Bard W3RV1, W5LV1, W3LV1, W5RV1, W6LV1 User Manual

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INSTALLATION INSTRUCTIONS

WALL MOUNTED

VARIABLE CAPACITY

ENVIRONMENTAL CONTROL UNITS

MODELS

W3RV1 W3LV1 W5RV1 W5LV1 W6RV1 W6LV1

Bard Manufacturing Company, Inc. Bryan, Ohio 43506

Since 1914...Moving ahead just as planned.

Manual : 2100-538E Supersedes: 2100-538D File: Volume III Tab 16 Date: 12-15-11

Manual 2100-538E Page 1 of 23

Contents

Getting Other Information and Publications 3

Wall Mount General Information

ECU 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 ............................................. 13

Wiring – Low Voltage Wiring ................................. 13

Digital Thermostat/Controller ................................. 13

Wiring Diagram ...................................................... 13

Figures

Figure 1 Fresh Air Damper Assembly ................... 5

Figure 2 Unit Dimensions ...................................... 7

Figure 3A Mounting Instructions .............................. 8

Figure 3B Mounting Instructions .............................. 9

Figure 4 Electric Heat Clearance ........................ 10

Figure 5 Wall Mounting Instructions ..................... 11

Figure 6 Wall Mounting Instructions ..................... 11

Figure 7 Common Wall Mounting Installations .... 12

Figure 8 Fan Blade Setting ................................. 19

Start Up

General .............................................................. 14

Topping Off System Charge ................................... 14

Safety Practices ..................................................... 14

Important Installer Note ......................................... 15

High Pressure Switch ............................................ 15

Three Phase Scroll Compressor............................ 15

Phase Monitor ....................................................... 15

Service Hints ......................................................... 15

Digital Controller .................................................... 15

Sequence of Operation .................................. 16 & 17

Lead/Lag Sequence .............................................. 17

Compressor Control Module .................................. 18

Adjustments ........................................................... 18

Pressure Service Ports .......................................... 18

Troubleshooting

Fan Blade Setting Dimensions .............................. 19

Removal of Fan Shroud ......................................... 19

Refrigerant Charge ................................................ 19

Tables

Table 1 Fan Blade Dimensions .......................... 19

Table 2 Cooling Pressure .................................. 20

Table 3 Electrical Specifications W*R/LV .......... 21

Table 4 Recommended Airflow .......................... 22

Table 5 Maximum ESP Electric Heat Only........ 22

Table 6 Electric Heat ......................................... 22

Table 7 Vent & Control Options ......................... 23

Manual 2100-538E Page 2 of 23

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

Manufactured under the following

U.S. Patent numbers: 5,485,878; 5,301,744

Manual 2100-538E Page 3 of 23

WALL MOUNT GENERAL INFORMATION

Environmental Control Unit (ECU) Wall-Mount Model Nomenclature

W 3 R V 1–R 10 X X X X X X

MODEL SERIES

Wall-Mount

SYSTEM DESIGN

Variable Capacity

(Digital Compressor) ECU

COMPRESSOR & CONTROLS LOCATION

R - Right Side L - Left Side

REVISIONS

SPECIAL FEATURES

ELECTRICAL RATING

R - 230/208-60-1 & 220/200-50-1 S - 230/208-60-3 & 220/200-50-3 T - 460-60-3 & 400-50-3

Electric Heat @ Rated Voltage

COLOR OPTIONS

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

COIL OPTIONS

X - Standard Copper Tube/Aluminum Fin 1 - Phenolic Coated Indoor Coil 2 - Phenolic Coated Outdoor Coil 3 - Phenolic Coated Indoor & Outdoor Coil

OTHER OPTIONS

X - None

NOMINAL TONS

3 - 3 Ton (37,000 on 60Hz; 33,700 on 50Hz) 5 - 5 Ton (54,000 on 60Hz; 49,200 on 50Hz) 6 - 6 Ton (68,000 on 60Hz; 61,900 on 50Hz)

NOTE: Vent options X and B 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.

VENTILATION OPTIONS

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

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.

FILTER OPTIONS

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

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.

OUTLET OPTIONS

X - Front (Standard)

Manual 2100-538E Page 4 of 23

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 5.

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.

For model series W3R/LV, W5R/LV and W6R/LV 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 3A, 3B 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.

NOTE: If no return air duct is used, applicable

installation codes may limit this cabinet to installation only in a single story structure.

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.

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.

FIGURE 1

FRESH AIR DAMPER

Manual 2100-538E Page 5 of 23

C a

W W W W

INSTALLATION INSTRUCTIONS

WALL MOUNTING INFORMATION

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

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 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

W3R/LV, W5R/LV and W6R/LV

generally recommended that a 1-inch clearance is used for ease of installation and maintaining the required clearance to combustible material. See Figures 3A & 3B for details on opening sizes.

3. Locate and mark lag bolt locations and bottom mounting bracket location. See Figures 3A & 3B.

. However, it is

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 Figures 3A & 3B.

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.

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1VR6W,1VR5

1VL6W,1VL5

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

See Specification Sheet.

Manual 2100-538E Page 6 of 23

EDISTFEL

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DISTHGIR

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FIGURE 2

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1VR3

002.83521.71365.0788.788.7288.3188.7200.0488.0157.5239.7157.6257.8252.9200.7257.291.9357.2241.991.400.2100.21

1VL3

1VR5

570.24234.22578.4888.988.9288.5188.9288.3465.3166.1300.0386.2349.6296.4334.2373.388.2488.3200.0144.100.6100.61

1VL5

1VR6

570.24234.22578.4988.988.9288.5188.9288.3465.3166.1400.0386.2449.6396.4434.2473.388.2488.3300.0144.100.6100.12

1VL6

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

W*RV RIGHT UNIT

5.75

Condenser

Air Outlet

YLPPUSNRUTER

AB C B E F G I J K L MNOP QR 1S2ST

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

Cond.

Air

Inlet

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0.5

8.1

E O

2.13 Side Wall

Mounting

Brackets

(Built In)

Top Rain

Flashing Shipping Location

Optional

HKC

Electrical

Entrances

Supply Air Opening

Return Air Opening

W*LV LEFT UNIT

Cond.

Air

Inlet

Side View

Drain

Low Voltage Electrical Entrance

High Voltage Electrical Entrance

Front View

.44

Bottom

Drain

Installation

Bracket

Supply Air Opening

Return Air Opening

Back View

9.06

Side Wall Mounting Brackets (Built In)

Top Rain

Flashing Shipping Location

Optional Electrical Entrances

2.63

Side View

2.13 A

Built In Rain Hood 4° Pitch

Electric Heat

Heater Access Panel

C. Breaker/ Disconnect Access Panel (Lockable)

Filter Access

Panel

Ventilation

Vent Option

Door

Air

Back View

Condenser

Bottom Installation Bracket

MIS-2921

5.75

Air Outlet

Front View

MIS-2922

Manual 2100-538E Page 7 of 23

1/4" CLEARANCE ON ALL

FOUR SIDES OF SUPPLY

MIS-311 C

MATERIALS

AIR DUCT IS REQUIRED

FROM COMBUSTABLE

FOAM AIR SEAL

RAIN FLASHING

SUPPLIED

FIGURE 3A

W3RV1, W3LV1

SEAL WITH BEAD

OF CAULKING ALONG

ENTIRE LENGTH OF TOP.

MOUNTING INSTRUCTIONS

EDCBA

17 5/83 13/165 1/48 1/228 1/2

WALL STRUCTURE

RETURN AIR

SUPPLY AIR

DUCT

PANEL

HEATER ACCESS

TOP

WALL

OPENING

NOTES:

IT IS RECOMMENDED THAT A BEAD OF

SILICONE CAULKING BE PLACED BEHIND

THE SIDE MOUNTING FLANGES AND UNDER

TOP FLASHING AT TIME OF INSTALLATION.

W*R UNIT SHOWN, W*L UNIT

CONTROLS AND HEATER ACCESS

IS ON OPPOSITE (LEFT) SIDE.

16 7/84 9/164 1/21030

14"

Typ.

Manual 2100-538E Page 8 of 23

28"

Supply Opening

Return Opening

C CA

12"

COMBUSTIBLE MATERIALS

1/4" MIN. CLEARANCE FROM

REQUIRED DIMENSIONS TO MAINTAIN

COMBUSTIBLE MATERIALS

RECOMMENDED 1" CLEARANCE FROM

REQUIRED DIMENSIONS TO MAINTAIN

12"

Typ.

Wall Opening and Hole Location View Right Side View

FOAM AIR SEAL

SUPPLIED

RAIN FLASHING

FOUR SIDES OF SUPPLY

AIR DUCT IS REQUIRED

1/4" CLEARANCE ON ALL

WALL STRUCTURE

FROM COMBUSTABLE

MATERIALS

DUCT

SUPPLY AIR

PANEL

RETURN AIR

OPENING

W*R UNIT SHOWN, W*L UNIT

CONTROLS AND HEATER ACCESS

IT IS RECOMMENDED THAT A BEAD OF

SILICONE CAULKING BE PLACED BEHIND

TOP FLASHING AT TIME OF INSTALLATION.

THE SIDE MOUNTING FLANGES AND UNDER

NOTES:

IS ON OPPOSITE (LEFT) SIDE.

MIS-416 C

Right Side View

TOP.

FIGURE 3B

SEAL WITH BEAD

ENTIRE LENGTH OF

OF CAULKING ALONG

MOUNTING INSTRUCTIONS

W5RV1, W5LV1, W6RV1, W6LV1

TOP

6 1/4 1 1/4 29 3/4

10 1/2

ABCDE

30 1/2

32 12 5 1/2

WALL

HEATER ACCESS

Supply Opening

16"

Return Opening

16"

Typ.

30"

Typ.

16"

" 6

Dimension is 21" on W6R and W6L Units.

Wall Opening and Hole Location View

1/4" MIN. CLEARANCE FROM

REQUIRED DIMENSIONS TO MAINTAIN

COMBUSTIBLE MATERIALS

REQUIRED DIMENSIONS TO MAINTAIN

RECOMMENDED 1" CLEARANCE FROM

COMBUSTIBLE MATERIALS

Manual 2100-538E Page 9 of 23

FIGURE 4

ELECTRIC HEAT CLEARANCE

W3RV1, W3LV1, W5RV1, W5LV1, W6RV1, W6LV1

SIDE SECTION VIEW OF SUPPLY AIR DUCT FOR WALL MOUNTED UNIT SHOWING 1/4 INCH CLEARANCE TO COMBUSTIBLE SURFACES.

WARNING

A minimum of 1/4 inch clearance must be maintained between the supply air duct and combustible materials. This is required for the first 3 feet of ducting.

It is important to insure that the 1/4 inch minimum spacing is maintained at all points.

Failure to do this could result in overheating the combustible material and may result in a fire causing damage, injury or death.

Manual 2100-538E Page 10 of 23

FIGURE 5

WALL MOUNTING INSTRUCTIONS

SEE FIGURES 3A & 3B – MOUNTING INSTRUCTIONS

SUPPLY AIR

OPENING

RETURN AIR

OPENING

CONCRETE BLOCK WA LL INS T A LL ATION

SUPPLY AIR

OPENING

RETURN AIR

OPENING

WOOD OR STEEL SIDING

WOOD FRAME WALL INSTALLATION

FACTORY SUPPLIED

RAIN FLASHING.

MOUNT ON UNIT

BEFORE INSTALLATION

BOTTOM MOUNTING

BRACKET. MOUNT ON

WALL BEFORE

INSTALLING UNIT.

SIDE VIEW

WALL STRUCTURE

SUPPLY AIR

DUCT

RETURN AIR

OPENING

MIS-548 A

MIS-549 A

WALL MOUNTING INSTRUCTIONS

FRAMING MATERIAL

2 x 4'S, 2 x 6'S &/OR

STRUCTURAL STEEL

FIGURE 6

ATTACH TO TOP

PLATE OF WALL

1.000" CLEARANCE

ALL AROUND DUCT

IF REQUIRED

INTERIOR FINISHED WALL OVER FRAME

1.000" CLEARANCE

ALL AROUND DUCT

IF REQUIRED

EXTERIOR FINISH WALL OVER FRAME

ATTACH TO BOTTOM

PLATE OF WALL

SEE UNIT DIMENSIONS, FIGURE 2, FOR ACTUAL DIMENSIONS.

E + 1.000

SUPPLY DUCT

OPENING

RETURN DUCT

OPENING

2 x 6

THIS STRUCTURAL MEMBER LOCATED TO MATCH STUD SPACING FOR REST OF WALL. A SECOND MEMBER MAY BE REQUIRED FOR SOME WALLS.

1.000

Manual 2100-538E Page 11 of 23

FIGURE 7

COMMON WALL MOUNTING INSTALLATIONS

SUPPLY DUCT MAY BE LOCATED IN AN ATTIC

OR BELOW CEILING RAFTERS AS SHOWN

RAIN

FLASHING

OUTSIDE

WALL

RAFTERS

FINISHED CEILING SURFACE

SUPPLY AIR DUCT W/ GRILLE

RETURN AIR OPENING W/ GRILLE

FREE AIR FLOW

SUPPLY DUCT MAYBE LOCATED IN AN ATTIC

OR BELOW CEILING RAFTERS AS SHOWN

RAIN

FLASHING

RAFTERS

RAIN

FLASHING

OUTSIDE

WALL

RAIN

FLASHING

RAFTERS

SUPPLY AIR DUCT

FINISHED CEILING SURFACE

RETURN AIR OPENING W/ GRILLE

DUCTED SUPPLY

RETURN AT UNIT NO DUCT

SUPPLY DUCT MAYBE LOCATED IN AN ATTIC

OR BELOW CEILING RAFTERS AS SHOWN

RAFTERS

OUTSIDE

WALL

FALSE WALL INSTALLATION

Manual 2100-538E Page 12 of 23

SUPPLY AIR DUCT

FINISHED CEILING SURFACE

WALL SLEEVE FALSE WALL RETURN AIR GRILLE

RETURN AIR

SPACE

OUTSIDE

WALL

SUPPLY AIR DUCT

LOWERED CEILING

CLOSET WALL

WALL

SLEEVE

RAISED FLOOR

RETURN AIR

SUPPLY AIR

GRILLE

FINISHED CEILING

CLOSET INSTALLATION

SURFACE

RETURN AIR GRILLE

MIS-550 B

WIRING – MAIN POWER

These units are rated for 60/50 Hz operation as follows.

NOTE: This system must be controlled only by the Bard

8403-064 Digital Thermostat/Controller that is supplied with the unit. See below for Wiring and Pages 16-17 for Operating Sequences.

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S-

T-

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1-06-802/032 1-05-002/022

3-06-802/032 3-05-002/022

3-06-064 3-05-004

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egnaR

352-791 242-081

605-414 044-063

Refer to the unit rating plate for wire sizing information and maximum fuse or “HACR” type circuit breaker size. Each outdoor unit is marked with a “Minimum Circuit Ampacity”. This means that the field wiring used must be sized to carry that amount of current. Depending on the installed KW of electric heat, there may be two field power circuits required. If this is the case, the unit serial plate will so indicate. All models are suitable only for connection with copper wire. Each unit and/or wiring diagram will be marked “Use Copper Conductors Only”. These instructions must be adhered to. Refer to the National Electrical Code (NEC) for complete current carrying capacity data on the various insulation grades of wiring material. All wiring must conform to NEC and all local codes.

The electrical data lists fuse and wire sizes (75° C copper) for all models including the most commonly used heater sizes. Also shown are the number of field power circuits required for the various models with heaters.

The unit rating plate lists a “Maximum Time Delay Relay Fuse” or “HACR” type circuit breaker that is to be used with the equipment. The correct size must be used for proper circuit protection and also to assure that there will be no nuisance tripping due to the momentary high starting current of the compressor motor.

The disconnect access door on this unit may be locked to prevent unauthorized access to the disconnect. To convert for the locking capability, bend the tab located in the bottom left-hand corner of the disconnect opening under the disconnect access panel straight out. This tab will now line up with the slot in the door. When shut, a padlock may be placed through the hole in the tab preventing entry.

See “Start Up” section for important information on three phase scroll compressor start ups.

See Table 3 for Electrical Specifications.

WIRING – LOW VOLTAGE WIRING

230/208V, 1 phase and 3 phase equipment dual primary voltage transformers. All equipment leaves the factory wired on 240V tap. For 208V operation, reconnect from

240V to 208V tap. The acceptable operating voltage range for the 240 and 208V taps are:

TAP RANGE

240 253 – 216 208 220 – 187

NOTE: The voltage should be measured at the field power

connection point in the unit and while the unit is operating at full load (maximum amperage operating condition).

DIGITAL THERMOSTAT/CONTROLLER

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A-)desuton(-PTSMsnoitacinummoC

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8403-066 DIGITAL

CONTROLLER

-A IN4 IN3 GND IN2 24 COM 24V

OUT 9

GND 7-9

OUT 8 OUT 7

RLY 6

SC 4-6

RLY 5 RLY 4 RLY 3

SC 1-3

RLY 2 RLY 1

Manual 2100-538E Page 13 of 23

UNIT LOW

VOLTAGE

TERMINAL

BLOCK

MIS-2852 C

F E

G W1 W2

START UP

THESE UNITS REQUIRE R-410A REFRIGERANT AND POLYOL ESTER OIL.

GENERAL:

1. Use separate service equipment to avoid cross contamination of oil and refrigerants.

2. Use recovery equipment rated for R-410A refrigerant.

3. Use manifold gauges rated for R-410A (800 psi/250 psi low).

4. R-410A is a binary blend of HFC-32 and HFC-125.

5. R-410A is nearly azeotropic - similar to R-22 and R-12. Although nearly azeotropic, charge with liquid refrigerant.

6. R-410A operates at 40-70% higher pressure than R-22, and systems designed for R-22 cannot withstand this higher pressure.

7. R-410A has an ozone depletion potential of zero, but must be reclaimed due to its global warming potential.

8. R-410A compressors use polyolester oil.

9. Polyol Ester oil is hygroscopic; it will rapidly absorb moisture and strongly hold this moisture in the oil.

10. A liquid line dryer must be used - even a deep vacuum will not separate moisture from the oil.

11. Limit atmospheric exposure to 15 minutes.

12. If compressor removal is necessary, always plug compressor immediately after removal. Purge with small amount of nitrogen when inserting plugs.

TOPPING OFF SYSTEM CHARGE

If a leak has occurred in the system, Bard Manufacturing recommends reclaiming, evacuating (see criteria above), and charging to the nameplate charge. If done correctly, topping off the system charge can be done without problems.

With R-410A, there are no significant changes in the refrigerant composition during multiple leaks and recharges. R-410A refrigerant is close to being an azeotropic blend (it behaves like a pure compound or single component refrigerant). The remaining refrigerant charge, in the system, may be used after leaks have occurred and then “top-off” the charge by utilizing the pressure charts on the inner control panel cover as a guideline.

REMEMBER: When adding R-410A refrigerant, it must come out of the charging cylinder/tank as a liquid to avoid any fractionation, and to insure optimal system performance. Refer to instructions for the cylinder that is being utilized for proper method of liquid extraction.

WARNING

Failure to conform to these practices could lead to damage, injury or death.

SAFETY PRACTICES:

1. Never mix R-410A with other refrigerants.

2. Use gloves and safety glasses, Polyol Ester oils can be irritating to the skin, and liquid refrigerant will freeze the skin.

3. Never use air and R-410A to leak check; the mixture may become flammable.

4. Do not inhale R-410A – the vapor attacks the nervous system, creating dizziness, loss of coordination and slurred speech. Cardiac irregularities, unconsciousness and ultimate death can result from breathing this concentration.

5. Do not burn R-410A. This decomposition produces hazardous vapors. Evacuate the area if exposed.

6. Use only cylinders rated DOT4BA/4BW 400.

7. Never fill cylinders over 80% of total capacity.

8. Store cylinders in a cool area, out of direct sunlight.

9. Never heat cylinders above 125°F.

10. Never trap liquid R-410A in manifold sets, gauge lines or cylinders. R-410A expands significantly at warmer temperatures. Once a cylinder or line is full of liquid, any further rise in temperature will cause it to burst.

Manual 2100-538E Page 14 of 23

START UP (Continued)

IMPORTANT INSTALLER NOTE

For improved start up performance wash the indoor coil with a dish washing detergent.

HIGH PRESSURE SWITCH

All W*R/LV wall mounted air conditioner series models are supplied with a remote reset for the high and low pressure switch. If tripped, this pressure switch may be reset by turning the thermostat off then back on again.

THREE PHASE SCROLL COMPRESSOR START UP INFORMATION

Scroll compressors, like several other types of compressors, will only compress in one rotational direction. Direction of rotation is not an issue with single phase compressors since they will always start and run in the proper direction.

However, three phase compressors will rotate in either direction depending upon phasing of the power. Since there is a 50-50 chance of connecting power in such a way as to cause rotation in the reverse direction, verification of proper rotation must be made. Verification of proper rotation direction is made by observing that suction pressure drops and discharge pressure rises when the compressor is energized. Reverse rotation also results in an elevated sound level over that with correct rotation, as well as substantially reduced current draw compared to tabulated values.

Verification of proper rotation must be made at the time the equipment is put into service. If improper rotation is corrected at this time, there will be no negative impact on the durability of the compressor. However, reverse operation for over one hour may have a negative impact on the bearing due to oil pump out.

NOTE: If compressor is allowed to run in reverse rotation

for several minutes, the compressor’s internal protector will trip.

PHASE MONITOR

All units with three phase scroll compressors are equipped with a 3 phase 60/50 Hz line monitor to prevent compressor damage due to phase reversal. No changes required for 60 or 50 Hz operation.

The phase monitor in this unit is equipped with two LEDs. If the Y signal is present at the phase monitor and phases are correct the green LED will light.

If phases are reversed, the red fault LED will be lit and compressor operation is inhibited.

If a fault condition occurs, reverse two of the supply leads to the unit. Do not reverse any of the unit factory

wires as damage may occur.

SERVICE HINTS

1. Caution owner/operator to maintain clean air filters at all times. Also, not to needlessly close off supply and return air registers. This reduces airflow through the system, which shortens equipment service life as well as increasing operating costs.

2. Check all power fuses or circuit breakers to be sure they are the correct rating.

3. Periodic cleaning of the outdoor coil to permit full and unrestricted airflow circulation is essential.

DIGITAL CONTROLLER

The W3R/LV1 through W6R/LV1 variable capacity air conditioners utilize dedicated controllers and components to optimize this unit for cooling operation from -40 degrees F up to 131 degrees F (-40 degrees C to +55 degrees C). These units are dual rated for 200240V operation on both 50 and 60 Hz. Please read the following sequence of operation before attempting any troubleshooting or repair. Troubleshooting & repair procedures will be outlined below & later in this Manual.

All three phase compressors are wired identically internally. As a result, once the correct phasing is determined for a specific system or installation, connecting properly phased power leads to the same Fusite terminal should maintain proper rotation direction.

The direction of rotation of the compressor may be changed by reversing any two line connections to the unit.

These models use a digital compressor and variable speed indoor and outdoor motors. The motors and compressor must be replaced with the exact same component to maintain the above stated temperature and voltage ranges of operation. The units are controlled by a Bard digital thermostat/controller. This thermostat/ controller contains proprietary programming and must be replaced with the exact same component to ensure proper operation.

See Controller Quick Start Manual 2100-559 and Controller Advanced Programming Manual 2100-560 for complete details.

Manual 2100-538E Page 15 of 23

SEQUENCE OF OPERATION

MODES OF OPERATION

Cool Only Mode:

• Compressor will modulate from 100% down to 20%.

• Compressor will cycle off if thermostat/controller setpoint is reached.

Heat Only Mode:

•

Electric heat Stage 1 operates at 1st-stage heating set-point.

• Electric heat Stage 2 (if equipped) operates on 2 stage (-2F below heating set-point).

Auto Mode:

• Cooling or heating automatically selected based on building temperature vs. thermostat/controller setpoints and operates as described above.

CCVC (Continuous Compressor Variable Capacity):

• Compressor will modulate from 100% down to 20%.

• Compressor

will not cycle off if thermostat/controller set-point is reached, and would stay running at the 20% minimum capacity.

• If space temperature drops -2F below cooling set-point electric heat Stage 1 will then cycle to maintain that condition.

• If Stage 2 electric heat is installed, and if required, will cycle at -4F below cooling set-point to maintain that condition.

• If CCVC is terminated the controller will revert to Cool or Auto operation.

•

CCVC would be an Operating Mode for all applications where continuous run of the compressor is a requirement.

Testing & Troubleshooting Mode CCFC (Continuous Compressor Fixed Capacity):

• This unit must be controlled with the digital thermostat controller supplied with the unit. To test or troubleshoot, change system mode to CCFC. This will ensure unit runs continuously and in full capacity mode. AHRI ratings are based on this mode of operation.

CCFC (Continuous Compressor Fixed Capacity):

• The compressor is turned ON and locked ON as long as the thermostat/controller is in Test Mode 2.

• When in CCFC the compressor does not modulate but will be locked ON at 100% capacity.

• If space temperature drops -2F below cooling set-point electric heat Stage 1 will then cycle to maintain that condition.

• If Stage 2 electric heat is installed, and if required, will cycle at -4F below cooling set-point to maintain that condition.

• If CCFC is terminated the controller will revert to Cool or Auto operation.

• CCFC would not be considered an Operating Mode and should only be used for system testing as required.

Indoor Blower Operation The indoor blower speed will modulate with the compressor operation from 50% to 100% of operation. Once compressor operation is at 50 or below, percent airflow will be at 50% and no further reduction of

Manual 2100-538E Page 16 of 23

airflow will occur. Modulation is accomplished by modulating a 0-10 volt signal from OUT 7 to the indoor blower control board which then sends a PWM signal to the indoor blower motor.

An additional option to maintain airflow at 100% is also available. This selection is done at the thermostat/ controller under Fan Modes. Default is No for “Always 100%”setting. Change to Yes to disable indoor blower modulation as described above.

2 LED’s are located on the Blower Control Board. The Red LED will light anytime 24V is applied to the board and it is connected to the ECM motor. The Green LED will flash a series of short and long flashes depending on the output from the digital thermostat/controller.

Outdoor Fan Motor Operation The outdoor fan motor speed is varied in response to outdoor air temperature and pressure. The fan motor will cycle on and off with the compressor when not in a CCVC or CCFC. At all times above 122 degrees OAT, the outdoor fan, OUT 9, will be energized at high speed. From 122 degrees to 55 degrees the outdoor fan, OUT 9, will be set at normal outdoor airflow. Below 55 degrees the outdoor fan will modulate to maintain a 300 psi head pressure. This will act as a low ambient fan cycling control. The output may go to zero output to maintain the 300 PSI. The outdoor ECM motor will be programmed with a minimum RPM allowed to protect the bearing system. Any signal that is less than the percent torque required to maintain the minimum RPM will cause the motor to shut off. Once head pressure rises the motor will restart.

These functions are regulated by the digital thermostat/ controller with input from the pressure transducer and output signal to the Fan Control Board.

2 LED’s are located on the outdoor Fan Control Board. The Red LED is not active and does not light under any condition. The Green LED will flash a series of short and long flashes depending on the output from the digital thermostat/controller.

Capacity Modulation and High Head Pressure Control The pressure transducer monitors the high side pressure providing input to the digital thermostat/controller. It is powered using a 5Vdc power supply with a digital relay signaling the compressor unloader solenoid as required. When the ECU head pressure exceeds 615 PSI based on outdoor and indoor ambient conditions the compressor will automatically start to reduce capacity to stay on-line keeping the pressure at or below 575 PSI. The thermostat/controller display alternates between OD temperature and discharge pressure. When compressor capacity is being reduced due to high pressure conditions it will also indicate “High Head Pressure Control” mode on the display. A separate 650 PSI high pressure cutout switch is also employed as additional safety device. See Compressor Control Module on following page for more details.

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COOLING SEQUENCE

Compressor Operation The cooling capacity of the WV series is controlled by loading or unloading the compressor. On a call for cooling, the unloader solenoid is energized for one second to ensure pressure equalization in the compressor. The compressor contactor, RLY 2, is then energized and the compressor will start. A PI control loop then calculates the compressor capacity needed to reach set point and modulates the compressor . Modulation range is from 20% to 100% capacity. Modulation is accomplished by a pulse width modulated signal from OUT 8 which energizes the solid state relay (SSR) and energizes or de-energizes the unloader solenoid. The required compressor capacity is calculated every 15 seconds. 20% load means 0 VDC for 3.0 seconds and 5 VDC for

12.0 seconds from OUT 8. 30% load means 0 VDC for 4.5 seconds and 5 VDC for

10.5 seconds from OUT 8. 40% load means 0 VDC for 6.0 seconds and 5 VDC for

9.0 seconds from OUT 8. 50% load means 0 VDC for 7.5 seconds and 5 VDC for

7.5 seconds from OUT 8. 60% load means 0 VDC for 9.0 seconds and 5 VDC for

6.0 seconds from OUT 8. 70% load means 0 VDC for 10.5 seconds and 5 VDC for 4.5 seconds from OUT 8. 80% load means 0 VDC for 12.0 seconds and 5 VDC for 3.0 seconds from OUT 8. 90% load means 0 VDC for 13.5 seconds and 5 VDC for 1.5 seconds from OUT 8. 100% load means 0 VDC for 15 seconds and 5 VDC for

0.0 seconds from OUT 8.

Outdoor Temperature Sensor A sensor probe projects out the bottom of the ECU control box into the outdoor section, and this provides input for the outdoor fan sequences below 55F and above 115F described under Outdoor Fan Motor Operation.

Discharge Temperature Sensor This sensor is mounted on the compressor discharge line and protects the compressor against overheating. It opens at 250F and closes at 200F.

HEATING SEQUENCE

On a call for heating, if the space temperature falls 1°F below setpoint, the first stage of heating, RLY 4, will cycle ON. If the space temperature falls 3°F below setpoint, the second stage of heating, RLY 5, will cycle ON. Indoor Blower airflow is maintained at the Rated unit airflow at all times during heating.

LEAD/LAG SEQUENCE

The digital controllers can be used for dual units used in a redundant application by using the scheduling function as follows:

1. The controllers should be mounted side by side so that they are in the same temperature zone.

2. The time setting on both controllers need to be synchronized to the same time of day. NOTE: there is a 72-hour time retention if power is removed. If power off-time exceeds 72 hours, the time clock in each device must be reset to match. The exact time is not important as long as both controllers are set the same unless it is critical to control the time of day when the units swap operating positions.

3. Set one controller #1 to be Occupied for a 12-hour period and Unoccupied for the other 12-hour period. Set controller #2 so that it is exactly the opposite. Unoccupied for the 12-hour period when #1 is Occupied and Occupied when #1 is Unoccupied.

4. Set Occupied cooling setpoint the same for each controller, and Unoccupied the same for each. 4°F difference is suggested.

5. Set controllers to “Auto” mode of operation.

Example:

1. Both Unit #1 and #2 have Occupied setpoint of 74°F and Unoccupied setpoint of 78°F

Unit #1 set for Occupied from 1:00 a.m. to 1:00 p.m. & Unoccupied from 1:00 p.m. to 1:00 a.m.

Unit #2 set for Unoccupied from 1:00 a.m. to 1:00 p.m. & Occupied from 1:00 p.m. to 1:00 a.m.

4. Every 12 hours the units will swap position as being the lead unit, and the lag unit is available for back up operation at the higher temperature should the situation ever arise.

Manual 2100-538E Page 17 of 23

COMPRESSOR CONTROL MODULE

The compressor control module is standard on all models covered by this manual. The compressor control module is an anti-short cycle/lockout timer with high and low pressure switch monitoring and alarm relay output.

Adjustable Delay On Make And Break Timer

On initial power up or anytime power is interrupted to the unit, the delay on make period begins, which will be 2 minutes plus 10% of the delay on break setting. When the delay on make is complete and the high pressure switch and low pressure switch is closed, the compressor contactor is energized. Upon shutdown, the delay on break timer starts and prevents restart until the delay on break and delay on make periods have expired.

During routine operation of the unit with no power interruptions, the compressor will operate on demand with no delay.

High Pressure Switch and Lockout Sequence

If the high pressure switch opens, the compressor contactor will de-energize immediately. The lockout timer will go into a soft lockout and stay in soft lockout until the high pressure switch closes and the delay on break time has expired. If the high pressure switch opens again in this same operating cycle, the unit will go into manual lockout condition and the alarm relay circuit will energize. Recycling the wall thermostat resets the manual lockout.

Low Pressure Switch, Bypass, and Lockout Sequence

If the low pressure switch opens for more than 120 seconds, the compressor contactor will de-energize and go into a soft lockout. Regardless the state of the low pressure switch, the contactor will reenergize after the delay on make time delay has expired. If the low pressure switch remains open, or opens again for longer than 120 seconds, the unit will go into manual lockout condition and the alarm relay circuit will energize. Recycling the wall thermostat resets the manual lockout.

Alarm Relay Output

Alarm terminal is output connection for applications where alarm relay is employed. This terminal is powered whenever the compressor is locked out due to HPC or LPC sequences as described.

NOTE: Both high and low pressure switch controls are

inherently automatic reset devices. The high pressure switch and low pressure switch cut out and cut in settings are fixed by specific air conditioner unit model. The lockout features, both soft and manual, are a function of the Compressor Control Module.

ADJUSTMENTS

Adjustable Delay on Make and Delay on Break Timer

The potentiometer is used to select Delay on Break time from 30 seconds to 5 minutes. Delay on Make (DOM) timing on power-up and after power interruptions is equal to 2 minutes plus 10% of Delay on Break (DOB) setting:

0.5 minute (30 seconds) DOB = 123 second DOM

1.0 minute (60 seconds) DOB = 126 second DOM

2.0 minute (120 seconds) DOB = 132 second DOM

3.0 minute (180 seconds) DOB = 138 second DOM

4.0 minute (240 seconds) DOB = 144 second DOM

5.0 minute (300 seconds) DOB = 150 second DOM

During routine operation of the unit with no power interruptions the compressor will operate on demand with no delay.

Typical Settings for Dual Unit Installation:

Unit 1: DOB set at 2 minutes, and DOM is 132 seconds

Unit 2: DOB set at 4 minutes, and DOM is 144 seconds

PRESSURE SERVICE PORTS

High and low pressure service ports are installed on all units so that the system operating pressures can be observed. A pressure table can be found later in the manual covering all models. It is imperative to match the correct pressure table to the unit by model number. See Table 2.

Manual 2100-538E Page 18 of 23

TROUBLESHOOTING

FAN BLADE SETTING DIMENSIONS

Shown in Figure 8 is the correct fan blade setting for proper air delivery across the outdoor coil. Refer to Table 1 for unit specific dimension.

Any service work requiring removal or adjustment in the fan and/or motor area will require that the dimensions below be checked and blade adjusted in or out on the motor shaft accordingly.

FIGURE 8

FAN BLADE SETTING

MIS-1724

TABLE 1

FAN BLADE DIMENSION

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1VR3W

1VL3W

1VR5W

1VL5W

1VR6W

1VL6W

noisnemiD

"52.1

"57.1

REMOVAL OF FAN SHROUD

1. Disconnect all power to the unit.

2. Remove the screws holding both grilles, one on each side of unit, and remove grilles.

3. Unwire condenser fan motor.

4. Remove the bolts and nuts holding the condenser fan motor bracket to the fan shroud.

5. Slide the condenser fan motor and bracket to the rear of the condenser section.

6. Remove screws holding fan shroud to condenser and bottom support plate.

7. Slide fan shroud out the left side of the unit.

8. Reverse steps to install.

R-410A

REFRIGERANT CHARGE

This unit was charged at the factory with the quantity of refrigerant listed on the serial plate. AHRI capacity and efficiency ratings were determined by testing with this refrigerant charge quantity.

The following pressure tables show nominal pressures for the units. Since many installation specific situations can affect the pressure readings, this information should only be used by certified technicians as a guide for evaluating proper system performance. They shall not be used to adjust charge. If charge is in doubt, reclaim, evacuate and recharge the unit to the serial plate charge.

Manual 2100-538E Page 19 of 23

TABLE 2

)

COOLING PRESSURE TABLE

Air Temperature Entering Outdoor Coil °F (°C)

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VR3W

VL3W

VR5W

VL5W

VR6W

VL6W

11111

F26/57

)C7.61/9.32(

F76/08

)C4.91/7.62(

27/58

)C2.22/4.92(

F26/57

)C7.61/9.32(

F76/08

)C4.91/7.62(

27/58

)C2.22/4.92(

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F76/08

)C4.91/7.62(

27/58

)C2.22/4.92(

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721

553 731

463 241

773 521

633 431

543 931

753 311

443

121

353 521

563

721

373

493

631

383

404

141

693

814

821

031

853

083

731

931

763

093

241

441

083

404

311

411

163

183

121

221

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193

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621

383

504

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721 614

631 724

141

244 231

304

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314 641

724 511

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414 721

824

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501

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511

021

521

131

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)1.64(

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0.55(

821

921

031

231

244

964

894

931

444 241

964 431

724 341

834 841

354 711

034 521

144

921 654

931

184

115

341

441

894

925

631

731

154

874

541

641

364

094

051 974

811 954

621

031 784

151

705 021

094 821

174

305 231

125

531

035

565

141

441

445

975

641

941

365

995

731

831

405 741

715 251

535 221

625 031

935 531

855

135

841 545

351 465

421 465

331 875

831 895

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Low side pressure ± 4 PSIG High side pressure ± 10 PSIG

Tables are based upon rated CFM (airflow) across the evaporator coil. If there is any doubt as to correct operating charge being in the system, the charge should be removed, system evacuated and recharged to serial plate charge weight.

NOTE 1:

NOTE 2:

Return air temperature at 50% R.H.

Units rated to 131F (55C) outdoor temperature, but higher fan speeds and automatic modulation of the compressor due to pressure control make pressure readings above 115°F very unstable. Pressure table is based on low speed condenser fan operation. Fan speed increases above 115°F. Check pressures on unit at outdoor ambient below 115°F. Set thermostat at least 3° below current room temperature to ensure 100% comp operation for purpose of pressure testing.

Manual 2100-538E Page 20 of 23

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Electrical Specifications — W*RV / W*LV Series

1-06-802/032

1-05-002/022

3-06-802/032

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50R

01R

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Z0T-1VL3W/1VR3

60S

90S

1-05-002/022

3-06-802/032

3-05-004

Z0R-1VL5W/1VR5

90T

21T

3-05-002/022

Z0S-1VL5W/1VR5

02R

90S

01R

81S

3-06-802/032

3-06-064

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3-05-002/022

3-05-004

90T

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3-05-004

Z0S-1VL6W/1VR6

Z0T-1VL6W/1VR6

90S

81S

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51T

three (3) current carrying conductors are in a raceway.

1 Maximum size of the time delay fuse or HACR type circuit breaker for protection of field wiring conductors.

Caution: When more than one field power circuit is run through one conduit, the conductors must be derated. Pay special attention to note 8 of Table 310 regarding Ampacity Adjustment Factors when more than

2 Based on 75C copper wire. All wiring must conform to the National Electrical Code and all local codes.

3 These “Minimum Circuit Ampacity” values are to be used for sizing the field power conductors. Refer to the National Electrical code (latest version), Article 310 for power conductor sizing.

* Top outlet supply option is available only factory installed and only on the selected models.

IMPORTANT: While this electrical data is presented as a guide, it is important to electrically connect properly sized fuses and conductor wires in accordance with the National Electrical Code and all local codes.

Manual 2100-538E Page 21 of 23

TABLE 4

RECOMMENDED AIRFLOW

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VL/R3W001151.055-0011

VL/R5W007102.058-0071

VL/R6W007102.058-0071

* Rated CFM and ESP on high speed tap.

*MFC

TABLE 5

MAXIMUM ESP OF OPERATION

ELECTRIC HEAT ONLY

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Z0B60B90B-

Z0C90C21C-

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54.

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Values shown are for units equipped with standard 1-inch throwaway filter or 1-inch washable filter. Derate ESP by .15 for 2-inch pleated filters.

TABLE 6

ELECTRIC HEAT

sledoM1-V0421-V8023-V0423-V8023-V064

WKspmAHUTBspmAHUTBspmAHUTBspmAHUTBspmAHUTB

47.61056314.4104201

58.02560711.8100821

64.41005025.21063512.700502

83.33003728.8257402

97.12006037.81030328.0100703

016.14031432.6300652 21 4.4105904

515.26052150.45004832.63002152.13004830.8100215

813.34034165.7300164

022.38062861.2700215

Manual 2100-538E Page 22 of 23

TABLE 7

VENT & CONTROL OPTIONS

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51-CMC)esahP-1V032(tiKtratSXX

3-DAFBdradnatS-repmaDriAhserFcirtemoraBX

3-POBetalPffOknalBX

5-DAFBdradnatS-repmaDriAhserFcirtemoraBX

POBetalPffOknalBXX

W3R/LV

W5R/LV

W6R/LV

Manual 2100-538E Page 23 of 23

Bard W3RV1, W5LV1, W3LV1, W5RV1, W6LV1 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual