Bard W70A1, W70L1, W42L, WALL MOUNTED PACKAGE AIR CONDITIONERS W42L User Manual

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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.

Manual :

2100-508A

Bryan, Ohio 43506

Supersedes:

2100-508

 

Since 1914...Moving ahead just as planned.

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

9

Figure 3C Mounting Instructions - W42, 48, 60, 70 ...

10

Figure 4

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

11

Figure 5

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

12

Figure 6

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

12

Figure 7

Common Wall Mounting Installations....

13

Figure 8

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

18

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: (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; 5,301,777; 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

MODEL NUMBER

CAPACITY

18 - 1½ Ton

24 - 2 Ton

30 - 2½ Ton

36 - 3 Ton

42 - 3½ Ton

48 - 4 Ton

60 - 5 Ton

70 - 6 Ton

REVISIONS

KW

VOLTS & PHASE

A - 230/208/60/1

B - 230/208/60/3

C - 460/60/3

A - Right Hand Air Conditioner

L - Left Hand Air Conditioner

VENTILATION OPTIONS

X - Barometric Fresh Air Damper (Standard)

B - Blank-offPlate

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)

X

X

X

X

X

A

 

 

 

 

 

 

CONTROLMODULES

 

 

 

 

 

 

(See Spec. Sheet S3397)

 

 

 

 

COIL OPTIONS

 

COLOR OPTIONS

X - Standard

 

X - Beige(Standard)

1

- PhenolicCoatedEvaporator

 

1

- White

 

2

- PhenolicCoatedCondenser

 

2

- Mesa Tan

3

- PhenolicCoatedEvaporator

 

4

- Buckeye Gray

 

 

andCondenser

 

5

- Desert Brown

 

 

 

 

6

- Dark Bronze

OUTLET OPTIONS

 

A - Aluminum

X - Front (Standard)

 

S - StainlessSteel

T - Top Outlet (W30A, W36A Only)

FILTER OPTIONS

X - One Inch Throwaway (Standard)

W - One Inch Washable

P - Two Inch Pleated

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

SHIPPING DAMAGE

Upon receipt of equipment, the carton should be checked for external signs of shipping damage. If damage is found, the receiving party must contact the last carrier immediately, preferably in writing, requesting inspection by the carrier’s agent.

GENERAL

The equipment covered in this manual is to be installed by trained, experienced service and installation technicians.

The refrigerant system is completely assembled and charged. All internal wiring is complete.

The unit is designed for use with or without duct work. Flanges are provided for attaching the supply and return ducts.

These instructions explain the recommended method to install the air cooled self-contained unit and the electrical wiring connections to the unit.

These instructions and any instructions packaged with any separate equipment required to make up the entire air conditioning system should be carefully read before beginning the installation. Note particularly “Starting Procedure” and any tags and/or labels attached to the equipment.

While these instructions are intended as a general recommended guide, they do not supersede any national and/or local codes in any way. Authorities having jurisdiction should be consulted before the installation is made. See Page 3 for information on codes and standards.

Size of unit for a proposed installation should be based on heat loss 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.

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.

FILTERS

A 1-inch throwaway filter is standard with each unit. The filter slides into position making it easy to service. This filter can be serviced from the outside by removing the filter access panel. A 1-inch washable filter and 2- inch pleated filter are also available as optional accessories. The internal filter brackets are adjustable to accommodate the 2-inch filter by bending two (2) tabs down on each side of the filter support bracket.

FRESH AIR INTAKE

All units are built with fresh air inlet slots punched in the service door.

If the unit is equipped with a fresh air damper assembly, the assembly is shipped already attached to the unit. The damper blade is locked in the closed position. To allow the damper to operate, the maximum and minimum blade position stops must be installed. See Figure 1.

All capacity, efficiency and cost of operation information is based upon the fresh air blank-off plate in place and is recommended for maximum energy efficiency.

The blank-off plate is available upon request from the factory and is installed in place of the fresh air damper shipped with each unit.

CONDENSATE DRAIN

A plastic drain hose extends from the drain pan at the top of the unit down to the unit base. There are openings in the unit base for the drain hose to pass through. In the event the drain hose is connected to a drain system of some type, it must be an open or vented type system to assure proper drainage.

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

FIGURE 1

FRESH AIR DAMPER

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.

4.Mount bottom mounting bracket.

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

WARNING

Failure to provide the 1/4 inch clearance between the supply duct and a combustible surface for the first 3 feet of duct can result in fire causing damage, injury or death.

6.Position unit in opening and secure with 5/16 lag bolts; use 7/8 inch diameter flat washers on the lag bolts.

7.Secure rain flashing to wall and caulk across entire length of top. See Figure 3.

8.For additional mounting rigidity, the return air and supply air frames or collars can be drilled and screwed or welded to the structural wall itself (depending upon wall construction). Be sure to observe required clearance if combustible wall.

9.On side-by-side installations, maintain a minimum of 20 inches clearance on right side to allow access to control panel and heat strips, and to allow proper airflow to the outdoor coil. Additional clearance may be required to meet local or national codes.

Clearances Required for Service Access and Adequate Condenser Airflow

MODELS

LEFT SIDE

RIGHT SIDE

W18A, W24A, W30A, W36A

15"

20"

W18L, W24L, W30L, W36L

20"

15"

W42A, W48A, W60A, W70A

20"

20"

W42L, W48L, W60L, W70L

20"

20"

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.

Minimum Clearances Required to Combustible Materials

MODELS

SUPPLY AIR DUCT

CABINET

FIRST THREE FEET

W18A, L / W24A, L

0"

0"

W30A, L / W36A, L

1/4"

0"

W42A, L / W48A, L

1/4"

0"

W60A, L / W70A, L

 

 

Manual

2100-508A

Page

6 of 25

FIGURE 2

Dimensions of Basic Unit for Architectural and Installation Requirements (Nominal)

MODEL

WIDTH

DEPTH

HEIGHT

SUPPLY

RETURN

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(W)

(D)

(H)

A

B

C

B

E

F

G

I

J

K

L

M

N

O

P

Q

R

S

T

W18A, L

33.300

17.125

70.563

7.88

19.88

11.88

19.88

35.00

11.00

25.75

20.56

26.75

28.06

29.25

27.00

2.63

34.13

22.06

10.55

4.19

12.00

5.00

W24A, L

W30A, L

38.200

17.125

70.563

7.88

27.88

13.88

27.88

40.00

11.00

25.75

17.93

26.75

28.75

29.25

27.00

2.75

39.19

22.75

9.14

4.19

12.00

5.00

W36A, L

W42A, L

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

W48A, L

42.075

22.432

84.875

9.88

29.88

15.88

29.88

43.88

13.63

31.66

30.00

32.68

26.94

34.69

32.43

3.37

42.88

23.88

10.00

2.00

16.00

1.88

W60A, L

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

W70A, L

42.075

22.432

94.875

9.88

29.88

15.88

29.88

43.88

13.63

41.66

30.00

42.68

36.94

44.69

42.43

3.37

42.88

33.88

10.00

2.00

16.00

1.88

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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

 

 

 

 

 

 

 

 

E

 

 

 

W**A

 

 

 

D

 

 

 

O

 

 

 

 

 

Built In

2

 

 

 

 

2

 

 

 

 

 

7.88

 

 

 

31.88

 

 

 

 

 

 

Rain Hood

 

2

 

 

 

 

RIGHT

 

W

 

1.00

 

 

 

.44

 

 

4° Pitch

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

UNIT

 

 

Heater

 

2.13

 

 

 

 

 

 

 

 

 

Access

 

 

 

 

 

 

R

 

 

 

 

 

 

Side Wall

 

 

 

 

 

 

Panel

 

 

 

 

 

 

 

 

 

 

A

 

Supply Air Opening

 

 

 

 

 

 

 

Mounting

 

 

 

 

Electric

 

 

 

 

 

 

 

 

 

 

 

 

Brackets

 

 

 

 

 

 

 

Heat

 

 

 

(Built In)

 

 

 

S

 

 

 

 

 

 

 

 

B

 

 

 

 

 

C. Breaker/

 

 

 

 

 

 

 

 

 

 

 

I

 

 

 

 

 

 

 

 

 

Disconnect

 

 

 

 

 

 

 

 

 

 

 

 

 

Top Rain

 

 

 

 

 

 

 

Access Panel

 

 

 

 

 

 

 

 

 

 

(Lockable)

 

 

 

Flashing

 

 

 

S

 

 

 

 

 

 

 

Shipping

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Filter Access

 

 

 

Location

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Panel

 

 

 

 

 

 

 

 

 

5.75

 

Vent Option

 

 

 

Optional

 

 

 

 

 

 

 

 

C

H

Return Air Opening

S

 

 

 

Door

 

Electrical

 

 

 

 

 

 

 

Entrances

 

 

 

 

 

F

 

Ventilation

 

 

 

 

 

 

 

 

 

 

Air

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Low Voltage

 

 

 

 

 

 

 

S 1

 

 

 

Electrical

 

 

 

 

 

 

 

 

 

 

 

Entrance

 

K

 

 

 

 

 

 

 

 

 

 

Cond.

 

 

 

 

 

 

 

G

Condenser

High Voltage

J

 

L

 

 

 

 

 

 

Electrical

Air

 

M

 

 

 

1

 

 

Air Outlet

Entrance

Inlet

 

 

P

 

 

 

S

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

T

 

 

Front View

 

Side View

Drain

 

N

Back View

Bottom Installation

 

 

 

 

 

 

 

 

 

 

 

 

Q

 

 

Bracket

MIS-2487 B

 

 

 

 

 

 

 

 

 

 

1Dimension is 21.00 inches on W70A & W70L models.

2Optional top outlet (factory installed only) for W30A and W36A models only.

W**L LEFT UNIT

 

E

 

 

 

Built In

 

 

O

 

 

 

 

 

 

 

 

Rain Hood

 

 

.44

 

 

D

4° Pitch

W

 

 

 

 

 

 

 

 

 

 

 

 

 

2.13

 

Electric

 

R

 

 

 

Heat

 

Supply Air Opening

Side Wall

 

 

Heater

 

 

A

 

 

 

Mounting

 

 

 

 

 

Access

 

 

 

Brackets

 

 

 

S

 

 

 

Panel

 

 

(Built In)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

C. Breaker/

 

 

 

 

 

 

 

 

Disconnect

 

 

 

 

 

Top Rain

I

 

Access Panel

 

 

 

 

 

 

 

(Lockable)

 

 

 

 

 

Flashing

 

 

 

 

S

 

 

 

 

 

 

 

 

 

Shipping

 

 

 

 

 

 

 

 

 

 

Filter Access

 

 

 

 

 

Location

 

 

 

 

 

 

 

 

 

 

Panel

 

 

 

 

 

Optional

 

 

Ventilation

 

5.75

 

 

 

C

 

Air

 

S

Return Air Opening

 

 

 

Electrical

 

 

Vent Option

 

 

 

 

 

Entrances

 

 

 

 

 

 

 

 

 

Door

 

 

 

 

 

 

 

 

 

F

 

 

 

 

 

 

 

 

1

 

 

 

H

 

Low Voltage

 

 

S

 

 

 

 

 

 

 

 

 

 

 

Electrical

 

 

 

 

 

 

 

 

 

 

 

 

 

L

K

 

Entrance

 

 

 

 

 

 

 

 

 

 

 

 

M

 

Cond.

High Voltage

Condenser

G

 

 

 

J

Air

Electrical

1

 

 

 

S

 

 

P

Entrance

Air Outlet

 

 

 

 

Inlet

 

 

 

 

 

 

 

 

 

T

 

 

 

 

 

 

 

 

Drain

Bottom

Back View

2.63

 

Side View

 

Front View

MIS-2488 B

 

 

 

 

 

 

 

Installation

 

9.06

 

 

 

 

 

 

Bracket

 

 

 

 

 

 

 

Manual

2100-508A

Page

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Page

Manual

25 of 8

508A-2100

3 1613 "

 

7 161 "

 

20"

7 161 "

 

 

 

Supply Opening

8"

 

 

 

 

12"

 

 

 

 

 

12"

 

 

 

 

20 21 "

 

 

 

 

 

12"

 

 

Return Opening

12"

12"

 

 

 

20"

 

 

 

 

 

 

12"

 

3"

 

3

81 "

7

"

1"

4"

1"

 

8

 

Typ.

5"

 

 

 

 

 

 

 

4"

 

 

 

 

Typ.

 

 

 

 

2"

 

2"

 

FIGURE 3A

W18A1, W18L1, W24A1, W24L1 MOUNTINGINSTRUCTIONS

SEAL WITH BEAD

OF CAULKING ALONG

ENTIRE LENGTH OF TOP.

TOP

WALL

HEATER ACCESS

PANEL

RAIN FLASHING

SUPPLIED

FOAM AIR SEAL

WALL STRUCTURE

1/4" CLEARANCE ON ALL FOUR SIDES OF SUPPLY AIR DUCT IS REQUIRED FROM COMBUSTABLE MATERIALS

SUPPLY AIR

DUCT

RETURN AIR

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**A UNIT SHOWN, W**L UNIT

CONTROLS AND HEATER ACCESS

IS ON OPPOSITE (LEFT) SIDE.

Wall Opening and Hole Location View

Right Side View

MIS-353 C

+ 17 hidden pages