Bard HAC601-BD040, HAC601-AD040, HAC421-AD040, HAC481-AD040, HAC181-AD040 User Manual

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: MA TCHING INDOOR BLOWER COIL UNITS AND MA TCHING ADD

ON COIL UNITS ONLY

Bard Manufacturing Company Bryan, Ohio 43506

Since 1914 . . . Moving ahead just as planned.

Manual No.: 2100-346C Supersedes: 2100-346B File: Volume 1, Tab 4 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

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 V alves....................................... 15

Service ................................................................17

Service Hints.......................................................... 17

Fan Blade Setting Dimensions ............................... 17

Pressure T ables ................................................ 20-23

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

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

FIGURE 1

UNIT DIMENSIONAL DRAWING

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

ALTERNATE ELECTRICAL ENTRANCES

ON BACK

HIGH VOLTAGE

ENTRANCE

LOW VOLTAGE

ENTRANCE

REFRIGERANT

SHUTOFF

VALVES

D

W

H

C

B

F

A

E

MIS-1789

TABLE 1

UNIT DIMENSIONS

"W"

.oNledoM

181CAH 142CAH

103CAH 163CAH

htdiW

00.0400.5100.62521.5881.0200.4521.7881.42

00.5400.5100.62521.5881.5200.4521.7881.92

"D"

htpeD

"H"

thgieHABCEF

124CAH 184CAH

00.0500.5100.23526.6886.8200.4526.8886.23

106CAH

Manual 2100-346 Page 1

TABLE 2

RATED CFM AND AIR FLOW DATA

(WET COIL – COOLING)

wolfriAdetaR

gnisnednoC

tinU

.oNledoM

A-181CAH

A142CAH

A-103CAH

A-163CAH

A-124CAH

B-,A-184CAH

B-,A-106CAH

rotaropavE

lioC

.oNledoM

A-SA03A A-SA42S

B42CB

A-SA03A A-SA42S

B42CB

A-SA63A

B63CB

A-SA73A

B63CB

A-SA24A

A-SA84A B63CB B06CB

B-SA16A B06CB

MFC

056 056 056

008 087 057

000,1 000,1

001,1 001,1

004,1 005,1 002,1 005,1

007,1 007,1

067,1 008,1

erusserP

O

HporD

2

51.

42.

81.

03.

02.

81.

03.

62.

82.

03.

detaR

.P.S.E

53.deM

02.hgiH

03.woL

72.hgiH

51.

83.

52.woL

82.hgiH

rotoM

deepS

paT

hgiH

woL

dednemmoceR

egnaRwolFriA

517-055 517-055 517-055

019-007 098-086 019-007

571,1-058 571,1-058

022,1-029 022,1-029

055,1-072,1 526,1-052,1 023,1-020,1 526,1-052,1

578,1-054,1 578,1-054,1

059,1-005,1 579,1-525,1

metsyS

ecifirO

deriuqeR

250.

550.

360.

960.

870.

180.

290.

* * *

* *

* * *

* *

Q Measured across the evaporator coil assembly, including drain pan. R External 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.

* IMPORT ANT INFORMA TION

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 T able 2.

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

Manual 2100-346 Page 2

!

TABLE 3

SPECIFICATIONS

SLEDOMA-181CAHA-142CAHA-103CAHA-163CAHA-124CAHA-184CAHB-184CAHA-106CAHB-106CAH

)HP/V/ZH06(gnitaRlacirtcelE1-802/0321-802/0321-802/0321-802/0321-802/0321-802/0323-802/0321-802/0323-802/032

egnaRegatloVgnitarepO352-791352-791352-791352-791352-791352-791352-781352-791352-781

yticapmAtiucriCmuminiM515191025262715312

¬

eziSeriWdleiF41412121010121801

rekaerBtiucriCromumixaMesuFyaleD020203030454520653

802/032spmAtinUlatoT6.8/9.74.11/2.010.41/4.318.51/5.416.91/1.910.12/4.914.31/8.217.62/7.222.71/3.51

ROSSERPMOC

802/032stloV802/032802/032802/032802/032802/032802/032802/032802/032802/032

spmAdaoLdetaR5.7/8.63.01/1.99.21/3.217.41/4.311.81/6.715.91/9.719.11/3.112.52/2.127.51/8.31

tnerruCnoitceleStiucriChcnarB6.83.017.317.411.815.916.213.627.51

802/032spmArotoRkcoL94/9465/6557/5728/28501/501201/20119/19531/531051/051

taeHesacknarCenoNenoNenoNenoN

RESNEDNOCdnaROTOMNAF

MPR/PH–rotoMnaF528–6/1528–6/1528–6/1528–6/1528–4/1528–4/1528–4/1528–4/1528–4/1

spmA–rotoMnaF1.11.11.11.15.15.15.15.15.1

noisremmI

epyT

noisremmI

epyT

noisremmI

epyT

enoNenoN

Manual 2100-346

Page 3

retemaiD–naF000,2–"02000,2–"02000,2–"02000,2–"02006,2–"42006,2–"42006,2–"42006,2–"42006,2–"42

METSYSTCENNOCTAEWS

DIeziSeniLnoitcuS"8/5"4/3"4/3"4/3"8/7"8/7"8/7"8/7"8/7

DIeziSeniLdiuqiL"4/1"8/3"8/3"8/3"8/3"8/3"8/3"8/3"8/3

.zO22-RegnahCyrotcaF.zo37.zo97.zo48.zo69.zo201.zo551.zo551.zo351.zo351

.SBL–THGIEWGNIPPIHS

551551081081052052052552552

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

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.

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

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 Page 4

MIS-589

FIGURE 3

INSTALLING REFRIGERANT TUBING

NOTE:

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

4. If existing orifice has not dropped out of the body when

5. Insert proper sized orifice fully into the flow control

Do not braze line to units! If orifice needs to be

changed, change out orifice first.

hex.

disassembled, remove by using a pin or paper clip. Discard this original orifice.

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.

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.

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.

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

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.

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.

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.

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.

cisaB

gnisnednoC ledoMtinU

181CAH"4/1"8/5"4/1"8/5"8/3"4/3 142CAH"8/3"8/5"8/3"4/3"8/3"4/3 103CAH"8/3"8/5"8/3"4/3"8/3"4/3 163CAH"8/3"8/5"8/3"4/32/1"8/7 124CAH"8/3"4/3"8/3"8/72/1"8/7 184CAH"8/3"8/7"8/3"8/72/1"8/1-1 106CAH"8/3"8/7"8/3"8/72/1"8/1-1

Manual 2100-346 Page 6

diuqiLnoitcuSdiuqiLnoitcuSdiuqiLnoitcuS

TABLE 4

TUBING CHART

).tF(htgneLeniLtnaregirfeR

02-006-12001-16