I-TEC and Q-TEC Manual 2100-034G Page 9 of 21 I-TEC and Q-TEC Products Condensate Drainage Condensate drainage for Bard indoor cooling units is a very important part of unit installation. During normal air conditioning operation, large amounts of condensate water are generated inside the unit as moisture is extracted from the supply air. This is collected in an evaporator pan and needs to be drained to an external drainage system. Your new Bard product includes provisions to allow condensate water to exit the unit and fittings will need to be field supplied to connect the unit drain to the building. Adequate drain sizing needs to be provided to allow proper drainage for condensate water generation and restriction in drain lines should be avoided. Evaporator drain traps are not necessary unless required by local codes. Defrost water for heat pump operation and outdoor water entering the condenser area also needs to be drained out of the unit. The I-TEC product uses a combined defrost and outdoor water drainage system. The Q-TEC has a combined defrost and evaporator drain connection unless an optional in-wall drain box is used. Outdoor water exits the Q-TEC through the wall sleeve. Follow all instructions provided in the unit installation instructions regarding drain connections and sleeve installation to avoid water leakage inside the building or structure. I-TEC Drain System: The I-TEC drainage system consists of a manifold drain kit that combines all drains behind the unit to allow connection to the building system. Q-TEC Drain System: The Q-TEC drainage system consists of a lower right side or lower right rear connection fitting. An optional in-wall drain box may also be purchased as an accessory that allows separate evaporator and defrost water drainage. Lower Right Side Drain Lower Right Rear Drain Optional In-Wall Drain Box Manual 2100-034G Page 10 of 21 Unit Installation I-TEC and Q-TEC All Products Power Supply Verification It is very important to follow all electrical and mechanical safety guidelines and instructions provided in the product installation instructions. Failure to do so may result in death, injury or product damage. A proper power supply to your new Bard unit is very important. Be sure to verify the following with a multi-meter or other power measuring device before applying power to your Bard product. Field-Supplied Voltage Electrical voltage ratings and proper voltage operating ranges are provided in the unit specification sheets and installation instructions. It is important that power supplied to the unit stay in the specified operating voltage range. Voltage above or below the minimum operating value given could result in improper unit startup, unit shutdown, low unit performance, improper thermostat and unit controller operation, compressor damage and premature failure of functional parts. As a general guideline, it is always best if the power source for the unit supplies the nominal electrical rating value given in the specification sheets, installation instructions and unit serial plate for the product being used. To do so will provide the best unit performance possible from your new Bard product. Single and Three Phase Power Bard products are available in single and three phase power options. It is important to connect the proper phase listed on the unit serial plate. Three phase power is often used to reduce energy usage, and units rated for 3 phase operation are equipped with a phase monitor safety device. The phase monitor will not allow unit operation with improper phase connection and a red LED light on the monitor indicates phase wiring issues. Connecting 3 phase power to a single phase unit will result in component damage and improper unit operation. Connecting single phase power to a 3 phase unit will also result in component damage and improper unit operation. Hertz (Frequency) Bard products are available in 50hz and 60hz power options. It is important to connect power with the proper hz value listed on the unit serial plate. 60hz power is often used in the United States and Canada and units rated for 50hz operation are normally for international sales outside of this area. Connecting 50hz power to a 60hz unit not rated for 50hz operation may result in component damage and improper unit operation. Some equipment may be rated for 50/60hz operation. Review the unit specifications and installation instructions for further information regarding the power requirements of the unit. The product installation instructions and unit specification sheets contain additional information regarding unit electrical data. This information may be accessed at www.bardhvac.com. Unit Installation Electrical Manual 2100-034G Page 11 of 21 Unit Maintenance All Products Filters and Filter Servicing All Bard products contain air filters that must be cleaned or replaced on a regular basis. Keeping air filter(s) clean is the single most important responsibility of the user of the equipment. Each type of system must be equipped with an air filter(s) in the indoor circulating air system to clean the air, keep the system itself clean for peak efficiency and capacity and prolong the useful life of the equipment. DO NOT operate the system without the proper air filters. Filters should be inspected at least monthly and replaced or cleaned (depending on type) as needed. The useful life of an air filter can vary widely depending upon application and use of the equipment, and it is critical to monitor filter condition and establish an acceptable maintenance schedule. Failure to do so will increase operating and repair costs, decrease capacity and efficiency and shorten the service life of the equipment. A common symptom of a dirty filter in the cooling mode is a freeze-up of the indoor coil. The air filters used may be a disposable (throwaway) type or may be a cleanable type that can be thoroughly cleaned, rinsed and reused many times. It is important to make sure that the correct filter size and type for your system is always used. If there is any question as to acceptable filter size or type, review the installation instructions for the specific equipment involved, if available. Otherwise, consult with your installing dealer or service company. Most equipment can have the filters inspected and serviced by the user with no problems. In some instances, because of equipment design or specific installation conditions, it may be necessary to have this procedure done by a qualified service company. Have your installer or service company show you where the filter(s) are and demonstrate the service procedure or make arrangements for them to provide this service on an as-needed basis. Outdoor Unit Wall Mount Room Air Filters Wall mount filters are normally accessed from the outside of the building. Bard does offer a return air grille with a filter frame built-in for indoor filter access. The return air filter grille is not acceptable as the only source of filtration if vent options are installed in the wall mount unit. Return Air Filter Grille: Bard offers the RFG return air filter grille, which may be used in applications where outdoor air is not brought into the structure through vent options. If vent options are used, the filter tray inside the Bard Wall Mount unit must be used. The product installation instructions contain additional information regarding unit maintenance. This information may be accessed at www.bardhvac.com. Manual 2100-034G Page 12 of 21 Unit Maintenance Filters WALL MOUNT Products Filters and Filter Servicing The built-in filter tray and room air filters in the wall mount are located in the middle of the cabinet below the indoor blowers. Units with vent options will have a washable screen behind the vent intake panel. Filter Door: The unit room air filter is located behind this panel for units without a vent hood. Vent Intake Panel Vent Hood Door: The unit indoor filter is located behind this panel for units with a vent hood. The hood contains a washable pre-filter that needs to be cleaned regularly. Vent Intake Panel Filter Door: The unit room air filter is located behind this panel. Unit Maintenance Filters Manual 2100-034G Page 13 of 21 I-TEC Indoor Products Filters and Filter Servicing The I-TEC indoor air conditioners and heat pumps have multiple filters that must be maintained and inspected when servicing the unit. Filters play an important part in proper unit operation and prevent dirt and dust buildup inside the I-TEC and the room the unit is installed in. To access the unit filters, open the front hinged doors by unlocking the door latches. The doors fold outward and are on hinges with lift-off pins. Use care when opening doors. If doors are lifted off of the hinge pins, use care as the dense insulation used for sound reduction causes the doors to be heavy. The upper section of the unit contains two 2" x 24" x 30" throwaway filters as standard with every unit. MERV ratings of the filter are available up to MERV13. These filters filter the air used for cooling inside the classroom or structure and should be changed regularly. If the unit has an air intake vent option installed, two 1" x 12" x 20" filters are located in the lower section of the front doors behind the louvers. These filters help keep the vent option clean and operating properly. Two washable filters are also installed in the air intake vent option. These should be inspected during servicing and cleaned when necessary. The washable filters are used to remove dirt and dust from outdoor air that is entering the vent area. If at any time these filters are damaged, they must be replaced with Bard-approved filters. I-TEC Filter Locations: Servicing the filters in your unit will help keep the inside of the unit clean and also the area it is installed in. The I-TEC product installation instructions contain additional information regarding unit maintenance. This information may be accessed at www.bardhvac.com. Manual 2100-034G Page 14 of 21 Unit Maintenance Filters Q-TEC Indoor Products Filters and Filter Servicing The Q-TEC indoor air conditioners and heat pumps have two room air filters that must be replaced when servicing the unit. Filters play an important part in proper unit operation and prevent dirt and dust buildup inside the Q-TEC and the room the unit is installed in. To access the unit filters, open the front hinged door by unlocking the door latch. The door folds outward and is on hinges with lift-off pins. Use care when opening doors. If the door is lifted off of the hinge pins, use care as the insulation and louver grille cause the door to be heavy. The upper section of the Q-TEC contains two 1" throwaway filters standard with every unit. These filters filter the air used for cooling inside the classroom or structure and should be changed regularly. QWS Unit QH/QA Unit Q-TEC Filter Location: The Q-TEC room air filters are located behind this hinged door. Unlock door latch and remove screw to open door. Screw location Filter locations Pre-filter location The Q-TEC will have a permanent pre-filter installed inside the wall sleeve if air intake vent options are inside the unit. The pre-filter must be inspected and cleaned when necessary. The easiest way to remove the pre-filter is through the outdoor louver. Clean the pre-filter with soapy water. The Q-TEC product installation instructions contain additional information regarding unit maintenance. This information may be accessed at www.bardhvac.com. Unit Maintenance Filters Manual 2100-034G Page 15 of 21 All Products Coil Cleaning The outdoor coil must be kept clean and free of any airborne debris, which can accumulate over time. Large volumes of air are circulated over the coil, and airborne debris such as lint, dust, materials shed from trees, paper or other types of airborne material that can become airborne can collect on the entering coil surface. The outdoor coil must dissipate heat during the cooling mode and for a heat pump, also absorb heat during the heating mode. If the coil is dirty and matted with debris, the airflow across the coil will be reduced causing poor performance, increased operating run time and associated utility bills and in extreme conditions can shorten the useful life of the equipment. Depending on the specific equipment involved, the surface that can accumulate debris can be on the opposite side that is exposed to view when standing in front of the machine. Closely review the machine when operating to see which direction or path the airflow takes as it moves through the machine. If the air inlet side of the coil is hidden, try to observe the back (hidden) side by looking into the side grilles, using a flashlight if necessary. While the user of the equipment needs to be aware of the potential of clogging of the outdoor coil surface, actual cleaning of the outdoor coil should not be attempted under most circumstances. If the user should attempt this procedure on their own, never do so without first having the installing dealer or service company instruct you in the proper procedure and technique. WARNING: Do not open or enter the equipment without first turning off the electrical service disconnect. Failure to do so can result in personal injury due to moving parts and/or electric shock hazard resulting in death. Other conditions that can cause reduction of airflow across the outdoor coil are flowers, shrubbery or other growth too near the outdoor coil air inlet and outlet openings. These living things, especially as they mature and grow, will be just as effective in blocking the airflow and create the same problems as will stacking things against the equipment. These conditions can be easily managed and controlled by the user, as they do not require actually entering into the equipment enclosure, which should only be done by qualified service technicians. Equipment Corrosion Protection 1. Avoid having any lawn sprinkler spray directly on the equipment, especially if from a brackish water source. 2. In coastal areas or corrosive environments, locate equipment as far away from the corrosion source as feasible. Units exposed directly to salt spray should be coated by a secondary protective coating operation to reduce corrosion on copper tubing, fasteners, motors and other metal parts. Coils should be ordered with a corrosion protective coating. Contact Bard for coating options. 3. Frequent cleaning and waxing of the cabinet using a good automobile polish will help extend its original appearance and protect painted surfaces. The product installation instructions contain additional information regarding unit coil cleaning. This information may be accessed at www.bardhvac.com. Manual 2100-034G Page 16 of 21 Condenser Coil Cleaning All Products Condenser Airflow W**A, W**H, T**H, T**S, W*RV Wall Mount Units: These units are called "blow through condenser airflow" units because they draw cool outdoor air from the sides and blow the warm condenser air exiting the coil through the front grille. C**H Wall Mount Units: These units are called "draw through condenser airflow" units because they draw cool outdoor air in the front through the coil and blow the exiting warm condenser air through the unit sides. I-TEC and Q-TEC Units: These units draw the cool outdoor air through the top section of the wall louver and exhaust the warmer condenser air out of the lower section of the louver. I-TEC units also draw a small amount of air through the outer right and left side of the louver. Condenser Coil Cleaning Manual 2100-034G Page 17 of 21 Unit Operation Air-to-Air Cooling Products (Air Conditioners) The cooling mode operates similar to a refrigerator, removing heat from inside the conditioned space and rejecting it outside of the space being controlled. There are three main parts of the system: 1. The evaporator (indoor) coil where cold refrigerant absorbs heat from the air, which circulates from the conditioned space through the machine and is returned to the space at a lower temperature and with some of the humidity (moisture) removed. The moisture exits through a condensate drain system. A motor/blower assembly moves the indoor air through the system. 2. The compressor, which is a sealed pump that moves the refrigerant through the system. 3. The condenser (outdoor) coil where the heat that was absorbed from the indoor space is discharged to the outdoor environment. A motor/fan system moves the outdoor air across the condenser coil. A properly sized air conditioner cannot cool a structure off rapidly and instead will pull down the temperature slowly. It also will remove a certain amount of moisture (humidity) from the circulating airstream in the process. It may take several hours to pull down a hot, moist building or structure on initial startup or anytime the system has been turned off for a long period of time. It is generally best to set the thermostat at a comfortable temperature and let it control the system as needed, rather than turning it on and off. Moisture (humidity) removal with a conventional air conditioner (cooling) unit, or heat pump when operating in the cooling mode, is not directly controlled and is a by-product of the unit operating to control temperature in response to the temperature (thermostat) control device. Oversized equipment can easily control temperature but will have short run-times, thus reducing its ability to remove moisture from the circulating air stream. There are also many additional influences that can affect humidity levels within the conditioned space such as laundry appliances, cooking, showers, exhaust fans and any other items that can generate moisture or affect its removal from the space. Therefore, while operation of the air conditioning or heat pump system in the cooling mode will remove some amount of moisture as it reduces the air temperature, precise humidity regulation in the conditioned space cannot be assured and additional equipment such as a dedicated dehumidifier may be required. Air-to-Air Cooling and Heating Products (Heat Pumps) A heat pump is a refrigerant-based system that has additional components and controls that both heats and cools using a compressor for both modes of operation. Most heat pumps will also be equipped with some amount of electric heat to supplement the heating capacity of the compressor system on an as-needed basis. This operation is entirely automatic and is controlled by the indoor thermostat and possibly also an outdoor thermostat. Cooling Mode The cooling mode of a heat pump is exactly the same as that described for an air conditioner in the above section. Heating Mode The system operates in reverse cycle, meaning that it absorbs and moves heat from the outdoors and transfers it indoors to be rejected into the circulating air stream. Even though it seems cold to humans, there is usable heat that can be extracted efficiently from the outdoor air down to 0ºF, although the colder the air is there is less heat to extract and the operating efficiency is diminished. Defrost Cycle When operating in the heating mode, the outdoor coil will be colder than the outdoor air that is forced over it by the fan system. When the outdoor air temperature is above approximately 40°F, moisture can accumulate on the coil and it will drain down and out the base of the unit. As the air temperature gets below approximately 40°F, the coil temperature will start to drop below 32°F, and frost or ice will begin to form on the coil. An automatic defrost system keeps track of system run time when the outdoor coil temperature is in the freezing zone and will initiate a defrost cycle at the appropriate time. The unit continues to operate during the defrost cycle, but the outdoor fan motor will stop and the reversing valve will shift positions to flow hot refrigerant gas through the outdoor coil to melt the accumulated frost. Water will start to drain freely from the unit, and steam may be emitted from the unit. The length of the defrost cycle will vary depending upon actual outdoor temperature, humidity levels and amount of accumulated frost. It could range from 1-2 minutes up to but not exceeding 8 minutes. When the defrost cycle Manual 2100-034G Page 18 of 21 Unit Modes of Operation terminates, the reversing valve will shift back to heating mode and the outdoor fan will restart. There is typically a large puff of steam emitted as the fan restarts. When the heat pump shifts from cool to heating mode, from heating to cooling mode and especially during defrost cycles, there will be a pressure transfer sound heard as the reversing valve redirects the flow of refrigerant. This is commonly described as a hissing noise and is a normal sound for this type equipment. For air source heat pumps, it is important to keep heavy snow from accumulating around the machine to the point of blocking the inlet and outlet openings to the outdoor coil section. For wall mounted or other equipment that is elevated, this should not be a factor; but for equipment installed on or near the ground, this can be an issue in areas prone to heavy and/or blowing snow. The air source heat pump cannot operate effectively and efficiently when snowbound just as a car cannot function well in heavy snow conditions. Water-to-Air Cooling and Heating Products (Geothermal Heat Pumps) These types of heat pumps are also commonly referred to as water source or geothermal systems. Just like the air source heat pump, they are refrigerant-based systems that both heat and cool using a compressor for both modes of operation. The primary difference is that the system uses water or antifreeze-protected water solution instead of an air-cooled outdoor heat transfer coil, and there is no outdoor motor/fan system but instead a water pump to provide adequate water flow to the system. Cooling Mode The cooling mode of a water-to-air heat pump is exactly the same as that described for an air conditioner in the previous Air Conditioner section, except that the outdoor coil uses water instead of air for the heat transfer medium. Heat Mode The system operates in reverse cycle, meaning that it acquires and moves heat from the water supply flowing through the water to refrigerant coil and transfers it indoors to be rejected into the circulating air stream. Most water-to-air heat pumps (but not all) will also be equipped with some amount of electric heat to supplement the heating capacity of the compressor system on an as-needed basis. This operation is entirely automatic and is controlled by the indoor thermostat. Because of the design of water-to-air heat pumps and the water temperatures involved, no defrost system is required as in air-to-air heat pumps. Water Supply Systems Depending upon the type and application of the water-to-air heat pump, the water side of the system could be one of the following: 1. Individual closed loop buried in a trench or vertical bore hole(s). 2. Individual loop submerged in a pond. 3. Water supplied from a well and discharged into pond, stream, ditch or another well. 4. Water supplied from a boiler/tower system, typically only in larger multi-unit installations. Unit Modes of Operation Manual 2100-034G Page 19 of 21 Dehumidification and Ventilation Operation Dehumidification (Air-to-Air or Water-to-Air Systems) Many Bard systems, typically those used in schools or other commercial applications, have a dedicated dehumidification capability by having a special additional refrigeration circuit (factory-installed option only) in addition to the basic system. These special systems, sometimes also referred to as hot gas reheat, are designed to control humidity on demand from a humidity controller much the same as the basic cooling and/or heating system is controlled by a wall thermostat. Consult your installer and/or service company to determine if your installation has any of these devices and for any instructions or maintenance requirements you should be aware of as the user. Ventilation Options (Air-to-Air or Water-to-Air Systems) All Bard systems are available with factory-installed vent options. Most units can have ventilation field installed after unit installation. Ventilation has multiple purposes: · Outside air intake for occupied structures · Positive pressurization · Energy savings when outdoor air can be used for cooling · Agricultural use of bringing in outdoor air and exhausting room air · Equipment and electronics ventilation Review product specifications and manuals for more details regarding available ventilation options and features. Product documentation is shipped with the product and also available at www.bardhvac.com. Manual 2100-034G Page 20 of 21 Dehumidification and Ventilation Operation Troubleshooting All Units Troubleshooting Your Bard product is made to operate for many trouble-free years if installed properly and maintenance practices are followed. Be sure to verify that all filters are clean, and condenser coils are free of dirt and debris. Often these items may look clean at first, but upon closer inspection, show signs of dirt and debris build-up. New units on new structures may have dirt and dust in filters from the building construction process. Thermostats and unit controllers often contain vent holes for proper sensor measurement inside the device. Make sure the thermostat or controller are not full of dirt and dust from building construction or years of use. Verify all requirements in the installation instructions and specification sheets are met. Unit voltages, airflow clearance requirements and clean unit power without brownouts or spikes play a critical role in unit performance. If 208 VAC power is supplied to the unit, the 208V tap must be used on the 24 VAC transformer located inside the control panel. Common sense must also be used when installing the unit in an environment that may put the unit at risk of improper operation. Helpful Hints and Good Operating Practices The following information will help you enjoy the full comfort and benefits of your Bard cooling and heating system, maximize the performance and efficiency and help extend the life of your system. 1. Always keep the equipment in peak operating condition with routine scheduled maintenance, especially for the air filters, and to assure a clean outdoor coil. 2. For most efficient operation, set the thermostat at the temperature you prefer and then let it take control. If any changes to the settings are required, they should be made in small adjustments and the system be allowed time to respond. Rapid changes either up or down should not be done. 3. Setting the thermostat very high does not make the system heat faster and setting it very low does not make it cool faster. 4. It is not recommended to turn the system "Off" then back "On" when you need it. This can allow temperature and humidity to build up in warm weather conditions and force the system to run continuously to try and catch up. If the building is to be unoccupied for a lengthy period, it is best to adjust the thermostat to a reasonable higher (or lower--depending on the season) setting rather than turning it completely off. Upon return, the inside conditions will not be totally out of control and recovery time to desired conditions would be much shorter. 5. Airflow inside the room or building is very important. Keep all supply registers open and all returns free and unrestricted. Avoid placing objects in areas that will hinder unit airflow. The heating and cooling system is designed to have a certain amount of airflow for proper operation. Therefore, closing off registers, in unused rooms as an example, could reduce airflow below acceptable levels and should not be done without review by your service company who can assess the overall situation and advise you accordingly. 6. Heat pumps, especially air-to-air heat pumps, may have the system (compressor) run continuously at lower outdoor temperatures, and this is normal. The heat pump (compressor) mode is controlled by the beginning stages of the thermostat and delivers the most efficient heat. As the outdoor temperature drops off, the heat pump mode heat will also diminish (because there is less heat in the outdoor air to absorb) and must be supplemented by additional electric heat stages, which are not as efficient as the heat pump. The thermostat automatically controls everything and the backup heat will only operate on demand as needed to maintain the desired temperature. 7. The thermostat or controller is the user's primary connection to the system so it is very important to have a thorough understanding of how it works and how to use it properly. Have your installer or service company explain and demonstrate proper operation of the controls. 8. Make sure you thoroughly understand how the heating and cooling system itself is intended to operate and what to expect from it. Have your installer or service company explain and demonstrate proper operation of the heating and cooling system. Troubleshooting Manual 2100-034G Page 21 of 21 SERVICING PROCEDURE R-410A LEAK TEST EVACUATION CHARGING Bard Manufacturing Company, Inc. Bryan, Ohio 43506 Since 1914...Moving ahead, just as planned. Manual No.: 2100-479 Supersedes: NEW File: Volume I, Tab 1 Date: 03-08-07 Manual 2100-479 Page 1 of 11 CONTENTS General Recovery Equipment Rated for R-410A...................3 Leak Detectors.........................................................3 Gauge Manifold........................................................3 Attaching Gauge Manifold........................................3 Attaching Manifold Hose to Schrader Valve.............4 Leak Test..................................................................4 Evacuation ........................................................ 4 & 5 Charging ..................................................................5 Preliminary Charging Steps .....................................5 Charging the System by Weight ..............................5 Troubleshooting the Mechanical System Air Conditioning & Heat Pump - Cooling.............9 Low Suction -- Low Head Pressure .........................9 High Suction -- Low Head Pressure ........................9 Low Suction -- High Head Pressure ........................9 High Suction -- High Head Pressure........................9 Heat Pump - Heating..............................................9 Low Suction -- Low Head Pressure .........................9 High Suction -- Low Head Pressure ........................9 Low Suction -- High Head Pressure ........................9 High Suction -- High Head Pressure........................9 Figures Figure 1: Typical AC System Cooling Cycle.............6 Figure 2: Typical HP System Cooling Cycle ............7 Figure 3: Heating Cycle ...........................................8 Charts Troubleshooting Chart for Air Conditioners ............10 Troubleshooting Chart for Air-to-Air Heat Pumps....11 Manual 2100-479 Page 2 of 11 GENERAL WARNING The oils used with R-410A refrigerant are hydroscopic and absorb water from the atmosphere readily. Do not leave systems open to the atmosphere for more than 5 minutes. If the system has been open for more than 5 minutes, change the filter dryer immediately before evacuation. Then recharge the system to the factory specified charge. Recovery equipment rated for R-410A refrigerant R-410A has an ozone depletion potential of zero, but must be reclaimed due to its global warming potential. The gauge manifold set is specially designed to withstand the higher pressure associated with R-410A. Manifold sets are required to range up to 800 psig on the high side and 250 psig on the low side with a 250 psig low side retard. All hoses must have a service rating of 800 psig. (This information will be indicated on the hoses.) Vacuum Pump and micron gauge must be used when evacuating a system to 500 microns. Leak Detectors An electronic leak detector capable of detecting HFC refrigerant can be used with R-410A refrigerant. GAUGE MANIFOLD WARNING Gauge manifold must be suitable for use with R-410A refrigerant and POE oils. A necessary instrument in checking and serving air conditioning and heat pump equipment is the gauge manifold. Its purpose is to determine the operating refrigerant pressures in order for the serviceman to analyze the condition of the system. The valving on the manifold is so arranged that when the valves are closed (front-seated) the center port on the manifold is closed to the gauges and gauge ports. With the valves in the closed position, the gauge ports are still open to the gauges, permitting the gauges to register system pressures. Opening either valve opens the center port to that side of the manifold and system. ATTACHING GAUGE MANIFOLD For leak testing, purging, checking charge, charging liquid or evacuating, connect high pressure side of gauge manifold to Schrader valve on liquid or discharge line. Connect suction side of gauge manifold to Schrader valve on suction line. On heat pumps the suction line is between compressor and reversing valve. Manual 2100-479 Page 3 of 11 ATTACHING MANIFOLD HOSE TO SCHRADER VALVE WARNING As a safety measure, it is wise to detach refrigerant hoses at the lowest pressure readings on the system. To do this: A. Put high pressure hose "B" on first. (Unit should not be running.) B. Put low pressure hose "A" on second. (Unit should be running.) 1. Remove cap from valve. 2. Make sure gauge manifold valves are closed. 3. If hose does not have an unseating pin, a number 395 Superior or equivalent unseating coupler must be used. 4. Make sure coupler is lined up straight with Schrader valve. Screw coupler on to valve. 5. Open gauge manifold valve slightly and purge air from hose with refrigerant. 6. Read the suction pressure on compound gauge and heat pressure on pressure gauge. 7. To remove, push end of hose tight against end of Schrader valve and hold in place while quickly unscrewing coupler nut from Schrader valve. 8. Remove coupler from Schrader valve. Replace caps on valve. Leak Test 1. Remove gauge port cap from suction and liquid service valve ports and attach manifold gauge hoses. Connect an upright R-410A drum to center port of gauge manifold. Open refrigerant drum valve and manifold high pressure gauge valve to pressurize system to a positive pressure with refrigerant vapor. Pressurize the complete system with dry nitrogen, or CO2 until the pressure reaches 200 psig. Do not exceed 250 psig. 2. Close manifold high pressure gauge valve. Check all soldered joints, including those on the evaporator coil with an Electronic Leak Detector suitable for use with HFC refrigerants or R-410A. If a leak is found which requires soldering, pressure in the system must be bled off since it is impossible to solder with unit pressurized. Be sure all leaks are located and marked before bleeding pressure from system. Manual 2100-479 Page 4 of 11 3. Close drum valve and disconnect from center port. Release nitrogen or CO2 into the atmosphere through suction line of gauge manifold. 4. Correct any leaks and recheck. When leaks, if any, have been repaired, system is ready to be evacuated and charged. Relieve all pressure from the system down to 0 psig. 5. Change the dryer. When leaks, if any, have been repaired, system is ready to be evacuated and charged. Relieve all pressure from the system down to 0 psig. EVACUATION Evacuation An evacuation to 500 microns is usually to remove moisture from a system using R-22 and mineral oil lubricant. A 500 micron evacuation, however, will not separate moisture from Polyol Ester oil (POE) in R-410A systems. In addition to a 500 micron evacuation, the liquid line dryer (R-410A compatible) must be replaced any time the system is open. When removing a dryer from a system, do not use a torch; use a tubing cutter to avoid releasing moisture back into the system. Older R-22 leak detectors, as well as halide torch leak detectors, will not detect leaks in R-410A systems. Never use air and R-410A to leak check, as the mixture may become at pressures above 1 atmosphere. A system can be safely leak-checked by using nitrogen or a trace gas of R-410A and nitrogen. Remember: Always use a pressure regulator with nitrogen and a safety valve down stream - set at no more than 150 psig. 1. Evacuate system to less than 500 microns, using a good vacuum pump and an accurate high vacuum gauge. Operate the pump below 500 microns for 60 minutes and then close valve to the vacuum pump. Allow the system to stand for 30 additional minutes to be sure a 500 micron vacuum or less is maintained. WARNING At no time use the compressor to evacuate the system or any part of it. 2. Disconnect charging line at vacuum pump and connect to refrigerant supply. Crack the cylinder valve and purge charging line at center on manifold. Then close cylinder valve. 3. The system is now ready for the correct operating charge of Refrigerant R-410A. R-410A System Charging Even though R-410A has a very small fractionation potential, it cannot be ignored completely when charging. To avoid fractionation, charging of an air conditioner or heat pump system incorporating R-410A shall be done with "liquid" to maintain optimum system performance. To insure that the proper blend composition is charged into the system, it is important that liquid only be removed from the charging cylinder. Some cylinders supplied by manufacturers have dip tubes, which allow liquid refrigerant to be removed from the cylinder when it is in the upright position. Cylinders without dip tubes have to be tipped upside down in order for liquid to be removed. The Service Technician must differentiate between which type of charging cylinder they are using to avoid removing vapor refrigerant instead of liquid refrigerant to avoid fractionation and for safety concerns. Connect the gauge manifold to the high and low side. Allow liquid to enter the high side only. The high side will hold 80100% of the total charge. When liquid stops close high side port. The remainder of the charge will be added to the low side. Keep in mind two issues: never start the compressor with less than 55 psig of suction pressure. Secondly, make sure the liquid is throttled, thus vaporized into the low side of the system to avoid compressor damage. A throttling valve can be used to insure that liquid is converted to vapor prior to entering the system. Proper manipulation (restricting) of the manifold gauge set can also act as a throttling device to insure liquid is not entering the compressor. CHARGING THE SYSTEM BY WEIGHT 1. Connect manifold as instructed. 2. Place refrigerant drum upright on scale and determine exact weight of the refrigerant and cylinder. 3. With manifold suction valve closed and manifold discharge valve open, open refrigerant cylinder liquid valve and allow pressure in system to balance with pressure of cylinder or 80% of charge is in the unit whichever comes 4. When there is approximately an 80% charge, front seat (close) the discharge manifold valve and let the system stabilize for about minutes. 5. Start compressor by setting thermostat. 6. Finish charging with liquid by cracking the suction valve. Open the manifold low pressure valve to allow refrigerant to into the system. Throttle the manifold valve to keep pressure about 100 psig for R-410A. 7. When the correct weight of refrigerant has been added to the unit, close refrigerant cylinder valve and allow unit to run for 30 minutes. Refer to Start-Up Procedure and Check List for further start-up details. 8. Front seat gauge manifold valves, disconnect charging and gauge hoses and replace all valve caps. CHARGING 1. Single Package Units -- Refer to the unit serial plate for the full operating charge. PRELIMINARY CHARGING STEPS If the system has been open to the atmosphere, the dryer should be replaced and then evacuated. Then proceed as follows: 1. Attach a drum of proper, clean refrigerant to the center port of the charging manifold with one of the charging hoses. 2. Attach a second charging hose to the suction gauge (low pressure) side of the gauge manifold. 3. Remove the cap from the suction line valve. 4. Loosely attach the suction gauge hose to the line valve. Open the valve on the refrigerant drum and the suction valve on the charging manifold slightly to purge the air from the manifold and hoses before tightening the 5. Attach the third hose to the high pressure side of the manifold and the liquid line valve. Repeat steps 3 and 4 above. Manual 2100-479 Page 5 of 11 FIGURE 1 TYPICAL AIR CONDITIONING SYSTEM COOLING CYCLE Manual 2100-479 Page 6 of 11 MIS-369 FIGURE 2 TYPICAL HEAT PUMP SYSTEM COOLING CYCLE MIS-368 Manual 2100-479 Page 7 of 11 WARNING To speed refrigerant flow, it may be necessary to place refrigerant drum in a pan of warm water (not greater than 130ºF). Remember to either consider the total weight of the pan of water or remove the drum for weighing frequently to keep track of the charging process. FIGURE 3 HEATING CYCLE Manual 2100-479 Page 8 of 11 MIS-289 TroubleshooTing The Mechanical sysTeM AIR CONDITIONING AND HEAT PUMP -- COOLING LOW SUCTION -- LOW HEAD PRESSURE 1. Restricted over indoor coil. 2. Defective indoor fan motor. 3. Low indoor temperature 4. Iced indoor coil. 5. Restricted liquid line, dryer, metering device, etc. 6. Low charge. 7. Low ambient entering air temperature. (Low entering water temperature to water coil.) HIGH SUCTION -- LOW HEAD PRESSURE 1. Defective or broken valves. 2. IPRV valve open. 3. Defective reversing valve. LOW SUCTION -- HIGH HEAD PRESSURE 1. Partial restriction and then overcharged. HIGH SUCTION -- HIGH HEAD PRESSURE 1. High entering outdoor air temperature. (High entering water temperature.) 2. Low outdoor coil. (Low water . ) 3. Overcharged. 4. Air in system. 5. Restricted outdoor coil. (Restricted water coil.) 6. High indoor air temperature. Water source heat pump. HEAT PUMP -- HEATING LOW SUCTION -- LOW HEAD PRESSURE 1. Restricted through outdoor coil. (Restricted water through water coil.) 2. Defective outdoor motor. (Defective water pump.) 3. Low outdoor air temperature. (Low water temperature.) 4. Frozen outdoor coil. (Frozen water coil.) 5. Restricted liquid line, dryer, metering device, etc. 6. Low charge. 7. Low indoor air temperature. HIGH SUCTION -- LOW HEAD PRESSURE 1. Defective or broken valves. 2. IPR valve open. 3. Defective reversing valve. LOW SUCTION -- HIGH HEAD PRESSURE 1. Partial restriction and then overcharged. HIGH SUCTION -- HIGH HEAD PRESSURE 1. High entering outdoor air temperature. (High entering water temperature.) 2. Low indoor . 3. Overcharged. 4. Air in system. 5. Restricted air coil. 6. High indoor air temperature. Water source heat pump. Manual 2100-479 Page 9 of 11 Manual 2100-479 Page 10 of 11 y Generally the cause. Always make these checks first. Occasionally the cause. Make these checks only if first checks fail to locate trouble. Rarely the cause. Make this check only if previous checks fail to locate trouble. Compressor and condenser fan motor will not start Compressor will not start but condenser fan will run Condenser fan motor will not start Compressor "hums" but will not start Compressor cycles on overload Compressor short cycles on low pressure Compressor runs continuously--no cooling Compressor runs continuously --cooling Compressor noisy Compressor loses oil Head pressure too high Head pressure too low Liquid line frosting or sweating Suction pressure too high Suction pressure too low Evaporator frosting Suction line frosting or sweating Evaporator blower will not start Condenser fan motor runs contactor not pulled in Liquid refrigerant flooding back to compressor-- cap tube system Space temperature too high Meter to Line Side of Contactor TROUBLESHOOTING CHART FOR AIR CONDITIONERS Power Supply Load Side of Contactor to Motor Terminal Control Circuit Motors Power Failure Blown Fuses or Tripped Circuit Breakers Faulty Wiring Loose Terminals Low Voltage Single 1PH Failure of 3PH Unbalanced Power Supply 3PH Voltage Too High Open Disconnect Switch Faulty Wiring Loose Terminal Low Voltage Defective Contacts in Contactor Compressor Overload Potential Relay Fails to Open Potential Relay Fails to Close Run Capacitor Start Capacitor Faulty Wiring Loose Terminals Control Transformer Low Voltage Thermostat Contactor Coil Pressure Control Condenser Fan Relay Evaporator Fan Relay Compressor Motor Condenser Motor Evaporator Motor Compressor Off on Internal Overload Hold Down Bolts Defective Compressor Bearings Seized Compressor Defective Compressor Valves Compressor Oil Level Open or Short Motor Windings Refrigerant Charge Low Overcharge of Refrigerant High Head Pressure High Suction Pressure Low Suction Pressure Temperatures Non-Condensables (Air, etc.) Excessive Load in Space Liquid Valve Partially Closed Condenser Fins Dirty or Plugged Condenser Fan Belt Slipping Condenser Air Short Circuiting Low Condenser Air Volume Condenser Air Temperature Low Plugged or Restricted Metering Device Evaporator Fins Dirty or Plugged Evaporator Belt Slipping Low Evaporator Air Volume Dirty Filters Ductwork Small or Restricted Restrictions Thermostat Setting Thermostat Location Stratified Air in Space Incorrect Refrigerant Piping System Too Small Compressor High Pressure Side of System System Operation Condenser Air Low Side Evaporator Air General Page 11 of 11 Manual 2100-479 Heating Cycle Cooling Cycle Heating or Cooling Cycles y Denotes common cause. Denotes occasional cause. TROUBLESHOOTING CHART FOR AIR TO AIR HEAT PUMPS Compressor and O.D. fan motor do not operate Compressor will not run O.D. fan motor runs Compressor "hums" but will not start Compressor cycles on overload Compressor off on high pressure control Compressor noisy Head pressure too high Head pressure too low Suction pressure too high Suction pressure too low I.D. blower will not start I.D. coil frosting or icing- High compressor amps Compressor runs continuously--no cooling Liquid refrigerant flooding back to compressor Compressor runs continuously--no heating Defrost cycle initiates no ice on coil Reversing valve does not shift Ice build up on lower part of O.D. coil Liquid refrigerant flooding back to compressor Auxiliary heat on I.D. blower off Excessive operating costs Excessive ice on O.D. coil Line Voltage Power Supply Control Circuit Compressor Refrigerant System Power Failure Blown Fuse or Tripped Breaker Faulty Wiring Loose Terminals Low Voltage Single 1PH Failure of 3PH Unbalanced 3PH Defective Contacts in Contactor Compressor Overload Potential Relay Run Capacitor Start Capacitor Faulty Wiring Loose Terminals Control Transformer Low Voltage Thermostat Contactor Coil Pressure Control or Impedance Relay Indoor Fan Relay Discharge Line Hitting Inside of Shell Bearings Defective Seized Valve Defective Motor Windings Defective Refrigerant Charge Low Refrigerant Overcharge High Head Pressure Low Head Pressure High Suction Pressure Low Suction Pressure Non-Condensables Unequalized Pressures Sensing Bulb Loose-Poorly Located Cycle Too Long (Clock timer) Defective Control, Timer or Relay Leaking Defective Valve or Coil Sticking Closed Leaking or Defective Plugged or Restricted Meter Device (Htg) Fins Dirty or Plugged Motor Winding Defective Recirculation or Air Air Volume Low (Cooling) Low Temperature Coil Air (Cooling) Plugged or Restricted Metering Device (Clg) Fins Dirty or Plugged Motor Winding Defective Air Volume Low Air Filters Dirty Undersized or Restricted Ductwork Sticking Closed Leaking or Defective Auxiliary Heat Upstream of Coil Outdoor Section Defrost Control Rev. Valve Check Valve Outdoor Fan Motor and Coil Indoor Section Indoor Blower Motor and Coil Aux. Heat Check INSTALLATION INSTRUCTIONS 11EER WA Series Wall Mount Air Conditioner W18AB-A Right Hand Models: W24AB-A W24AB-B W24AB-C W24AB-D W24AB-F W30AB-A W30AB-B W30AB-C W30AB-D W30AB-F W36AB-A W36AB-B W36AB-C W36AB-D W36AB-E W36AB-F W30ABDA W36ABDA W30ABDB W36ABDB W30ABDC W36ABDC W18LB-A Left Hand Models: W24LB-A W24LB-B W24LB-F W30LB-A W30LB-B W30LB-C W30LB-F W36LB-A W36LB-B W36LB-C W36LB-F Bard Manufacturing Company, Inc. Bryan, Ohio 43506 www.bardhvac.com Manual: 2100-689H Supersedes: 2100-689G Date: 3-1-21 Page 1 of 42 CONTENTS Getting Other Information and Publications .... 3 Wall Mount General Information ......................... 4 Air Conditioner Wall Mount Model Nomenclature..... 4 Shipping Damage ................................................. 4 General ............................................................... 4 Duct Work ........................................................... 5 Filters ................................................................. 5 Fresh Air Intake ................................................... 5 Installation ............................................................... 6 Basic Installation Design and Application Planning.. 6 Wall Construction ............................................. 6 Outdoor Area Inspection.................................... 6 Condensate Water Drainage ............................... 6 Indoor Ducted and Non-Ducted Applications........... 6 Indoor Supply Airflow........................................ 6 Indoor Return Airflow ........................................ 6 Ducted Applications ......................................... 7 Free Blow Applications...................................... 7 Thermostat or Indoor Temperature Sensor Placement ....................................................... 7 Unit Installation ................................................... 7 Materials/Tool List ............................................ 7 Wall Preparation............................................... 8 Wall Mount Installation to Wall Surface .............. 8 Wiring Main Power........................................... 16 Wiring Low Voltage........................................... 16 Low Voltage Connections ................................. 16 Unit Shutdown Feature ................................... 16 Balanced ClimateTM Feature............................. 16 Dehumidification Feature ................................ 17 Ventilation Features ........................................ 17 Low Ambient Control (LAC) ............................. 17 Outdoor Temperature Switch and Freeze Protection Thermostat................................. 17 Alarm Relay Feature ....................................... 17 DDC Controls Feature...................................... 17 Dirty Filter Switch Indicator (DFS) ............... 17 Discharge Air Sensor .................................. 17 Airflow Switch ............................................ 17 Compressor Current Sensor ......................... 18 Start Up ................................................................... 21 General ............................................................. 21 Topping Off System Charge ................................. 21 Safety Practices ................................................. 21 Important Installer Note...................................... 21 High Pressure Switch.......................................... 21 Three Phase Scroll Compressor Start Up Information........................................................ 21 Phase Monitor.................................................... 22 Condenser Fan Operation .................................... 22 Service Hints ..................................................... 22 Sequence of Operation........................................ 22 Balanced ClimateTM Mode................................ 22 Vent Connection Plug.......................................... 23 Compressor Control Module ................................. 23 Features ........................................................ 23 Delay-on-Make Timer ...................................... 23 Short Cycle/Delay-on-Break ............................. 23 Low Pressure Detection................................... 23 High Pressure Detection.................................. 23 Test Mode...................................................... 23 Brownout Protection with Adjustment ............... 23 Pressure Service Ports ........................................ 24 Service ..................................................................... 25 Troubleshooting Nidec SelecTech Series ECM Motors............................................................... 25 If the Motor is Running ................................... 25 If the Motor is Not Running ............................. 25 Model SelecTech Communication Diagnostics ... 26 Fan Blade Setting Dimensions ............................. 27 R-410A Refrigerant Charge ................................. 27 Removal of Fan Shroud....................................... 27 Setting Unit Airflow ............................................ 32 Blower Speeds ............................................... 32 Speed Tap 1 Vent/Blower Only .................. 33 Speed Tap 2 Balanced Climate ................. 33 Speed Tap 3 Default LO Cooling & Heating ............................... 33 Speed Tap 4 Optional MED Cooling & Heating ............................... 33 Speed Tap 5 Optional HI Cooling & Heating ............................... 33 Dirty Filter Switch .............................................. 34 Dirty Filter Switch Adjustment ......................... 34 FIGURES Figure 1 Fresh Air Damper .................................. 5 Figure 2 Unit Dimensions ................................. 10 Figure 3A Mounting Instructions W18, 24 .......... 11 Figure 3B Mounting Instructions W30, 36............. 12 Figure 4 Electric Heat Clearance ....................... 13 Figure 5 Wall Mounting Instructions .................. 14 Figure 6 Wall Mounting Instructions .................. 14 Figure 7 Common Wall Mounting Installations .... 15 Figure 8 Programmable Thermostat Connections ....................................... 19 Figure 9 Thermostat Connections ...................... 20 Figure 10 8201-169 Compressor Control Module ...24 Figure 11 Motor Connections .............................. 25 Figure 12 Motor Connections .............................. 26 Figure 13 Fan Blade Setting ............................... 27 Figure 14 Speed Taps......................................... 32 Figure 15 Speed Taps......................................... 33 Figure 16 Dirty Filter Switch Location.................. 34 Figure 17 Adjusting Dirty Filter Switch................. 35 Manual 2100-689H Page 2 of 42 TABLES Table 1 Clearance Required for Service Access and Adequate Condenser Airflow............. 9 Table 2 Minimum Clearances Required to Combustible Materials ........................... 9 Table 3 Additional Low Voltage Connections (if applicable) ..................................... 16 Table 4 Low Voltage Connections for DDC Control ....................................... 18 Table 5 Humidity Controls ............................... 18 Table 6 CO2 Controllers ................................... 18 Table 7 Thermostat Wire Size........................... 18 Table 8 Wall Thermostats ................................ 18 Table 9 Fan Blade Dimensions ......................... 27 Table 10 Cooling Pressure Standard Airflow ...... 28 Table 11 Cooling Pressure Balanced Climate Airflow ............................................... 29 Table 12 Electrical Specifications W**AB ........... 30 Table 13 Electrical Specifications W**LB ........... 31 Table 14 Recommended Airflow ......................... 32 Table 15 Blower Speeds for Unit Operational Modes................................................ 33 Table 16 Indoor Blower Performance .................. 36 Table 17 Maximum ESP Electric Heat Only......... 37 Table 18 Electric Heat ...................................... 37 Table 19 Vent and Control Options ..................... 38 Table 20A Optional Accessories Right Hand ....... 39 Table 20B Optional Accessories Left Hand .............40 GRAPHS Graph 1 Graph 2 Graph 3 Graph 4 W18*B FAD-NE2, 3 W/O Exhaust Ventilation Delivery ............................. 41 W24*B FAD-NE2, 3 W/O Exhaust Ventilation Delivery ............................. 41 W30*B FAD-NE2, 3 W/O Exhaust Ventilation Delivery ............................. 42 W36*B FAD-NE2, 3 W/O Exhaust Ventilation Delivery ............................. 42 GETTING OTHER INFORMATION AND PUBLICATIONS These publications can help when installing the air conditioner. They can usually be found at the local library or purchased directly from the publisher. Be sure to consult the current edition of each standard. National Electrical Code ......................ANSI/NFPA 70 Standard for the Installation of Air Conditioning and Ventilating Systems .......................................................ANSI/NFPA 90A Standard for Warm Air Heating and Air Conditioning Systems .......................................................ANSI/NFPA 90B Load Calculation for Winter and Summer Air Conditioning ....................................... ACCA Manual J Residential Duct Design for Residential Winter and Summer Air Conditioning and Equipment Selection ....................................................... ACCA Manual D For more information, contact these publishers: ACCA Air Conditioning Contractors of America 1712 New Hampshire Ave. N.W. Washington, DC 20009 Telephone: (202) 483-9370 Fax: (202) 234-4721 ANSI American National Standards Institute 11 West Street, 13th Floor New York, NY 10036 Telephone: (212) 642-4900 Fax: (212) 302-1286 ASHRAE American Society of Heating, Refrigeration and Air Conditioning Engineers, Inc. 1791 Tullie Circle, N.E. Atlanta, GA 30329-2305 Telephone: (404) 636-8400 Fax: (404) 321-5478 NFPA National Fire Protection Association Batterymarch Park P.O. Box 9101 Quincy, MA 02269-9901 Telephone: (800) 344-3555 Fax: (617) 984-7057 Manual 2100-689H Page 3 of 42 WALL MOUNT GENERAL INFORMATION AIR CONDITIONER WALL MOUNT MODEL NOMENCLATURE W 36 A B A 0Z X X X X X X MODEL SERIES CAPACITY 18 1½ Ton 24 2 Ton 30 2½ Ton 36 3 Ton A Right Hand L Left Hand CONTROL MODULES (See Spec. Sheet S3573) COIL OPTIONS X Standard 1 Phenolic Coated Evaporator 2 Phenolic Coated Condenser 3 Phenolic Coated Evaporator and Condenser REVISION SPECIALTY PRODUCTS (Non-Standard) VOLTS & PHASE A 230/208/60/1 E 240/220/50/3 B 230/208/60/3 or 220/200/50/3 KW C 460/60/3 F 415/380/50/3 D 240/220/50/1 Insert "D" for dehumidification with hot gas reheat. Reference Form 7960-811 for complete details. PLACEHOLDER X Future Use COLOR OPTIONS X Beige (Standard) 1 White 4 Buckeye Gray 5 Desert Brown 8 Dark Bronze A Aluminum S Stainless Steel FILTER OPTIONS X 1" Throwaway (Standard) W 1" Washable P 2" Pleated M 2" MERV 11 N 2" MERV 13 VENTILATION OPTIONS X Fresh Air Damper - No Exhaust (Standard) R Energy Recovery Ventilator - Motorized with Exhaust A Fresh Air Damper - With Barometric Exhaust S Economizer - Standard Partial Flow Version without Hood B Blank-off Plate V Commercial Ventilator - No Hood with Exhaust D DDC, 0-10V Economizer Y Economizer - DB Full Flow M Commercial Ventilator - ON/OFF Operation Only Z Economizer - DB & WB, Full Flow NOTE: Vent options X and B are without exhaust capability. May require separate field-supplied barometric relief 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. This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety. Children should be supervised to ensure that they do not play with the appliance. The refrigerant system is completely assembled and charged. All internal wiring is complete. The unit is designed for use with or without duct work. Flanges are provided for attaching the supply and return ducts. These instructions explain the recommended method to install the air cooled self-contained unit and the electrical wiring connections to the unit. These instructions and any instructions packaged with any separate equipment required to make up the entire air conditioning system should be carefully read before beginning the installation. Note particularly "Starting Procedure" and any tags and/or labels attached to the equipment. While these instructions are intended as a general recommended guide, they do not supersede any national and/or local codes in any way. Authorities having jurisdiction should be consulted before the installation is made. See page 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. Manual 2100-689H Page 4 of 42 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 17 on page 37. 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 1" 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. Model series W18 and W24 are approved for 0" clearance to the supply duct. For model series W30 and W36, a 1/4" clearance to combustible material for the first 3' of duct attached to the outlet air frame is required. See wall mount installation instructions beginning on page 6 and Figures 3 - 7 (pages 11 15) for further details. Ducts through the walls must be insulated and all joints taped or sealed to prevent air or moisture entering the wall cavity. Some installations may not require a 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". Any grille that meets with 5/8" louver criteria may be used. It is recommended that Bard Return Air Grille Kits RG2 through RG3 or RFG2 through RFG3 be installed when no return duct is used. Contact distributor or factory for ordering information. If using a return air filter grille, filters must be of sufficient size to allow a maximum velocity of 400 fpm. NOTE: If no return air duct is used, applicable installation codes may limit this cabinet to installation only in a single story structure. Filters A 1" 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. Additional 1" and 2" filters are also available as optional accessories. The internal filter brackets are adjustable to accommodate the 2" filter by bending two 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). Graphs found on pages 41 and 42 give approximate fresh air amounts based on the blade position stop location. 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. FIGURE 1 Fresh Air Damper INSTALL STOPS HERE MIS-3973 Manual 2100-689H Page 5 of 42 INSTALLATION Basic Installation Design and Application Planning Successful unit installations require proper planning and site inspection before installation begins. Before installing the wall mount unit, make sure that all service and airflow clearances are met and that the unit can meet all applicable code and regulation requirements. Provide an inspection of both the inside and outside of the structure by reviewing floorplans and/or visiting the installation site. Wall Construction The wall must be inspected to ensure that the weight of the unit can be supported. Be sure to review all applicable construction codes and regulations including seismic requirements. When inspecting wood frame walls, the wall construction must be strong and rigid enough to carry the weight of the unit without transmitting any unit vibration. It is important that the side unit wall mounting lags and optional bottom bracket are supported by structural members inside the wall cavity. Concrete block and brick walls must be thoroughly inspected to ensure that they are capable of carrying the weight of the installed unit. Metal buildings must contain structural components to support the unit weight. If heavily corrugated siding is present, it may need to be trimmed and flashed similar to a window to provide a flat, even surface to attach and seal the unit to the wall. Heavy gauge corrugations that would be present on shipping containers and blast-proof structures may require the installation of a metal plate over the corrugated area. It is important that the unit area is weatherized and sealed to avoid air and water infiltration into the area between the unit and the wall. Outdoor Area Inspection Inspect the outdoor area of the jobsite or review construction plans and locate the area where the wall mount is to be installed. The outdoor area must be free from obstructions including fences, bushes and walls that will hinder unit operation regarding outdoor condenser airflow and unit serviceability. Do not install units in enclosed areas that limit the amount of ambient temperature airflow. Warm air will exit the front condenser section of the unit, and outdoor ambient temperature air must be able to enter side intake condenser openings of the unit. Portable or modular building placement must be in a way that the wall mount units have a constant supply of outdoor air for proper unit operation. Make sure that the service panels of the unit are accessible. Inspect wall surfaces for obstructions that could hinder unit installation and servicing including outdoor electrical conduits, junction boxes, wall drains, vent hoods, windows, doors, overhangs and posts. Manual 2100-689H Page 6 of 42 Condensate Water Drainage Review all codes and requirements for unit condensate drainage. A clear, flexible PVC drain hose (3/4" ID, 1" OD) extends from the drain pan in the upper section of the unit and extends down to the unit base. An opening is supplied towards the back of the unit base for the drain hose to pass through, and the hose extends 1" to 2" below the unit base. Water removed from the indoor air (condensate) will be expelled from the unit in large amounts during cooling operation through the hose. Units running in cooling operation in cold outdoor below freezing conditions can cause the condensate to freeze after leaving the drain hose. 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 ensure proper drainage throughout seasonal use. Indoor Ducted and Non-Ducted Applications Air distribution inside the structure being conditioned plays an important role in making sure the area is a consistent temperature. Improper air distribution can result in areas being cooler or warmer, electrical equipment not receiving sufficient airflow or occupancy discomfort felt inside an area. Thermostat or indoor temperature sensor placement inside the area being conditioned also plays an important role in indoor climate control. Indoor Supply Airflow Indoor installation areas must provide a non-restrictive path for the conditioned supply air to leave supply grilles and registers. Inspect the area to ensure that all indoor portions of the room or rooms will have access to supply air. Ductwork may be used to ensure proper air circulation and all provided ductwork guidelines and clearances must be followed. Non-ducted applications must use a supply louver grille installed over the supply opening inside the room. Be sure to adjust supply deflectors to properly disperse the conditioned supply air to all parts of the room. Avoid closing sections of the supply grilles which would cause unneeded supply duct pressurization. Indoor Return Airflow A non-restrictive path for room air returning to the center section of the unit must be provided inside the room. Avoid placing objects including furniture, electronics equipment, equipment racks and cabinets directly in front of the unit return grilles and registers. Bard recommends at least 2' between solid objects and return grilles or registers. Ductwork may be used to ensure proper air circulation and all provided ductwork guidelines and clearances must be followed. Nonducted applications must use a return louver grille installed over the return opening inside the room. Ducted Applications Field fabricated supply and return duct work may be installed inside the structure being conditioned. A short supply and/or return stub duct may be connected to the unit supply and return flanges before unit installation to help with duct connections inside the structure. Supply and return ducts 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 conserve energy, reduce heat conductivity, and prevent condensation or moisture damage. Refer to Maximum External Static Pressure (ESP) of Operation Table 17 on page 37. Design the duct work according to methods given by the Air Conditioning Contractors of America (ACCA). When duct work is installed in unheated spaces, it should be insulated with a minimum of 1" 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. Ducts through the walls must be insulated and all joints taped or sealed to prevent air or moisture from entering the wall cavity. Model series W18 and W24 are approved for 0" clearance to the supply duct. For model series W30 and W36, a 1/4" clearance to combustible material for the first 3' of duct attached to the outlet air frame is required. See instructions on page 8 and Figures 3 - 7 (pages 11 15) for further details. ! WARNI NG Fire hazard. Maintain minimum 1/4" clearance between the supply air duct and combustible materials in the first 3' of ducting. Failure to do so could result in fire causing damage, injury or death. Free Blow Applications Some installations may not require extensive supply duct work throughout the structure and are referred to as free blow applications. A short field-fabricated supply duct must be used in the wall cavity to transition between the supply collar on the unit and the supply louver grille in the room. The duct must be properly insulated in order to conserve energy, reduce heat conductivity and prevent condensation or moisture damage. All joints must be taped or sealed to prevent air or moisture entering the wall cavity. Follow all clearances including distances to combustible materials and all instructions provided in this manual. A non-restrictive metallic supply air grille with deflectors is required for free blow applications. Contact the local Bard distributor or visit www.bardhvac.com for ordering information. A metallic return air grille is required for non-ducted applications. The spacing between louvers on the grille shall not be larger than 5/8". It is recommended that a Bard Return Air Grille Kit is installed that is designed specifically for the wall mount product. Contact the local Bard distributor or visit www.bardhvac.com for ordering information. A field-supplied return grille that meets the 5/8" louver criteria and does not cause the unit to exceed the maximum specified external static pressure (ESP) may be used. If using a return air filter grille, filters must be of sufficient size to allow a maximum velocity of 400 fpm. Filter return air grilles do not filter air being brought into the structure through ventilation options including fresh air dampers, ventilators, economizers and energy recovery ventilators. Be sure to install the return grille with the louvers pointed downward towards the floor. This will help ensure return air is drawn upward from the floor and improve air circulation in the room. NOTE: If no return air duct is used, applicable installation codes may limit this cabinet to installation only in a single story structure. Thermostat or Indoor Temperature Sensor Placement The location and installation of the thermostat or temperature sensor that monitors indoor temperature is very important regarding unit operation. Avoid placing the thermostat in an area exposed to direct sunlight or air from doorways leading outdoors. Use a piece of insulating material to close off conduit openings or holes in the wall surface for wire entry into the thermostat or temperature sensor. This will help avoid non-conditioned air from entering the thermostat and effecting temperature and/or humidity readings. As common practice, the thermostat or temperature sensor should measure the temperature of the air being returned to the unit, and not the conditioned air being supplied by the unit. Placing the thermostat or temperature sensor near a return air opening will normally result in optimal unit performance. Unit Installation Make sure to have the proper tools at the work site that are needed for unit installation. The following steps are provided to ensure the unit is installed properly to the wall surface, and that the unit will provide years of service with minimal service requirements. Materials/Tools List Additional hardware and miscellaneous supplies are needed for installation. These items are field supplied and must be sourced before installation. The following list also includes tools needed for installation. Manual 2100-689H Page 7 of 42 · Appropriate safety gear including gloves and safety glasses · 5/16" hex bit with drill driver · Phillips head screwdriver · Small straight (thermostat) screwdriver · Tape measure · Leveling device · Two (2) tubes of caulk and caulk gun · Utility knife · Tools for cutting holes in the wall surface (if needed) · Electrical components and wiring along with electrical tools · Multimeter · Wall fasteners for side flanges, bottom mounting bracket and top rain flashing. · Duct tape and/or other duct sealing materials. Wall Preparation 1. Two holes for the supply and return air openings must be cut through the wall as shown in Figures 3A and 3B on pages 11 and 12. Be sure the openings are square and level. Follow all clearances including distances to combustible materials and all instructions provided in this manual. 2. Review all electrical requirements provided in this manual and plan out electrical entrances into the building. Also plan electrical conduit routing and thermostat placement, if necessary. 3. Install necessary duct work and prepare the openings for unit installation. 4. Clean the exterior wall where the unit is to be installed and make sure it is able to provide a smooth, level, debris-free surface. Remove all construction debris from the supply, return and electrical hole cutting process. Wall Mount Installation to Wall Surface 1. Remove packaging from unit and make sure the unit is not damaged before installation. A top rain flashing is supplied for field use and is mounted to the back of the unit for shipping. Remove the rain flashing before locating the unit against the wall. Top rain flashing is required to avoid water entering the area behind the unit that is against the wall. A bottom mounting bracket, attached to the skid for shipping, is provided for ease of installation but is not required. Review all requirements listed on unit labels and on serial plate located on the side of the unit. 2. Locate and mark bolt hole locations and bottom mounting bracket location. Install bottom mounting bracket with field-supplied fasteners to wall if it is to be used (optional). Bracket must be level and installed in the correct location to help support the unit during the installation process (see Figures 3A and 3B). 3. Position the wall mount unit close to the wall surface where it will be installed. Install rain flashing at the top of the unit facing the wall by hooking the hem bend into the rear bend of the unit top (see Figures 3A and 3B). 4. Apply a liberal amount of caulk on left and right cabinet side wall mount brackets and back of top rain flashing. Place unit back surface flush against wall. Unit must be level to ensure proper condensate drainage. Optional bottom bracket may be used to help support the unit. 5. Units are secured to the wall by using fieldsupplied fasteners along each side of the wall mount through the built-in wall mounting brackets. It is the responsibility of the installer to select the proper fastener to secure the unit to the wall based on wall construction and applicable building codes. Typical installations may include 5/16" fasteners with 7/8" diameter flat washers. Be sure unit is securely mounted and all weight-bearing fasteners are attached to the weight supporting structural members of the wall. 6. Apply a bead of caulk between the back of the unit top and the front surface of the top rain flashing (see Figures 3A and 3B). 7. Connect unit duct work from the inside of the building following all clearances and instructions provided. 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 use code approved duct tape or other sealing materials to seal the duct work to the unit. 8. On side-by-side installations, maintain a minimum of 20" clearance on right side (on W**A units) to allow access to control panel and heat strips and proper airflow to the outdoor coil (20" clearance on left side on W**L units). Additional clearance may be required to meet local or national codes. Manual 2100-689H Page 8 of 42 TABLE 1 Clearance Required for Service Access and Adequate Condenser Airflow Model W18A W24A W30A W36A W18L W24L W30L W36L Left Right Discharge Side Side Side 15" 20" 10' 20" 15" 10' NOTE: For side-by-side installation of two 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 W**A (right side compressor and controls) for right unit. See Specifications Sheet S3573. TABLE 2 Minimum Clearances Required to Combustible Materials Model W18A, L W24A, L W30A, L W36A, L Supply Air Duct (1st 3') 0" 1/4" Cabinet 0" 0" Manual 2100-689H Page 9 of 42 FIGURE 2 Unit Dimensions Width Depth (W) (D) W18*B W24*B 33.300 17.125 W30*B W36*B 38.200 17.125 Height (H) 74.563 74.563 Supply Return A B C B E F G I J K L MNO P Q R S T 7.88 19.88 11.88 19.88 35.00 10.88 29.75 20.56 30.75 32.06 33.25 31.00 2.63 34.13 26.06 10.55 3.94 12.00 9.00 7.88 27.88 13.88 27.88 40.00 10.88 29.75 17.93 30.75 32.75 33.25 31.00 2.75 39.13 26.75 9.14 3.94 12.00 9.00 All dimensions are in inches. Dimensional drawings are not to scale. W**A* RIGHT UNIT 5.88 F G W 1 Filter Access Panel Ventilation Air Condenser Air Outlet Front View Built In Rain Hood 4° Pitch Heater Access Panel Electric Heat C. Breaker/ Disconnect Access Panel (Lockable) Hood for full flow ECON models only D 1.250 2.13 Side Wall A Mounting Brackets (Built In) I Top Rain Flashing Shipping Location Standard flush vent door for non- 3" ERV Econ. models Hood for ERV 7.00 models only Low Voltage Electrical Entrance High Voltage Electrical Entrance Optional C H Electrical Entrances K Cond. J Air Inlet L M P Drain N Side View E O .44 Supply Air Opening R B S S Return Air Opening S S S T Bottom Installation Q Back View Bracket MIS-3976 A R S W**L* LEFT UNIT S E O .44 Supply Air Opening B S Return Air Opening S S T Drain Bottom Back View Installation Q Bracket Side Wall Mounting Brackets (Built In) Built In Rain Hood 4° Pitch D 2.13 A Top Rain I Flashing Shipping Location 1.250 Electric Heat Heater Access Panel C. Breaker/ Disconnect Access Panel (Lockable) Standard flush vent door for non-ERV Econ. models Hood for full flow ECON models only Optional C Electrical Entrances H L K M J P N Cond. Air Inlet Side View 3" Hood for ERV models only 7.000 Low Voltage Electrical Entrance High Voltage Electrical Entrance W Filter Access Panel 1 5.88 Ventilation Air F Condenser G Air Outlet Front View MIS-3972 A Manual 2100-689H Page 10 of 42 FIGURE 3A W18AB, W18LB, W24AB, W24LB Mounting Instructions SEAL WITH BEAD OF CAULKING ALONG ENTIRE LENGTH OF TOP. TOP WALL RAIN FLASHING SUPPLIED FOAM AIR SEAL WALL STRUCTURE 3 1 2 " 12" 12" 7 1 16 " 20" 7 1 16 " Supply Opening 8" 20 1 2 " 12" Return Opening 12" 12" 20" 12" 9" 7 8 " 2" 3" 1" 4" Typ. 3 1 8 " 4" Typ. 5" 2" Wall Opening and Hole Location View HEATER ACCESS PANEL SUPPLY AIR DUCT RETURN AIR OPENING 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. Right Side View MIS-4036 A Manual 2100-689H Page 11 of 42 Manual 2100-689H Page 12 of 42 FIGURE 3B W30AB, W30LB, W36AB, W36LB Mounting Instructions AB REQUIRED DIMENSIONS TO MAINTAIN 1/4" MIN. CLEARANCE FROM 28 3/8 8 3/8 COMBUSTIBLE MATERIALS REQUIRED DIMENSIONS TO MAINTAIN RECOMMENDED 1" CLEARANCE FROM 29 7/8 9 7/8 COMBUSTIBLE MATERIALS C D E 5 3/8 3 3/4 17 5/8 4 5/8 4 1/2 16 7/8 SEAL WITH BEAD OF CAULKING ALONG ENTIRE LENGTH OF TOP. TOP WALL C A C D Supply Opening B 12" E 12" 12" Return Opening 14" 12" 12" 7 8 " 9 1 16 " 4 11 16 " 28" 2 7 8 " 7 8 " 3 1 8 " 4" Typ. 4" Typ. 4 7 8 " 4 11 16 " HEATER ACCESS PANEL RAIN FLASHING SUPPLIED FOAM AIR SEAL WALL STRUCTURE SUPPLY AIR DUCT 1/4" CLEARANCE ON ALL FOUR SIDES OF SUPPLY AIR DUCT IS REQUIRED FROM COMBUSTABLE MATERIALS RETURN AIR OPENING 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. Wall Opening and Hole Location View Right Side View MIS-3820 A FIGURE 4 Electric Heat Clearance W30AB, W30LB, W36AB, W36LB NOTE 1: SIDE SECTION VIEW OF SUPPLY AIR DUCT FOR WALL MOUNTED UNIT SHOWING 1/4" CLEARANCE TO COMBUSTIBLE SURFACES. ! WARNI NG Fire hazard. Maintain minimum 1/4" clearance between the supply air duct and combustible materials in the first 3' of ducting. Failure to do so could result in fire causing damage, injury or death. Manual 2100-689H Page 13 of 42 FIGURE 5 Wall Mounting Instructions See Figures 3A and 3B Mounting Instructions SUPPLY AIR OPENING SUPPLY AIR OPENING FACTORY SUPPLIED RAIN FLASHING. MOUNT ON UNIT BEFORE INSTALLATION WALL STRUCTURE SUPPLY AIR DUCT RETURN AIR OPENING RETURN AIR OPENING RETURN AIR OPENING CONCRETE BLOCK WALL INSTALLATION WOOD OR STEEL SIDING WOOD FRAME WALL INSTALLATION BOTTOM MOUNTING BRACKET. MOUNT ON WALL BEFORE INSTALLING UNIT. SIDE VIEW MIS-548 A MIS-549 B Manual 2100-689H Page 14 of 42 FIGURE 6 Wall Mounting Instructions ATTACH TO TOP PLATE OF WALL 1.000" CLEARANCE ALL AROUND DUCT INTERIOR FINISHED WALL OVER FRAME 1.000" CLEARANCE ALL AROUND DUCT EXTERIOR FINISH WALL OVER FRAME FRAMING MATERIAL 2 x 4'S, 2 x 6'S &/OR STRUCTURAL STEEL ATTACH TO BOTTOM PLATE OF WALL SEE UNIT DIMENSIONS, FIGURE 2, FOR ACTUAL DIMENSIONS. E + 1.000 B 1.000 SUPPLY DUCT OPENING A I RETURN DUCT OPENING C K 2 x 6 CL THIS STRUCTURAL MEMBER LOCATED TO MATCH STUD SPACING FOR REST OF WALL. A SECOND MEMBER MAY BE REQUIRED FOR SOME WALLS. FIGURE 7 Common Wall Mounting Installations Non-Ducted Installations Unit is sealed to wall. Wall Mount Unit Ceiling Supply Air Adjustable Supply Grille Fixed Blade Return Grille Ducted Installations Unit is sealed to wall. Wall Mount Unit Ceiling Supply Air Duct Optional Dropped Ceiling Fixed Blade Return Grille Outside Wall Room Air Outside Wall Supply Air Supply Air Return Air Return Air Room Air Indoor Area Indoor Area Non-ducted installations supply conditioned air into indoor room areas without extensive duct work. The supply airstream is directed by adjusting the 4-way supply grille to reach areas being conditioned. The supply air mixes with the room air and cools or heats occupants and/or equipment in the area. Unconditioned room air is returned to the unit through the return grille. Avoid supply air leaving supply grille and re-entering the unit return grille without mixing with room air. Ducted installations supply conditioned air into indoor room areas using solid or flexible ducts. The supply air is distributed throughout a single area or multiple areas. The supply air mixes with the room air and cools or heats occupants and/or equipment. Unconditioned room air is returned to the unit through a return grille or return duct work. Avoid using restrictive duct work to provide the best unit performance and efficiency. Review duct static pressure requirements provided in this manual. Outdoor Wall Curb Installations Curb is sealed to wall. Ceiling Supply Air Wall Mount Unit Adjustable Supply Grille Fixed Blade Return Grille WAPR11 Indoor Sound Plenum Installations Unit is sealed to wall. Ceiling Wall Mount Unit Supply Air Duct Optional Dropped Ceiling Wall Curb Outside Wall Room Air Outside Wall Supply Air Supply Air Return Air Unit is sealed to curb. Indoor Area Outdoor Wall curbs are installed between the wall mount unit and the outer wall surface. Wall curb use may avoid resizing supply and return openings that are currently in an existing wall. Wall curbs may also provide sound isolation and indoor area sound reduction. Various curb options are available, and it is important to select a curb that will meet the application requirements and also be the correct size for the unit. Unit duct static requirements cannot be exceeded when using a wall curb. Follow all instructions provided with the wall curb when installing the product. WAPR11 Plenum Return Air Room Air Indoor Area Indoor sound plenums are installed inside the room over the unit return air opening. Plenum use can provide sound isolation and indoor area sound reduction. The WAPR11 sound plenum provides a single solution for all unit tonnage sizes. The WAPR11 may be installed horizontally or vertically in the room. Unit duct static requirements cannot be exceeded when using a sound plenum. Follow all instructions provided with the sound plenum when installing the product. MIS-550 D Manual 2100-689H Page 15 of 42 Wiring Main Power ! WARNI NG Electrical shock hazard. Do not operate this equipment without an earth ground attached and always disconnect the remote electric power supplies before servicing. Electrical shock can result in serious injury or death. Refer to the unit rating plate for wire sizing information and maximum fuse or 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 circuit breaker that is to be used with the equipment. The correct size must be used for proper circuit protection and also to ensure that there will be no nuisance tripping due to the momentary high starting current of the compressor motor. The disconnect access door on this unit may be locked to prevent unauthorized access to the disconnect. To convert for the locking capability, bend the tab located in the bottom left-hand corner of the disconnect opening under the disconnect access panel straight out. This tab will now line up with the slot in the door. When shut, a padlock may be placed through the hole in the tab preventing entry. See "Start Up" section for important information on three phase scroll compressor start ups. See Tables 12 and 13 on pages 30 and 31 for electrical specifications. Wiring Low Voltage All 230/208V 1 phase and 3 phase equipment have dual primary voltage transformers. All equipment leaves the factory wired on 240V tap. For 208V operation, Manual 2100-689H Page 16 of 42 reconnect from 240V to 208V tap. The acceptable operating voltage range for the 240 and 208V taps are: Tap: 240 Tap: 208 Range: 253 216 Range: 220 187 NOTE: The voltage should be measured at the field power connection point in the unit and while the unit is operating at full load (maximum amperage operating condition). For low voltage wiring, an 18 gauge copper, color-coded cable is recommended. See Table 7 on page 18 for more information. Low Voltage (24VAC) Connections These units use a 24-volt AC low voltage circuit. C terminal is the 24VAC common and is grounded. G terminal is the indoor blower input. Y1 terminal is the 1st Stage input for cooling. Y2 terminal is the 2nd Stage compressor input for cooling (if equipped with an economizer) or Y2 disables Balanced Climate mode if the Y1-Y2 jumper is removed (see page 22). B/W1 terminal is the 1st stage electric heat. W2 terminal is the 2nd stage heat (if equipped). A terminal is the ventilation input. This terminal energizes any factory-installed ventilation option and indoor blower. D terminal is the dehumidification input. If installed, this terminal energizes any factory-installed dehumidification option. L terminal is 24 volt alarm active output. For units equipped with an alarm relay: 1 terminal is the normally closed contact on the relay. 2 terminal is the normally open contact on the relay. 3 terminal is the common contact on the relay. See Table 3 for additional low voltage connections on auxiliary terminal strip. Unit Shutdown Feature (Standard on All Models) The RT terminal is the 24VAC transformer output, and the R terminal is the 24VAC hot terminal for the operation of the equipment. RT and R are connected with a brass jumper bar which can be removed and RT and R connected to an external NC (normally closed) contact such as a fire/smoke detector that will cause shutdown of the equipment upon activation. Balanced ClimateTM Feature (Standard on All Models) All units are equipped with the capability of running in Balanced Climate mode. This mode is designed to enhance the comfort level by reducing the indoor airflow amount and extending the run time to help extract more humidity during cooling operation. The Y1 terminal is the 24VAC input for Balanced Climate compressor cooling operation. The Y2 terminal is the 24VAC input TABLE 3 Additional Low Voltage Connections (if applicable) Terminal 9 10 11 12 13 14 15 16 Unit V Control Option Only V Control Option Only F, V Control Options F, V Control Options V Control Option Only V Control Option Only V Control Option Only V Control Option Only Description Discharge Air Sensor, 10K Ohm Discharge Air Sensor, 10K Ohm Filter Switch, Normally Open Contact Filter Switch, Normally Open Contact Blower Airflow Switch, Normally Open Contact Blower Airflow Switch, Normally Open Contact Compressor Current Sensor, Normally Open Contact Compressor Current Sensor, Normally Open Contact for compressor cooling standard operation. Y1 and Y2 are connected with a brass jumper bar which can be removed to enable Balanced Climate mode. Units with an economizer will not have the brass jumper installed. Refer to vent manuals for instructions on how Balanced Climate works with each vent. NOTE: Units with mechanical dehumidification require an additional connection to be made when enabling Balanced Climate. Refer to dehumidification supplemental instructions for this step. To operate in Balanced Climate mode, a 2-stage cooling thermostat is required. The lower indoor airflow operation is overridden by utilizing a 2-stage thermostat. If the call for cooling is not satisfied within a given time frame or temperature differential (specified by the thermostat), the thermostat will send a signal to Y2 which then increases the blower speed back to the selected speed. See pages 32 34 for blower speed selection options. Refer to page 22 for additional Balanced Climate requirements and limitations. Dehumidification Feature (Optional) The D terminal is the 24VAC input for dehumidification operation on dehumidification hot gas reheat equipped units. When 24VAC is applied to the D terminal, a 3-way valve solenoid is energized. The reheat coil located behind the evaporator coil is then active to reheat the supply air during cooling mode. This allows humidity to be removed from the air entering the unit without a large amount of sensible cooling capacity. During dehumidification, the indoor blower speed is reduced to help with the humidity removal. A humidity sensing thermostat or humidistat is required to control dehumidification operation. Ventilation Features (Optional) See ventilation instructions provided with unit for low voltage wiring. Low Ambient Control (LAC) The low ambient control is a pressure switch that is attached to the liquid line of the system and monitors high side pressure. Operation of the LAC occurs as outdoor temperatures drop below 60°F. On/Off and modulating controls are used which operate based on pressure changes caused by outdoor temperature changes. On/Off LAC operation cycles the condenser fan on/off to maintain desired liquid pressure while modulating LAC operation is factory adjusted and slows the condenser fan speed (rpm). Outdoor Temperature Switch and Freeze Protection Thermostat An outdoor temperature switch and an evaporator freeze protection thermostat is supplied with all units that have a low ambient control. The outdoor switch disables Balanced Climate mode (if enabled) when the temperature drops below 50°F. This prevents potential evaporator coil freeze up issues. For units with mechanical dehumidification, this switch must remain disconnected when Balanced Climate mode is not being used. Refer to unit wiring diagram. The freeze thermostat cuts out compressor operation if the evaporator begins to freeze up. Alarm Relay Feature (Controls Option) The alarm relay provides a set of NO (normally open) and NC (normally closed) pilot duty contacts that operate when the compressor control module locks out compressor operation because of a high or low system refrigerant pressure event. DDC Controls Feature (Controls Option) The DDC controls option provides additional sensors that can be used with a field-supplied advanced logic controller. The DDC controls option contains the following installed components: Dirty Filter Switch Indicator (DFS) The switch is adjustable and measures pressure drop across the unit filter surface. When pressure drop is higher than the switch setting, NO contacts are provided to indicate the filter needs to be serviced. Refer to page 34 for instructions on making switch adjustments. Discharge Air Sensor The discharge air sensor provides a temperature reading of the supply air leaving the unit. The sensor is a 10K OHM @ 77°F measuring device. It is installed in the supply airstream in the heater bracket. Airflow Switch The airflow switch measures the pressure differential between the blower inlet and outlet. It is located directly above the blower partition. Relay contacts (NO) are Manual 2100-689H Page 17 of 42 provided for the DDC controls option that indicates the indoor blower assembly needs to be serviced. Compressor Current Sensor The compressor current sensor indicates when the compressor is operational by measuring amp draw. It is located inside the unit control panel. Relay contacts (NO) are provided to indicate the compressor is not operating See Table 4 for low voltage connections for DDC control. TABLE 4 Low Voltage Connections for DDC Control Standard Units Units w/ Economizers Fan Only Energize G Energize G 1st Stage Cooling Mode/ Balanced Climate 2nd Stage Cooling Mode Energize Y1, G Energize Y1, G Energize Y2 to overide Balanced Climate mode when Y1-Y2 jumper is removed Energize Y1, Y2, G 1st Stage Heating Energize B/W1 Energize B/W1 2nd Stage Heating (if employed) Energize B/W1, W2 Energize B/W1, W2 Ventilation Dehumidification (if employed) Energize A Energize D Energize A Energize D TABLE 5 Humidity Controls Part Number Predominate Features 8403-038 SPDT switching, pilot duty 50VA @ 24V; (H600A1014) Humidity range 20-80% RH 8403-047 (H200-10-21-10) Electronic dehumidstat SPST closeson-rise; Humidity range 10-90% with adjustable stops TABLE 6 CO2 Controllers Part Number Predominate Features 8403-056 8403-096 CO2 ventilation control with digital display. Normally Open SPST (Default: Close at 800ppm) Normally Open SPST relay closes-on-rise 24V dual wave length sensor. Default setting 950ppm, adjustable to 0-2000ppm Default off setting 1000ppm, adjustable to 0-200 ppm can be calibrated Transformer VA 55 TABLE 7 Thermostat Wire Size FLA Wire Gauge 18 gauge 2.3 16 gauge 14 gauge 12 gauge Maximum Distance In Feet 60 100 160 250 Part Number 8403-060 (1120-445) CS9B-THOA CS9B-THOCA CS9BE-THOA CS9BE-THOCA 8403-089 (T4 Pro) 8403-090 (T6 Pro) 8403-091 8403-092 (T6 Pro Wi-Fi) TABLE 8 Wall Thermostats Predominate Features 3 stage Cool; 3 stage Heat; Electronic Programmable/Non-Programmable; HP or Conventional; Auto or Manual changeover; Dehumidification Output 3 stage Cool, 3 stage Heat; Programmable/Non-Programmable; HP or Conventional; Auto or Manual Changeover; Humidity Sensor w/ dehumidification; Motion Sensor w/Intelligent Learning Control; BACnet-compatible 3 stage Cool, 3 stage Heat; Programmable/Non-Programmable; HP or Conventional; Auto or Manual Changeover; Humidity Sensor w/ dehumidification; CO2 Sensor; Motion Sensor w/Intelligent Learning Control; BACnet-compatible 3 stage Cool, 3 stage Heat; Programmable/Non-Programmable; HP or Conventional; Auto or Manual Changeover; Humidity Sensor w/ dehumidification; Motion Sensor w/Intelligent Learning Control; BACnet-compatible; Ethernet-compatible 3 stage Cool, 3 stage Heat; Programmable/Non-Programmable; HP or Conventional; Auto or Manual Changeover; Humidity Sensor w/dehumidification; CO2 Sensor; Motion Sensor w/Intelligent Learning Control; BACnet-compatible; Ethernet-compatible 1 stage Cool, 1 stage Heat Heat Pump; 1 stage Cool, 1 stage Heat Conventional; Programmable/NonProgrammable Electronic; Auto or Manual changeover 2 stage Cool, 3 stage Heat Heat Pump; 2 stage Cool, 2 stage Heat Conventional; Programmable/NonProgrammable Electronic; Auto or Manual changeover 1 stage Cool, 1 stage Heat; Non-Programmable; FEMA use 2 stage Cool, 3 stage Heat Heat Pump; 2 stage Cool, 2 stage Heat Conventional; Programmable/NonProgrammable Electronic; Auto or Manual changeover; Wi-Fi Manual 2100-689H Page 18 of 42 FIGURE 8 Programmable Thermostat Connections SC SC SC Completestat Model #CS9B-THOA or Model #CS9BE-THOA 24V COM G Y1 Y2 O/B W2 W1/E L A D GND 2 43 6 Thermostat Bard #8403-060 R C G Y1 Y2 O/B W2 W1/E L A YO/D 2 4 3 5 Optional CO2 Controller Bard Part #8403-096 1 24VAC 2 7 3 CO2 OUT Unit Low Voltage R RT C G Y1 Y2 B/W1 W2 W3 L A D 1 2 3 4 5 6 Term. Strip 1 9 8 4 TEMP-OUT 5 6 12-Pin 9 6 3 2 5 11 7 Vent Plug 4 12 10 ALL VENT OPTIONS PLUG IN HERE If not equipped with a ventilation option to plug in, a jumper plug must be installed. 1 Factory installed jumper. Remove jumper and connect to N.C fire alarm circuit if emergency shutdown required. 2 Wire not needed below 15KW. 3 Wire required for dehumidification models only. 4 Do not connect "A" from thermostat if optional CO2 controller is used 5 0-10 VDC modulating C02 control signal for modulating ventilation control (optional for ECON only - see vent instruction manuals) Change model configuration from heat pump to heat/cool. Must be configured to programmable 6 and fan set to be programmed fan for the "A" output to function during scheduled occupied periods. Must be configured for multi-stage for Y1 output to be active 1st stage cooling. For dehumidification, must be configured for "No Economizer" for YO/D to be active for humidity control. 7 Install jumper for 1 stage electric heat on units with less than 15KW 8 Do not add these wires if setting up for modulating control. See note 5. 9 Factory installed jumper. Remove jumper to activate Balanced ClimateTM mode. A 2-stage thermostat is recommended for Balanced Climate mode. MIS-3974 C Manual 2100-689H Page 19 of 42 FIGURE 9 Thermostat Connections 8 T4 Pro 8403-089 R Rc C GY WOB T6 Pro 8403-090 8403-092 R Rc C GY Y2 W W2 Units With Dehumidification 8403-038 Mechanical Humidistat 7 6 5 3 4 8403-047 Electronic Humidistat 2A 9 3 Optional CO2 Controller 6 Bard Part #8403-096 1 2 24VAC 2B 3 CO2 OUT Unit Low Voltage R RT C G Y1 Y2 B/W1 W2 W3 L A D 1 2 3 4 5 6 Term. Strip 1 5 4 4 TEMP-OUT 5 6 12-Pin 9 6 3 2 5 11 7 Vent Plug 4 12 10 ALL VENT OPTIONS PLUG IN HERE If not equipped with a ventilation option to plug in, a jumper plug must be installed. 1 Factory installed jumper. Remove jumper and connect to N.C fire alarm circuit if emergency shutdown required. 6 0-10 VDC Modulating CO2 control signal for modulating ventilation control (Optional for ECON Only) - See vent installation manual. 2A Wire not needed below 15KW. 2B Install Jumper for 1 stage electric heat on units with more than 10KW. 7 Jumper needs added. 8 Thermostat will not work with units equipped with economizers. 3 Wire required for dehumidification models only. For vent operation, add jumper if optional CO2 controller is not used. 4 Vent will run while blower is energized. 9 Factory installed jumper. Remove jumper to activate Balanced ClimateTM Mode. A 2-stage thermostat is recommended for Balanced Climate mode. For ECON & CRV-V an additional wire change is required See install Manual. 5 Do not add these wires if setting up for modulating control. See note 6. MIS-3975 D Manual 2100-689H Page 20 of 42 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 R-410A refrigerant. 3. Use manifold gauges rated for R-410A (800 psi/250 psi low). 4. R-410A is a binary blend of HFC-32 and HFC-125. 5. R-410A is nearly azeotropic--similar to R-22 and R-12. Although nearly azeotropic, charge with liquid refrigerant. 6. R-410A operates at 40-70% higher pressure than R-22 and systems designed for R-22 cannot withstand this higher pressure. 7. R-410A has an ozone depletion potential of zero, but must be reclaimed due to its global warming potential. 8. R-410A compressors use polyol ester 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 refrigerant charge, in the system, may be used after leaks have occurred and then "top-off" the charge by utilizing the pressure charts on the inner control panel cover as a guideline. REMEMBER: When adding R-410A refrigerant, it must come out of the charging cylinder/tank as a liquid to avoid any fractionation, and to ensure optimal system performance. Refer to instructions for the cylinder that is being utilized for proper method of liquid extraction. 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-410A to leak check; the mixture may become flammable. 4. Do not inhale R-410A--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 burn R-410A. 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 expands significantly at warmer temperatures. Once a cylinder or line is full of liquid, any further rise in temperature will cause it to burst. Important Installer Note For improved start up performance, wash the indoor coil with a dishwashing 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, the pressure switch may be reset by turning the thermostat off then back on again. High pressure switch settings: Opens 650 +/ 15 PSI, Closes 520 +/ 15 PSI. Three Phase Scroll Compresser 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. Manual 2100-689H Page 21 of 42 However, three phase compressors will rotate in either direction depending upon phasing of the power. Since there is a 50-50 chance of connecting power in such a way as to cause rotation in the reverse direction, verification of proper rotation must be made. Verification of proper rotation direction is made by observing that suction pressure drops and discharge pressure rises when the compressor is energized. Reverse rotation also results in an elevated sound level over that with correct rotation, as well as substantially reduced current draw compared to tabulated values. Verification of proper rotation must be made at the time the equipment is put into service. If improper rotation is corrected at this time, there will be no negative impact on the durability of the compressor. However, reverse operation for over 1 hour may have a negative impact on the bearing due to oil pump out. NOTE: If compressor is allowed to run in reverse rotation for an extended period of time, 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. Phase Monitor All units with three phase scroll compressors are equipped with a three 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 (call for cooling) 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 unit factory wires as damage may occur. Condenser Fan Operation NOTE: Certain models may be equipped with a low ambient control (LAC), and if so, the condenser fan motor will have a delayed start until system refrigerant operating pressure builds up. After starting, the fan motor may or may not cycle depending upon ambient conditions. This is normal operation. 50 Hz models must have fan wired on low speed. These models are factory wired on low speed. Manual 2100-689H Page 22 of 42 Service Hints 1. Caution owner/operator to maintain clean air filters at all times and 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. Sequence of Operation Circuit R-Y1 makes at thermostat pulling in compressor contactor, starting the compressor and outdoor motor. (See NOTE under CONDENSER FAN OPERATION concerning models equipped with low ambient control.) The G (indoor motor) circuit is automatically completed by the thermostat 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-W1 makes at the thermostat pulling in heat contactor 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. Balanced ClimateTM Mode Balanced ClimateTM is a great comfort feature that can easily be applied under any normal circumstances. If the Bard air conditioning system is being set up in a typical environment where 72°F is the lowest cooling setpoint, remove the Y1/Y2 jumper and install a 2-stage cooling thermostat. This will increase the humidity removal up to 35% and provide a much more comfortable environment. NOTE: Units with mechanical dehumidification require an additional connection to be made when enabling Balanced Climate. Refer to dehumidification supplemental instructions for this step. If the application is likely to require air conditioning operation below 60°F outdoor conditions, a low ambient control (LAC) kit must be installed. The LAC kit is equipped with an outdoor temperature switch that disables Balanced Climate mode when the outdoor temperature drops below 50°F. This prevents potential evaporator coil freeze up issues. The LAC kit also comes with an evaporator freeze protection thermostat that cuts out the compressor if the evaporator begins to freeze up. If the unit is being installed with any ventilation package, a Bard LAC kit must be installed. Failure to utilize an LAC with any air conditioner can cause coil freeze up. Balanced Climate can readily be applied to duct-free (supply and return air grille) applications. It may also be applied to ducted applications with limited static of 0.20" ESP (total including both supply and return statics). Consult Bard Application Engineering for details prior to implementation. CAUTION: Balanced Climate is not a replacement for a dehumidification (hot gas reheat) unit for extreme applications, but rather an enhancement feature for limited climates and applications. Vent Connection Plug All units are equipped with a vent connection plug in the side of the control panel for the different ventilation packages to plug in to. If the compressor will not start and there is no "Y1" at the compressor control module, first check to make sure that either the optional vent is plugged into the vent connection plug or the supplied jumper plug is in place. The unit will not operate without anything plugged in. This plug is located on the side of the control panel behind the front vent door (behind the filter access door). If the unit is supplied with a factory-installed vent package, it will be plugged in but the jumper plug will also be tethered next to the connection for troubleshooting purposes, if necessary. Compressor Control Module The compressor control module (CCM) is standard on all models covered by this manual. Features Delay-on-Make Timer Short Cycle Protection/Delay-on-Break Low Pressure Detection High Pressure Detection LPC and HPC Status LEDs Test Mode Brownout Protection with Adjustment Delay-on-Make Timer A delay-on-make timer is included to be able to delay startup of the compressor. This is desired when more than one unit is on a structure so that all of the units do not start at the same time which could happen after a power loss or building shutdown. The delayon-make time period is 2 minutes plus 10% of the delay-on-break time period. To ensure that all of the units do not start at the same time, adjust the delayon-break timer on each unit to a slightly different delay time. Short Cycle Protection/Delay-on-Break An anti-short cycle timer is included to prevent short cycling the compressor. This is adjustable from 30 seconds to 5 minutes via the adjustment knob (see Figure 10 on page 24). Once a compressor call is lost, the time period must expire before a new call will be initiated. Low Pressure Detection Low pressure switch monitoring allows for a lockout condition in a situation where the switch is open. If the low pressure switch remains open for more than 2 minutes. the CCM will de-energize the compressor for the delay-on-break time. If the switch closes again, it will then restart the compressor. If the switch trips again during the same Y call, the compressor will be de-energized and the alarm terminal will be energized indicating an alarm. The blue LED will light and stay on until power is cycled to the control or a loss of voltage is present at Y terminal for more than ½ second. High Pressure Detection High pressure switch monitoring allows for a lockout condition in a situation where the switch is open. If the high pressure switch opens, the CCM will deenergize the compressor. If the switch closes again, it will then restart the compressor after the delayon-break setting has expired on the device. If the switch trips again during the same thermostat call, the compressor will be de-energized and the alarm terminal will be energized indicating an alarm. The red LED will light and stay on until power is cycled to the control or a loss of voltage is present at Y terminal for more than ½ second. Test Mode By rapidly rotating the potentiometer (POT) clockwise (see Figure 10 on page 24), all timing functions will be removed for testing. The conditions needed for the unit to enter test mode are as follows: POT must start at a time less than or equal to the 40 second mark. The POT must then be rapidly rotated to a position greater than or equal to the 280 second mark in less than ¼ second. Normal operation will resume after power is reset or after the unit has been in test mode for at least 5 minutes. Brownout Protection with Adjustment Brownout protection may be necessary if the utility power or generator power has inadequate power to prevent the voltage from dropping when the compressor starts. This is rare but can happen if the generator is undersized at the site or if the site is in a remote location far from the main power grid. Under normal circumstances, allowing the brownout to be ignored for a time period should not be needed. The 8201-169 is shipped with all the DIP switches in the 'off' or 'do not ignore' position (see Figure 10 on page 24). If ignoring the brownout is needed because of the above conditions, three preset timers can be set by DIP switches in order to delay signaling a power brownout for a specific length of time after compressor contactor is energized. This allows the compressor a time period to start even if the voltage has dropped and allows the voltage to recover. This delay only happens when the CC terminal energizes. The delay can be set to 1 second (A DIP switch), 5 seconds (B DIP switch) or 10 seconds (C DIP switch); time is not cumulative--only Manual 2100-689H Page 23 of 42 High Pressure Switch 18-30 VAC Input Y Input from Thermostat and High Pressure Switch FIGURE 10 8201-169 Compressor Control Module Compressor Contactor Output Alarm Output Common Troubleshooting Light Delay-on-Break Time Adjustment Potentiometer Low Pressure Switch Brownout Ignore Time DIP Switches* * Turn on only one switch for that specific ignore time setting. 10 seconds is the maximum brownout ignore time. If all switches are "off", the control is in "do not ignore". the longest setting will apply. If the voltage recovers during the brownout delay period, the compressor will start. If a brownout condition is detected by the 8201-169, the troubleshooting light will flash blue. The light will continue to flash until the cooling call is satisfied or power is removed from the Y terminal. This condition does not prevent operation, it only indicates that a brownout condition was present at some point during the cooling call. If a brownout condition is detected, CC will be de-energized and will retry after the delayon-make timer is satisfied; this process will continue until call is satisfied. If user chooses the 'do not ignore' position (all three DIP switches "off") when the site has inadequate utility or generator power, this could lead to the compressor never starting. The control will see the brownout immediately and not start. A common scenario and one that has been seen in the field is when a unit or units switches from utility power to generator power. With slower transfer switches, the time delay between the utility power and generator power didn't cause a problem. The units lost power, shut off and came back on line normally. With the introduction of almost instantaneous transfer switches, the millisecond long power glitch can be enough that the compressor will start to run backwards. In this scenario, the CCM will catch this and restart the units normally. Pressure Service Ports High and low pressure service ports are installed on all units so that the system operating pressures can be observed. Pressure tables covering all models can be found on pages 28 and 29. It is imperative to match the correct pressure table to the unit by model number. This unit employs high-flow Coremax valves instead of the typical Shrader type valves. WARNING! Do NOT use a Schrader valve core removal tool with these valves. Use of such a tool could result in eye injuries or refrigerant burns! To change a Coremax valve without first removing the refrigerant, a special tool is required which can be obtained at www.fastestinc.com/en/SCCA07H. See the replacement parts manual for replacement core part numbers. Manual 2100-689H Page 24 of 42 SERVICE Troubleshooting NIDEC SELECTECH Series ECM Motors If the Motor Is Running 1. It is normal for the motor to rock back and forth on start up. Do not replace the motor if this is the only problem identified. 2. If the system is excessively noisy, does not appear to change speeds in response to a demand (Heat, Cool, Other) or is having symptoms during the cycle such as tripping limit or freezing coil, check the following: A. Wait for programmed delays to time out. B. Ensure that the motors control inputs are wired as shown in the factory-supplied wiring diagram to ensure motor is getting proper control signals and sequencing. C. Remove the filter and check that all dampers, registers and grilles are open and free flowing. If removing the filters corrects the problem, clean or replace with a less restrictive filter. Also check and clean the blower wheel or coil as necessary. D. Check the external static pressure (total of both supply and return) to ensure it is within the range as listed on the unit serial plate. If higher than allowed, additional duct work is needed. E. If the motor does not shut off at the end of the cycle, wait for any programmed delays to time out (no more than 90 seconds). Also make sure that there is no call for "Continuous Fan" on the G terminal. F. If the above diagnostics do not solve the problem, confirm the voltage checks in the next section below, then continue with the Model SelecTech Communication Diagnostics. If the Motor Is Not Running 1. Check for proper high voltage and ground at the L/ L1, G, N/L2 connections at the motor (see Figure 11). Correct any voltage issues before proceeding to the next step. The SelecTech motor is voltage specific. Only the correct voltage should be applied to the proper motor. Input voltage within plus or minus 10% of the nominal line power VAC is acceptable. FIGURE 11 Motor Connections LINE POWER GROUND LINE POWER L2 LINE EARTH POWER GROUND L1 LINE POWER NOTE: MOTOR IS CONSTANTLY POWERED BY LINE VOLTAGE Manual 2100-689H Page 25 of 42 2. If the motor has proper high voltage and ground at the L/L1, G, N/L2 connections, then continue with the Model SelecTech Communication Diagnostics. Model SelecTech Communication Diagnostics The SelecTech motor is communicated through 24 VAC low voltage (thermostat control circuit wiring). 1. Start with unit wiring diagram to confirm proper connections and voltage (see Figure 12). 2. Initiate a demand from the thermostat and check the voltage between the common and the appropriate motor terminal (1-5). (G input is typically on terminal #1, but always refer to wiring diagram.) A. If the low voltage communication is not present, check the demand from the thermostat. Also check the output terminal and wire(s) from the terminal strip or control relay(s) to the motor. B. If the motor has proper high voltage (verified in Step 1 of If the Motor Is Not Running on page 21), proper low voltage to a programmed terminal and is not operating, the motor is failed and will require replacement. FIGURE 12 Motor Connections 24VAC Common 24VAC "R" Signal through thermostat output. Speed Tap 1: Vent Speed Speed Tap 2: Balanced Climate Speed Speed Tap 3: Default Speed Speed Tap 4: Medium Speed Speed Tap 5: High Speed 24VAC Common 24VAC "R" Signal through thermostat output. Manual 2100-689H Page 26 of 42 Fan Blade Setting Dimensions Shown in Figure 13 is the correct fan blade setting for proper air delivery across the outdoor coil. Refer to Table 9 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 13 Fan Blade Setting A IRFLO W M IS-1 7 2 4 "A " TABLE 9 Fan Blade Dimensions Model W18AB/W18LB W24AB/W24LB W30AB/W30LB W36AB/W36LB Dimension A 1.00" 1.25" R-410A Refrigerant Charge This unit was charged at the factory with the quantity of refrigerant listed on the serial plate. AHRI capacity and efficiency ratings were determined by testing with this refrigerant charge quantity. The following pressure table shows nominal pressures for the units. Since many installation specific situations can affect the pressure readings, this information should only be used by certified technicians as a guide for evaluating proper system performance. They shall not be used to adjust charge. If charge is in doubt, reclaim, evacuate and recharge the unit to the serial plate charge. 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 nine screws holding fan shroud to condenser and bottom. 4. Unwire condenser fan motor. 5. Slide complete motor, fan blade and shroud assembly out the left side of the unit. 6. Service motor/fan as needed. 7. Reverse steps to reinstall. Manual 2100-689H Page 27 of 42 TABLE 10 Cooling Pressure Standard Airflow Air Temperature Entering Outdoor Coil °F Model W18A/L W24A/L W30A/L W36A/L Return Air Temp (DB/WB) 75/62 80/67 85/72 75/62 80/67 85/72 75/62 80/67 85/72 75/62 80/67 85/72 Pressure Low Side High Side Low Side High Side Low Side High Side Low Side High Side Low Side High Side Low Side High Side Low Side High Side Low Side High Side Low Side High Side Low Side High Side Low Side High Side Low Side High Side 75 80 85 90 95 100 105 110 115 120 125 131 120 122 126 129 132 134 137 138 139 141 142 144 296 318 340 364 388 413 440 466 494 524 553 590 128 131 135 138 141 143 146 148 149 151 152 154 304 326 349 373 398 424 451 478 507 537 567 605 132 136 140 143 146 148 151 153 154 156 157 159 315 337 361 386 412 439 467 495 525 556 587 626 123 125 127 129 132 134 136 137 139 141 143 146 302 323 344 367 391 415 441 467 494 523 552 589 132 134 136 138 141 143 145 147 149 151 153 156 310 331 353 376 401 426 452 479 507 536 566 604 137 139 141 143 146 148 150 152 154 156 158 161 321 343 365 389 415 441 468 496 525 555 586 625 122 124 126 129 131 133 135 137 138 140 142 143 317 337 360 383 409 435 462 490 520 551 583 622 130 133 135 138 140 142 144 146 148 150 152 153 325 346 369 393 419 446 474 503 533 565 598 638 135 138 140 143 145 147 149 151 153 155 157 336 358 382 407 434 462 491 521 552 585 619 --* 128 130 132 133 135 137 138 140 142 144 146 148 318 339 362 385 410 436 463 491 521 552 583 623 137 139 141 142 144 146 148 150 152 154 156 158 326 348 371 395 421 447 475 504 534 566 598 639 142 144 146 147 149 151 153 155 157 159 161 337 360 384 409 436 463 492 522 553 586 619 --* Low side pressure ± 4 PSIG High side pressure ± 10 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 and system evacuated and recharged to serial plate charge weight. NOTE: Pressure table based on high speed condenser fan operation. If condensing pressures appear elevated check condenser fan wiring. See Condenser Fan Operation on page 22. * Operating at these conditions would be outside the compressor operating envelope and is not recommended. Manual 2100-689H Page 28 of 42 TABLE 11 Cooling Pressure Balanced Climate Airflow Air Temperature Entering Outdoor Coil °F Model W18A/L W24A/L W30A/L W36A/L Return Air Temp (DB/WB) 75/62 80/67 85/72 75/62 80/67 85/72 75/62 80/67 85/72 75/62 80/67 85/72 Pressure Low Side High Side Low Side High Side Low Side High Side Low Side High Side Low Side High Side Low Side High Side Low Side High Side Low Side High Side Low Side High Side Low Side High Side Low Side High Side Low Side High Side 75 80 85 90 95 100 105 110 115 120 125 131 117 119 121 122 124 126 129 131 133 135 137 139 295 317 338 362 385 410 436 463 491 520 550 587 125 127 129 131 133 135 138 140 142 144 146 149 303 325 347 371 395 421 447 475 504 533 564 602 129 131 134 136 138 140 143 145 147 149 151 154 314 336 359 384 409 436 463 492 522 552 584 623 116 118 120 122 123 125 128 130 132 135 137 139 296 318 339 362 385 410 434 460 488 515 544 579 124 126 128 130 132 134 137 139 141 144 146 149 304 326 348 371 395 420 445 472 500 528 558 594 128 130 132 135 137 139 142 144 146 149 151 154 315 337 360 384 409 435 461 489 518 546 578 615 117 120 122 124 126 128 130 132 134 135 137 138 312 334 357 381 406 432 458 486 514 543 572 609 125 128 130 133 135 137 139 141 143 144 146 148 320 343 366 391 416 443 470 498 527 557 587 625 129 132 135 138 140 142 144 146 148 149 151 153 331 355 379 405 431 459 486 515 545 576 608 647 120 122 123 124 126 128 130 132 135 137 138 141 312 332 354 377 402 427 454 483 513 543 576 616 128 130 132 133 135 137 139 141 144 146 148 151 320 341 363 387 412 438 466 495 526 557 591 632 132 135 137 138 140 142 144 146 149 151 153 156 331 353 376 401 426 453 482 512 544 576 612 654 Low side pressure ± 4 PSIG High side pressure ± 10 PSIG Tables are based upon Balanced Climate 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 and system evacuated and recharged to serial plate charge weight. NOTE: Pressure table based on high speed condenser fan operation. If condensing pressures appear elevated check condenser fan wiring. See Condenser Fan Operation on page 22. Manual 2100-689H Page 29 of 42 TABLE 12 Electrical Specifications - W**AB Series Single Circuit Multiple Circuit Model W18AB-A00, A0Z A05 A08 A10 W24AB-A00, A0Z A05 A08 A10 W24AB-B00, B0Z B06 W24AB-C00, C0Z C06 W30AB-A00, A0Z A05 A08 A10 A15 W30AB-B00, B0Z B06 B09 B15 W30AB-C00, C0Z C06 C09 C12 C15 W36AB-A00, A0Z A05 A08 A10 A15 W36AB-B00, B0Z B06 B09 B15 W36AB-C00, C0Z C06 C09 C15 Rated Volts & Phase 230/208-1 230/208-1 230/208-3 460-3 230/208-1 230/208-3 460-3 230/208-1 230/208-3 460-3 No. Field Power Circuits Minimum Circuit Ampacity Maximum External Fuse or Ckt. Brkr. Field Power Wire Size Ground Wire 1 16 1 30 1 45 1 56 1 21 1 30 1 46 1 57 1 15 1 23 1 8 1 12 1 23 1 31 1 47 1 57 1 or 2 83 1 17 1 23 1 32 1 50 1 9 1 12 1 16 1 21 1 25 1 27 1 32 1 48 1 58 1 or 2 84 1 20 1 24 1 33 1 51 1 11 1 12 1 17 1 26 20 12 12 30 10 10 45 8 10 60 6 10 25 10 10 30 10 10 50 8 10 60 6 10 20 12 12 25 10 10 15 14 14 15 14 14 35 8 10 35 8 10 50 8 10 60 6 10 90 4 8 20 12 12 25 10 10 35 8 10 50 8 10 15 14 14 15 14 14 20 12 12 25 10 10 25 10 10 35 8 10 35 8 10 50 8 10 60 6 10 90 4 8 25 10 10 25 10 10 35 8 10 60 6 10 15 14 14 15 14 14 20 14 14 30 12 12 Minimum Circuit Ampacity Maximum External Fuse Field Power or Wire Size Ckt. Breaker Ckt. Ckt. Ckt. Ckt. Ckt. Ckt. ABABAB 57 26 60 30 6 10 58 26 60 30 6 10 Ground Wire Size Ckt. Ckt. AB 10 10 10 10 These "Minimum Circuit Ampacity" values are to be used for sizing the field power conductors. Refer to the National Electrical code (latest version), Article 310 for power conductor sizing. CAUTION: When more than one field power circuit is run through one conduit, the conductors must be derated. Pay special attention to note 8 of Table 310 regarding Ampacity Adjustment Factors when more than three (3) current carrying conductors are in a raceway. Maximum size of the time delay fuse or circuit breaker for protection of field wiring conductors. Based on 75°copper wire. All wiring must conform to the National Electrical Code and all local codes. NOTE: The Maximum Overcurrent Protection (MOCP) value listed is the maximum value as per UL 1995 calculations for MOCP (branchcircuit conductor sizes in this chart are based on this MOCP). The actual factory-installed overcurrent protective device (circuit breaker) in this model may be lower than the maximum UL 1995 allowable MOCP value, but still above the UL 1995 minimum calculated value or Minimum Circuit Ampacity (MCA) listed. IMPORTANT: While this electrical data is presented as a guide, it is important to electrically connect properly sized fuses and conductor wires in accordance with the National Electrical Code and all local codes. Manual 2100-689H Page 30 of 42 TABLE 13 Electrical Specifications - W**LB Series Single Circuit Multiple Circuit Model W18LB-A00, A0Z A05 A08 A10 W24LB-A00, A0Z A05 A08 A10 W24LB-B00, B0Z B06 W30LB-A00, A0Z A05 A08 A10 A15 W30LB-B00, B0Z B09 B15 W30LB-C00, C0Z C09 C15 W36LB-A00, A0Z A05 A10 A15 W36LB-B00, B0Z B09 B15 W36LB-C00, C0Z C09 C15 Rated Volts & Phase 230/208-1 230/208-1 230/208-3 230/208-1 230/208-3 460-3 230/208-1 230/208-3 460-3 No. Field Power Circuits Minimum Circuit Ampacity Maximum External Fuse or Ckt. Brkr. Field Power Wire Size Ground Wire 1 16 1 30 1 46 1 56 1 21 1 30 1 46 1 57 1 15 1 23 1 23 1 31 1 46 1 57 1 or 2 83 1 17 1 32 1 50 1 9 1 16 1 26 1 27 1 32 1 58 1 or 2 84 1 20 1 33 1 51 1 9 1 15 1 24 20 12 12 30 10 10 50 8 10 60 6 10 25 10 10 35 8 10 50 8 10 60 6 10 20 12 14 25 10 10 35 8 10 35 8 10 50 8 10 60 6 10 90 4 8 20 12 12 35 8 10 50 8 10 15 14 14 20 12 12 30 10 10 35 8 10 35 8 10 60 6 10 90 4 8 25 10 10 35 8 10 60 6 10 15 14 14 15 14 14 25 10 10 Minimum Circuit Ampacity Maximum External Fuse Field Power or Wire Size Ckt. Breaker Ckt. Ckt. Ckt. Ckt. Ckt. Ckt. ABABAB 57 26 60 30 6 10 58 26 60 30 6 10 Ground Wire Size Ckt. Ckt. AB 10 10 10 10 These "Minimum Circuit Ampacity" values are to be used for sizing the field power conductors. Refer to the National Electrical code (latest version), Article 310 for power conductor sizing. CAUTION: When more than one field power circuit is run through one conduit, the conductors must be derated. Pay special attention to note 8 of Table 310 regarding Ampacity Adjustment Factors when more than three (3) current carrying conductors are in a raceway. Maximum size of the time delay fuse or circuit breaker for protection of field wiring conductors. Based on 75°copper wire. All wiring must conform to the National Electrical Code and all local codes. NOTE: The Maximum Overcurrent Protection (MOCP) value listed is the maximum value as per UL 1995 calculations for MOCP (branchcircuit conductor sizes in this chart are based on this MOCP). The actual factory-installed overcurrent protective device (circuit breaker) in this model may be lower than the maximum UL 1995 allowable MOCP value, but still above the UL 1995 minimum calculated value or Minimum Circuit Ampacity (MCA) listed. IMPORTANT: While this electrical data is presented as a guide, it is important to electrically connect properly sized fuses and conductor wires in accordance with the National Electrical Code and all local codes. Manual 2100-689H Page 31 of 42 Setting Unit Airflow The unit is set from the factory at the default speed. Most units have three selectable cooling speed taps that can be utilized. The default speed is the lowest cooling speed. The two higher speed taps can be used for higher duct static applications so that the unit can maintain the recommended airflow as shown in Table 14. The higher speeds can also be used when higher sensible cooling is desired. To change to the higher speed taps, move the orange/black wire on the blower speed terminal block to either MED or HI. Refer to Table 16 on page 36 for the corresponding airflow of each tap. Set the unit duct static based on the highest airflow that the unit will run at. NOTE: Be sure to adjust the system static or blower speed to maintain airflows above the minimum recommendations to prevent freeze up conditions if Balanced Climate mode is activated. Do not operate the unit in Balanced Climate mode if running high static applications as indicated in the blower performance table. If Balanced Climate mode is activated as described on page 17, the unit will run in this mode at all times unless there is a call for ventilation, electric heat or 2nd stage cooling from a 2-stage thermostat. At that time, the unit will automatically activate a higher speed tap. Blower Speeds Five factory programmed speed taps (torque settings) are available for the motor, and are selected through different unit modes of operation. These modes are energized by 24VAC signals from the low voltage terminal block located inside the control panel by a thermostat or other controlling device. Each speed tap is programmed by Bard at the factory to different motor torque settings (see Figure 14). FIGURE 14 Speed Taps 24VAC Common 24VAC "R" signal through thermostat output Speed Tap 1: Vent Speed Speed Tap 2: Balanced Climate Speed Speed Tap 3: Default Speed Speed Tap 4: Medium Speed Speed Tap 5: High Speed Multiple motor speed taps may be energized simultaneously by 24VAC power during different modes of operation. The highest number speed tap energized takes priority with 5 being the highest and 1 being the lowest. See Table 15 for the corresponding blower speeds with the different modes of operation. Programmed blower speed taps are as follows (see also Figure 15): Speed Tap 1: Vent/blower only speed Speed Tap 2: Balanced Climate speed Speed Tap 3: Default LO cooling & heating speed. Energized by default for cooling operation through the blower speed tap selection and is labeled as LO. Speed Tap 4: Optional MED Cooling & heating speed. Selected manually through the blower speed tap selection and is labeled as MED. Speed Tap 5: Optional HI cooling & heating speed. Selected manually through the blower speed tap selection and is labeled as HI. TABLE 14 Recommended Airflow Model W18A W18L W24A W24L W30A W30L W36A W36L Nominal Rated CFM* 600 800 950 1150 Nominal Rated ESP* .10 .10 .15 .15 Recommended Airflow Range 550 - 725 700 - 950 900 - 1125 1000 - 1200 * Rated CFM and ESP on factory speed connection. Factory Speed Connection Default Manual 2100-689H Page 32 of 42 TABLE 15 Blower Speeds for Unit Operational Modes Unit Operation Blower Only Balanced Climate Cooling Full Load Cool 1st Stage Heat 2nd Stage Heat Dehumidify2 Thermostat Inputs 24VAC G Y1 Y2 W1 W2 A D X XX XXX X XX X Speed Taps 1 2 3-4-51 Blower Speed Compressor Operation X Vent/Blower Only Off XX Balanced Climate On XX X Lo/Med/Hi On X Lo/Med/Hi Off X Lo/Med/Hi Off XX Balanced Climate On ¹ Fan speed is selectable through the blower speed control terminal block. LO (default), MED or HI speeds can be used. 2 Dehumidification operation is disabled when a call for heating or cooling occurs. Unit runs at Balanced Climate speed during dehumidification operation. FIGURE 15 Speed Taps Orange Wire w/Black Stripe Speed Tap 1 Vent/Blower Only Speed taps 1 and 3 are programmed to identical torque settings in the ECM motor. This means that if speed tap 1 is energized, the airflow amount will be the same as default airflow. Tap 1 is used when a vent is installed and ventilation is called for by energizing the A terminal of the low voltage terminal block with 24VAC. Speed tap 1 is the lowest priority; if any of the other speed taps are energized, they will override speed tap 1. Speed Tap 2 Balanced Climate Speed tap 2 is programmed to a lower than rated speed in the ECM motor. In order for Balanced Climate speed to be used during compressor cooling mode, the jumper between Y1 and Y2 must be removed. This means that if speed tap 2 is energized, the airflow amount will be lower than default airflow. Tap 2 is used when Balanced Climate is called for by energizing the Y1 terminal of the low voltage terminal block with 24VAC. Speed tap 2 is overridden if taps 3, 4, or 5 are energized. Speed Tap 3 Default LO Cooling & Heating Speed tap 3 is programmed for rated speed in the SelecTech motor. This means that if speed tap 3 is energized, the airflow amount will be the default airflow. Tap 3 is used by default when cooling is called for by energizing the Y1 terminal of the low voltage terminal block with 24VAC. The unit is shipped with the jumper between Y1 and Y2 installed and it must be removed to use Balanced Climate mode. The unit is shipped with the orange/black wire connected to terminal LO (rated speed) on the blower selection speed terminal block. Speed tap 3 can be overridden if taps 4 or 5 are energized by changing the position of the orange/black wire on the blower selection speed terminal block to MED (4) or HI (5) positions. Speed Tap 4 Optional MED Cooling & Heating Speed tap 4 is programmed to a higher than rated speed in the ECM motor. This is a user-selectable airflow amount that will be higher than rated airflow. Tap 4 is used for cooling operation if the orange/black wire on the blower speed selection terminal block is moved to MED. Speed tap 4 can be overridden if tap 5 is energized. Speed Tap 5 Optional HI Cooling & Heating Speed tap 5 is programmed to the highest speed in the ECM motor. This is a user-selectable airflow amount that will provide the highest rated airflow. Tap 5 is used for cooling operation if the orange/black wire on the blower speed selection terminal block is moved to HI. Manual 2100-689H Page 33 of 42 Dirty Filter Switch 1. Disconnect all power to the unit. Remove control panel outer cover and upper front panel. 2. The dirty filter switch is located on top of the filter partition to the right of the blower wheels on W**AB units and to the left of the blower wheels on W**LB units (see Figure 16). The dirty filter indicator light and reset switch is attached to the side of the control panel on the right side of the filter access opening on W**AB units and on the left side of the filter access opening on W**LB units. Remove the cover on the dirty filter switch and ensure the knob is set at 0.4" W.C. (see Figure 17). This is only a recommended starting point prior to making switch adjustments. Switch setting is highly dependent on filter type used, blower speed, unit ducting and other unit installation characteristics. See Dirty Filter Switch Adjustment for instructions on how to make proper switch adjustments. 3. Re-install upper front panel. Dirty Filter Switch Adjustment 1. Apply power to the unit. 2. Turn the unit indoor blower on (energize R-G on low voltage terminal board). 3. With air filters installed and switch initially set at 0.4" W.C. (see Step 2 under Dirty Filter Switch), begin restricting the air filter of the unit using a piece of cardboard under the filters until the switch trips and the light comes on. If the filter is restricted by 75% (or desired restriction amount), skip to Step 6. 4. If switch setting adjustment is required, disconnect power to the unit. Remove the upper front panel and the cover on the airflow switch so that adjustment can be made. If the switch tripped before 75% restriction was reached, turn the knob slightly clockwise. If the switch tripped after 75%, turn the knob counter-clockwise (see Figure 17). 5. Replace the upper front panel and repeat Steps 1-3. Continue to make adjustments described in Step 4 until the desired restriction is obtained. 6. Remove the restriction and reset the filter switch. Replace the switch cover once adjustment is complete. 7. Install the outer control panel cover. This completes the adjustment. W**LB Units FIGURE 16 Dirty Filter Switch Location W**AB Units Manual 2100-689H Page 34 of 42 FIGURE 17 Adjusting Dirty Filter Switch TURN CLOCKWISE TO INCREASE RESTRICTION AMOUNT REQUIRED TO ACTIVATE THE SWITCH AND COUNTER-CLOCKWISE TO DECREASE RESTRICTION AMOUNT MIS-4086 B Manual 2100-689H Page 35 of 42 TABLE 16 Indoor Blower Performance W18AB/W18LB W24AB/W24LB W30AB/W30LB W36AB/W36LB E.S.P.1 (In. H2O) 0.00 0.10 0.15 0.20 0.25 0.30 0.40 0.50 0.00 0.10 0.15 0.20 0.25 0.30 0.40 0.50 0.00 0.10 0.15 0.20 0.25 0.30 0.40 0.50 0.00 0.10 0.15 0.20 0.25 0.30 0.40 0.50 Balanced ClimateTM Speed Dry Coil 520 435 395 Wet Coil 510 420 380 630 625 580 565 550 535 525 500 830 825 765 745 730 705 700 670 925 900 850 825 815 790 780 755 Default LO Cooling & Heating/ Ventilation Speed2 Dry Coil Wet Coil 680 665 615 600 585 565 555 535 525 510 495 480 440 425 385 375 890 835 825 800 795 780 770 755 740 730 715 705 670 650 630 585 1050 1020 1000 975 975 950 950 925 920 900 890 870 830 815 770 755 1255 1225 1205 1175 1180 1150 1155 1125 1130 1100 1100 1070 1050 1015 1000 960 Optional MED Cooling & Heating Speed Dry Coil Wet Coil Dedicated electric heat speed (same airflows as W24AB/LB default airflows) 1005 960 935 910 890 870 825 785 1170 1120 1095 1070 1050 1025 975 930 1365 1320 1295 1275 1250 1225 1180 1130 980 930 910 885 865 840 805 765 1135 1105 1085 1060 1040 1015 955 890 1345 1300 1275 1250 1220 1195 1140 1075 Optional HI Cooling & Heating Speed Dry Coil 865 810 785 760 735 710 665 620 1025 990 975 955 935 915 870 825 1200 1170 1150 1130 1110 1085 1040 985 1495 1445 1415 1385 1350 1310 1225 1130 Wet Coil 855 800 770 745 720 695 650 605 1035 980 955 930 910 885 845 805 1205 1155 1130 1105 1080 1055 1000 945 1480 1425 1395 1360 1320 1280 1185 1075 1 E.S.P. is the total combined external static pressure of both the supply and return ducts or grills. 2 This is the speed set at the factory. Manual 2100-689H Page 36 of 42 TABLE 17 Maximum ESP of Operation Electric Heat Only Model Outlet Speed -A0Z -A05 -A08 -A10 -A15 -B0Z -B06 -B09 -B15 -C0Z -C06 -C09 -C15 W18A/L, W24A/L FRONT Single .50 .50 .50 .30 .50 .40 .50 .50 W30A/L, W36A/L FRONT High Low .50 .50 .50 .50 .50 .50 .40 .35 .40 .35 .50 .50 .50 .40 .50 .50 .35 .30 .50 .50 .50 .50 .50 .40 .45 .35 Values shown are for units equipped with standard 1" throwaway filter or 1" washable filter. Derate ESP by .15 for 2" pleated filters. Models KW 5 6 8 9 10 15 240V-1 Amps BTUH 20.8 17065 33.3 27300 41.6 34130 62.5 51250 TABLE 18 Electric Heat 208V-1 Amps BTUH 18.1 12800 28.8 20475 36.2 25600 54.0 38400 240V-3 Amps BTUH 14.4 20500 21.7 30600 36.2 51200 208V-3 Amps BTUH 12.5 15360 18.7 23030 31.2 38400 460V-3 Amps BTUH 7.2 20500 10.8 30700 18.0 51200 Manual 2100-689H Page 37 of 42 W18, W24 W30, W36 TABLE 19 Vent and Control Options Part Number CMA-14 CMC-15 CMC-31 CMC-34 CMC-36 CMC-37 CMA-37 CMA-38 CMA-39 CMA-40 BOP2 FAD-NE2 FAD-BE2 CRV-F2-* CRV-V2-* ECON-NC2-* ECON-S2-* ECON-WD2-* ECON-DB2-* ERV-FA2-* ERV-FC2-* BOP3 FAD-NE3 FAD-BE3 CRV-F3-* CRV-V3-* ECON-NC3-* ECON-S3-* ECON-WD3-* ECON-DB3-* ERV-FA3-* ERV-FC3-* Description ODT Start Kit (230V 1-Phase) Dirty Filter Sensor Kit Alarm Relay Crankcase Heater (230V) Crankcase Heater (460V LAC - Modulating (230V) LAC - Modulating (460V) LAC - On/Off DDC Blank Off Plate Fresh Air Damper - No Exhaust Fresh Air Damper - Barometric Exhaust Commercial Ventilator - On/Off, Spring Return Commercial Ventilator - 0-10V, Spring Return Economizer - Bldg. Equipment, 0-10V, No Controls Economizer - School Economizer - Bldg. Equipment, Enthalpy Economizer - Bldg. Equipment, Temperature Energy Recovery Ventilator (230V) Energy Recovery Ventilator (460V) Blank Off Plate Fresh Air Damper - No Exhaust Fresh Air Damper - Barometric Exhaust Commercial Ventilator - On/Off, Spring Return Commercial Ventilator - 0-10V, Spring Return Economizer - Bldg. Equipment, 0-10V, No Controls Economizer - School Economizer - Bldg. Equipment, Enthalpy Economizer - Bldg. Equipment, Temperature Energy Recovery Ventilator (230V) Energy Recovery Ventilator (460V) XX XX XX XX XX XX X X X XX X X X X X X X X X X X X X X X X X X X X X X * Insert color to match unit (X = Beige, 1 = White, 4 = Buckeye Gray, 5 = Desert Brown, 8 = Dark Bronze, S = Stainless, A = Aluminum Manual 2100-689H Page 38 of 42 W18AB-A W24AB-A W24AB-B W24AB-C W30AB-A W30AB-B W30AB-C W36AB-A W36AB-B W36AB-C TABLE 20A Optional Accessories Right Hand Heater Kits Circuit Breaker (WMCB) and Pull Disconnect (WMPD) EHW1TAB-A05 EHW1TAB-A08 EHW2TAB-A05 EHW2TAB-A08 EHW2TA-A10 EHW2TA-B06 EHWH24B-C06 EHW3TA-A05 EHW3TA-A08 EHW3TA-A10 EHW3TAB-A10 EHW3TA-A15 EHW3TAB-A15 EHW30A-B06 EHW3TA-B06 EHW3TA-B09 EHW3TAB-B09 EHW3TA-B15 EHW3TAB-B15 EHW3TA-C06 EHW3TA-C09 EHW3TA-C12 EHW3TA-C15 EHW3TAB-C15 WMCB-02A WMCB-02B WMCB-03A WMCB-03B WMCB-05A WMPD-01C X X X X XX X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X Manual 2100-689H Page 39 of 42 W18LB-A W24LB-A W24LB-B W30LB-A W30LB-B W30LB-C W36LB-A W36LB-B W36LB-C TABLE 20B Optional Accessories Left Hand Heater Kits Circuit Breaker (WMCB) and Pull Disconnect (WMPD) EHW1TAB-A05L EHW1TAB-A08L EHW2TAB-A05L EHW2TAB-A08L EHW2TA-A10L EHW2TA-B06L EHW3TA-A05L EHW3TA-A08L EHW3TA-A10L EHW3TAB-A10L EHW3TA-A15L EHW3TA-B09L EHW3TAB-B09L EHW3TA-B15L EHW3TAB-B15L EHW3TA-C09L EHW3TA-C15L EHW3TAB-C15L WMCB-02AL WMCB-02BL WMCB-03AL WMCB-03BL WMCB-05AL WMPD-01CL X X X X XX X X X X X X X X X X X X X X X X X X X X X X X X X Manual 2100-689H Page 40 of 42 GRAPH 1 W18*B FAD-NE2, 3 W/O Exhaust Ventilation Delivery GRAPH 2 W24*B FAD-NE2, 3 W/O Exhaust Ventilation Delivery Manual 2100-689H Page 41 of 42 GRAPH 3 W30*B FAD-NE2, 3 W/O Exhaust Ventilation Delivery GRAPH 4 W36*B FAD-NE2, 3 W/O Exhaust Ventilation Delivery Manual 2100-689H Page 42 of 42 SUPPLEMENTAL INSTRUCTIONS 50 HZ ELECTRICAL DATA Model Rated Volts and Phases Operating Voltage Range No. Field Power Circuits Minimum Circuit Ampacity Maximum External Fuse or Ckt. Brkr. Field Power Wire Size Ground Wire Size W24AB-D0Z 240/220-1 1 15 20 12 12 D05 240/220-1 198 - 254 1 28 30 10 10 D08 240/220-1 1 44 45 8 10 W24A/LB-F0Z F05 415/380-3 342 - 456 1 1 10 11 15 14 14 15 14 14 W30AB-D0Z 1 15 20 12 12 D05 240/220-1 198 - 254 1 28 30 10 10 D10 1 54 60 6 10 W30AB-F0Z 1 10 15 14 14 F07 415/380-3 342 - 456 1 16 20 12 12 F12 1 26 30 10 10 W36AB-D0Z 1 17 25 8 10 D05 240/220-1 198 - 254 1 28 30 8 10 D10 1 54 60 6 10 W36AB-E0Z 1 17 25 10 10 E06 240/220-3 198 - 254 1 21 25 10 10 E12 1 39 40 8 10 W36A/LB-F0Z 1 10 15 14 14 F07 415/380-3 342 - 456 1 14 15 12 12 F12 1 22 25 10 10 W42AC-E0Z 1 21 30 10 10 E09 240/220-3 198 - 254 1 30 30 8 10 E15 1 48 50 8 10 W42A/LC-F0Z 1 12 15 14 14 F07 415/380-3 342 - 456 1 16 20 12 12 * F14 1 29 30 10 10 W48AC-E0Z 1 23 35 8 10 E09 240/220-3 198 - 254 1 31 35 8 10 E15 1 50 50 8 10 W48A/LC-F0Z 1 12 15 14 14 F07 415/380-3 342 - 456 1 17 20 12 12 * F14 1 31 35 8 10 W60AC-E0Z 1 25 35 8 10 E09 240/220-3 198 - 254 1 32 35 8 10 E15 1 50 50 8 10 W60A/LC-F00 1 15 15 12 12 F07 415/380-3 342 - 456 1 18 20 12 12 * F14 1 31 35 8 10 W72A/LC-F00 1 21 25 10 10 F07 400/380-3 342 - 440 1 21 25 10 10 F14 1 32 35 8 10 These "Minimum Circuit Ampacity" values are to be used for sizing the field power conductors. Refer to the National Electric Code (latest version), Article 310 for power conductor sizing. Maximum size of the time delay fuse or "D" type circuit breaker for protection of field wiring conductors. Based on 75°C copper wire. All wiring must conform to all local and national electrical codes. * F14 only offered on W**A units. CAUTION: When more than one field power circuit is run through one conduit, the conductors must be derated. Pay special attentionto Note 8 of Table 310 regarding Ampacity Adjustment Factors when more than three conductors are in a raceway. IMPORTANT: While this electrical data is presented as a guide, it is important to electrically connect properly sized fuses and conductor wires in accordance with all existing local codes. Bard Manufacturing Company, Inc. Bryan, Ohio 43506 www.bardhvac.com Manual: 7960-810 Supersedes: NEW Date: 3-1-19 Page 1 of 2 OUTDOOR FAN MOTOR 50 HZ Models W42AC-E, W42AC-F, W48AC-E, W48AC-F, W60AC-E and W60AC-F have a condenser fan motor with a red and black speed tap. These units are shipped from the factory with the red lead connected. At no time is the black lead to be connected for 50HZ application. WIRING MAIN POWER The disconnect means must have contact separation of 3 mm or greater in all poles. Manual 7960-810 Page 2 of 2 REPLACEMENT PARTS MANUAL Wall Mounted Packaged Air Conditioner Models: W18LB-A W24LB-A W24LB-B W24LB-F General Notes Revised and/or additional pages may be issued from time to time. A complete and current manual consists of pages shown in the following contents section. Important Contact the installing and/or local Bard distributor for all parts requirements. Make sure you have the complete model and serial number available from the unit rating plates. Contents Description Page Cabinet Components Exploded View ..............................................2 Usage List ....................................................3 Functional Components Exploded View ..............................................4 Usage List ....................................................5 Control Panel Layout View ..................................................6 Usage List ....................................................7 Blower Assembly Exploded View ..............................................8 Usage List ....................................................8 Bard Manufacturing Company, Inc. Bryan, Ohio 43506 www.bardhvac.com Manual: 2110-1448E Supersedes: 2110-1448D Date: 4-5-21 Page 1 of 8 CABINET COMPONENTS 1 2 32 3 31 4 5 29 6 28 7 27 8 26 25 10 24 11 23 12 22 13 14 15 16 33 17 18 19 20 21 SEXP-946 A Manual 2110-1448E Page 2 of 8 CABINET COMPONENTS W18LB-A W24LB-A, -B W24LB-F Dwg No. 1 1 1 2 2 2 3 3 4 4 4 5 6 6 6 7 7 7 8 9 10 11 12 12 12 13 13 13 14 14 14 15 16 17 17 18 18 19 19 20 20 21 22 22 22 23 23 23 24 24 24 25 25 25 26 27 28 29 29 29 30 31 32 33 33 33 NS Part Number 113-141-* 113-361 113-141-4 S507-311-* S507-317 S507-318 S123-131 S123-142 S509-445 S509-449 S509-447 105-1302 S501-935-* S501-998 501-943 S543-175-* S543-185 S543-184 113Y480 137-259 S132-104 113-140 S153-218 S153-405 S153-387 S533-228-* S533-235 S533-236 118-124-* 118-140 118-141 Control Panel Assembly 105-1392 S536-176 S536-878 127-468 127-537 125-080 125-082 S521Y528 S521-562 FAD-NE2 118-102-* 118-107 118-146 S553-537-* S553-547 S553-548 S553-538-* S553-551 S553-552 S514-240-* S514-236 S514-237 121Y480 105Y850 137-694 S501-936-* S501-999 S501-946 147-044 S111Y032 135Y127 109-444 109-448 109-446 5252-033 Description Top Rain Flashing Top Rain Flashing Top Rain Flashing Top Top Top Drain Pan Drain Pan Upper Back Upper Back Upper Back Grommet Retainer Right Side Right Side Right Side Right Side Cover Plate (Outer) Right Side Cover Plate (Outer) Right Side Cover Plate (Outer) Filter Bracket Fill Plate Control Panel Cover (Inner) Bottom Mounting Bracket Disconnect Access Door Disconnect Access Door Disconnect Access Door Control Panel Cover (Outer) Control Panel Cover (Outer) Control Panel Cover (Outer) Side Grille Side Grille Side Grille See Control Panel Assy. Drawing & Parts List Assy. Close Off Angle Cond. Partition Block Off Plate Cond. Partition Block Off Plate Lower Base Lower Base Fan Shroud Fan Shroud Condenser Partition Condenser Partition Fresh Air Damper Assembly Condenser Grille Condenser Grille Condenser Grille Vent Option Door Vent Option Door Vent Option Door Filter Door Filter Door Filter Door Upper Front Upper Front Upper Front Blower Partition Side Support Bottom Evaporator Fill Left Side Left Side Left Side Evaporator Support Outlet Air Frame Assembly Heat Shield Lower Back Lower Back Lower Back Bard Nameplate XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX 222 XXX XXX XXX XXX XXX XXX XXX XXX XXX 222 222 222 XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX EXterior cabinet parts are manufactured with various paint color options. To ensure the proper paint color is received, include the complete model and serial number of the unit for which cabinet parts are being ordered. Exterior cabinet parts are manufactured from stainless steel Code "S" Exterior cabinet parts are manufactured from aluminum Code "A" Manual 2110-1448E Page 3 of 8 FUNCTIONAL COMPONENTS 2 3 7 4 5 6 10 8 9 11 12 Manual 2110-1448E Page 4 of 8 1 14 13 SEXP-945 FUNCTIONAL COMPONENTS W18LB-A W24LB-A W24LB-B W24LB-F Dwg No. 1 1 2 2 2 2 3 3 4 5 6 7 8 8 9 9 10 11 12 12 12 12 13 13 13 13 14 14 14 14 14 NS NS NS NS NS NS NS NS NS Part Number S900-363-002 S900-363-001 917-0381BX 917-0382BX 917-0353BX 917-0354BX 800-0458 800-0481 1171-023 1171-024 1171-022 8103-028 8200-001 8200-050 5151-033 5151C033 CMC-31 CMA-37 8000-433 8000-434 8000-435 8000-436 5051-205BX 5054-205BX 5051-204BX 5054-204BX 7004-011 7003-032 7004-025 7004-059 7004-061 8406-142 8406-140 5201-021 5451-024 6031-009 1171-028 1171-057 1171-027 CMC-29 Description Blower Assembly Blower Assembly Evaporator Coil with Distributor Assembly Evaporator Coil Coated with Distributor Assembly Evaporator Coil with Distributor Assembly Evaporator Coil Coated with Distributor Assembly Distributor Assembly Distributor Assembly 1/4" Receptacle 1/4" Turn Retainer 1/4" Turn Fastener Condenser Motor Fan Motor Mount Stainless Steel Fan Motor Mount Fan Blade Coated Fan Blade Dirty Filter Switch Kit Low Ambient Control (Screw On) Compressor Compressor Compressor Compressor Condenser Coil Condenser Coil Coated Condenser Coil Condenser Coil Coated Air Filter 1" Throw-Away (16x25x1) Air Filter 1" Washable (16x25x1) Air Filter 2" Pleated (16x25x2) Air Filter 2" Pleated MERV11 (16x25x2) Air Filter 2" Pleated MERV13 (16x25x2) High Pressure Switch (Screw On) Low Pressure Switch (Screw On) Filter Drier Tubing Isolation Grommet Coremax Valve Core Filter Door Clip Filter Door Screw Filter Door Screw Retainer Freeze Thermostat Kit XXX X X X XXX XXX X XXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXX X X X X X X XXX XXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX 2222 2222 2222 XXXX NS Not Shown Used with stainless steel cabinet option Optional on these models Manual 2110-1448E Page 5 of 8 CONTROL PANEL 1 2 3 4 5 6 7 9 Manual 2110-1448E Page 6 of 8 10 11 12 18 17 16 15 14 13 SEXP-947 CONTROL PANEL W18LB-A W24LB-A W24LB-B W24LB-F Dwg No. Part Number Description 1 117Y137 Control Panel Top 2 117Y407 Control Panel 3 8407-068 Transformer 4 8611-006 Ground Terminal 5 8401-033 5 8401-035 Compressor Contactor Compressor Contactor 6 135-122 Wire Shield 7 S8201-164 Compressor Control Module 9 8607-017 Terminal Block (Optional) 10 8552-047 10 8552-050 10 S8552-002 Compressor Capacitor Compressor Capacitor Outdoor Motor Capacitor 11 8201-130 Alarm Relay (Optional) 12 8551-004 Start Device (PTCR) (Optional) 13 8607-062 Low Voltage Terminal Strip 14 8611-140-1400 Cable Duct 14" Piece 14 8611-140-0500 Cable Duct 5" Piece 15 8201-126 Phase Monitor 16 8607-042 Blower Speed Terminal 17 8201-130 Blower Control Relay 18 141-188 Plug Support Bracket NS 3000-1598 Bower Power Plug NS 3000-1607 NS 3000-1599 Blower Speed Plug Blower Speed Plug NS 3000-1524 Vent Jumper Plug NS 8615-035 Circuit Breaker 20A 2 Pole (Opt.) NS 8615-036 Circuit Breaker 25A 2 Pole (Opt.) NS S8615-067 Toggle Disconnect (Optional) NS 8615-056 Circuit Breaker 15A 3 Pole (Opt.) NS 8607-013 NS 113-601 Terminal Block 2 Pole Terminal Block Bracket NS 4095-197 Wiring Diagram NS 4095-196 Wiring Diagram NS 4095-296 Wiring Diagram NS 4095-640 Wiring Diagram NS 3000-1224 NS 3000-1231 Compressor Plug/Harness Compressor Plug/Harness NS 3003-047 NS 3003-048 NS 3003-049 NS 3003-052 Control Panel Harness Control Panel Harness Control Panel Harness Control Panel Harness NS 3000-1608 Low Voltage Terminal Block Harness NS S910-2048 Complete Low Voltage Box Assembly (Sheet Metal, LVTS & Wire Harness) XXXX XXXX XXXX XXXX XX XX XXXX XXXX XXXX X X XX XXXX XXXX XXXX XXXX XXXX XX XXXX XXXX XXXX XXXX X XXX XXXX X X X X X X X X X X XX XX X X X X XXXX XXXX NS = Not Shown Circuit breakers listed are for units without electric heat, "0Z" models. See heater replacement parts manual for units with electric heat. Manual 2110-1448E Page 7 of 8 BLOWER ASSEMBLY 6 1 2 3 4 5 3 2 1 10 9 8 7 SEXP-944 S900-363-001 S900-363-002 Dwg No. 1 1 1 1 2 3 4 5 6 7 8 9 10 Part Number S8105-064-0147 S8105-064-0148 C8105-064-0147 C8105-064-0148 151-115 144-183 5152-092 5152-093 105-1061 5451-011 8200-031 103-435 113-761 Description Blower Motor & Control (230/208V) Blower Motor & Control (230/208V) Programmed Control Only (230/208V) Programmed Control Only (230/208V) Housing Cutoff Wheel 9-6 CW Wheel 9-6 CCW Back Brace Grommets Motor Mount Front Brace Motor Control Bracket X X O O 22 XX XX XX XX 66 XX XX XX Manual 2110-1448E Page 8 of 8 Limited Warranty For units applied within the United States, Puerto Rico, US Virgin Islands, Guam, Canada and Mexico Limited Warranty To Original Purchaser: Bard Manufacturing Company, Inc. Bryan, Ohio 43506 warrants to you, the original purchaser, that your Bard product will be free from defects in materials and workmanship when used under normal conditions from the installation date through the time periods outlined in the "Duration of Warranty" section (see reverse side). Proof Of Purchase: You must be able to show us the date on which you purchased your product when you make a claim under this warranty. Your owner's registration card filed online at www.wallmountwarranty.com or your contractor's invoice, bill of sale, or similar document is sufficient at time of warranty claim. If you can not show us the actual date of purchase, the time periods in this warranty will start on the date that we shipped your Bard product from our factory. What This Warranty Does Not Cover: (Also see Duration of Warranty on reverse side.) This warranty does not cover defects or damage caused by: 1. Alterations not approved by us; improper installation (including over or under sizing), improper repairs, or servicing; or improper parts and accessories not supplied by us. 2. Misuse or failure to follow installation and operating instructions (including failure to perform preventative maintenance) or limitations on the rating plate. This includes failure to use low ambient controls on all applications requiring compressor operation in cooling mode below 60F outdoor ambient. 3. Any corrosion from operation in a corrosive atmosphere (examples: acids, halogenated hydrocarbons or environmental conditions). 4. Parts that must be replaced periodically (such as filters, oil nozzles, mist eliminators, ERV belts, pile seals, etc.). 5. Improper fuel or electrical supply (such as low voltage, voltage transients, power interruption, and units on generators with no brownout protection). 6. Accidents or other events beyond our reasonable control (such as storm, fire, or transportation damage). 7. Defects that happen after (a) Anyone has tampered with the product. (b) The product has been improperly serviced according to accepted trade practices; (c) The product has been moved from its original place of installation; or, (d) The product has been damaged by an event beyond Bard's control (See also No. 5 above). 8. Consequential damages (such as increased living expenses while the product is being repaired). Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you. 9. This warranty has certain limitations for units installed on over-the-road trucks, vans and trailers. (See reverse side.) 10. Cost of service call at installation site to diagnose causes of trouble, labor to replace defective component or transportation costs for replacement parts. 11. This Limited Warranty does not apply to products installed or operated outside of the US, Puerto Rico, US Virgin Islands, Guam, Canda and Mexico. Units operated in coastal areas where the operating environment is exposed to airborne saline particles (typically 5 miles from coast line) must have corrosion protection or warrenty claims will be declined on corrosion-based cabinet and part failures. 12. Bard does not endorse, approve or certify any online sales of its products through auction websites, online retailers, liquidators or any other method of online sales direct to consumers. Bard will not honor the factory warranty of any Bard equipment purchased over the Internet. Your Responsibilities: You are responsible for 1. Preventative maintenance of the product (such as cleaning and replacement of filters, nozzles and other consumable parts). 2. Insuring that the instruction manual is followed for care and use of your product. 3. Insuring that your product is installed by a competent, qualified contractor, following all local and national codes, and industry standards. What We Will Do About A Defect: We will either repair or replace the defective part only. Replacement parts may be reconditioned parts. The warranty for the repaired or replaced part will last only for the remainder of the warranty period for the original part. For Heat Exchangers that are no longer available, we will give you credit equal to the then current retail price of an equivalent Heat Exchanger. Defective parts and a properly completed Bard parts warranty form must be returned to a Bard distributor for submitting to Bard to be eligible for a warranty credit or replacement. Credits are issued to the Bard distributor. We will not pay or be responsible for labor or defective/replacement part transportation costs or delays in repairing or failures to complete repairs caused by events beyond our reasonable control. What You Must Do 1. Tell your heating and air conditioning contractor as soon as you discover a problem and have the contractor make repairs. 2. Pay for all transportation, related service labor, diagnostic charges, refrigerant, refrigerant recovery and related items. Service If your product requires service, you should contact the contractor who installed it or the contractor that has been providing the product's preventative maintenance and repair service. You may find the installing contractor's name on the product or in your Owner's packet. If you do not know who that is, you should contact a competent, qualified contractor to make the repairs. If in doubt, you should contact the nearest distributor that handles Bard products (www.bardhvac.com). Please note that contractors and distributors that handle Bard products are independent contractors and distributors, and therefore, are not under the direction of Bard Manufacturing Company, Inc. Only Warranty This is the only warranty that we make. There are no other express warranties. All implied warranties are limited in duration to the duration of the applicable written warranty made above. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation or exclusion may not apply to you. Other Rights This warranty gives you specific legal rights and you may have other rights which vary from state to state. BARD MANUFACTURING CO., INC. -- BRYAN, OHIO 43506 Dependable quality equipment . . . since 1914 Form No. 7960-420 Issued: 12/04/19 Supersedes: 08/22/19 Duration Of Warranty is limited to defects arising during the periods shown in the following table: Model Number Series: Includes all Models in each Series & which may have additional characters. (Example: W12-70A includes W36A w/additional characters.) -- Number of Years from Installation Date -- Compressor Sealed System All Other Heat Components Functional Parts Exchangers AIR CONDITIONERS W12A, W17A, W18A, W24A, W30A, W36A, W42A, W48A, W60A, W70A, W72A, W090A, W120A, W150, W180A, W17L, W18L, W24L, W30L, W36L, W42L, W48L, W60L, W70L, W72L, WA3S, WA4S, 5 5 WA5S, WL3S, W4LS, WL5S, D25A, D28A, D35A, D36A, D42A, D48A, D60A, D25L, D28L, D35L, D36L, D42L, D48L, D60L, Q24A, Q30A, Q36A, Q42A, Q48A, Q60A, I30A, I36A, I42A, I60A 5 N/A AIR SOURCE HEAT PUMPS W18H, W24H, W30H, W36H, W42H, W48H, W60H, C24H, C30H, C36H, C42H, C48H, C60H, T24H, T30H, T36H, T42H, T48H, T60H, T24S, T30S, T36S, T42S, T48S, T60S, Q24H, Q30H, 5 5 Q36H, Q42H, Q43H, Q48H, Q60H, I30H, I36H, I42H, I48H, I60H, I36Z, I48Z, I60Z 5 N/A ENVIRONMENTAL CONTROL UNITS W3RV, W4RV, W5RV, W6RV, W3LV, W4LV, W5LV, W6LV 5 5 1 N/A EQUIPMENT SHELTER UNITS W**A2P, W**AAP, WR**, D**AAP, HR**, H12A, H72A 5 5 1 N/A GEOTHERMAL/WATER SOURCE HEAT PUMPS QW2S, QW3S, QW4S, QW5S 5 5 5 N/A CHILLED WATER QC50 (No Compressor) N/A 5 5 N/A GAS/ELECTRIC WALL-MOUNT W24G, W30G, W36G, W42G, W48G, W60G, WG3S, WG4S, WG5S 5 5 5 10 OIL FURNACES N/A N/A ECM "V" Blower Models FC085, FH085, FH110, FLF075, FLF110, FLR075, FLR100, FLR130 PSC "D" Blower Models FC085, FH085D, FH110D, FLF085, FLF110, FLR085, FLR110, FLR140 N/A N/A SOF: SOF175, SOF265 N/A N/A ACCESSORIES Factory/Field Installed Bard Ventilation and Heater Packages Bard branded Thermostats/Temperature Controllers LC1000, LC1500, LC2000, LC5000, LC6000, LV1000, MC4002, DC3003, TEC40, BG1000, PGD, PGDX Humidistats, C02 Controllers and all other field installed accessories not listed separately N/A N/A N/A N/A N/A N/A N/A N/A 10 5 1 5 5 1 1 LIFETIME LIFETIME 10 N/A N/A N/A N/A For equipment that does not have an online warranty registration, the warranty period starts when the product was shipped from the factory. Heat transfer coils (refrigerant to air coils for air source and coaxial coils for water source units) are covered for leaks for 5 years. Physical damage to air side coils resulting in leaks or insufficient airflow, or fin deterioration due to corrosive atmosphere (such as acids, halogenated hydrocarbons or coastal environmental conditions) are not covered. Leaks in coaxial coils due to freezing of the coils are not covered. Copper coaxial coils for QW are not warranted for ground water/open loop installations. Functional parts warranty is 1-year for all telecommunication, electric switch stations, pump stations and similar applications. This also applies to all OTR (over the road) applications. Limited lifetime warranty on Heat Exchangers applies to original purchaser in private, owner occupied residences. Subsequent owners and commercial uses are warranted for 20 years from date of installation. All OTR (over the road) applications that are moved from one location to another: Factory Warranty applies up to the point of initial start-up and test at all OEM manufacturing locations or subsequent outfitting facility. Once it goes into OTR service, the warranty expires immediately for compressor and sealed system components. This OTR exemption does not apply to relocatable classrooms, construction or office trailers. Standard warranty for non-registered Oil Furnaces is 5-year parts. Must be registered at www.wallmountwarranty.com within 90 days of installation for the 10-year parts coverage to be in effect. Factory coated coils have a "5" year warranty in corrosive environments that are listed as approved. Internet Resources Recognized as a leader in the HVAC industry, Bard combines quality products and outstanding service with innovation and technological advances to deliver highperformance heating and cooling products around the world. Please visit www.bardhvac.com for additional information regarding warranty and product information. BARD MANUFACTURING CO., INC. -- 1914 Randolph Dr. -- BRYAN, OHIO 43506 Form No. 7960-420 Dependable quality equipment . . . since 1914 Issued: 12/04/19 Supersedes: 08/22/19Microsoft Word 2013