Bard D28A2PA, D36A2PA, D35A2PA, D28A2PB, D36A2PB Installation And Service Instructions Manual

INSTALLATION AND

SERVICE INSTRUCTIONS

DUAL-TEC™

WALL-MOUNT PACKAGE

AIR CONDITIONER

Models:

D25A2PA

D28A2PA
D28A2PB

D35A2PA
D35A2PB

D36A2PA
D36A2PB

D42A2PA
D42A2PB

D48A2PA
D48A2PB

D60A2PA
D60A2PB

D25L2PA
D25L2PB

D28L2PA
D28L2PB

D35L2PA
D35L2PB

D36L2PA
D36L2PB

Part of the Bard DC Free Cooling Unit System

NOTE: LC Series Controllers must be used with

D-Series Wall-Mount Units

D42L2PA
D42L2PB

D48L2PA
D48L2PB

D60L2PA
D60L2PB

Bard Manufacturing Company, Inc.
Bryan, Ohio 43506

www.bardhvac.com

Manual: 2100-643C
Supersedes: 2100-643B
Date: 7-28-16

Page 1 of 59

CONTENTS

SECTION 1: Installation Instructions ......................................................................................................... 5

List of Necessary Materials/Tools .........................................................................................................................6

Site Preparation .................................................................................................................................................7

Wall-Mount Unit Installation ...............................................................................................................................9

Wall-Mount Unit Supply Wiring ..........................................................................................................................15

Preliminary Start-Up .........................................................................................................................................19

SECTION 2: Service Instructions ............................................................................................................... 21

General Refrigerant Information .........................................................................................................................22

Sequence of Operation .....................................................................................................................................24

Using the TEC-EYE

Componentry Specifications ..............................................................................................................................30

Maintenance and Troubleshooting ......................................................................................................................38

SECTION 3: Appendix .................................................................................................................................. 45

Wall-Mount Unit Architecture ............................................................................................................................46

FIGURES AND TABLES

Figure 1.1 Wall-Mount Unit Model Nomenclature ......6

Figure 1.2 Dimensions ............................................8

Figure 1.3A D25A, D25L, D35A, D35L

Mounting Instructions ...........................10

Figure 1.3B D28A, D28L, D36A, D36L, D42A, D42L,

Mounting Instructions ...........................11

Figure 1.3C D48A, D48L, D60A, D60L

Mounting Instructions ...........................12

Figure 1.4 Electric Heat Clearance .........................13

Figure 1.5 Wall Mounting Instructions ....................13

Figure 1.6 Wall Mounting Instructions ....................14

Figure 1.7 Common Wall Mounting Installations ......14

Figure 1.8 Circuit Routing Label ............................15

Figure 1.9 WIRING: VAC and VDC Supply Wiring

Landing Points .....................................17

Figure 1.10 Adjusting the 230/208VAC Transformer ..17

Figure 1.11 Bard Polarity-Voltage Monitor .................18

Figure 2.1 Refrigerant Sight Glass .........................23

Figure 2.2 Wall-Mount Unit Control Board ..............25

Figure 2.3 TEC-EYE
Figure 2.4 TEC-EYE
Figure 2.5 TEC-EYE

Figure 2.6 Fan Blade Setting .................................32

Figure 2.7 Dirty Filter Switch .................................32

Figure 2.8 Power Loss Relay Circuit .......................33

Figure 2.9 High Pressure Relay Circuit ...................33

Figure 2.10 Blower Motor Start Relay Circuit ............33

Figure 2.11 D25A/L, D35A/L Unit Control Panel .......34

Figure 2.12 D28A/L, D36A/L, D42A/L, D48A/L,

D60A/L Unit Control Panel ....................35

Figure 2.13 WIRING: D25A/L, D35A/L

Unit Wiring Diagram .............................36

Figure 2.14 WIRING: D28A/L, D36A/L, D42A/L, ..........

D48A/L, D60A/L Unit Wiring Diagram ....37

Figure 2.15 Troubleshooting Motor Power Supply ......39

Figure 2.16 Troubleshooting Motor Start Command ...40

Figure 2.17 Troubleshooting Speed Voltage ...............40

Figure 2.18 VDC Polarity Check ...............................41

Figure 2.19 Verifying Incoming Voltage: VDC .............42

TM

........................................................................................................................................27

Table 1.1 Electrical Specifications ..........................16

Table 2.1 Nominal Pressures ..................................23

Table 2.2 Blower Speed Voltage Chart .....................24

Table 2.3 Temp vs. Resistance of Temp Sensor. ........31

Table 2.4 Indoor Blower Performance ......................32

Table 2.5 Troubleshooting 48VDC Blower Motor ........39

Table 2.6 Blower Speed Voltage Chart .....................40

TM

Display ................................27

TM

Connection to Unit Control ....27

TM

Status Display......................28

Manual 2100-643C
Page 2 of 59

GENERAL INFORMATION

DC FREE COOLING UNIT SYSTEM

The Bard DC Free Cooling Unit system is composed
of two (2) D-Series DUAL-TEC™ wall-mount air
conditioners matched with one (1) LC Series lead/lag
controller. The D-Series, specifically engineered for the
telecom market, can provide outdoor air cooling during
power loss situations through the use of onsite -48VDC
positive ground battery banks.

NOTE: The LC Series lead/lag controller and the

D-Series wall-mount units are designed
specifically to work together. The controller
cannot run other Bard models or other brands
of systems, nor can other controllers or
thermostats run the D-Series wall-mount units.
They are a complete system, and must be used
together.

WALL-MOUNT AIR CONDITIONER
UNITS

The D-Series units operate on both VAC and VDC power
under normal power supply conditions. If there is loss
of VAC power supply (shore and/or back-up generator)
the unit will continue to operate as free cooling or
ventilation system using the shelter’s VDC power. The
indoor blower and free cooling unit operate from -48VDC
and no inverter is required.

The units will supply 100% of rated cooling airflow
in free cooling mode with ability to exhaust the same
amount through the unit itself without any additional
relief openings in the shelter.

Each of these units are fully charged with refrigerant
and have auxilliary heat installed.

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 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 ADDITIONAL PUBLICATIONS for
information on codes and standards.

Sizing of systems for 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.

SHIPPING DAMAGE

Upon receipt of equipment, the cartons 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.

These units must remain in upright position at all
times.

ADDITIONAL PUBLICATIONS

These publications can help when installing the air
conditioning system. 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 Residential Winter

and Summer Air Conditioning ............. ACCA Manual J

Duct Design for Residential Winter and Summer
Air Conditioning and Equipment Selection

....................................................... ACCA Manual D

For more information, contact these publishers:

Air Conditioning Contractors of America (ACCA)
1712 New Hampshire Ave. N.W.
Washington, DC 20009
Telephone: [phone] Fax: [phone]

American National Standards Institute (ANSI)

11 West Street, 13th Floor
New York, NY 10036
Telephone: [phone] Fax: [phone]

Manual 2100-643C
Page 3 of 59

American Society of Heating, Refrigeration and Air
Conditioning Engineers, Inc. (ASHRAE)

1791 Tullie Circle, N.E.
Atlanta, GA 30329-2305
Telephone: [phone] Fax: [phone]

National Fire Protection Association (NFPA)

Batterymarch Park
P. O. Box 9101
Quincy, MA 02269-9901
Telephone: [phone] Fax: [phone]

ANSI Z535.5 Definitions:

Danger: Indicate[s] a hazardous situation which, if

not avoided, will result in death or serious injury. The
signal word “DANGER” is to be limited to the most
extreme situations. DANGER [signs] should not be used
for property damage hazards unless personal injury risk
appropriate to these levels is also involved.

Warning: Indicate[s] a hazardous situation which, if
not avoided, could result in death or serious injury.
WARNING [signs] should not be used for property
damage hazards unless personal injury risk appropriate
to this level is also involved.

Caution: Indicate[s] a hazardous situation which, if
not avoided, could result in minor or moderate injury.
CAUTION [signs] without a safety alert symbol may be
used to alert against unsafe practices that can result in
property damage only.

Notice: [this header is] preferred to address practices
not related to personal injury. The safety alert symbol
shall not be used with this signal word. As an
alternative to “NOTICE” the word “CAUTION” without
the safety alert symbol may be used to indicate a
message not related to personal injury.

!

WARNING

Electrical shock hazard.

Have a properly trained individual perform
these tasks.

Failure to do so could result in electric shock
or death.

!

WARNING

Fire hazard.

Maintain minimum 1/4” clearance between the
supply air duct and combustible materials in

the rst 3’ feet of ducting.

Failure to do so could result in re causing
damage, injury or death.

!

WARNING

Heavy item hazard.

Use more than one person to handle unit.

Failure to do so could result in unit damage or
serious injury.

Manual 2100-643C
Page 4 of 59

!

CAUTION

Cut hazard.

Wear gloves to avoid contact with sharp
edges.

Failure to do so could result in personal injury.

SECTION 1:

INSTALLATION

INSTRUCTIONS

Manual 2100-643C
Page 5 of 59

LIST OF NECESSARY MATERIALS/TOOLS

Additional hardware and miscellaneous supplies are needed for installation. These items are field supplied and must
be sourced before installation. This list also includes tools needed for installation.

LIST OF MATERIALS/TOOLS

• Personal protective equipment/safety devices

• Supply/return grilles

• Field-fabricated sleeves (if necessary)

• Fasteners sufficient for mounting the units such as
5/16" diameter anchor/carriage/lag bolts

• 7/8" diameter washers

• Caulking materials

• Miscellaneous hand and power tools and jobsite or
shop materials

• Lifting equipment with the necessary capacity and
rigging to safely move/install the systems

• Electrical supplies:

- Two (2) 20A circuit breakers for the shelter DC

power plant (one per wall-mount unit)

- Two (2) various size circuit breakers for

the shelter AC breaker box (see Table 1.1:
Electrical Specifications on page 16)

- High-voltage wire of various gauges (see Table

1.1)

- Communication wire: 2-wire, 18 gauge,

shielded with drain

- Miscellaneous electrical supplies including

rigid/flexible conduit and fittings, junction
boxes, wire connectors and supports

The following are required and must be sourced
prior to installation of these units.

• Two (2) 20A circuit breakers for the shelter DC
power plant (one per wall-mount unit)

Circuit breakers for Emerson Network Power (ENP)
power plants (used in most telecomm shelters built
today) are available directly through the following
distributors:

• Emerson Network Power: 440.288.1122

• Master Electronics: 888.473.5297 or

www.onlinecomponents.com

Emerson Network Power (ENP) Part Number

• 20A circuit breaker: P/N 101601

Always confirm the application before ordering.

FIGURE 1.1

D-Series DUAL-TEC™ Wall-Mount Unit Model Nomenclature

D 25 A 2 P A 05 4 P X X X J

MODEL

SERIES

CAPACITY

25 – 2 Ton

28 – 2½ Ton

35 – 3 Ton
36 – 3 Ton

Manual 2100-643C
Page 6 of 59

42 – 3½ Ton
48 – 4 Ton
60 – 5 Ton

A – Right Hand

L – Left Hand

REVISION

PLC

VOLTS & PHASE

A – 230/208-60-1
B – 230/208-60-3

KW

0Z – 0 KW
05 – 5 KW
06 – 6 KW

-48VDC

Free Cooling

Unit

COIL OPTIONS

X – Standard
3 – Phenolic Coated Evaporator and
Condenser

SPECIAL FEATURES

COLOR OPTIONS

X – Beige
1 – White
4 – Buckeye Gray

FILTER OPTIONS

P – 2-Inch Pleated (MERV 8)
M – 2-Inch Pleated (MERV 11)

CONTROL MODULES

J – High Pressure Switch, Low Pressure
Switch, Compressor Control Module,
Low Ambient Control, Alarm Contacts,
Start Assist
C – J Module + Compressor Crankcase
Heater

SITE PREPARATION

NEW SHELTER INSTALLATION VS.
RETROFIT INSTALLATION

These installation instructions cover both new shelter
installations and retrofit installations. Each installation
is unique and may require special accomodations and
modifications. Although Bard Manufacturing follows a
long-established tradition of manufacturing equipment
using industry standard dimensions for building
penetration, it is occasionally necessary to move or
enlarge supply and return openings when replacing
non-standardized equipment in a retrofit application.

MINIMUM CLEARANCE

D-Series wall-mount air conditioners are available in
both right-hand access models and left-hand access
models. Right-hand access models have the heat strip
access panel, external circuit breakers access panel
and internal controls access panel on the right side of
the unit. Left-hand access models are a mirror image
of the right-hand access models, and allow two wall­mount units to be placed in relatively close proximity
and yet still allow complete access for maintenance
and repair.

On side-by-side installations, maintain a minimum of
26" clearance on control side to allow access to control
panel and heat strips, and to allow proper airflow to the
outdoor coil. For installations where units are installed
with both control panels facing each other (inward),
maintain a minimum of 36" clearance to allow access.
Additional clearance may be required to meet local or
national codes.

Care should be taken to ensure that the recirculation
and obstruction of condenser discharge air does not
occur. Recirculation of condenser discharge air can
be from either a single unit or multiple units. Any
object such as shrubbery, a building or a large object
can cause obstructions to the condenser discharge air.
Recirculation or reduced airflow caused by obstructions
will result in reduced capacity, possible unit pressure
safety lockouts and reduced unit service life.

For units with blow through condensers, such as the
D-Series units, it is recommended there be a minimum
distance of 10' between the front of the unit and
any barrier or 20' between the fronts of two opposing
(facing) units.

CLEARANCE TO COMBUSTIBLES

!

WARNING

Fire hazard.

Maintain minimum 1/4" clearance between the
supply air duct and combustible materials in

the rst 3' of ducting.

Failure to do so could result in re causing
damage, injury or death.

The unit itself is suitable for 0" clearance, but the
supply air duct flange and the first 3' of supply air duct
require a minimum of 1/4" clearance to combustible
material. However, it is generally recommended that
a 1" clearance is used for ease of installation and
maintaining the required clearance to combustible
material. See Figures 1.3A-C on pages 10-12 for
details on opening sizes.

Minimum Clearances Required to
Combustible Materials

MODELS

All covered by this
manual

SUPPLY AIR DUCT

FIRST 3'

1/4" 0"

CABINET

MODEL IDENTIFICATION

Identify the specific model using the model
nomenclature information found in Figure 1.1 and/
or model/serial tag found on the unit on the opposite
side of the control and access panels. See Figure 1.2
on page 8 for dimensions and critical installation
requirements.

Clearances Required for Service Access
and Adequate Condenser Airflow

MODELS LEFT SIDE RIGHT SIDE

All covered by this manual 26" 26"

Units with control panels
facing each other (inward)

36" between units

Manual 2100-643C
Page 7 of 59

FIGURE 1.2

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

Width

Depth

Model

D25A/L
D35A/L

D28A/L
D36A/L
D42A/L

D48A/L
D60A/L

(W)

38.200 17.125 74.563 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 4.19 12.00 9.00

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 43.00 23.88 10.00 1.44 16.00 1.88

42.075 22.432 93.000 9.88 29.88 15.88 29.88 43.88 13.56 37.00 30.00 40.81 35.06 42.81 40.56 3.37 43.00 31.00 10.00 1.44 16.00 10.00

Height

(D)

Supply Return

(H)

A B C B E F G I J K L M N O P Q R S T

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

Side View

Built In
Rain Hood
4° Pitch

D

1.250

Cond.

Air

Inlet

D

1.250

2.13

J

Drain

Electric
Heat

A

I

C H

K

Heater
Access
Panel

C. Breaker/
Disconnect
Access Panel
(Lockable)

Econ. Hood

Side Wall
Mounting

Brackets

(Built In)

Top Rain

Flashing
Shipping
Location

Optional

Electrical

Entrances

L

M

N

E
O

Supply Air Opening

B

Return Air Opening

P

Back View

Q

W

D**A

RIGHT

HAND

UNIT

D**L
LEFT

HAND

UNIT

Built In

Rain Hood

W

ECON Hood

F

Ventilation Air

Cond.

G

Air

Outlet

4° Pitch

Heater

Access

Panel

Electric

Heat

C. Breaker/
Disconnect

Access Panel

(Lockable)

7.000

Low Voltage

Electrical

Entrance

High Voltage

Electrical

Entrance

Front View

E

.44

R

S

S

O

Supply Air Opening

B

Side Wall
Mounting
Brackets
(Built In)

Top Rain

Flashing
Shipping
Location

2.13

A

I

.44

Bottom Installation
Bracket

MIS-3849

R

S

S

S

S

S

T

S

S

S

T

Drain

Return Air Opening

Bottom

Installation

Bracket

Back View

Manual 2100-643C
Page 8 of 59

Optional
Electrical
Entrances

M

P

N

Q

C

Ventilation Air

H

K

L

Cond.

J

Air

Inlet

7.000

Low Voltage
Electrical
Entrance

High Voltage
Electrical
Entrance

Condenser

Air Outlet

Front ViewSide View

F

G

MIS-3848

WALL-MOUNT UNIT INSTALLATION

MOUNTING THE UNITS

!

WARNING

Heavy item hazard.

Use more than one person to handle unit.

Failure to do so could result in unit damage or
serious injury.

NOTE: It may be best to spot some electrical knockouts
(such as those located on the back of the wall­mount unit) before units are mounted and access is
unavailable or limited (see Figure 1.2 to locate pre­punched knockouts).

Two holes for the supply and return air openings must
be cut through the wall as shown in Figures 1.3A­C on pages 10-12. 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. Concrete block walls must be thoroughly
inspected to insure that they are capable of carrying
the weight of the installed unit.

In retrofit (unit replacement) installations, the openings
cut for the original equipment may not line up exactly
with needs of this installation. Modifications may need
to be made, such as increasing or decreasing the size
of the wall cutouts. The existing bolt placement may
not line up in which case the original bolts would need
to be removed or cut away.

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

2. The unit itself is suitable for 0" clearance, but the
supply air duct flange and the first 3' of supply
air duct require a minimum of 1/4" clearance to
combustible material. However, it is generally
recommended that a 1" clearance is used for
ease of installation and maintaining the required
clearance to combustible material. See Figures

1.3A-C for details on opening sizes.

3. Locate and mark lag bolt locations and location for
optional bottom mounting bracket, if desired (see
Figures 1.3A-C).

4. Mount bottom mounting bracket (if used).

5. If desired, hook top rain flashing (attached to front­right of supply flange for shipping) under back
bend of top.

6. Position unit in opening and secure with fasteners
sufficient for the application such as 5/16" lag/
anchor/carriage bolts; use 7/8" diameter flat washers
on the bolts. It is recommended that a bead of
silicone caulking be placed behind the side
mounting flanges.

7. Secure optional rain flashing to wall and caulk
across entire length of top (see Figures 1.3A-C).

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. 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.

Manual 2100-643C
Page 9 of 59

FOUR SIDES OF SUPPLY

Wall Opening and Hole Location View

1/4" MIN. CLEARANCE FROM

COMBUSTIBLE MATERIALSCRECOMMENDED 1" CLEARANCE FROM

REQUIRED DIMENSIONS TO MAINTAIN

COMBUSTIBLE MATERIALS

REQUIRED DIMENSIONS TO MAINTAIN

AIR DUCT IS REQUIRED

1/4" CLEARANCE ON ALL

FROM COMBUSTABLE

MIS-3820

MATERIALS

FOAM AIR SEAL

SUPPLIED

RAIN FLASHING

SEAL WITH BEAD

FIGURE 1.3A

OF CAULKING ALONG

Mounting Instructions

ENTIRE LENGTH OF TOP.

D25A, D25L, D35A, D35L

ED

17 5/8

3 11/16

TOP

4 7/16

WALL STRUCTURE

WALL

SUPPLY AIR

DUCT

PANEL

HEATER ACCESS

B

TOP FLASHING AT TIME OF INSTALLATION.

IT IS RECOMMENDED THAT A BEAD OF

THE SIDE MOUNTING FLANGES AND UNDER

RETURN AIR

OPENING

NOTES:

SILICONE CAULKING BE PLACED BEHIND

W**A UNIT SHOWN, W**L UNIT

CONTROLS AND HEATER ACCESS

IS ON OPPOSITE (LEFT) SIDE.

Right Side View

"

7

8

4

E

14"

"

16

11

4

5 3/8

B

8 3/8A9 7/829 7/8

4 5/8 16 7/8

28 3/8

Manual 2100-643C
Page 10 of 59

C

A

Supply Opening

Return Opening

28"

C

D

12"

12"

12"

12"

4"

"

Typ.

1

8

3

"

7

8

"

7

8

2

"

7

8

12"

4"

Typ.

"

1

16

9

"

16

11

4

D

16"

16"

16"

16"

16"

1

7

8

"

6

1

2

" 6

1

2

"

2

1

8

"

7

8

"

1"

3"

4"

Typ.

4"

Typ.

6

1

2

"

30"

E

16"

A CC

3

1

8

"

B

Wall Opening and Hole Location View

RETURN AIR

1

REQUIRED DIMENSIONS TO MAINTAIN

1/4" MIN. CLEARANCE FROM

COMBUSTIBLE MATERIALS

REQUIRED DIMENSIONS TO MAINTAIN

29

DUCT

COMBUSTIBLE MATERIALS

A B C DE

30 1/2

10 1/2

6 1/4 1 1/4 29 3/4

32 12 5 1/2

2

NOTES:

WALL STRUCTURE

1

SUPPLY AIR

IT IS RECOMMENDED THAT A BEAD OF

OPENING

Right Side View

RAIN FLASHING

SILICONE CAULKING BE PLACED BEHIND

RECOMMENDED 1" CLEARANCE FROM

THE SIDE MOUNTING FLANGES AND UNDER

TOP FLASHING AT TIME OF INSTALLATION.

TOP.

PANEL

HEATER ACCESS

FOUR SIDES OF SUPPLY

AIR DUCT IS REQUIRED

FROM COMBUSTABLE

WALL

1/4" CLEARANCE ON ALL

MATERIALS

Supply Opening

FOAM AIR SEAL

SUPPLIED

SEAL WITH BEAD

OF CAULKING ALONG

ENTIRE LENGTH OF

TOP

1

Return Opening

MIS-416 E

Dimension is 21" on 95" tall units.

2

Dimension is 10" on T48H1 & T60H1.

2

Dimension is 6" on T48H1 & T60H1.

3

3

FIGURE 1.3B

Mounting Instructions

D28A, D28L, D36A, D36L, D42A, D42L

Manual 2100-643C
Page 11 of 59

D

16"

16"

16"

16"

16"

2

"6

8

" 5

8 97

"

1"

3"

Typ.

1

4"

4"

Typ.

6

1

2

"

30"

E

16"

A CC

"

7

8

3

B

"

8

7

1

1

2

"6

1 1/430 1/2

1/4" CLEARANCE ON ALL

SUPPLIED

FOAM AIR SEAL

A

Supply Opening

SILICONE CAULKING BE PLACED BEHIND

DUCT

FOUR SIDES OF SUPPLY

FROM COMBUSTABLE

1/4" MIN. CLEARANCE FROM

COMBUSTIBLE MATERIALS

REQUIRED DIMENSIONS TO MAINTAIN

OPENING

COMBUSTIBLE MATERIALS

B D E

PANEL

AIR DUCT IS REQUIRED

32

10 1/2

Right Side View

SUPPLY AIR

RECOMMENDED 1" CLEARANCE FROM

MIS-3789

RAIN FLASHING

REQUIRED DIMENSIONS TO MAINTAIN

12

TOP.

MATERIALS

5 1/2

WALL STRUCTURE

2

6 1/4

29

29 3/4

IT IS RECOMMENDED THAT A BEAD OF

THE SIDE MOUNTING FLANGES AND UNDER

WALL

C

Wall Opening and Hole Location View

NOTES:

TOP FLASHING AT TIME OF INSTALLATION.

HEATER ACCESS

RETURN AIR

SEAL WITH BEAD

OF CAULKING ALONG

ENTIRE LENGTH OF

TOP

Return Opening

FIGURE 1.3C

Mounting Instructions

D48A, D48L, D60A, D60L

Manual 2100-643C
Page 12 of 59

FIGURE 1.4

DUCT

OPENING

RETURN AIR

SUPPLY AIR

WOOD FRAME WALL INSTALLATION

OPENING

WALL BEFORE

MOUNT ON UNIT

OPENING

BEFORE INSTALLATION

BOTTOM MOUNTING

CONCRETE BLOCK WALL INSTALLATION

BRACKET. MOUNT ON

OPENING

WOOD OR STEEL SIDING

OPENING

INSTALLING UNIT.

RETURN AIR

WALL STRUCTURE

RETURN AIR

SUPPLY AIR

FACTORY SUPPLIED

RAIN FLASHING.

SUPPLY AIR

MIS-548 A

SIDE VIEW

Electric Heat Clearance

Wall Mounting Instructions

See FIGURE 2 – Mounting Instructions

FIGURE 1.5

Manual 2100-643C
Page 13 of 59

FIGURE 1.6

I

A

C

K

E + 1.000

B

1.000

SUPPLY DUCT

OVER FRAME

INTERIOR FINISHED WALL

ALL AROUND DUCT

FRAMING MATERIAL

EXTERIOR FINISH WALL

OPENING

FOR ACTUAL DIMENSIONS.

2 x 4'S, 2 x 6'S &/OR

STRUCTURAL STEEL

ATTACH TO TOP

1.000" CLEARANCE

1.000" CLEARANCE

PLATE OF WALL

C

SEE UNIT DIMENSIONS, FIGURE 2,

OPENING

RETURN DUCT

2 x 6

ATTACH TO BOTTOM

OVER FRAME

PLATE OF WALL

L

THIS STRUCTURAL MEMBER
LOCATED TO MATCH STUD
SPACING FOR REST OF WALL.
A SECOND MEMBER MAY BE
REQUIRED FOR SOME WALLS.

MIS-549 B

ALL AROUND DUCT

SUPPLY DUCT MAY BE LOCATED IN AN ATTIC

OPENING W/ GRILLE

SUPPLY AIR DUCT

RAFTERS

RAFTERS

RETURN AIR
OPENING W/ GRILLE

DUCTED SUPPLY

OR BELOW CEILING RAFTERS AS SHOWN

FINISHED CEILING SURFACE

RAIN

FLASHING

RAIN

FLASHING

RETURN AT UNITNO DUCT

RETURN AIR

FINISHED CEILING SURFACE

FREE AIR FLOW

OUTSIDE

WALL

OUTSIDE

WALL

SUPPLY AIR DUCT
W/ GRILLE

Wall Mounting Instructions

SEE UNIT DIMENSIONS, FIGURE 1-2,
FOR ACTUAL DIMENSIONS

FIGURE 1.7

Common Wall Mounting Installations

Manual 2100-643C
Page 14 of 59

WALL-MOUNT UNIT SUPPLY WIRING

NOTICE / AVIS

ROUTE ALL HIGH VOLTAGE FIELD

WIRES TO THE RIGHT OF THE WIRE

SHIELD AS SHOWN

ACHEMINER LES FILS HAUTE

TENSION SUR LA DROITE VERS LA

PROTECTION, COMME INDIQUÉ

VAC CIRCUIT BREAKER

/DISJONCTEUR

WIRE SHIELD /

PROTECTION

WHITE 3/16" LETTERING

7961-807

VDC CIRCUIT BREAKER

/DISJONCTEUR

All models covered by this installation
instruction require dual power sources:
VAC utility power to run the compressor, heat
and outdoor fan motor and -48 VDC power
to operate the indoor blower and DC free
cooling damper.

These units require a positive ground

-48 VDC copper conductor field wire
connection. Refer to the unit wiring diagram

for more information.

!

WARNING

Route all field wires to the right of the wire shield as
shown in the circuit routing label found in Figure 1.8
(and also on the wall-mount units).

Run communication wires in separate conduit
whenever possible. If a unique installation occurs
where it is not possible to isolate the communication
wires, it is permissible to run communication wires
in a conduit which contains a dedicated VDC voltage
line. In all cases, the communication wires must be
shielded, twisted wire and utilize proper filtration at the
main communications board. It is never permissible to

run communication wires with VAC voltage lines.

FIGURE 1.8

Circuit Routing Label

Electrical shock hazard.

Have a properly trained individual perform
these tasks.

Failure to do so could result in electric shock
or death.

Refer to the unit rating plate or Table 1.1 on page
16 for wire sizing information and maximum fuse or
circuit breaker size. Each outdoor unit is marked with
a “Minimum Circuit Ampacity”. The field wiring used
must be sized to carry
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 assure that there
will be no nuisance tripping due to the momentary high
starting current of the compressor motor.

that amount of current. All

See Figure 1.9 on page 17 to reference VAC and VDC
supply wiring landing points.

IMPORTANT: 230/208V 1 phase and 3 phase
equipment use dual primary voltage transformers. All
equipment leaves the factory wired on 240V tap. It is
very important that the correct voltage tap is used. For
208V operation, reconnect from 240V to 208V tap (see
Figure 1.10). The acceptable operating voltage range
for the 240 and 208V taps are: 240V Tap (253 – 216)
and 208 Tap (220 – 197).

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.

Manual 2100-643C
Page 15 of 59

TABLE 1.1

Electrical Specifications

AC POWER CIRCUIT DC POSITIVE GROUND POWER CIRCUIT

Model

D25A2PA0Z/D25L2PA0Z 208/230-60-1 19 30 10/10 15.6 20 12

D25A2PA05/D25L2PA05 208/230-60-1 26 30 8/10 15.6 20 12

D35A2PA0Z/D35L2PA0Z 208/230-60-1 24 40 8/10 15.6 20 12

D35A2PA05/D35L2PA05 208/230-60-1 26 40 8/10 15.6 20 12

D35A2PB0Z/D35L2PB0Z 208/230-60-3 19 25 10/10 15.6 20 12

D35A2PB06/D35L2PB06 208/230-60-3 19 25 10/10 15.6 20 12

D28A2PA05/D28L2PA05 208/230-60-1 26 30 10/10 15.6 20 12

D28A2PB06/D28L2PB06 208/230-60-3 18 20 12/12 15.6 20 12

D36A2PA05/D36L2PA05 208/230-60-1 26 40 8/10 15.6 20 12

D36A2PB06/D36L2PB06 208/230-60-3 18 25 10/10 15.6 20 12

D42A2PA05/D42L2PA05 208/230-60-1 26 40 8/10 15.6 20 12

D42A2PB06/D42L2PB06 208/230-60-3 20 25 10/10 15.6 20 12

D48A2PA05/D48L2PA05 208/230-60-1 30 50 8/10 15.6 20 12

D48A2PB06/D48L2PB06 208/230-60-3 20 30 10/10 15.6 20 12

D60A2PA05/D60L2PA05 208/230-60-1 36 60 6/10 15.6 20 12

D60A2PB06/D60L2PB06 208/230-60-3 30 40 8/10 15.6 20 12

Rated Volts,

Hertz & Phase

Minimum

Circuit

Ampacity

Maximum

External Fuse or

Ckt. Breaker

Field Power/
Ground Wire

Size

Minimum

Circuit

Ampacity

Maximum

External Fuse

or Ckt. Breaker

Field Power/

Ground Wire

Size

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.

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 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°C copper wire. All wiring must conform to the National Electric Code and all local codes.

Manual 2100-643C
Page 16 of 59

FIGURE 1.9

VAC and VDC Supply Wiring Landing Points

.

Field
Wiring

VDC

.

.

-

Factory

Wiring

VAC

Field Wiring

Factory

+

NOTE: Right-hand access model wiring landing points

are shown here; left-hand access models will
mirror this image.

Wiring

NOTE: Right-hand access model wiring landing points

are shown here; left-hand access models will
mirror this image.

FIGURE 1.10

Adjusting the 230/208 VAC Transformer

230/208V 1 phase and 3 phase equipment use dual primary voltage transformers. All equipment leaves the factory wired on
240V tap. It is very important that the correct voltage tap is used. For 208V operation, reconnect from 240V to 208V tap.
The acceptable operating voltage range for the 240 and 208V taps are: 240V Tap (253 – 216) and 208 Tap (220 – 197).

1. Verify incoming AC voltage: Multimeter set to VAC

2. If incoming AC voltage is 220VAC or above...

...do not adjust transformer

.

Shelter supply breaker in ON position

Bard system breaker in OFF position

230V/208V Single Phase Voltage Range:

197VAC – 253VAC

230V/208V Three Phase Voltage Range:

197VAC – 253VAC

(not shown)

230VAC

+

3. If incoming AC voltage is below 220VAC...

...shut off AC breaker to unit

and move factory "240V" wire to "208V" terminal

Manual 2100-643C
Page 17 of 59

FIGURE 1.11

Bard Polarity-Voltage Monitor

If the VDC wiring is not terminated correctly on the specific polarity-indicated
terminals of the VDC terminal block, the VDC controls and motors will not activate
and the wall-mounted unit will not function.

The Bard Polarity-Voltage Monitor continually monitors for correct polarity and
voltage. If field wiring is connected improperly, or the voltage is outside of the
system parameters, the Polarity-Voltage Monitor will not allow any VDC voltage to
enter the system, protecting the internal controls and equipment.

+

When field wiring is correct in voltage and polarity, the
green power (PWR) LED and yellow polarity (POL) LED
will light, and system will operate normally.

If field wiring is incorrect in polarity, the red FAULT
LED will light, and the monitor will not allow VDC
voltage into the system.

If field wiring is correct in polarity but outside of the
required 40VDC – 56VDC, the green PWR LED will not
illuminate and the monitor not allow VDC voltage into
the system.

If the Polarity-Voltage Monitor is showing a problem with polarity and/or voltage, see pages 41 and 42 of the Service
section of this manual for instructions on checking VDC polarity and verifying incoming VDC voltage.

Manual 2100-643C
Page 18 of 59