Bard HAC181-AD040 User Manual

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WIRING INSTRUCTIONS

GENERAL

All wiring must be installed in accordance with the National Electrical Code and local codes. In Canada, all wiring must be installed in accordance with the Canadian Electrical Code and in accordance with the regulations of the authorities having jurisdiction. Power supply voltage must conform to the voltage shown on the unit serial plate. A wiring diagram of the unit is attached to the inside of the electrical cover. The power supply shall be sized and fused according to the specification supplied. A ground lug is supplied in the control compartment for equipment ground.

The unit rating plate lists a “Maximum Time Delay 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.

CONTROL CIRCUIT WIRING

For split systems, the minimum control circuit wiring gauge needed to insure proper operation of all controls in both indoor and outdoor units will depend on two factors:

1.The rated VA of the control circuit transformer.

2.The maximum total distance of the control circuit wiring. (This is the distance between the wall thermostat to the indoor unit plus the distance between the indoor unit to the outdoor unit.)

The following table should be used to determine proper gauge of control circuit wiring required.

TABLE 6

CONTROL CIRCUIT WIRING

 

 

Mximum Total

Rated VA of

Transformer

Distance of

Control Circuit

Secondary

Control Circuit

Transformer

FLA @ 24 V

Wiring in Feet

 

 

 

 

 

 

20 gauge

65

40

1.6

18 gauge

90

16 gauge

145

 

 

 

 

14 gauge

230

 

 

 

 

 

 

20 gauge

45

 

 

18 gauge

60

50

2.1

16 gauge

100

 

 

14 gauge

160

 

 

12 gauge

250

 

 

 

 

 

 

20 gauge

40

 

 

18 gauge

55

65

2.7

16 gauge

85

 

 

14 gauge

135

 

 

12 gauge

210

 

 

 

 

Example: 1. Control circuit transformer rated at 40 VA

2.Maximum total distance of control circuit wiring 85 feet.

From Table 6, minimum of 18 gauge wire should be used in the control circuit wiring.

For control circuit transformers rated other than those listed, use the next lower rated transformer listed.

Example: 1. Control circuit transformer rated at 55 VA

From table use 50VA transformer.

There are two (2) separate control diagrams for fossil fuel furnaces with air conditioners.

Control diagrams for the various circuit which could be encountered with blower coils can be found in the installation instructions of the blower coil.

TABLE 7

CONTROL DIAGRAMS

System

Gas Furnace

Oil Furnace

Control Diagram

Control Diagram

 

 

 

 

All Models

4091-100

4091-101

 

 

 

WALL THERMOSTATS

The following wall thermostats and subbases should be used as indicated, depending on the application.

TABLE 8

WALL THERMOSTAT and SUBBASE

COMBINATIONS

Thermostat

Subbase

Predominate Features

 

 

 

 

8403-002

8404-003

1 stage heat, 1 stage cool;

Mercury

T87F311

Q529A1220

System: heat-off-cool

Fan: on-auto

 

 

 

 

 

8403-041

- - -

1 stage heat,

1 stage cool;

Mercury

T8034-C

System: heat-off-cool

Fan: on-auto

 

 

 

 

 

8403-035

 

2 stage heat, 2 stage cool

 

- - -

Programmable

 

 

1F95-80

 

 

 

Electronic

 

 

 

 

 

 

 

 

 

 

 

 

 

8403-042

 

2 stage heat,

1 stage cool

 

- - -

System: heat-off-auto-cool

 

T8511G

 

 

Fan: on-auto

Electronic

 

 

 

 

 

 

 

 

 

8403-043

 

1 stage heat,

1 stage cool

 

- - -

System: heat-off-cool

Fan: on-auto

CM200

 

Snap Action

 

 

 

 

 

 

 

 

 

 

 

 

 

8403-027

 

3 stage heat,

2 stage cool

 

- - -

Programmable

 

 

1F92-71

 

 

 

Electronic

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Manual 2100-346

Page 9

Manual

2100-346

Page

10

Manual

2100-346

Page

11

OPTIONAL CONTROLS

FIGURE 5

COMPONENT MOUNTING LOCATION

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CMA-5&CMA-13ALOW

CMA-5COMPRESSOR

AMBIENT FAN CYCLING

TIME DELAY RELAY

CONTROL

TERMINAL BLOCK

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SK109 LOW VOLTAGE

CMA-10A&CMA-13A

START KIT

COMPRESSOR

 

 

CONTROL

MIS-1302

INSTALLATION INSTRUCTIONS — CMA-5

Disconnect all power to the unit. Remove control panel cover.

1.Mount compressor TDR in position shown in Figure 5 with screw provided.

2.Disconnect yellow low voltage (Y) wire at the compressor contactor coil and reconnect to the Y1 or #3 terminal of the TDR.

3.Connect yellow wire from terminal (Y) of the TDR to the (Y) terminal of the compressor contactor coil. This is the terminal that the wire was removed from in Step 2.

4.Recheck wiring. Refer to Figure 9. Energize unit. Compressor should start. Remove power and reapply. Compressor should not start until the 5 minute time delay has expired.

5.Apply “This unit equipped with CMA-5control module” label to inside of the inner control panel cover above wiring diagram.

6.Replace all panels and covers. This completes installation.

FIGURE 6

INSTALLATION INSTRUCTIONS

FOR CMA-5COMPRESSOR TIME DELAY RELAY

MIS-598

INSTALLATION INSTRUCTIONS — CMA-6

Disconnect all power to unit. Remove control panel inner and outer cover.

1.Mount terminal block in position shown in Figure 5.

2.Disconnect black high voltage outdoor motor lead from compressor contactor and reconnect to terminal block.

3.Route low ambient control wires up through the bushing in the bottom of the control panel. Connect the low ambient control wires between the terminal block and T2 of the compressor contactor.

4.Remove service port cap on discharge line. Install the low ambient control on the discharge line with the flare tee adapter that is brazed to the low ambient control. Check for pressure at the flare tee dill valve after installation to insure that the dill valve in the unit service port was depressed by the flare tee connector. Check for leaks at the flare tee connectors. Replace service port cap on the flare tee service port and tighten.

5.Recheck wiring. See Figure 10. Check for proper operation of the unit by energizing in cooling mode. The condenser fan motor should not run until the discharge pressure has exceeded 300 PSI. Should the discharge pressure fall below 200 PSI while running, the condenser fan motor will de-energizeuntil the head pressure builds to 300 PSI.

6.Apply “This unit equipped with CMA-6control module” label to the inside of the control panel cover above the wiring diagrams.

7.Replace all panels and covers. This completes installation.

FIGURE 7

INSTALLATION INSTRUCTIONS FOR CMA-6LOW AMBIENT FAN CYCLING CONTROL

MIS-594

Manual 2100-346

Page 12

INSTALLATION INSTRUCTIONS – CMA-10A

Disconnect all power to unit. Remove control panel cover.

1.Screw compressor control module and terminal block into control panel as shown in Figure 5.

2.Disconnect yellow low voltage wire form compressor contactor and reconnect to terminal “Y” of the compressor control module.

3.Connect the yellow wire from the compressor control module to “Y” side of the compressors contactor coil. This is the same terminal from which the wire was removed in Step 2.

4.Connect the black wire form the compressor control module to common “C” side of the compressor contactor coil.

5.Connect a field supplied wire from “R” of the indoor unit to “R” on the compressor control module.

6.Route the high (red) and low (blue) pressure switch wires through the bushing in the bottom of the control panel. Connect the low pressure switch wire to terminals LPC of the compressor control module.

7.Remove service port caps on both the suction and discharge lines. Install the high pressure switch on the discharge line to the flare tee adapter that is brazed to the controls. Install the low pressure switch on the suction line. Check for pressure at the flare tee dill valves after installation to insure that the dill valve in the unit service port was depressed by the flare tee connector. Check for leaks at the flare tee connectors. Replace service port caps on the flare tee service ports and tighten.

8.Adjust the compressor time delay relay to the desired delay on break. Two minutes are recommended. This TDR is variable form 30 seconds to 5 minutes.

9.Recheck wiring. Energize unit is first stage cooling. Compressor should not start until the time delay has expired. This will be 10% of the delay on break period. Run the unit for at least 5 minutes. The unit should not go into lockout.

10.Apply “This unit equipped withCMA-10Acontrol module.” label to the inside of the inner control panel cover above the wiring diagram.

11.Replace all panels and covers. This completes installation.

FIGURE 8

INSTALLATION INSTRUCTIONS FOR CMA-10ADUAL PRESSURE CONTROL and COMPRESSOR TIME DELAY RELAY

MIS-1303

Manual 2100-346

Page 13

INSTALLATION INSTRUCTIONS – CMA-13A

Disconnect all power to unit. Remove control panel cover.

1.Screw compressor control module and terminal block into control panel as shown in Figure 5.

2.Disconnect yellow low voltage wire from compressor contactor and reconnect to terminal “Y” of the compressor control module.

3.Connect the yellow wire from the compressor control module to “Y” side of the compressor’s contactor coil. This is the same terminal from which the wire was removed in Step 2.

4.Connect the black wire from the compressor control module to common “C” side of the compressor contactor coil.

5.Connect a field supplied wire from “R” of the indoor unit to “R” on the compressor control module.

6.Route the high (red) and low (blue) pressure switch wires through the bushing in the bottom of the control panel. Connect the low pressure switch wire to terminals LPC of the compressor control module. Connect the high pressure switch wires to terminals HPC of the compressor control module.

7.Disconnect the high voltage outdoor motor lead and reconnect to the terminal block installed in Step 1.

8.Route the LAC (black) wires up through the busing in the bottom of the control panel. Connect one wire to the terminal block and the other to “T2” of the contactor. This will be the same terminal from which

the high voltage outdoor motor lead was removed in Step 7.

9.Remove service port caps on both the suction and discharge lines. Install the high pressure switch and the low ambient control on the discharge line with the flare tee adapter that is brazed to the controls. Install the low pressure switch on the suction line. Check for pressure at the flare tee dill valves after installation to insure that the dill valve in the unit service port was depressed by the flare tee connector. Check for leaks at the flare tee connectors. Replace service port caps on the flare tee service ports and tighten.

10.Adjust the compressor time delay relay to the desired delay on break. Two minutes are recommended. This TDR is variable from 30 seconds to 5 minutes.

11.Recheck wiring. Energize unit in first stage cooling. Compressor should not start until the time delay has expired. This will be 10% of the delay on break period. Run the unit for at least 5 minutes. The unit should not go into lockout. The condenser fan motor should not run until the discharge pressure has exceeded 300 PSI. Should the discharge pressure fall below 200 PSI while running the condenser fan motor will de-energizeuntil the head pressure builds to 300 PSI.

12.Apply “This unit equipped withCMA-13Acontrol module.” label to the inside of the inner control panel cover above the wiring diagram.

13.Replace all panels and covers. This completes installation.

FIGURE 9

INSTALLATION INSTRUCTIONS FOR

CMA-13ADUAL PRESSURE CONTROL, LOW AMBIENT FAN CYCLING CONTROL

and COMPRESSOR TIME DELAY RELAY

MIS-1304

Manual 2100-346

Page 14

CHARGING INSTRUCTIONS

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 can be found later in the manual covering all models. It is imperative to match the correct pressure table to the unit by model number.

SYSTEM START-UP(INDOOR UNITS WITHOUT EXPANSION VALVES)

1.Close disconnect switch(es) and set the thermostat to cool and the temperature to the highest setting.

2.Check for proper airflow across the indoor coil by referring to indoor unit installation.

3.Connect the service gauges and allow the unit to run for at least 10 minutes or until pressures are stable. Check pressures to the system pressure table attached to the outdoor unit service panel. For optimum system performance, go to Step 4.

4.Install a thermometer on the suction line approximately 6" to 10" from the compressor. Optimum system performance will occur with a refrigerant charge resulting in a suction line superheat as determined from the following calculations.

A. Measure outdoor air dry bulb temperature

 

 

________ ºF

B.

Measure indoor air wet bulb temperature

 

 

________ ºF

C. Measure suction pressure

______ PSIG

D. Measure suction line temperature

________ ºF

E.Determine optimum system superheat from Table 9 using outdoor air dry bulb (Step B) and indoor air wet bulb (Step A)

________ ºF

F.Determine saturated suction temperature

from suction pressure using Table 10 ________ ºF

G.Determine system superheat:

Suction line temperature (Step D)

________ ºF

-Saturated suction temperature (Step F)

-________ ºF

= System superheat

= ________ ºF

H.Adjust the system superheat (Step G) to the optimum system superheat (Step E) by adding charge to lower the superheat or removing charge to raise the superheat.

I.Check final system operating pressures to the system pressure tables as was done in Step 3.

TABLE 9

SYSTEM SUPERHEAT

Outdoor Ambient

Return Air Temperature

 

F

Wet Bulb

 

Temperature ( F

 

 

 

 

 

 

 

 

Dry Bulb)

59

 

63

67

 

71

 

 

 

 

 

 

 

 

 

 

105

1

 

1

5

 

 

95

1

 

3

(8)

 

20

90

1

 

7

14

 

26

85

3

 

9

19

 

33

80

8

 

14

25

 

39

75

10

 

20

30

 

42

 

 

 

 

 

 

 

TABLE 10

SATURATED SUCTION TEMPERATURE R-22

 

Saturated Suction

Suction Pressure PSIG

Temperature ( F)

 

 

50

26

53

28

55

30

 

 

58

32

61

34

63

36

 

 

65

38

67

39

70

41

 

 

73

43

76

45

79

47

 

 

82

49

86

51

 

 

Manual 2100-346

Page 15

TABLE 11

TOTAL SYSTEM OPERATING CHARGE (Includes charge for the basic outdoor unit, indoor coil and 25’ of interconnecting tubing.)

 

 

Total R-22

Outdoor Section

Indoor Section

Charge (Oz.)

 

 

 

 

 

A30AS-A

73 oz.

 

HAC181-A

S24AS-A

73 oz.

Q

 

BC24B

78 oz.

 

 

 

 

 

 

A30AS-A

80 oz.

 

HAC241-A

S24AS-A

80 oz.

R

 

BC24B

79 oz.

 

 

 

 

 

HAC301-A

A36AS-A

84 oz.

R

BC36B

95 oz.

 

 

 

 

 

 

 

HAC361-A

A37AS-A

98 oz.

R

BC36B

96 oz.

 

 

 

 

 

 

 

 

A42AS-A

102 oz.

 

HAC421-A

A48AS-A

117 oz. R

BC36B

105 oz.

 

 

 

 

BC60B

142 oz.

 

 

 

 

HAC481-A,-B

A61AS-A

155 oz. R

BC60B

175 oz.

 

 

 

 

 

 

HAC601-A,-B

A61AS-A

153 oz. R

BC60B

165 oz.

 

 

 

 

 

 

 

QIncludes 25’ of 1/4” diameter liquid line. For other than 25’ and other tube sizes, adjust the total charge according to the following schedule.

RIncludes 25’ of 3/8” diameter liquid line. For other than 25’ and other tube sizes, adjust the total charge according to the following schedule.

SCHEDULE FOR TABLE 11

Liquid Line Diameter

Oz. R-22Per Ft.

 

 

1/4"

0.25

3/8"

0.60

1/2"

1.20

 

 

Installer Note: Stamp or mark the final system charge determined above on the outdoor unit serial plate.

Manual 2100-346

Page 16

SERVICE

SERVICE HINTS

1.Caution homeowner to maintain clean air filters at all times. Also, not to needlessly close off supply and return air registers. This reduces air flow 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 that they are the correct rating.

3.Periodic cleaning of the outdoor coil to permit full and unrestricted air flow circulation is essential.

FAN BLADE SETTING DIMENSIONS

Shown in Figure 10 are the correct fan blade setting dimensions for proper air delivery across the outdoor coil.

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 10

FAN BLADE

C

B

A

 

 

 

7960-337

 

TABLE 12

 

 

FAN BLADE SETTING

 

 

 

 

Model

Dimension A

 

Fan Hub Locations

 

 

 

 

HAC181

 

 

 

HAC241

5"

 

B

HAC301

 

 

 

 

HAC361

 

 

 

 

 

 

 

HAC421

 

 

 

HAC481

4-3/4"

 

C

HAC601

 

 

 

 

 

 

 

Manual 2100-346

Page 17

Manual

2100-346

Page

18