Bard W42L User Manual

INSTALLATION INSTRUCTIONS

WALL MOUNTED

PACKAGE AIR CONDITIONERS

MODELS
W18A1 W18L1
W24A1 W24L1
W30A1 W30L1
W36A1 W36L1
W42A1 W42L1
W48A1 W48L1
W60A1 W60L1
W70A1 W70L1

Bard Manufacturing Company, Inc.
Bryan, Ohio 43506

Since 1914...Moving ahead just as planned.

Manual : 2100-508A
Supersedes: 2100-508
File: Volume III Tab 16
Date: 02-10-09

© Copyright 2008

Manual 2100-508A
Page 1 of 25

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
Figure 3C

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 Fan Blade Setting ................................. 18

Mounting Instructions - W18, 24, 30, 36 .... 9

Mounting Instructions - W42, 48, 60, 70 ... 10

Start Up

General .............................................................. 15

Topping Off System Charge ................................... 15

Safety Practices ..................................................... 15

Important Installer Note ......................................... 16

High Pressure Switch ............................................ 16

Three Phase Scroll Compressor............................ 16

Phase Monitor ....................................................... 16

Condenser Fan Operation ..................................... 16

Service Hints ......................................................... 16

Sequence of Operation .......................................... 17

Compressor Control Module .................................. 17

Adjustments ........................................................... 17

Pressure Service Ports .......................................... 17

Troubleshooting

Fan Blade Setting Dimensions .............................. 18

Removal of Fan Shroud ......................................... 18

Refrigerant Charge ................................................ 18

Tables

Table 1 Fan Blade Dimensions .......................... 18

Table 2A Refrigerant Charge ............................... 18

Table 2B Refrigerant Charge ............................... 18

Table 3 Cooling Pressure .................................. 19

Table 4 Electrical Specifications W**A .............. 20

Table 5 Electrical Specifications W**L ............... 21

Table 6 Recommended Airflow .......................... 22

Table 7 Indoor Blower Performance .................. 22

Table 8 Maximum ESP Electric Heat Only........ 22

Table 9 Electric Heat ......................................... 23

Table 10 Optional Accessories ............................ 24

Table 11 Vent & Control Options ......................... 25

Manual 2100-508A
Page 2 of 25

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: [phone]
Fax: [phone]

ANSI American National Standards Institute

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

ASHRAE American Society of Heating, Refrigeration

and Air Conditioning Engineers, Inc.

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

NFPA National Fire Protection Association

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

Manufactured under the following

U.S. Patent numbers:

5,485,878; 5,301,777; 5,002,116; 4,924,934;

4,875,520; 4,825,936

Manual 2100-508A
Page 3 of 25

WALL MOUNT GENERAL INFORMATION

AIR CONDITIONER WALL MOUNT MODEL NOMENCLATURE

W 42 A 1– A 10 X X X X X A

MODEL NUMBER

CAPACITY

½

Ton

18 - 1
24 - 2 Ton

½ Ton

30 - 2
36 - 3 Ton
42 - 3½ Ton
48 - 4 Ton
60 - 5 Ton
70 - 6 Ton

NOTE: Vent options X, B and M are without exhaust capability. May require separate field supplied barometric relief in building.

A - Right Hand Air Conditioner
L - Left Hand Air Conditioner

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 S3397)

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.

REVISIONS

VOLTS & PHASE

A - 230/208/60/1
B - 230/208/60/3
C - 460/60/3

KW

COLOR OPTIONS

X - Beige (Standard)
1 - White
2 - Mesa Tan
4 - Buckeye Gray
5 - Desert Brown
6 - Dark Bronze
A - Aluminum
S - Stainless Steel

FILTER OPTIONS

X - One Inch Throwaway (Standard)
W - One Inch Washable
P - Two Inch Pleated

OUTLET OPTIONS

X - Front (Standard)
T - Top Outlet (W30A, W36A Only)

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.

CONTROL MODULES

(See Spec. Sheet S3397)

COIL OPTIONS

X - Standard
1 - Phenolic Coated Evaporator
2 - Phenolic Coated Condenser
3 - Phenolic Coated Evaporator

and Condenser

While these instructions are intended as a general

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.

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.

Manual 2100-508A
Page 4 of 25

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 6.

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 2­inch 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.

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 as approved for zero inch clearance to
the supply duct. For model series W30, W36, W42, W48,
W60 and W70 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.

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

Manual 2100-508A
Page 5 of 25

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, W60 and W70. 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.

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.

4. Mount bottom mounting bracket.

5. Hook top rain flashing, attached to front - right of
supply flange for shipping, under back bend of top.

sseccAecivreSrofderiuqeRsecnaraelC

wolfriAresnednoCetauqedAdna

SLEDOM EDISTFEL EDISTHGIR

A63W,A03W,A42W,A81W "51 "02

L63W,L03W,L42W,L81W "02 "51

A07W,A06W,A84W,A24W "02 "02

L07W,L06W,L84W,L24W "02 "02

NOTE: For side by side installation of two (2) W**A models there
must be 20" between units. This can be reduced to 15" by using
a W**L model (left side compressor and controls) for the left unit
and WA (right side compressor and controls) for right unit.

See W**A Specification S3397 & W**L Specification S3400.

Manual 2100-508A
Page 6 of 25

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slairetaMelbitsubmoC

SLEDOM

L,A42W/L,A81W"0"0
L,A63W/L,A03W"4/1"0
L,A84W/L,A24W

L,A07W/L,A06W

TCUDRIAYLPPUS

TEEFEERHTTSRIF

"4/1"0

TENIBAC

FIGURE 2

HTDIW

HTPED

LEDOM

)W(

)D(

L,A81W

003.33521.71365.0788.788.9188.1188.9100.5300.1157.5265.0257.6260.8252.9200.7236.231.4360.2255.0191.400.2100.5

L,A42W
L,A03W

002.83521.71365.0788.788.7288.3188.7200.0400.1157.5239.7157.6257.8252.9200.7257.291.9357.2241.991.400.2100.5

L,A63W

THGIEH

)H(

L,A24W
L,A84W

570.24234.22578.4888.988.9288.5188.9288.3436.3166.1300.0386.2349.6296.4334.2373.388.2488.3200.0100.200.6188.1

L,A06W
L,A07W570.24234.22578.4988.988.9288.5188.9288.3436.3166.1400.0386.2449.6396.4434.2473.388.2488.3300.0100.200.6188.1

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

W**A
RIGHT

W

UNIT

5.75

F

G

Condenser

Air Outlet

YLPPUSNRUTER

AB C B E F G I J K L MNO P QRST

E

Built In

Rain Hood

4° Pitch

Heater

Access

Panel

Electric

C. Breaker/
Disconnect

Access Panel

(Lockable)

Filter Access
Panel

Vent Option
Door

Ventilation
Air

Low Voltage

Electrical
Entrance

High Voltage

Electrical
Entrance

Heat

D

Cond.

Air

Inlet

7.88

2

2

1.00

2.13
Side Wall

A

Mounting

Brackets

(Built In)

I

Top Rain

Flashing
Shipping
Location

Optional

C H

Electrical

Entrances

K

J

L

M

P

O

2

31.88

Supply Air Openi ng

B

Return Air Openi ng

.44

)lanimoN(stnemeriuqeRnoitallatsnIdnalarutcetihcrAroftinUcisaBfosnoisnemiD

R

S

S

S

1

S

1

S

Front View

Side View

Drain

1 Dimension is 21.00 inches on W70A & W70L models.
2 Optional top outlet (factory installed only) for W30A and W36A models only.

W**L
LEFT
UNIT

R

S

S

S

S

S

T

1

1

Drain

.44

Supply Air Openi ng

Return Air Openi ng

Bottom

Installation

Bracket

E
O

Back View

9.06

Side Wall
Mounting
Brackets
(Built In)

Top Rain

Flashing
Shipping
Location

Optional
Electrical
Entrances

M

P

2.63

D

2.13
A

I

C

H

K

L

Cond.

J

Air

Inlet

Built In
Rain Hood
4° Pitch

Electric
Heat

Heater
Access
Panel

C. Breaker/
Disconnect
Access Panel
(Lockable)

Filter Access

Low Voltage
Electrical
Entrance

High Voltage
Electrical
Entrance

N

Panel

Ventilation

Vent Option

Door

T

W

Bottom Installation
Bracket

MIS-2487 B

5.75

F

G

Back View

Q

Air

Condenser

Air Outlet

Front ViewSide View

MIS-2488 B

Manual 2100-508A
Page 7 of 25

1/4" CLEARANCE ON ALL

FOUR SIDES OF SUPPLY

MIS-353 C

MATERIALS

AIR DUCT IS REQUIRED

FROM COMBUSTABLE

WALL STRUCTURE

FOAM AIR SEAL

RAIN FLASHING

SUPPLIED

FIGURE 3A

SEAL WITH BEAD

OF CAULKING ALONG

TOP

ENTIRE LENGTH OF TOP.

MOUNTING INSTRUCTIONS

W18A1, W18L1, W24A1, W24L1

WALL

DUCT

SUPPLY AIR

PANEL

HEATER ACCESS

8"

NOTES:

THE SIDE MOUNTING FLANGES AND UNDER

SILICONE CAULKING BE PLACED BEHIND

IT IS RECOMMENDED THAT A BEAD OF

RETURN AIR

OPENING

CONTROLS AND HEATER ACCESS

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

TOP FLASHING AT TIME OF INSTALLATION.

IS ON OPPOSITE (LEFT) SIDE.

Right Side View

"

1

2

20

12"

1"

Manual 2100-508A
Page 8 of 25

"

1

16

20"

Supply Opening

" 7

1

16

7

12"

"

13

16

3

12"

Return Opening

12"

20"

12"

"

1

8

3

4"

Typ.

1"

4"

3"

"

7

8

12"

Typ.

2" 2"

Wall Opening and Hole Location View

5"