Bard W30H1, W42H1D, W18H1, W24H1D, W36H1, W42H1, W30H1D, W24H1, W48H1D, W48H1, W60H1, W60H1D User Manual

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INSTALLATION INSTRUCTIONS

WALL MOUNTED

PACKAGE HEAT PUMPS

 

MODELS

W18H1

 

W24H1

W24H1D

W30H1

W30H1D

W36H1

W36H1D

W42H1

W42H1D

W48H1

W48H1D

W60H1

W60H1D

Bard Manufacturing Company, Inc.

Manual:

2100-511F

Bryan, Ohio 43506

Supersedes:

2100-511E

Since 1914...Moving ahead just as planned.

File:

Volume III Tab 17

Date:

02-17-12

 

 

Manual

2100-511F

 

 

Page

1 of 27

 

Contents

Getting Other Information and Publications

3

Wall Mount General Information

 

Wall Mount Model Nomenclature ............................

4

Shipping Damage ....................................................

4

General ................................................................

4

Duct Work ................................................................

5

Filters ................................................................

5

Fresh Air Intake .......................................................

5

Condensate Drain ....................................................

5

Installation Instructions

 

Wall Mounting Information .......................................

6

Mounting the Unit ....................................................

6

Clearances Required ...............................................

6

Minimum Clearances ...............................................

6

Wiring – Main Power .............................................

14

Wiring – Low Voltage Wiring .................................

14

Figures

 

 

Figure 1

Fresh Air Damper Assembly ...................

5

Figure 2

Unit Dimensions ......................................

7

Figure 3A

Mounting Instructions ..............................

8

Figure 3B Mounting Instructions - W18, W24, W30, W36 ....

9

Figure 3C Mounting Instructions - W42, W48, W60 .....

10

Figure 4

Electric Heat Clearance .........................

11

Figure 5

Wall Mounting Instructions ....................

12

Figure 6

Wall Mounting Instructions ....................

12

Figure 7

Common Wall Mounting Installations....

13

Figure 8

Defrost Control Board ...........................

18

Figure 9

Fan Blade Setting .................................

21

Start Up

 

General ..............................................................

15

Topping Off System Charge...................................

15

Safety Practices.....................................................

15

Important Installer Note .........................................

16

Wall Mounted Air Conditioner ................................

16

Three Phase Scroll Compressor............................

16

Phase Monitor .......................................................

16

Condenser Fan Operation .....................................

16

Service Hints .........................................................

16

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

17

Pressure Service Ports ..........................................

17

Defrost Cycle .........................................................

17

Troubleshooting

 

Solid State Heat Pump Control ..............................

19

Checking Temperature Sensor ..............................

20

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

21

Removal of Fan Shroud .........................................

21

Refrigerant Charge ................................................

21

Tables

 

 

 

Table

1

Troubleshooting ....................................

19

Table

2

Fan Blade Dimension............................

21

Table

3A

Cooling Pressure ..................................

22

Table

3B

Heating Pressure ..................................

22

Table

4

Electrical Specifications W**H ..............

23

Table

5

Recommended Airflow ..........................

24

Table

6

Indoor Blower Performance ..................

24

Tables 7

Maximum ESP Electric Heat Only........

25

Table

8

Electric Heat .........................................

25

Table

9

Optional Accessories ...........................

26

Table

10

Vent & Control Options .........................

27

Manual

2100-511F

Page

2 of 27

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: (202) 483-9370

 

Fax: (202) 234-4721

ANSI

American National Standards Institute

 

11 West Street, 13th Floor

 

New York, NY 10036

 

Telephone: (212) 642-4900

 

Fax: (212) 302-1286

ASHRAE American Society of Heating, Refrigeration

and Air Conditioning Engineers, Inc.

1791 Tullie Circle, N.E.

Atlanta, GA 30329-2305

Telephone: (404) 636-8400

Fax: (404) 321-5478

NFPA

National Fire Protection Association

 

Batterymarch Park

 

P.O. Box 9101

 

Quincy, MA 02269-9901

 

Telephone: (800) 344-3555

 

Fax: (617) 984-7057

Manual

2100-511F

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WALL MOUNT GENERAL INFORMATION

HEAT PUMP WALL MOUNT MODEL NOMENCLATURE

 

W

42

H

1

A

10

MODEL NUMBER

REVISIONS

 

 

 

 

 

 

 

 

 

KW 1

CAPACITY

 

 

 

 

 

 

18

- 1½ Ton

H - Heat Pump

 

VOLTS & PHASE

 

 

24

- 2 Ton

 

A - 230/208/60/1

 

 

30

- 2½ Ton

 

 

B - 230/208/60/3

 

 

36

- 3 Ton

 

 

C - 460/60/3

 

 

42

- 3½ Ton

 

 

 

 

 

 

48

- 4 Ton

SPECIALTY PRODUCTS 2

 

 

 

60

- 5 Ton

 

 

 

(Non-Standard)

 

 

 

 

 

 

 

 

 

 

VENTILATION OPTIONS

X - Barometric Fresh Air Damper (Standard) B - Blank-off Plate

M - Motorized Fresh Air Damper

V - Commercial Ventilator - Motorized with Exhaust

E - Economizer (Internal) - Fully Modulating with Exhaust

R- Energy Recovery Ventilator - Motorized with Exhaust (See Spec. Sheet S3398)

X

X

X

X

 

X

A

 

 

 

 

 

 

 

CONTROL MODULES

 

 

 

 

 

 

 

(See Spec. Sheet S3398)

 

 

 

 

 

COIL OPTIONS

 

COLOR OPTIONS

 

X -

Standard

 

X -

Beige (Standard)

 

1

-

Phenolic Coated Evaporator

 

1

-

White

 

2

-

Phenolic Coated Condenser

 

4

-

Buckeye Gray

 

3

- Phenolic Coated Evaporator

 

5

-

Desert Brown

 

 

 

and Condenser

 

8

-

Dark Bronze

 

 

 

 

OUTLET OPTIONS

X - Front (Standard)

T - Top Outlet (W30H, W36H Only)

FILTER OPTIONS

X - One Inch Throwaway (Standard)

W - One Inch Washable

P - Two Inch Pleated

1 For 0 KW and circuit breakers (230/208 volt) or toggle disconnect (460V) applications, insert 0Z in the KW field of the model number. 2 Insert “D” for dehumidification with hot gas reheat. Reference Form 7960-576 for complete details.

NOTE: Vent options X, B and M 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/gain 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

2100-511F

Page

4 of 27

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 Tables 7.

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.

Models W18 & W24 are approved for zero inch clearance to the supply duct. For model series W30, W36, W42, W48 and W60 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 3 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.

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.

NOTE: If no return air duct is used, applicable installation codes may limit this cabinet to installation only in a single story structure.

FIGURE 1

FRESH AIR DAMPER

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2100-511F

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5 of 27

INSTALLATION INSTRUCTIONS

WALL MOUNTING INFORMATION

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

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 unit itself is suitable for 0 inch clearance, but 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 W30, W36, W42, W48 and W60. 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 Figure 3 for details on opening sizes.

3.Locate and mark lag bolt locations and bottom mounting bracket location. See Figure 3.

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 Figure 3.

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

 

 

 

W18H, W24H, W30H, W36H

15"

20"

W42H, W48H, W60H

20"

20"

Minimum Clearances Required to Combustible Materials

MODELS

SUPPLY AIR DUCT

CABINET

FIRST THREE FEET

 

 

 

 

W18H

/ W24H

0"

0"

 

 

 

 

W30H

/ W36H

1/4"

0"

 

 

 

 

W42H

/ W48H / W60H

1/4"

0"

 

 

 

 

Manual

2100-511F

Page

6 of 27

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

S

T

W18H1

33.300

17.125

70.563

7.88

19.88

11.88

19.88

35.00

18.50

25.75

20.56

26.75

28.06

29.25

27.00

2.63

34.13

22.06

10.55

5.00

12.00

5.00

W24H1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

W30H1

38.200

17.125

70.563

7.88

27.88

13.88

27.88

40.00

18.50

25.75

17.93

26.75

28.75

29.25

27.00

2.63

39.13

22.75

9.14

5.00

12.00

5.00

W36H1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

W42H1

42.075

22.432

84.875

9.88

29.88

15.88

29.88

43.88

19.10

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

W48H1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

W60H1

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

43.00

33.88

10.00

1.44

16.00

1.88

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

W**H

RIGHT

UNIT

FRONT VIEW

SIDE VIEW

BACK VIEW

*Optional top outlet (factory installed only) for W30H and W36H models only.

Manual

2100-511F

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MOUNTING INSTRUCTIONS

W18H1, W24H1

FIGURE 3A

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2100-511F

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FIGURE 3B

W30H1, W36H1

MOUNTING INSTRUCTIONS

 

 

 

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2100-511F

 

 

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