Bard 2100-404E User Manual

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WALL MOUNTED

INSTALLATION

PACKAGED

AIR CONDITIONER

 

INSTRUCTIONS

Models: WA302

 

 

WA372

 

 

Bard Manufacturing Company, Inc.

Manual No.:

2100-404E

Bryan, Ohio 43506

Supersedes:

2100-404D

Since 1914...moving ahead just as planned.

File:

Volume III, Tab 16

Date:

01-16-09

 

 

 

 

 

 

 

© Copyright 2002

 

Manual 2100-404E

Page

1 of 19

Contents

Getting Other Information and Publications

 

Start Up

 

For more information,

 

Important Installer Note .........................................

15

contact these publishers ..........................................

3

High Pressure Switch ............................................

15

 

 

Three Phase Scroll Compressor Start Up

 

Wall Mount General Information

 

Information.............................................................

15

Air Conditioner Wall Mount Model Nomenclature .... 4

Phase Monitor .......................................................

15

Shipping Damage ....................................................

6

Service Hints .........................................................

15

General ....................................................................

6

Sequence of Operation..........................................

15

Duct Work ................................................................

7

Compressor Control Module ..................................

16

Filters .......................................................................

7

Adjustments ...........................................................

16

Fresh Air Intake .......................................................

7

Pressure Service Ports ..........................................

16

Condensate Drain....................................................

7

 

 

 

 

Troubleshooting

 

Installation Instructions

 

Fan Blade Setting Dimensions ..............................

17

Wall Mounting Information .......................................

8

Removal of Fan Shroud .........................................

17

Mounting the Unit ....................................................

8

Refrigerant Charge ................................................

17

Top Outlet Only ........................................................

8

Cooling Pressures .................................................

18

Wiring — Main Power ........................................

8 & 9

Optional Accessories .............................................

19

Low Voltage Connections ........................................

9

 

 

Wiring — Low Voltage Wiring ..................................

9

 

 

Figures

 

Tables

 

 

 

Figure 1 Unit Dimensions .......................................

5

Table

1

Electrical Specifications ..........................

4

Figure 2 Blower Damper Assembly.........................

7

Table

2

Dimensions of Basic Unit ........................

5

Figure 3 Mounting Instructions .............................

10

Table

3

Electric Heat Table ..................................

6

Figure 4 Wall-MountingInstructions ......................

11

Table

4

Operating Voltage Range........................

9

Figure 5 Wall-MountingInstructions ......................

11

Table

5

Thermostat Wire Size .............................

9

Figure 6 Common Wall-MountingInstallations .....

12

Table

6

Wall Thermostat ......................................

9

Figure 7 Electric Heat Clearances ........................

13

Table

7

Fan Blade Dimensions ..........................

17

Figure 8 Low Voltage Wiring .................................

14

Table

8

Suction Line Temperatures ...................

17

Figure 9 Fan Blade Setting ...................................

17

Table

9

Indoor Blower Performance ..................

17

 

 

Table

10

CFM and ESP .......................................

17

 

 

Table

11

Maximum ESP of Operation

 

 

 

 

 

Electric Heat Only .................................

17

 

 

Table

12

Cooling Pressure ..................................

18

 

 

Table

13

Optional Accessories ............................

19

Manual

2100-404E

Page

2 of 19

Getting Other Information and Publications

These publications can help you install the air conditioner or heat pump. You can usually find these at your local library or purchase them directly from the publisher. Be sure to consult current edition of each standard.

National Electrical Code .......................

ANSI/NFPA 70

Standard for the Installation ...............

ANSI/NFPA 90A

of Air Conditioning and Ventilating Systems

Standard for Warm Air ........................

ANSI/NFPA 90B

Heating and Air Conditioning Systems

 

Load Calculation for .............................

ACCA Manual J

Residential Winter and Summer Air Conditioning

Duct Design for Residential ................

ACCA Manual D

Winter and Summer Air Conditioning and Equipment

Selection

FOR MORE INFORMATION, CONTACT THESE PUBLISHERS:

ACCA

Air Conditioning Contractors of America

 

1712 New Hampshire Avenue NW

 

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 Refrigerating,

and Air Conditioning Engineers, Inc.

1791 Tullie Circle, N.E.

Atlanta, GA 30329-2305

Telephone: (404) 636-8400

Fax: (404) 321-5478

NFPA

National Fire Protection Association

 

Batterymarch Park

 

P.O. Box 9101

 

Quincy, MA 02269-9901

 

Telephone: (800) 344-3555

 

Fax: (617) 984-7057

Manufactured under the following U.S. patent numbers:

5,485,878; 5,301,744; 5,002,116; 4,924,934; 4,875,520; 4,825,936; 4,432,409

Manual

2100-404E

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3 of 19

WALL MOUNT GENERAL INFORMATION

AIR CONDITIONER WALL MOUNT MODEL NOMENCLATURE

WA 37 2

A

10

X

X

X

X X A

 

 

 

 

 

 

 

 

 

MODEL

 

KW

NUMBER

REVISIONS

 

 

 

CAPACITY

 

VOLTS & PHASE

 

 

25

-

2 Ton

 

A - 230/208/60/1

 

 

37

-

3 Ton

 

B - 230/208/60/3

 

 

 

 

 

 

C - 460/60/3

VENTILATION OPTIONS

X - Barometric Fresh Air Damper (Standard) B - Blank-offPlate

M - Motorized Fresh Air Damper

V - Commercial Room Ventilator - Motorized with Exhaust E - Economizer (Internal - Fully Modulating with Exhaust R - Energy Recovery Ventilator - with Exhaust

 

CONTROL

 

MODULES

 

(See Spec.

COLOR OPTIONS

Sheet S3208)

X - Beige (Standard)

1

- White

COIL OPTIONS

2

- Mesa Brown

X- Standard

4

- Buckeye Gray

1 - Phenolic Coated Evaporator

5

- Desert Brown

2 - Phenolic Coated Condenser

6

- Dark Bronze

3 - Phenolic Coated Evaporator

 

and Condenser

FILTER OPTIONS

OUTLET OPTIONS

X - 1-InchThrowaway

X- Front (Standard)

(Standard)

T - Top on WA30 & WA37 Models

W- 1-InchWashable

 

P - 2-InchPleated

 

NOTE: For 0KW and circuit breakers (230/208 Volt) or pull disconnects (460 Volt) applications, insert 0Z in the KW field of model no.

TABLE 1 – ELECTRICAL SPECIFICATIONS

 

 

 

3

1

2

2

3

1

2

2

 

 

 

 

 

 

 

 

 

Maximum

 

 

 

 

 

 

 

 

 

 

 

Minimum

External

Field Power

 

 

 

 

 

 

 

 

 

Fuse

 

 

 

 

No.

 

Maximum

 

 

Circuit

or Ckt.

Wire Size

Ground

 

 

 

External

Field

 

Ampacity

Breaker

 

 

Wire Size

 

Rated

Field

Minimum

Fuse or

Power

Ground

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Volts/

Power

Circuit

Ckt.

Wire

Wire

CKT

CKT

CKT

CKT

CKT

CKT

CKT

CKT

Models

Phases

Circuits

Ampacity

Breaker

Size

Size

A

B

A

B

A

B

A

B

WA302-A0Z

 

1

24

35

8

10

NA

NA

NA

NA

NA

NA

NA

NA

A05

230/208-1

1

31

35

8

10

NA

NA

NA

NA

NA

NA

NA

NA

A10

 

1

57

60

6

10

NA

NA

NA

NA

NA

NA

NA

NA

A15

 

1 or 2

83

90

4

8

55

26

60

30

4

10

8

10

WA302-B0Z

 

1

17

20

12

12

NA

NA

NA

NA

NA

NA

NA

NA

B09

230/208-3

1

32

35

8

10

NA

NA

NA

NA

NA

NA

NA

NA

B15

 

1

50

50

8

10

NA

NA

NA

NA

NA

NA

NA

NA

WA302-C0Z

 

1

10

15

14

14

NA

NA

NA

NA

NA

NA

NA

NA

C09

460-3

1

17

20

12

12

NA

NA

NA

NA

NA

NA

NA

NA

C15

 

1

26

30

10

10

NA

NA

NA

NA

NA

NA

NA

NA

WA372-A0Z

 

1

28

35

8

10

NA

NA

NA

NA

NA

NA

NA

NA

A05

 

1

32

35

8

10

NA

NA

NA

NA

NA

NA

NA

NA

A08

230/208-1

1

47

50

8

10

NA

NA

NA

NA

NA

NA

NA

NA

A10

 

1

58

60

6

10

NA

NA

NA

NA

NA

NA

NA

NA

A15

 

1 or 2

84

90

4

8

58

26

60

30

6

10

10

10

WA372-B0Z

 

1

20

25

10

10

NA

NA

NA

NA

NA

NA

NA

NA

B06

230/208-3

1

24

25

10

10

NA

NA

NA

NA

NA

NA

NA

NA

B09

1

33

35

8

10

NA

NA

NA

NA

NA

NA

NA

NA

B15

 

1

51

60

6

10

NA

NA

NA

NA

NA

NA

NA

NA

WA372-C0Z

 

1

11

15

14

14

NA

NA

NA

NA

NA

NA

NA

NA

C06

 

1

12

15

14

14

NA

NA

NA

NA

NA

NA

NA

NA

C09

460-3

1

17

20

12

12

NA

NA

NA

NA

NA

NA

NA

NA

C12

 

1

21

25

10

10

NA

NA

NA

NA

NA

NA

NA

NA

C15

 

1

26

30

10

10

NA

NA

NA

NA

NA

NA

NA

NA

1 Maximum size of the time delay fuse or HACR type circuit breaker for protection of field wiring conductors. 2 Based on 75° copper wire. All wiring must conform to the National Electrical Code and all local codes.

3These "Minimum Circuit Ampacity" values are to be used for sizing the field power conductors. Refer to the National Electric Code (latest revision), Article 310 for power conductor sizing.

CAUTION: When more than one field power conductor 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 conductors are in a raceway.

Manual

2100-404E

Page

4 of 19

Page

Manual

19 of 5

404E-2100

TABLE 2

DIMENSIONS OF BASIC UNIT (NOMINAL)

 

Width

Depth

Height

Supply

Return

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Model

(W)

(D)

(H)

A

B

C

B

E

F

G

I

J

K

L

M

N

O

P

Q

R

S

T

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WA302

38.20

17.125

70.563

7.88

27.88

13.88

27.88

40.00

18.50

25.75

17.93

26.75

28.75

29.25

27.00

2.75

39.125

22.75

9.14

4.19

12.00

5.00

WA372

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FIGURE 1

UNIT DIMENSIONS

FRONT VIEW

SIDE VIEW

BACK VIEW

TABLE 3

ELECTRIC HEAT TABLE

Models

 

WA302-A

 

 

 

WA302-B

 

 

WA302-C

 

WA372-A

 

 

 

WA372-B

 

 

WA372-C

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

240V-1

208V-1

 

240V-3

208V-3

 

460V-3

 

 

 

 

 

 

 

 

 

 

 

 

 

KW

AMPS

BTUH

AMPS

BTUH

 

AMPS

BTUH

AMPS

BTUH

 

AMPS

BTUH

 

 

 

 

 

 

 

 

 

 

 

 

 

5.0

20.8

17,065

18.1

12,800

 

---

---

---

---

 

---

---

 

 

 

 

 

 

 

 

 

 

 

 

 

10.0

41.6

34,130

36.2

25,600

 

---

---

---

---

 

---

---

 

 

 

 

 

 

 

 

 

 

 

 

 

15.0

62.5

51,200

54.1

38,400

 

---

---

---

---

 

---

---

 

 

 

 

 

 

 

 

 

 

 

 

 

6.0

---

---

---

---

 

14.4

20,500

12.5

15,360

 

7.2

20,475

 

 

 

 

 

 

 

 

 

 

 

 

 

9.0

---

---

---

---

 

21.7

30,600

18.7

23,030

 

10.8

30,700

 

 

 

 

 

 

 

 

 

 

 

 

 

15.0

---

---

---

---

 

36.2

51,200

31.2

38,400

 

18.0

51,200

 

 

 

 

 

 

 

 

 

 

 

 

 

12.0

---

---

---

---

 

---

---

---

---

 

14.4

40,950

 

 

 

 

 

 

 

 

 

 

 

 

 

SHIPPING DAMAGE

Upon receipt of equipment, the carton should be checked for external signs of shipping damage. If damage is found, the receiving party must contact the last carrier immediately, preferably in writing, requesting inspection by the carrier’s agent.

GENERAL

The equipment covered in this manual is to be installed by trained, experienced service and installation technicians.

The refrigerant system is completely assembled and charged. All 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-containedunit 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

2100-404E

Page

6 of 19

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 Table 11 for maximum static pressure available for duct design.

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-inchof 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.

A 1/4 inch clearance to combustible material for the first 3 feet of duct attached to the outlet air frame is required. See Wall Mounting Instructions and Figures 3 and 4 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.

CAUTION

Some installations may not require any return air duct. A metallic return air grille is required with installations not requiring a return air duct. The spacing between louvers on the grille shall not be larger than 5/8 inches.

Any grille that meets the 5/8 inch louver criteria may be used. It is recommended that Bard Return Air Grille Kit RG-2throughRG-5orRFG-2throughRFG-5be 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.

FILTERS

A 1-inchthrow away filter is suppled with each unit. The filter slides into position making it easy to service. This filter can be serviced from the outside by removing the service door. A1-inchwashable filter and a2-inchpleated filter are also available as optional accessories. The internal filter brackets are adjustable to accommodate the2-inchfilter by bending the metal tabs holding the1-inchfilter down. There are two tabs on each side of the filter.

FRESH AIR INTAKE

All units are built with fresh air inlet slots punched in the service panel.

If the unit is equipped with the 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 2.

All capacity, efficiency and cost of operation information as required for Department of Energy “Energyguide” Fact Sheets is based upon the fresh air blank-offplate in place and is recommended for maximum energy efficiency.

The blank-offplate is available upon request from the factory and is installed in place of the fresh air damper shipped with each unit.

CONDENSATE DRAIN

A plastic drain hose extends from the drain pan at the top of the unit down to the unit base. There are openings in the unit base for the drain hose to pass through. In the event the drain hose is connected to a drain system of some type, it must be an open or vented type system to assure proper drainage.

FIGURE 2

FRESH AIR DAMPER ASSEMBLY

Manual

2100-404E

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INSTALLATION INSTRUCTIONS

WALL MOUNTING INFORMATION

1.Two holes, for the supply and return air openings, must be cut through the wall as shown in Figure 3.

2.On wood-framewalls, the wall construction must be strong and rigid enough to carry the weight of the unit without transmitting any unit vibration.

WARNING

Fire hazard can result if 1/4 inch clearance to combustible materials for supply air duct is not maintained. See Figure 3.

3.Concrete block walls must be thoroughly inspected to insure that they are capable of carrying the weight of the installing unit.

MOUNTING THE UNIT

1.These units are secured by wall mounting brackets which secure the unit to the outside wall surface at both sides. A bottom mounting bracket is provided for ease of installation, but is not required.

2.The unit itself is suitable for “0” inch clearance, but the supply air duct flange and the first 3 feet of supply air duct require a minimum of 1/4 inch clearance to combustible material. If a combustible wall, use a minimum of 28½" x 8½" dimensions for sizing. However, it is generally recommended that a 1-inchclearance is used for ease of installation and maintaining the required clearance to combustible material.

WARNING

Failure to provide the 1/4 inch clearance between the supply duct and a combustible surface for the first 3 feet of duct can result in fire.

3.Locate and mark lag bolt locations and bottom mounting bracket location. See Figure 3.

4.Mount bottom mounting bracket, if used The supply air opening would then be 30" x 10". See Figures 3 and 4 for details.

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

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

7.Secure rain flashing to wall and caulk across entire length of top. See Figure 3.

8.For additional mounting rigidity, the return air and supply air frames or collars can be drilled and screwed or welded to the structural wall itself (depending upon wall construction). Be sure to observe required clearance of combustible wall.

9.On side-by-sideinstallations, maintain a minimum of 20 inches clearance on right side to allow access to heat strips and control panel and to allow proper airflow to the outdoor coil. Additional clearance may be required to meet local or national codes.

TOP OUTLET ONLY

1.Remove airframe angles from the back of the unit.

2.Coat angles with two 1/8" beads of silicone as shown. Silicone is shipped in the control panel. See Figure 5.

3.Secure angles to the top of the unit with 14 screws provided. Use of prepunched holes provided. Do not relocate. See Figure 5.

4.After installation duct work, seal around airframe and duct work to provide a rain tight seal.

5.It is strongly recommended, but not required, that this unit be installed under a soffit area large enough to shield the top of the unit. See Figure 6.

WIRING — MAIN POWER

Refer to the unit rating plate for wire sizing information and maximum fuse or “HACR Type” circuit breaker size. Each outdoor unit is marked with a “Minimum Circuit Ampacity”. This means that the field wiring used must be sized to carry that amount of current. Depending on the installed KW of electric heat, there may be two field power circuits required. If this is the case, the unit serial plate will so indicate. All models are suitable only for connection with copper wire. Each unit and/or wiring diagram will be marked “Use Copper Conductors Only”. These instructions must be adhered to. Refer to the National Electrical Code (NEC) for complete current carrying capacity data on the various insulation grades of wiring material. All wiring must conform to NEC and all local codes.

Manual 2100-404E

Page 8 of 19

The electrical data lists fuse and wire sizes (75ºC 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 “HACR Type” circuit breaker that is to be used with the equipment. The correct size must be used for proper circuit protection and also to assure that there will be no nuisance tripping due to the momentary high starting current of the compressor motor.

The disconnect access door on this unit may be locked to prevent unauthorized access to the disconnect. To convert for the locking capability, bend the tab located in the bottom left hand 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.

WIRING — LOW VOLTAGE WIRING

230/208V, 1 phase and 3 phase equipment dual primary voltage transformers. All equipment leaves the factory wired on 240V tap. For 208V operation, reconnect from 240V to 208V tap. The acceptable operating voltage range for the 240 and 208V taps are:

TABLE 4

OPERATING VOLTAGE RANGE

TAP

RANGE

240V

253 – 216

 

 

208V

220 – 187

 

 

NOTE: The voltage should be measured a the field power connection point in the unit and while the unit is operating at full load (maximum amperage operating condition.)

Five (5) wires should be run from thermostat subbase to the 24V terminal board in the unit. A five conductor, 18 gauge copper, color-codedthermostat cable is recommended. The connection points are shown in Figure 8.

LOW VOLTAGE CONNECTIONS

These units use a grounded 24 volt AC low voltage circuit.

The "R" terminal is the hot terminal and the "C" terminal is grounded.

"G" terminal is the fan input.

"Y" terminal is the compressor input for cooling.

"W1" terminal is the 1st stage electric heat. The reversing valve must be energized for heating mode.

"W2" terminal is second stage heat (if equipped).

"F" terminal is the ventilation input. This terminal energizes any factory installed ventilation option.

LOW VOLTAGE CONNECTIONS

FOR DDC CONTROL

Fan Only

Energize G

Cooling Mode

Energize Y, G

1st Stage Heating

Energize W1

2nd Stage Heating

Energize W1, W2

(if employed)

 

Ventilation

Energize G, F

TABLE 6

WALL THERMOSTAT

TABLE 5

THERMOSTAT WIRE SIZE

 

 

 

Maximum

Transformer

 

 

Distance

VA

FLA

Wire Gauge

In Feet

 

 

20 gauge

45

 

 

18 gauge

60

55

2.3

16 gauge

100

 

 

14 gauge

160

 

 

12 gauge

250

Thermostat

Predominate Features

 

 

8403-057

1 stage Cool, 1 stage Heat

Electronic Non-Programmable

TH5220D1153

Auto or Manual changeover

 

 

8403-058

2 stage Cool, 2 stage Heat

Electronic Non-Programmable

TH5220D1151

Auto or Manual changeover

 

 

 

3 stage Cool; 3 stage Heat

8403-060

Programmable/Non-ProgrammableElectronic

(1120-445)

HP or Conventional

 

Auto or Manual changeover

 

 

Manual

2100-404E

Page

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FIGURE 3

MOUNTINGINSTRUCTIONS

Manual

2100-404E

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10 of 19