Bard W3RV1, W5LV1, W3LV1, W5RV1, W6LV1 User Manual

INSTALLATION INSTRUCTIONS

WALL MOUNTED

VARIABLE CAPACITY

ENVIRONMENTAL CONTROL UNITS

MODELS

W3RV1 W3LV1

W5RV1 W5LV1

W6RV1 W6LV1

	Bard Manufacturing Company, Inc.	Manual :	2100-538E
	Bryan, Ohio 43506	Supersedes:	2100-538D
	Since 1914...Moving ahead just as planned.	File:	Volume III Tab 16
		Date:	12-15-11

	Manual	2100-538E
	Page	1 of 23

Contents

Getting Other Information and Publications	3	Start Up
		General ..............................................................	14
Wall Mount General Information		Topping Off System Charge...................................	14
ECU Wall Mount Model Nomenclature ....................	4	Safety Practices.....................................................	14
Shipping Damage ....................................................	4	Important Installer Note .........................................	15
General ................................................................	4	High Pressure Switch ............................................	15
Duct Work ................................................................	5	Three Phase Scroll Compressor............................	15
Filters ................................................................	5	Phase Monitor .......................................................	15
Fresh Air Intake .......................................................	5	Service Hints .........................................................	15
Condensate Drain....................................................	5	Digital Controller ....................................................	15
		Sequence of Operation..................................	16 & 17
		Lead/Lag Sequence ..............................................	17
Installation Instructions		Compressor Control Module ..................................	18
Wall Mounting Information .......................................	6	Adjustments ...........................................................	18
Mounting the Unit ....................................................	6	Pressure Service Ports ..........................................	18
Clearances Required ...............................................	6
Minimum Clearances ...............................................	6	Troubleshooting
Wiring – Main Power .............................................	13	Fan Blade Setting Dimensions ..............................	19
Wiring – Low Voltage Wiring .................................	13	Removal of Fan Shroud .........................................	19
Digital Thermostat/Controller .................................	13	Refrigerant Charge ................................................	19
Wiring Diagram ......................................................	13

Figures			Tables
Figure 1	Fresh Air Damper Assembly ...................	5	Table 1 Fan Blade Dimensions ..........................		19
Figure 2	Unit Dimensions ......................................	7	Table 2	Cooling Pressure ..................................	20
Figure 3A	Mounting Instructions ..............................	8	Table 3	Electrical Specifications W*R/LV ..........	21
Figure 3B	Mounting Instructions ..............................	9	Table 4	Recommended Airflow ..........................	22
Figure 4	Electric Heat Clearance ........................	10	Table 5	Maximum ESP Electric Heat Only........	22
Figure 5	Wall Mounting Instructions .....................	11	Table 6	Electric Heat .........................................	22
Figure 6	Wall Mounting Instructions .....................	11	Table 7 Vent & Control Options .........................		23
Figure 7	Common Wall Mounting Installations....	12
Figure 8	Fan Blade Setting .................................	19

Manual	2100-538E
Page	2 of 23

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 Ave. N.W.
	Washington, DC 20009
	Telephone: [phone]
	Fax: [phone]
ANSI	American National Standards Institute
	11 West Street, 13th Floor
	New York, NY 10036
	Telephone: [phone]
	Fax: [phone]
ASHRAE	American Society of Heating, Refrigeration
	and Air Conditioning Engineers, Inc.
	1791 Tullie Circle, N.E.
	Atlanta, GA 30329-2305
	Telephone: [phone]
	Fax: [phone]
NFPA	National Fire Protection Association
	Batterymarch Park
	P.O. Box 9101
	Quincy, MA 02269-9901
	Telephone: [phone]
	Fax: [phone]

Manufactured under the following U.S. Patent numbers:

5,485,878; 5,301,744

Manual	2100-538E
Page	3 of 23

WALL MOUNT GENERAL INFORMATION

Environmental Control Unit (ECU) Wall-Mount Model Nomenclature

W

3

R

V

1

–

R

10

X

X

X

X

X

X

MODEL

REVISIONS

OTHER OPTIONS

KW

X - None

SERIES

Electric

Wall-Mount

SPECIAL

Heat @

SYSTEM DESIGN

FEATURES

Rated

Voltage

Variable Capacity

COLOR OPTIONS

COIL OPTIONS

(Digital Compressor) ECU

X

-

Beige (Standard)

X - Standard Copper Tube/Aluminum Fin

1

-

White

1 - Phenolic Coated Indoor Coil

COMPRESSOR &

ELECTRICAL RATING

4

-

Buckeye Gray

2 - Phenolic Coated Outdoor Coil

5

-

Desert Brown

3 - Phenolic Coated Indoor & Outdoor Coil

CONTROLSLOCATION

R - 230/208-60-1 & 220/200-50-1

6

-

Dark Bronze

R -

Right Side

S - 230/208-60-3 & 220/200-50-3

A -

Aluminum

L

-

Left Side

T - 460-60-3 & 400-50-3

S

-

Stainless Steel

NOMINAL TONS

OUTLET OPTIONS

3 - 3 Ton (37,000 on 60Hz; 33,700 on 50Hz)

FILTER OPTIONS

X - Front (Standard)

VENTILATION OPTIONS

5 - 5 Ton (54,000 on 60Hz; 49,200 on 50Hz)

X - One Inch Throwaway (Standard)

X -

Barometric Fresh Air Damper (Standard)

6 - 6 Ton (68,000 on 60Hz; 61,900 on 50Hz)

W - One Inch Washable

B -

Blank-off Plate

P - Two Inch Pleated

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.

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	2100-538E
Page	4 of 23

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 5.

Design the duct work according to methods given by the Air Conditioning Contractors of America (ACCA). When duct runs through unheated spaces, it should be insulated with a minimum of one inch of insulation. Use insulation with a vapor barrier on the outside of the insulation. Flexible joints should be used to connect the duct work to the equipment in order to keep the noise transmission to a minimum.

For model series W3R/LV, W5R/LV and W6R/LV a 1/4 inch clearance to combustible material for the first three feet of duct attached to the outlet air frame is required.

See Wall Mounting Instructions and Figures 3A, 3B 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.

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

Any grille that meets with 5/8 inch louver criteria may be used. It is recommended that Bard Return Air Grille Kit RG2 through RG5 or RFG2 through RFG5 be installed when no return duct is used. Contact distributor or factory for ordering information. If using a return air filter grille, filters must be of sufficient size to allow a maximum velocity of 400 fpm.

NOTE: 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-inch throwaway filter is standard with each unit. The filter slides into position making it easy to service. This filter can be serviced from the outside by removing the filter access panel. A 1-inch washable filter and 2- inch pleated filter are also available as optional accessories. The internal filter brackets are adjustable to accommodate the 2-inch filter by bending two (2) tabs down on each side of the filter support bracket.

FRESH AIR INTAKE

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

If the unit is equipped with a fresh air damper assembly, the assembly is shipped already attached to the unit. The damper blade is locked in the closed position. To allow the damper to operate, the maximum and minimum blade position stops must be installed. See Figure 1.

All capacity, efficiency and cost of operation information is based upon the fresh air blank-off plate in place and is recommended for maximum energy efficiency.

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

CONDENSATE DRAIN

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

FIGURE 1

FRESH AIR DAMPER

Manual	2100-538E
Page	5 of 23

INSTALLATION INSTRUCTIONS

WALL MOUNTING INFORMATION

1.Two holes for the supply and return air openings must be cut through the wall as shown in Figures 3A & 3B.

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

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

MOUNTING THE UNIT

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

2.The supply air duct flange and the first 3 feet of supply air duct require a minimum of 1/4 inch clearance to combustible material for model series

W3R/LV, W5R/LV and W6R/LV. However, it is generally recommended that a 1-inch clearance is used for ease of installation and maintaining the required clearance to combustible material. See Figures 3A & 3B for details on opening sizes.

3.Locate and mark lag bolt locations and bottom mounting bracket location. See Figures 3A & 3B.

4.Mount bottom mounting bracket.

5.Hook top rain flashing, attached to front - right of supply flange for shipping, under back bend of top.

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 causing damage, injury or death.

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

7.Secure rain flashing to wall and caulk across entire length of top. See Figures 3A & 3B.

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

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

Clearances Required for Service Access and Adequate Condenser Airflow

MODELS	LEFT SIDE	RIGHT SIDE
W3RV1	15"	20"
W3LV1	20"	15"
W5RV1, W6RV1	20"	20"
W5LV1, W6LV1	20"	20"

NOTE: For side by side installation of two (2) W*RV models there must be 20" between units. This can be reduced to 15" by using a W*LV model (left side compressor and controls) for the left unit and W*R (right side compressor and controls) for right unit.

See Specification Sheet.

Minimum Clearances Required to Combustible Materials

	MODELS	SUPPLY AIR DUCT	CABINET
		FIRST THREE FEET
	W3R/LV1	1/4"	0"
	W5R/LV1	1/4"	0"
	W6R/LV1

Manual	2100-538E
Page	6 of 23

FIGURE 2

Dimensions of Basic Unit for Architectural and Installation Requirements (Nominal)

MODEL

WIDTH DEPTH HEIGHT

SUPPLY

RETURN

(W)

(D)

(H)

A

B

C

B

E

F

G

I

J

K

L

M

N

O

P

Q

R

S1

S2

T

W3RV1

38.200

17.125

70.563

7.88 27.88 13.88 27.88 40.00 10.88 25.75 17.93 26.75 28.75 29.25 27.00 2.75 39.19 22.75

9.14

4.19 12.00 12.00 5.00

W3LV1

W5RV1

42.075

22.432

84.875

9.88 29.88 15.88 29.88 43.88 13.56 31.66 30.00 32.68 26.94 34.69 32.43 3.37 42.88 23.88 10.00 1.44 16.00 16.00 1.88

W5LV1

W6RV1

42.075

22.432

94.875

9.88 29.88 15.88 29.88 43.88 13.56 41.66 30.00 42.68 36.94 44.69 42.43 3.37 42.88 33.88 10.00 1.44 16.00 21.00 1.88

W6LV1

All dimensions are in inches. Dimensional drawings are not to scale.

E

D

O

W*RV

Built In

W

Rain Hood

RIGHT

4° Pitch

Heater

UNIT

2.13

Access

R

Side Wall

Panel

A

Supply Air Opening

Mounting

Electric

Brackets

Heat

(Built In)

S1

B

C. Breaker/

I

Disconnect

Top Rain

Access Panel

(Lockable)

Flashing

S1

Shipping

Filter Access

Location

Panel

5.75

Vent Option

Optional

Return Air Opening

C

H

Electrical

S1

Door

Entrances

F

Ventilation

Air

Low Voltage

S2

Electrical

Entrance

K

Cond.

G

Condenser

High Voltage

J

L

Air

Electrical

M

Air Outlet

S2

Entrance

Inlet

P

T

Front View

Side View

Drain

N

Back View

Bottom Installation

Q

Bracket

MIS-2921

W*LV LEFT UNIT

	E				Built In
	O
					Rain Hood
	.44			D	4° Pitch	W
					Electric
			2.13
R					Heat
	Supply Air Opening	Side Wall			Heater
			A
		Mounting
					Access
		Brackets
S1					Panel
		(Built In)
					C. Breaker/
					Disconnect
		Top Rain	I		Access Panel
					(Lockable)
		Flashing
S1
		Shipping
					Filter Access
		Location
					Panel

			Optional			Ventilation		5.75
				C		Air
S1	Return Air Opening
			Electrical			Vent Option
			Entrances
						Door
								F
S2				H		Low Voltage
						Electrical
			L	K		Entrance
			M		Cond.	High Voltage	Condenser	G
				J	Air	Electrical
S2			P			Entrance	Air Outlet
					Inlet
T
Drain	Bottom	Back View	2.63		Side View		Front View	MIS-2922
	Installation		9.06
	Bracket

Manual	2100-538E
Page	7 of 23