Bard HAC361-AD040, HAC301-AD040, HAC481-BD040, HAC181-AD040, HAC481-AD040, HAC601-BD040, HAC241-AD040, HAC421-AD040, HAC601-AD040 User Manual

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INSTALLATION INSTRUCTIONS

SPLIT AIR CONDITIONER

OUTDOOR SECTION

Models: HAC181-AD040 HAC241-AD040 HAC301-AD040 HAC361-AD040 HAC421-AD040 HAC481-AD040 HAC481-BD040 HAC601-AD040 HAC601-BD040

FOR USE WITH: MATCHING INDOOR BLOWER COIL UNITS AND MATCHING ADD ON COIL UNITS ONLY

Bard Manufacturing Company	Manual No.:	2100-346C
Bryan, Ohio 43506	Supersedes:	2100-346B
Since 1914 . . . Moving ahead just as planned.	File:	Volume 1, Tab 4
Since 1914 . . . Moving ahead just as planned.	Date:	09-04-02
	Date:	09-04-02

CONTENTS

Split Air Conditioner General Information .........	1
Split Air Conditioner Model Nomenclature ...............	1
Application and Location ....................................	4
General ....................................................................	4
Shipping Damage ....................................................	4
Application ...............................................................	4
Location ...................................................................	4
Mounting Unit Outside on Slab .................................	4
Important Installer Note ............................................	4
Installing Refrigerant Tubing .....................................	4
Sweat Style Tubin Connections: Sweat
Indoor Unit and Sweat Outdoor Unit ........................	5
Field Fabricated Tubing Connections:
Quick Connect Indoor Unit and Sweat
Outdoor Unit Using CTO Kit .....................................	6

FIGURES
Figure 1 ....................................................................	1
Figure 2 ....................................................................	4
Figure 3 ....................................................................	5
Figure 4 ....................................................................	5
Figure 5 ..................................................................	12
Figure 6 ..................................................................	12
Figure 7 ..................................................................	12
Figure 8 ..................................................................	13
Figure 9 ..................................................................	14

Wiring Instructions ..............................................	9
General ....................................................................	9
Control Circuit Wiring ...............................................	9
Wall Thermostats .....................................................	9
Optional Controls ...................................................	12
Installation Instructions – CMA-5 ............................	12
Installation Instructions – CMA-6 ............................	12
Installation Instructions – CMA-10A ........................	13
Installation Instructions – CMA-13A ........................	14
Charging Instructions ........................................	15
Pressure Service Ports ..........................................	15
System Start-Up (Indoor Units
without Expansion Valves .......................................	15
Service ................................................................	17
Service Hints ..........................................................	17
Fan Blade Setting Dimensions ...............................	17
Pressure Tables ................................................	20-23

TABLES
Table 1 .....................................................................	1
Table 2 .....................................................................	2
Table 3 .....................................................................	3
Table 4 .....................................................................	6
Table 6 .....................................................................	9
Table 7 .....................................................................	9
Table 8 .....................................................................	9
Table 9 ...................................................................	15
Table 10 .................................................................	15
Table 11 .................................................................	16
Table 12 .................................................................	17
Table 13 .................................................................	20
Table 14 .................................................................	20
Table 15 .................................................................	21
Table 16 .................................................................	21
Table 17 .................................................................	22
Table 18 .................................................................	22
Table 19 .................................................................	23

SPLIT AIR CONDITIONER MODEL NOMENCLATURE

HAC 36 1 – A DXXX

Customized Unit Code

Electrical Characteristics

A – 230/208-60-1

B – 230/208-60-3

Modification Code

Capacity – 3 Ton or approx. 36,000 BTU

Basic Model Number

FIGURE 1

UNIT DIMENSIONAL DRAWING

ALTERNATE

ELECTRICAL

ENTRANCES

ON BACK

HIGH VOLTAGE

ENTRANCE

LOW VOLTAGE

ENTRANCE

REFRIGERANT

SHUTOFF

VALVES

MIS-1789

TABLE 1

UNIT DIMENSIONS

	"W"	"D"	"H"
Model No.	Width	Depth	Height	A	B	C	E	F
HAC181	40.00	15.00	26.00	5.125	20.188	4.00	7.125	24.188
HAC241	40.00	15.00	26.00	5.125	20.188	4.00	7.125	24.188
HAC241
HAC301	45.00	15.00	26.00	5.125	25.188	4.00	7.125	29.188
HAC361	45.00	15.00	26.00	5.125	25.188	4.00	7.125	29.188
HAC361
HAC421
HAC481	50.00	15.00	32.00	6.625	28.688	4.00	8.625	32.688
HAC601

Manual 2100-346

Page 1

TABLE 2

RATED CFM AND AIR FLOW DATA

(WET COIL – COOLING)

		Rated Airflow

Condensing	Evaporator		Pressure	Rated	Motor	Recommended		System
Unit	Coil	CFM	Pressure	Rated	Speed	Recommended		Orifice
Unit	Coil	CFM	Drop H2O	E.S.P.	Speed	Air Flow Range		Orifice
Model No.	Model No.		Drop H2O	E.S.P.	Tap	Air Flow Range		Required
Model No.	Model No.				Tap			Required

	A30AS-A	650	.15			550	- 715	.052	*
HAC181-A	S24AS-A	650	.24			550	- 715	.052	*
	BC24B	650		.35	Med	550	- 715	.052	*

	A30AS-A	800	.18			700	- 910	.055	*
HAC241A	S24AS-A	780	.30			680	- 890	.055	*
	BC24B	750		.20	High	700	- 910	.055	*

HAC301-A	A36AS-A	1,000	.20			850 - 1,175		.063	*
HAC301-A	BC36B	1,000		.30	Low	850 - 1,175		.063	*
	BC36B	1,000		.30	Low	850 - 1,175		.063	*

HAC361-A	A37AS-A	1,100	.18			920 - 1,220		.069	*
HAC361-A	BC36B	1,100		.27	High	920 - 1,220		.069	*
	BC36B	1,100		.27	High	920 - 1,220		.069	*

	A42AS-A	1,400	.30			1,270	- 1,550	.078	*
HAC421-A	A48AS-A	1,500	.26			1,250	- 1,625	.078	*
HAC421-A	BC36B	1,200		.15	High	1,020	- 1,320	.078	*
	BC36B	1,200		.15	High	1,020	- 1,320	.078	*
	BC60B	1,500		.38	Low	1,250	- 1,625	.078	*

HAC481 -A,-B	A61AS-B	1,700	.28			1,450	- 1,875	.081	*
HAC481 -A,-B	BC60B	1,700		.25	Low	1,450	- 1,875	.081	*

HAC601-A,-B	A61AS-B	1,760	.30			1,500	- 1,950	.092
HAC601-A,-B	BC60B	1,800		.28	High	1,525	- 1,975	.092

QMeasured across the evaporator coil assembly, including drain pan.

RExternal static pressure available for the duct system -- supply and return. All blower coils have multispeed motors, and value shown is at the recommended rated speed. Consult specification air flow charts with the blower coil units for complete information at other speeds.

*IMPORTANT INFORMATION

Proper sized orifice is not factory installed in indoor section. Proper orifice size is shipped with outdoor unit packaged with its installation instructions for indoor sections listed on this page. The orifice must be replaced with the proper system orifice shown above in Table 2.

For other evaporator coil models not listed, see indoor coil installation instructions for proper orifice information.

Manual 2100-346

Page 2

Page	Manual
3	346-2100

TABLE 3

SPECIFICATIONS

MODELS	HAC181-A	HAC241-A	HAC301-A	HAC361-A	HAC421-A	HAC481-A	HAC481-B	HAC601-A	HAC601-B

Electrical Rating (60HZ / V/ PH)	230/208-1	230/208-1	230/208-1	230/208-1	230/208-1	230/208-1	230/208-3	230/208-1	230/208-3

Operating Voltage Range	197 - 253	197 - 253	197 - 253	197 - 253	197 - 253	197 - 253	187 - 253	197 - 253	187 - 253

Minimum Circuit Ampacity	15	15	19	20	25	26	17	35	21

¬ Field Wire Size	14	14	12	12	10	10	12	8	10

! Delay Fuse Maximum or Circuit Breaker	20	20	30	30	40	45	25	60	35
Total Unit Amps 230/208	7.9 / 8.6	10.2 / 11.4	13.4 / 14.0	14.5 / 15.8	19.1 /19.6	19.4 / 21.0	12.8 / 13.4	22.7 / 26.7	15.3 / 17.2


COMPRESSOR

Volts 230/208	230/208	230/208	230/208	230/208	230/208	230/208	230/208	230/208	230/208
Rated Load Amps	6.8 / 7.5	9.1 / 10.3	12.3 / 12.9	13.4 / 14.7	17.6 / 18.1	17.9 / 19.5	11.3 / 11.9	21.2 / 25.2	13.8 / 15.7

Branch Circuit Selection Current	8.6	10.3	13.7	14.7	18.1	19.5	12.6	26.3	15.7
Lock Rotor Amps 230/208	49/49	56/56	75/75	82/82	105/105	102/102	91/91	135/135	150/150

Crankcase Heat	None	None	None	None	Immersion	Immersion	Immersion	None	None
Crankcase Heat	None	None	None	None	Type	Type	Type	None	None
					Type	Type	Type

FAN MOTOR and CONDENSER

Fan Motor – HP / RPM	1/6 – 825	1/6 – 825	1/6 – 825	1/6 – 825	1/4 – 825	1/4 – 825	1/4 – 825	1/4 – 825	1/4 – 825
Fan Motor – Amps	1.1	1.1	1.1	1.1	1.5	1.5	1.5	1.5	1.5

Fan – Diameter	20"–2,000	20"–2,000	20"–2,000	20"–2,000	24"–2,600	24"–2,600	24"–2,600	24"–2,600	24"–2,600


SWEAT CONNECT SYSTEM

Suction Line Size ID	5/8"	3/4"	3/4"	3/4"	7/8"	7/8"	7/8"	7/8"	7/8"
Liquid Line Size ID	1/4"	3/8"	3/8"	3/8"	3/8"	3/8"	3/8"	3/8"	3/8"

Factory Change R-22 Oz.	73 oz.	79 oz.	84 oz.	96 oz.	102 oz.	155 oz.	155 oz.	153 oz.	153 oz.


SHIPPING WEIGHT – LBS.	155	155	180	180	250	250	250	255	255

APPLICATION and LOCATION

GENERAL

These instructions explain the recommended method to install the air cooled remote type condensing unit, the interconnecting refrigerant tubing and the electrical wiring connections to the unit.

The condensing units are to be used in conjunction with the matching evaporator coils or evaporator blower units for comfort cooling applications as shown in the specification sheet.

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.

SHIPPING DAMAGE

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

APPLICATION

Size of unit for a proposed installation should be based on heat loss calculation and air duct sizing made according to methods of Air Conditioning Contractors of America. 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 90A, and Residence Type Warm Air Heating and Air Conditioning Systems, NFPA 90B. Where local regulations are at a variance with instructions, installer should adhere to local codes.

FIGURE 2

INSTALLATION CLEARANCE

MIS-589

LOCATION

The condensing unit is designed to be located outside with free and unobstructed condenser air inlet and discharge. It must also permit access for service and installation.

Condenser air enters the coil from the rear of the unit as shown in Figure 2 with electrical service access.

MOUNTING UNIT OUTSIDE ON SLAB

A solid level base or platform, capable to support the unit’s weight, must be set at the outdoor unit predetermined location. The base should be at least two inches larger than the base dimensions of the unit and at least two inches higher than surrounding grade level. The required unit minimum installed clearances must be maintained as called out in Figure 2 when locating and setting the base.

Remove the unit from its shipping carton and position the unit on the prepared base or platform.

NOTE: These units employ internally sprung compressors; therefore, it is not necessary to remove or loosen the base mounting bolts on the compressor prior to operation.

Consideration should be given to the electrical and tubing connections when placing the unit to avoid unnecessary bends or length of material.

IMPORTANT INSTALLER NOTE

For improved start up performance, wash the indoor coil with a dishwashing detergent.

INSTALLATION REFRIGERANT TUBING

The information that follows on installing refrigerant tubing and for changing the system orifice (if required) covers applications listed in the front of this installation instruction only. Although other indoor units may be of similar construction, the installation instructions for these units should be consulted for proper installation of those units prior to installation.

This information is provided for the field service personnel to install refrigerant tubing in compliance with Section 608 of Title VI National Recycling and Emission Reduction Program for the U.S. Clean Air Act effective July 1, 1992.

Consult manual 2100-002 on procedure for leak test – evacuation – charging before installation refrigerant tubing that requires any refrigerant recovery or system evacuation. Manual 2100-002 is included with the unit installation instruction package when shipped from the factory.

Manual 2100-346

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FIGURE 3

INSTALLING REFRIGERANT TUBING

pp5

SWEAT STYLE TUBING CONNECTIONS: SWEAT INDOOR UNIT and SWEAT OUTDOOR UNIT

Use only refrigeration grade (dehydrated and sealed) copper tubing. Care must be taken to insure that the tubing is kept clean and dry before and during installation. Do not remove the plugs from the tubing ends, coil connections or base valves until the connection is ready to be brazed.

The suction line must be insulated with a minimum of 3/8” Armaflex or equivalent before cutting and making connections.

1.Being careful not to kink, route both the suction line and liquid line between the indoor unit and outdoor unit. Use a tubing bender to make any necessary bends in tubing. When necessary to bend the insulated tube suction line, cut the insulation around its circumference at a distance far enough beyond the point of the bend so as to clear the tubing bender. Slip the insulation back together and vapor seal the joint with tape. Coil any excess tubing in a horizontal place with the slope of the tubing toward the condensing unit. See Figure 3.

CAUTION

1. Be careful not to tear the insulation when pushing it through hole in masonry or frame walls. 2. When sealing the tube opening in house wall, use a soft material to prevent tube damage and vibration transmission. 3. Avoid excessive bending in any one place to avoid kinking.

2.The tubing ends should be cut square. Make sure it is round and free of burrs at the connecting ends. Clean the tubing to prevent contaminants from entering the system.

NOTE: Do not braze line to units! If orifice needs to be changed, change out orifice first.

If the orifice does not have to be changed, skip the instructions outlined further in Step 3 and proceed to Step 8.

3.Disassemble Flow Control Assembly by turning body hex.

4.If existing orifice has not dropped out of the body when disassembled, remove by using a pin or paper clip. Discard this original orifice.

5.Insert proper sized orifice fully into the flow control body with rounded “bullet” nose towards the unit as shown in Figure 4. Insure the orifice stays inserted in body before connecting mating half. See chart in the outdoor unit installation instructions for proper size.

CAUTION

Be sure there is no dirt introduced into the flow control - orifice assembly. Be sure to install the orifice with the bullet nose pointing in the proper direction as shown in Figure 4. Failure to do so will result in improper operation.

FIGURE 4

FLOW CONTROL ASSEMBLY

FIELD ORIFICE REPLACEMENT INSTRUCTIONS

pp5

6.Thread assembly halves together by hand to insure proper mating of threads and tighten until bodies “bottom” or a definite resistance is felt.

7.Using a marker pen or ink pen, mark a line lengthwise from the union nut to the bulkhead. Then tighten an additional 1/6 turn (or 1 hex flat). The misalignment of the line will show the amount the assembly has been tightened. This final 1/6 turn is necessary to insure the formation of the leakproof joint.

8.Wrap a wet rag around the copper stub before brazing.

9.Flux the copper tube and insert into the stub. Braze the joint using an alloy of silver or copper and phosphorus with a melting temperature above 1,100° F for copper to copper joints. The phosphorus will act as a flux, therefore, no flux will be required.

Manual 2100-346

Page 5

A copper-silver alloy with a high silver content should be used when iron or steel material is involved in the joint. These alloys require the use of silver solder flux. Alloys containing phosphorus should not be used with iron or steel. Phosphorus reacts with the iron forming iron phosphate which is extremely brittle.

CAUTION

1. Brazing alloys with a melting temperature below 700° F should not be used. 2. Leadtin or tin-antimony solders should not be used due to their low melting point and necessity for corrosive fluxes.

To further prevent the formation of copper oxide inside the tubing, dry nitrogen may be purged through the refrigerant system during brazing.

WARNING

Never purge or pressurize a system with oxygen. An explosion and fire will result.

10.After brazing, quench with wet rag to cool the joint and remove any flux residue.

11.Leak test all connections using an electronic leak detector or a halide torch.

12.Evacuate suction line, liquid line and indoor unit through outdoor unit base valves.

13.Open both the suction and liquid base valves to the fully open position. Refer to section later in installation instructions for details on setting proper system charge.

FIELD FABRICATED TUBING CONNECTIONS: QUICK CONNECT INDOOR UNIT and SWEAT OUTDOOR UNIT USING CTO KIT

The suction line must be insulated with a minimum of 3/8” Armaflex or equivalent before cutting and making connections.

CAUTION

TABLE 4

TUBING CHART

		Refrigerant Line Length (Ft.)
Basic
Basic	0 - 20		21 - 60		61 - 100
Condensing	0 - 20		21 - 60		61 - 100
Condensing
Unit Model	Liquid	Suction	Liquid	Suction	Liquid	Suction

HAC181	1/4"	5/8"	1/4"	5/8"	3/8"	3/4"

HAC241	3/8"	5/8"	3/8"	3/4"	3/8"	3/4"

HAC301	3/8"	5/8"	3/8"	3/4"	3/8"	3/4"

HAC361	3/8"	5/8"	3/8"	3/4"	1/2	7/8"

HAC421	3/8"	3/4"	3/8"	7/8"	1/2	7/8"

HAC481	3/8"	7/8"	3/8"	7/8"	1/2	1-1/8"

HAC601	3/8"	7/8"	3/8"	7/8"	1/2	1-1/8"

Manual 2100-346

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