W42AC-A
Bard W42AC-A, W42AC-B, W42AC-C, W48AC-B, W48AC-C Installation Instructions Manual
...
INSTALLATION INSTRUCTIONS
11EER WA SERIES
WALL MOUNT AIR CONDITIONER
Models:
W42AC-A
W42AC-B
W42AC-C
W48AC-A
W48AC-B
W48AC-C
W60AC-A
W60AC-B
W60AC-C
W72AC-A
W72AC-B
W72AC-C
Bard Manufacturing Company, Inc.
Bryan, Ohio 43506
www.bardhvac.com
Manual: 2100-692
Supersedes: NEW
Date: 6-13-19
Page 1 of 38
CONTENTS
Getting Other Information and Publications .... 3
Wall Mount General Information .........................4
Air Conditioner Wall Mount Model Nomenclature ..... 4
Shipping Damage ................................................. 4
General ............................................................... 4
Duct Work ........................................................... 5
Filters ................................................................. 5
Filter Removal/Installation ................................. 5
Switching Filter Sizes ....................................... 6
Fresh Air Intake ................................................... 7
Condensate Drain ................................................ 7
Installation ............................................................... 8
Basic Installation Design and Application Planning .. 8
Wall Construction ............................................. 8
Outdoor Area Inspection .................................... 8
Condensate Water Drainage ............................... 8
Indoor Ducted and Non-Ducted Applications ........... 8
Indoor Supply Airflow ........................................ 8
Indoor Return Airflow ........................................ 8
Ducted Applications ......................................... 8
Free Blow Applications...................................... 9
Thermostat or Indoor Temperature Sensor
Placement ....................................................... 9
Unit Installation ................................................... 9
Materials/Tool List ............................................ 9
Wall Preparation ............................................. 10
Wall Mount Installation to Wall Surface ............ 10
Wiring – Main Power ........................................... 17
High Voltage Connections ................................ 17
Wiring – Low Voltage ........................................... 18
Low Voltage (24VAC) Connections .................... 18
Unit Shutdown Feature ................................... 18
Balanced Climate
TM
Feature ............................. 18
Dehumidification Feature ................................ 19
Ventilation Features ........................................ 19
Alarm Relay Feature ....................................... 19
DDC Controls Feature ...................................... 19
Dirty Filter Switch Indicator (DFS) ............... 19
Discharge Air Sensor .................................. 19
Airflow Switch ............................................ 19
Compressor Current Sensor ......................... 19
Start Up ................................................................... 23
General ............................................................. 23
Topping Off System Charge ................................. 23
Safety Practices ................................................. 23
Important Installer Note ...................................... 23
High Pressure Switch .......................................... 23
Three Phase Scroll Compressor Start Up
Information ........................................................ 23
Phase Monitor .................................................... 24
Condenser Fan Operation .................................... 24
Service Hints ..................................................... 24
Sequence of Operation ........................................ 24
Balanced Climate
TM
Mode ................................ 24
Vent Connection Plug .......................................... 25
Compressor Control Module ................................. 25
Features ........................................................ 25
Delay-on-Make Timer ...................................... 25
Short Cycle/Delay-on-Break ............................. 25
Low Pressure Detection ................................... 26
High Pressure Detection .................................. 26
Test Mode ...................................................... 26
Brownout Protection with Adjustment ............... 26
Pressure Service Ports ........................................ 26
Service ..................................................................... 27
Troubleshooting Nidec SelecTech Series ECM
Motors ............................................................... 27
If the Motor is Running ................................... 27
If the Motor is Not Running ............................. 27
Model SelecTech Communication Diagnostics ... 28
Fan Blade Setting Dimensions ............................. 29
R-410A Refrigerant Charge ................................. 29
Removal of Fan Shroud ....................................... 29
Setting Unit Airflow ............................................ 33
Blower Speeds ............................................... 33
Speed Tap 1 – Vent/Blower Only .................. 34
Speed Tap 2 – Balanced Climate ................. 34
Speed Tap 3 – Default LO Cooling &
Heating ............................... 34
Speed Tap 4 – Optional MED Cooling &
Heating ............................... 34
Speed Tap 5 – Optional HI Cooling &
Heating ............................... 34
TABLES
Table 1 Clearance Required for Service Access
and Adequate Condenser Airflow ........... 10
Table 2 Minimum Clearances Required to
Combustible Materials ......................... 11
Table 3 Additional Low Voltage Connections
(if applicable) ..................................... 18
Table 4 Low Voltage Connections for
DDC Control ....................................... 19
Table 5 Wall Thermostats ................................ 20
Table 6 Humidity Controls ............................... 20
Table 7 CO
Controllers ................................... 20
2
Table 8 Thermostat Wire Size ........................... 20
Table 9 Fan Blade Dimensions ......................... 29
Table 10 Cooling Pressure – Standard Airflow ...... 30
Table 11 Cooling Pressure – Balanced Climate
Airflow ............................................... 31
Table 12 Electrical Specifications W**AC ........... 32
Table 13 Recommended Airflow ......................... 33
Table 14 Blower Speeds for Unit Operational
Modes ................................................ 33
Table 15 Indoor Blower Performance .................. 35
Table 16 Maximum ESP Electric Heat Only ......... 36
Table 17 Electric Heat ...................................... 36
Table 18 Vent and Control Options ..................... 37
Table 19 Optional Accessories ........................... 38
Manual 2100-692
Page 2 of 40
FIGURES
Figure 1 Front Control Panel Cover ...................... 5
Figure 2 Removing Left Filter .............................. 5
Figure 3 Removing Second Filter ......................... 6
Figure 4 Filter Tabs in Up Position ....................... 6
Figure 5 Bend FIlter Tabs Down ........................... 6
Figure 6 Remove Four Screws ............................. 6
Figure 7 Re-Install Filter Support Brackets into
Lower Slots .......................................... 6
Figure 8 Re-Install Screws and Bend Tabs Up ....... 6
Figure 9 Install Right 2" Filter ............................. 7
Figure 10 Install Left 2" Filter ............................... 7
Figure 11 Fresh Air Damper .................................. 7
Figure 12 Vent Installation/Removal Clearance
Required ............................................ 11
Figure 13 Unit Dimensions ................................. 12
Figure 14 Mounting Instructions.......................... 13
Figure 15 Electric Heat Clearance ....................... 14
Figure 16 Wall Mounting Instructions .................. 15
Figure 17 Wall Mounting Instructions .................. 15
Figure 18 Common Wall Mounting Installations .... 16
Figure 19 High Voltage Connections .................... 17
Figure 20 Programmable Thermostat
Connections ....................................... 21
Figure 21 Non-Programmable Thermostat
Connections ....................................... 22
Figure 22
Figure 23 Motor Connections .............................. 27
Figure 24 Motor Connections .............................. 28
Figure 25 Fan Blade Setting ............................... 29
8201-164 Compressor Control Module ...
Figure 26 Fan Shroud Removal ........................... 29
Figure 27 Speed Taps ......................................... 33
Figure 28 Speed Taps ......................................... 33
GRAPHS
Graph 1 W42AC FAD-NE5 W/O Exhaust
Ventilation Delivery ............................. 39
Graph 2 W48AC FAD-NE5 W/O Exhaust
Ventilation Delivery ............................. 39
Graph 3 W60AC FAD-NE5 W/O Exhaust
Ventilation Delivery ............................. 40
Graph 4 W72AC FAD-NE5 W/O Exhaust
Ventilation Delivery ............................. 40
25
GETTING OTHER INFORMATION AND PUBLICATIONS
These publications can help when installing the air
conditioner. 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 Winter and Summer Air
Conditioning
....................................... ACCA Manual J Residential
Duct Design for Residential Winter and Summer Air
Conditioning and Equipment Selection
....................................................... ACCA Manual D
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 2100-692
Page 3 of 40
WALL MOUNT GENERAL INFORMATION
AIR CONDITIONER WALL MOUNT MODEL NOMENCLATURE
W 42 A C – A 0Z X X X X X X
MODEL SERIES
CAPACITY
42 – 3½ Ton
48 – 4 Ton
60 – 5 Ton
72 – 6 Ton
A – Air Conditioner
REVISION
SPECIALTY PRODUCTS
Insert “D” for dehumidification with hot gas reheat.
Reference Form 7960-811 for complete details.
NOTE: Vent options X and B are without exhaust capability. May require separate field-supplied barometric relief in building.
(Non-Standard)
VOLTS & PHASE
A – 230/208/60/1
B – 230/208/60/3
C – 460/60/3
X – Fresh Air Damper - No Exhaust (Standard)
A – Fresh Air Damper - With Barometric Exhaust
B – Blank-off Plate
D – DDC, 0-10V Economizer
KW
VENTILATION OPTIONS
PLACEHOLDER
X – Future Use
COLOR OPTIONS
X – Beige (Standard)
1 – White
4 – Buckeye Gray
5 – Desert Brown
FILTER OPTIONS
X – 1" Throwaway (Standard) M – 2" MERV 11
W – 1" Washable N – 2" MERV 13
P – 2" Pleated
M – Commercial Ventilator - ON/OFF Operation Only
R – Energy Recovery Ventilator - Motorized with Exhaust
V – Commercial Ventilator - No Hood with Exhaust
Z – Economizer - DB & WB, Full Flow
CONTROL MODULES
(See Spec. Sheet S3583)
COIL OPTIONS
X – Standard
1 – Phenolic Coated Evaporator
2 – Phenolic Coated Condenser
3 – Phenolic Coated Evaporator
and Condenser
4 – Coated Coils and Condenser
Section
5 – Coated Coils, Inside and
Outside of Unit
8 – Dark Bronze
A – Aluminum
S – Stainless Steel
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.
This appliance is not intended for use by persons
(including children) with reduced physical, sensory
or mental capabilities, or lack of experience and
knowledge, unless they have been given supervision or
instruction concerning use of the appliance by a person
responsible for their safety.
Children should be supervised to ensure that they do
not play with the appliance.
The refrigerant system is completely assembled and
charged. All internal wiring is complete.
Manual 2100-692
Page 4 of 40
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.
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
16 on page 36.
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 1" 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.
All model series require a 1/4" clearance to
combustible material for the first 3' of duct attached
to the outlet air frame is required. See wall mounting
instructions on page 6 and Figures 3 − 7 (pages 8 –
12) 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 a 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".
Any grille that meets with 5/8" louver criteria may be
used. It is recommended that Bard Return Air Grille
Kits RG5 or 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
The filters can be serviced from the outside by
removing the front control panel cover (see Figure 1).
Two (2) 20" x 20" x 1" throwaway filters come standard
with each unit. Additional 1" and 2" filter options are
available as optional accessories. To be notified when
filters need changed, a dirty filter switch option is
available. See page 36 for the dirty filter switch kit.
FIGURE 1
Front Control Panel Cover
Front
Control Panel
Cover
Filter Removal/Installation
1. Remove left filter first by pulling on filter removal
slide (see Figure 2).
FIGURE 2
Removing Left Filter
2. Slide second filter to the left around the wires and
pull the filter out (see Figure 3 on page 6).
Manual 2100-692
Page 5 of 40
FIGURE 3
Removing Second Filter
2. Locate the filter support brackets and remove the
four (4) screws holding them to the top of the
control panel (see Figure 6).
FIGURE 6
Remove Four Screws
3. Reverse the order for new filter installation.
NOTE: When installing new filters, make sure that
airflow arrows on filters point up.
Switching Filter Sizes
1. To switch from 1" to 2" filters, start by removing
the filter slide and bend the tabs down out of the
way (see Figures 4 and 5).
FIGURE 4
Filter Tabs in Up Position
FIGURE 5
Bend Filter Tabs Down
3. Pull the brackets out towards the front of the unit.
The back of the bracket will slip out of the upper
slots at the back of the filter tray.
4. Re-install the filter support brackets into the lower
slots at the back of the filter tray (see Figure 7).
FIGURE 7
Re-Install Filter Support Brackets into Lower Slots
Upper slots for
1" filters
Lower slots for
2" filters
5. Re-install the four (4) screws into the upper screw
holes on the filter support brackets. Then bend the
tab up out of the way (see Figure 8).
FIGURE 8
Re-Install Screws and Bend Tabs Up
Manual 2100-692
Page 6 of 40
6. Install the right 2" filter first followed by the left
filter (see Figures 9 and 10).
NOTE: When installing new filters, make sure that
airflow arrows on filters point up.
7. Reverse the steps above to switch from 2" to 1"
filters.
FIGURE 9
Install Right 2" Filter
FIGURE 10
Install Left 2" Filter
Fresh Air Intake
All units are built with fresh air inlet louvers punched
in the side grilles.
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, remove the two (2) screws
in the bottom of the blade (see Figure 11). Remove right
side grille to access the damper blade.
FIGURE 11
Fresh Air Damper
SED
Blade is screwed closed for
shipping. Remove two (2)
screws for fresh air intake
during unit operation.
AKE
ION.
(2)
MIS-3977
There is an adjustable slide on the side of the fresh air
intake that can be adjusted to limit how far the damper
opens so that the amount of fresh air that enters the
structure is regulated.
Graphs found on pages 38 and 39 give approximate
fresh air amounts based on the slide adjustment
setting.
All capacity, efficiency and cost of operation
information is based upon the fresh air blank-off plate
in place.
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 clear, flexible PVC drain hose (3/4" ID, 1" OD)
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 2100-692
Page 7 of 40
INSTALLATION
Basic Installation Design and
Application Planning
Successful unit installations require proper planning
and site inspection before installation begins. Before
installing the wall mount unit, make sure that all
service and airflow clearances are met and that the
unit can meet all applicable code and regulation
requirements. Provide an inspection of both the inside
and outside of the structure by reviewing floorplans
and/or visiting the installation site.
Wall Construction
The wall must be inspected to ensure that the weight
of the unit can be supported. Be sure to review all
applicable construction codes and regulations including
seismic requirements. When inspecting wood frame
walls, the wall construction must be strong and
rigid enough to carry the weight of the unit without
transmitting any unit vibration. It is important that
the side unit wall mounting lags and optional bottom
bracket are supported by structural members inside
the wall cavity. Concrete block and brick walls must be
thoroughly inspected to ensure that they are capable
of carrying the weight of the installed unit. Metal
buildings must contain structural components to
support the unit weight. If heavily corrugated siding
is present, it may need to be trimmed and flashed to
provide a flat, even surface to attach and seal the unit
to the wall.
Outdoor Area Inspection
Inspect the outdoor area of the jobsite or review
construction plans and locate the area where the wall
mount is to be installed. The outdoor area must be
free from obstructions including fences, bushes and
walls that will hinder unit operation regarding outdoor
condenser airflow and unit serviceability. Do not
install units in enclosed areas that limit the amount
of ambient temperature airflow. Warm air will exit
the front condenser section of the unit, and outdoor
ambient temperature air must be able to enter side
intake condenser openings of the unit. Portable or
modular building placement must be in a way that the
wall mount units have a constant supply of outdoor air
for proper unit operation. Make sure that the service
panels of the unit are accessible. Inspect wall surfaces
for obstructions that could hinder unit installation
and servicing including outdoor electrical conduits,
junction boxes, wall drains, vent hoods, windows, doors,
overhangs and posts.
Condensate Water Drainage
Review all codes and requirements for unit condensate
drainage. A plastic drain hose extends from the drain
pan in the upper section of the unit and extends down
to the unit base. An opening is supplied towards
the back of the unit base for the drain hose to pass
through, and the hose extends 1" to 2" below the unit
base. Water removed from the indoor air (condensate)
will be expelled from the unit in large amounts during
cooling operation through the hose. Units running
in cooling operation in cold outdoor below freezing
conditions can cause the condensate to freeze after
leaving the drain hose. 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 ensure proper
drainage throughout seasonal use.
Indoor Ducted and Non-Ducted
Applications
Air distribution inside the structure being conditioned
plays an important role in making sure the area is
a consistent temperature. Improper air distribution
can result in areas being cooler or warmer, electrical
equipment not receiving sufficient airflow or occupancy
discomfort felt inside an area. Thermostat or indoor
temperature sensor placement inside the area being
conditioned also plays an important role in indoor
climate control.
Indoor Supply Airflow
Indoor installation areas must provide a non-restrictive
path for the conditioned supply air to leave supply
grilles and registers. Inspect the area to ensure that all
indoor portions of the room or rooms will have access
to supply air. Ductwork may be used to ensure proper
air circulation and all provided ductwork guidelines and
clearances must be followed. Non-ducted applications
must use a supply louver grille installed over the supply
opening inside the room. Be sure to adjust supply
deflectors to properly disperse the conditioned supply
air to all parts of the room. Avoid closing sections of
the supply grilles which would cause unneeded supply
duct pressurization.
Indoor Return Airflow
A non-restrictive path for room air returning to the
center section of the unit must be provided inside
the room. Avoid placing objects including furniture,
electronics equipment, equipment racks and cabinets
directly in front of the unit return grilles and registers.
Bard recommends at least 2' between solid objects
and return grilles or registers. Ductwork may be used to
ensure proper air circulation and all provided ductwork
guidelines and clearances must be followed. Nonducted applications must use a return louver grille
installed over the return opening inside the room.
Ducted Applications
Field fabricated supply and return duct work may be
installed inside the structure being conditioned. A short
Manual 2100-692
Page 8 of 40
supply and/or return stub duct may be connected to the
unit supply and return flanges before unit installation to
help with duct connections inside the structure. Supply
and return ducts 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 conserve energy, reduce heat conductivity,
and prevent condensation or moisture damage. Refer to
Maximum External Static Pressure (ESP) of operation
and Electric Heat Table 16 on page 36. Design the
duct work according to methods given by the Air
Conditioning Contractors of America (ACCA). When
duct work is installed in unheated spaces, it should
be insulated with a minimum of 1" 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. Ducts through the
walls must be insulated and all joints taped or sealed to
prevent air or moisture from entering the wall cavity.
All model series require a 1/4" clearance to
combustible material for the first 3' of duct attached
to the outlet air frame is required. See instructions
on page 11 and Figures 14 − 18 (pages 13 – 16) for
further details.
!
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.
A metallic return air grille is required for non-ducted
applications. The spacing between louvers on the grille
shall not be larger than 5/8". It is recommended that a
Bard Return Air Grille Kit is installed that is designed
specifically for the wall mount product. Contact the
local Bard distributor or visit www.bardhvac.com for
ordering information. A field-supplied return grille
that meets the 5/8" louver criteria and does not cause
the unit to exceed the maximum specified external
static pressure (ESP) may be used. If using a return
air filter grille, filters must be of sufficient size to
allow a maximum velocity of 400 fpm. Filter return
air grilles do not filter air being brought into the
structure through ventilation options including fresh air
dampers, ventilators, economizers and energy recovery
ventilators. Be sure to install the return grille with the
louvers pointed downward towards the floor. This will
help ensure return air is drawn upward from the floor
and improve air circulation in the room.
NOTE: If no return air duct is used, applicable
installation codes may limit this cabinet to
installation only in a single story structure.
Thermostat or Indoor Temperature Sensor Placement
The location and installation of the thermostat or
temperature sensor that monitors indoor temperature is
very important regarding unit operation. Avoid placing
the thermostat in an area exposed to direct sunlight
or air from doorways leading outdoors. Use a piece
of insulating material to close off conduit openings
or holes in the wall surface for wire entry into the
thermostat or temperature sensor. This will help avoid
non-conditioned air from entering the thermostat
and effecting temperature and/or humidity readings.
As common practice, the thermostat or temperature
sensor should measure the temperature of the air
being returned to the unit, and not the conditioned
air being supplied by the unit. Placing the thermostat
or temperature sensor near a return air opening will
normally result in optimal unit performance.
Free Blow Applications
Some installations may not require extensive supply
duct work throughout the structure and are referred
to as free blow applications. A short field-fabricated
supply duct must be used in the wall cavity to
transition between the supply collar on the unit and
the supply louver grille in the room. The duct must
be properly insulated in order to conserve energy,
reduce heat conductivity and prevent condensation or
moisture damage. All joints must be taped or sealed to
prevent air or moisture entering the wall cavity. Follow
all clearances including distances to combustible
materials and all instructions provided in this manual.
A non-restrictive metallic supply air grille with
deflectors is required for free blow applications. Contact
the local Bard distributor or visit www.bardhvac.com for
ordering information.
Unit Installation
Make sure to have the proper tools at the work site that
are needed for unit installation. The following steps
are provided to ensure the unit is installed properly to
the wall surface, and that the unit will provide years of
service with minimal service requirements.
Materials/Tools List
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.
• Appropriate safety gear including gloves and safety
glasses
• 5/16" hex bit with drill driver
• Phillips head screwdriver
Manual 2100-692
Page 9 of 40
• Small straight (thermostat) screwdriver
• Tape measure
• Leveling device
• Two (2) tubes of caulk and caulk gun
• Utility knife
• Tools for cutting holes in the wall surface (if
needed)
• Electrical components and wiring along with
electrical tools
• Multimeter
• Wall fasteners for side flanges, bottom mounting
bracket and top rain flashing.
• Duct tape and/or other duct sealing materials.
Wall Preparation
1. Two holes for the supply and return air openings
must be cut through the wall as shown in Figure
14 on page 13. Be sure the openings are square
and level. Follow all clearances including distances
to combustible materials and all instructions
provided in this manual.
2. Review all electrical requirements provided in this
manual and plan out electrical entrances into the
building. Also plan electrical conduit routing and
thermostat placement, if necessary.
3. Install necessary duct work and prepare the
openings for unit installation.
4. Clean the exterior wall where the unit is to be
installed and make sure it is able to provide a
smooth, level, debris-free surface. Remove all
construction debris from the supply, return and
electrical hole cutting process.
Wall Mount Installation to Wall Surface
1. Remove packaging from unit and make sure the
unit is not damaged before installation. A top rain
flashing is supplied for field use and is mounted to
the back of the unit for shipping. Remove the rain
flashing before locating the unit against the wall.
Top rain flashing is required to avoid water entering
the area behind the unit that is against the wall. A
bottom mounting bracket, attached to the skid for
shipping, is provided for ease of installation but is
not required. Review instruction manuals located
inside control panel area. Review all requirements
listed on unit labels and on serial plate located on
the side of the unit.
2. Locate and mark bolt hole locations and bottom
mounting bracket location. Install bottom
mounting bracket with field-supplied fasteners to
wall if it is to be used (optional). Bracket must be
level and installed in the correct location to help
support the unit during the installation process
(see Figure 14).
3. Position the wall mount unit close to the wall
surface where it will be installed. Install rain
flashing at the top of the unit facing the wall by
hooking the hem bend into the rear bend of the
unit top (see Figure 14).
4. Apply a liberal amount of caulk on left and right
cabinet side wall mount brackets and back of
top rain flashing. Place unit back surface flush
against wall. Unit must be level to ensure proper
condensate drainage. Optional bottom bracket may
be used to help support the unit.
5. Units are secured to the wall by using fieldsupplied fasteners along each side of the wall
mount through the built-in wall mounting brackets.
It is the responsibility of the installer to select
the proper fastener to secure the unit to the wall
based on wall construction and applicable building
codes. Typical installations may include 5/16"
fasteners with 7/8" diameter flat washers. Be sure
unit is securely mounted and all weight-bearing
fasteners are attached to the weight supporting
structural members of the wall.
6. Apply a bead of caulk between the back of the unit
top and the front surface of the top rain flashing
(see Figure 14).
7. Connect unit duct work from the inside of the
building following all clearances and instructions
provided. 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 use code approved duct tape or other sealing
materials to seal the duct work to the unit.
8. On side-by-side installations, maintain a minimum
of 20" clearance on both sides to allow access to
heat strips and to provide proper airflow to the
outdoor coil. Additional clearance may be required
to meet local or national codes.
TABLE 1
Clearance Required for Service Access and
Adequate Condenser Airflow
Model
W42AC
W48AC
W60AC
W72AC
Left
Side
20" 20" 10'
Right
Side
Discharge –
Front
* For vent installation and removal, one side of the unit
requires 45" clearance in the vent area. See Figure
11 for clarity.
See Specifications Sheet S3583.
Manual 2100-692
Page 10 of 40
TABLE 2
Minimum Clearances Required
to Combustible Materials
Model Supply Air Duct (1st 3') Cabinet
W42AC
W48AC
W60AC
W72AC
1/4" 0"
Vent Installation/Removal Clearance Required
OBJECT OR WALL
FIGURE 12
VENTS CAN BE INSTALLED
FROM EITHER SIDE OF UNIT.
45.000
20.750
2.000
AVOID LOCATING UNIT DISCONNECT
IN THIS SECTION OR ANY
OTHER OBSTRUCTION
45.000
CLEARANCE NEEDED ON LEFT
OR RIGHT SIDE OF UNIT
17.750
VENT SHOWN
OUTSIDE OF UNIT
KEEP AREA
CLEAR FOR 45"
37.250
MIS-4042
Manual 2100-692
Page 11 of 40
FIGURE 13
Unit Dimensions
Width
Depth
(W)
W42AC
42.00 25.52 84.88 9.88 29.88 15.88 25.52 43.88 12.63 39.06 30.00 53.75 26.94 55.59 52.59 8.82 43.00 1.44 16.00 1.88
W48AC
W60AC
42.00 25.52 93.00 9.88 29.88 15.88 25.52 43.88 12.63 45.00 30.00 59.75 35.06 61.72 58.72 8.82 43.00 1.44 16.00 10.00
W72AC
Height
(D)
Supply Return
(H)
A B C B E F G I J K L M N O R S T
All dimensions are in inches. Dimensional drawings are not to scale.
W
Built In
Rain Hood
4° Pitch
Electric Heat
D
Heater Access
C. Breaker/
Disconnect
Access Panel
(Lockable)
Panel
High Voltage
Electrical
Entrance
1.375
2.250
Filter Behind Control Panel Door
F
Exhaust Air
Low Voltage
Electrical
Entrance
Ventilation Air
J
G
Condenser Air Outlet
Cond. Air
Inlet
R
2.000
A
S
E
O
Supply Air Opening
B
.375
Top Rain
Flashing
Shipping
Location
Optional
I
S
Electrical
Entrance
Side Wall
H
S
C
S
L
Return Air Opening
Mounting
Brackets
(Built In)
M
K
S
.375
TYP.
Drain
T
N
MIS-3978
Manual 2100-692
Page 12 of 40
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