Bard WA121 User Manual

INSTALLATION INSTRUCTIONS

WALL MOUNTED

PACKAGE AIR CONDITIONERS

Model:

WA121

	Bard Manufacturing Company, Inc.	Manual :	2100-234I
	Bryan, Ohio 43506	Supersedes:	2100-234H
	Since 1914....Moving ahead just as planned.	File:	Volume III Tab 16
		Date:	08-01-07

© Copyright 2002

Manual 2100-234I

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CONTENTS

Getting Other Informations and Publications	3	Start Up
		Important Installer Note ..........................................	14
Wall Mount General Information		Service Hints ..........................................................	14
Air Conditioner Wall Mount Model Nomenclature	..... 4	High Pressure Switch .............................................	14
Shipping Damage .....................................................	6	Sequence of Operation...........................................	14
General .....................................................................	6	Compressor Control Module ...................................	14
Duct Work .................................................................	7	Adjustments ............................................................	15
Filters ........................................................................	7	Pressure Service Ports ...........................................	15
Fresh Air Intake ........................................................	7
Condensate Drain.....................................................	7	Troubleshooting
		Fan Blade Setting Dimension .................................	16
Installation Instructions		Refrigerant Charge .................................................	16
Wall Mounting Information ........................................	8	Pressure Tables ......................................................	17
Mounting the Unit .....................................................	8	Option Field Installed Accessories..........................	17
Wiring – Main Power ..............................................	12
Wiring – Low Voltage Wiring ..................................	12

	Figures			Tables
	Figure 1	Unit Dimensions......................................	5	Table 1	Electric Heat Table	4
	Figure 2	Blower Damper Assembly	7
				Table 2	Electrical Specifications	6
	Figure 3	Mounting Instructions	9
				Table 3	Thermostat Wire Size	12
	Figure 4	Wall Mounting Instructions	10
				Table 4	Wall Thermostats	12
	Figure 5	Wall Mounting Instructions	10
				Table 5	Fan Blade Dimensions	16
	Figure 6 Common Wall Mounting
				Table 6	Suction Line Temperatures	16
		Instructions	11
				Table 8	Recommended Operating Ranges	16
	Figure 7	Low Voltage Wiring	13
				Table 7	Indoor Blower Performance	16
	Figure 8 Fan Blade Setting Dimensions		16
				Table 9	Maximum ESP of Operation
					Electric Heat Only .................................	16
				Table 10	Pressure Table - Cooling ......................	17
				Table 11	Optional Accessories ............................	17

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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 of ..........	ANSI/NFPA 90A
Air Conditioning and
Ventilating Systems
Standard for Warm Air Heating ........	ANSI/NFPA 90B
and Air Conditioning Systems
Load Calculation for ............................	ACCA Manual J
Residential Winter and
Summer Air Conditioning
Duct Design for .................................	ACCA Manual D
Residential Winter and
Summer Air Conditioning
and Equipment Selection

For more information, contact these publishers:

ACCA	Air Conditioning Contractors of America
	1712 New Hampshire Avenue NW
	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, Refrigerating

and Air Conditioning Engineers, Inc.

1791 Tullie Circle, NE

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; and 5,301,744

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WALL MOUNT GENERAL INFORMATION

AIR CONDITIONER WALL MOUNT MODEL NOMENCLATURE

MODEL NUMBER

CAPACITY

12 - 1 Ton

WA 12 1 – A 00 X X X X X J

CONTROL MODULES

E - Low Ambient Control

J - Telecommunication

	REVISIONS					COIL OPTIONS
				COLOR OPTIONS		X - Standard Coils
		KW		X - Beige
	VOLTS & PHASE			4 - Buckeye Gray
		00	- No KW
	A - 230/208/60/1			VENTILATION OPTIONS	OUTLET OPTIONS
		02	- 2.2 KW	X - Barometric Fresh Air
	K - 115/60/1
		03	- 3.6 KW		X -	Front
				Damper (Standard)
		05	- 5.0 KW
				B - Blank-off Plate
				E - Economizer (Internal) - Fully FILTER OPTIONS

Modulating with Exhaust	X - One Inch Throwaway
	(Standard)
	P - Two Inch Pleated

TABLE 1

ELECTRIC HEAT TABLE

Models		WA121-A			WA121-K			WA121-G
	240V		208V		120V		240V		220V
		1		1		1		1		1
KW	A	BTU	A	BTU	A	BTU	A	BTU	A	BTU
02					18.3	7,985	10.0	8,665	9.1	7,300
03	15.0	12,760	13.0	9,705			15.0	12,760	13.8	10,800
05	20.8	17,540	18.1	13,275

1 With blower watts included

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UNIT DIMENSIONS

FIGURE 1

FACTORY BUILT AT 5 INCHES

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TABLE 2

ELECTRICAL HEAT SPECIFICATIONS

SINGLE CIRCUIT

				3	1	2	2
		Rated Volts	No. Field		Maximum
				Minimum	External Fuse
		and	Power	Circuit	or Circuit	Field Power	Ground
	Models	Phase	Circuits	Ampacity	Breaker	Wire Size	Wire Size
	WA121-A00		1	8	15	14	14
	A03	230/208-1	1	20	20	12	12
	A05		1	27	30	10	10
	WA121-K00	115-1	1	17	25	10	10
	K02		1	25	30	10	10
	WA121-G00		1	7	15	14	14
	G02	220-50-1	1	13	15	14	14
	G03		1	20	20	12	12

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

Based on 75° C copper wire. All wiring must conform to NEC and all local codes.

These “Minimum Circuit Ampacity” values are to be used for sizing the field power conductors. Refer to the National Electrical Code (latest revision), article 310 for power conductor sizing.

CAUTION: When more than one field power conductor 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 3 conductors are in a raceway.

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 air 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.

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DUCT WORK

All duct work, supply and return must be properly sized for the design air flow 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 Table 9 for maximum static pressure available for duct design.

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.

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. It is recommended that on this type of installation that a filter grille be located in the wall. 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 one inch throwaway filter is supplied with each unit. The filter slides into position making it easy to service. This filter can be serviced from the outside by removing the service door. A 2-inch pleated filter is also available as an optional accessory. The internal filter brackets are adjustable to accommodate the 2-inch filter by bending the metal tabs holding the 1-inch filter down. There are two tabs on each side of the filter.

FRESH AIR INTAKE

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

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 2.

All capacity, efficiency and cost of operation information as required for Department of Energy “Energyguide” Fact Sheets 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

This unit employs an automatic condensate disposal system consisting of a base drain pan, drain valve and fan blade with slinger ring. A plastic drain hose extends from the evaporator drain pain at the top of the unit to the base drain pan at the bottom. At temperatures above 40°, the drain valve located between the condenser coil and fan shroud is closed allowing water to build up in the base to a height of 5/8" to 3/4". The fan blade with slinger then rotates in this water and throws the water onto the condenser coil. This disposes of the water by evaporating it on the hot condenser.

At temperatures below 40°, the drain valve opens draining the base pan and preventing freeze ups that could damage the coil or fan blade.

FIGURE 2

FRESH AIR DAMPER

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INSTALLATION INSTRUCTIONS

WALL MOUNTING INFORMATION

1.These units are secured by wall mounting brackets which secure the unit to the outside wall surface at both sides.

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

NOTE: If the combination SUPPLY / RETURN Grille Assembly model CRSG-1 is to be used in conjunction with this unit a different size wall opening is required.

2.Locate and mark lag bolt locations, if desired. See Figure 3.

3.Hook top rain flashing under back bend of top. Top rain flashing is shipped attached to the back of the unit on the right side.

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

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

6.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.

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

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FIGURE 3

MOUNTING INSTRUCTIONS

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FIGURE 4

WALL MOUNTING INSTRUCTIONS

SEE FIGURE 3 - MOUNTING INSTRUCTIONS

FIGURE 5

WALL MOUNTING INSTRUCTIONS

SEE UNIT DIMENSIONS, FIGURE 1,

FOR ACTUAL DIMENSIONS

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FIGURE 6

COMMON WALL-MOUNTING INSTALLATIONS

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WIRING – MAIN POWER

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” of “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.

WIRING – LOW VOLTAGE WIRING

230/208, 1 phase equipment use 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).

Five (5) wires should be run from thermostat subbase to the 24V terminal board in the unit. A five conductor, 18 gauge copper, color-coded thermostat cable is recommended. The connection points are shown in Figure 7.

TABLE 3

THERMOSTAT WIRE SIZE

Transformer			Maximum Distance
VA	FLA	Wire Gauge	in Feet
		20 Gauge	45
		18 Gauge	60
40	2.3	16 Gauge	100
		14 Gauge	160
		12 Gauge	250

		TABLE 4
		WALL THERMOSTAT
	Thermostat	Predominate Features
	8403-057	1 stage Cool, 1 stage Heat
		Electronic Non-Programmable
	TH5220D1153
		Auto or Manual changeover
	8403-058	2 stage Cool, 2 stage Heat
		Electronic Non-Programmable
	TH5220D1151
		Auto or Manual changeover
		3 stage Cool; 3 stage Heat
	8403-060	Programmable/Non-Programmable Electronic
	(1120-445)	HP or Conventional
		Auto or Manual changeover

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FIGURE 7

LOW VOLTAGE WIRING

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START UP

IMPORTANT INSTALLER NOTE

For improved start up performance, wash the indoor coil with a dishwasher detergent.

SERVICE HINTS

1.Caution owner 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 operation costs.

2.The unit is equipped with a high pressure cut out switch.

3.Check all power fuses or circuit breakers to be sue they are the correct rating.

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

HIGH PRESSURE SWITCH

The WA121 models are supplied with a remote reset high pressure switch. If tripped, this pressure switch may be reset by turning the thermostat off then back on again.

SEQUENCE OF OPERATION

COOLING – Circuit R-Y makes at thermostat pulling in compressor contactor, starting the compressor and outdoor motor. The G (indoor motor) circuit is automatically completed on any call for cooling operation or can be energized by manual fan switch on subbase for constant air circulation. On a call for heating, circuit R-W1 make at the thermostat pulling in heat contact for the strip heat and blower operation.

COMPRESSOR CONTROL MODULE

The compressor control module is optional on the models covered by this manual. The compressor control 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 any time 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 if employed) is closed, the compressor contactor is energized. Upon shutdown the delay on break time 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 that 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 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 or heat pump unit model. The lockout features, both soft and manual, are a function of the Compressor Control Module.

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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 of Make (DOM) timing on power up and after power interruptions is equal to 2 minutes plus 10% of Delay of 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 not delay.

Typical Settings for Dual Unit Installation:

Unit No. 1: DOB set at 2 minutes, and DOM is 132 seconds.

Unit No. 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. Pressure chart can be found later in the manual covering all models. It is imperative to match the correct pressure chart to the unit by model number.

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TROUBLESHOOTING

FAN BLADE SETTING DIMENSIONS

Show in Figure 8 is the correct fan blade setting dimension for proper air delivery across the outdoor coil.

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

FIGURE 8

FAN BLADE SETTING DIMENSION

TABLE 5

FAN BLADE DIMENSION

Model Dimension A

WA121 1/2"

REFRIGERANT CHARGE

The correct system R-22 charge is shown on the unit rating plate. Optimum unit performance will occur with a refrigerant charge resulting in a suction line temperature 6" from compressor as shown in Table 6.

TABLE 6

SUCTION LINE TEMPERATURE

	Rated	95o OD	82o OD
Model	Airflow	Temperature	Temperature
WA121	400	54 - 56	65 - 67

The suction line temperatures in Table 6 are based upon 80° F dry bulb / 67° F wet bulb (50% R.H.) temperature and rated airflow across the evaporator during cooling cycle.

TABLE 7

INDOOR BLOWER

PERFORMANCE

CFM @ 230V

	WA121
E.S.P.	230V
in H2O	Dry /		Wet
.0	530	/	500
.1	485	/	460
.2	440	/	425
.3	390	/	375
.4	325	/	300

TABLE 8

RATED CFM AND ESP

RECOMMENDED AIRFLOW RANGE

	Rated	Rated	Recommended
Model	CFM*	ESP*	Airflow Range
WA121	400	.25	500 - 300

* Rated CRM and ESP on high speed tap.

TABLE 9

MAXIMUM ESP OF OPERATION

ELECTRIC HEAT ONLY

Model	ESP
WA121-A00	.35
A03	.35
A05	.35
WA121-K00	.35
K02	.35
WA121-G00	.35
G02	.35
G03	.35

Values shown are for units equipped with STD 1" throwaway filters. Derate ESP by .15 for 2" pleated filters.

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TABLE 10

PRESSURE TABLE

COOLING				Air Temperature Entering Outdoor Coil oF
	Return Air
Model	Temperature	Pressure	75o	80o	85o	90o	95o	100o	105o		100o	115o
	75 deg. DB	Low Side	72	74	76	79	81	83	86		88	91
	62 deg. WB	High Side	187	201	216	232	248	265	282		300	319
WA121	80 deg. DB	Low Side	76	79	82	84	87	90	92		95	97
	67 deg. WB	High Side	192	207	222	238	255	272	290		309	328
	85 deg. DB	Low Side	81	85	88	91	94	97	99		102	104
	72 deg. WB	High Side	198	214	230	247	264	282	300		319	339

TABLE 11

OPTIONAL FIELD INSTALLED ACCESSORIES

Model Description

WA121

BOP-1A	Blank Off Plate	X
BFAD-1	Barometric Fresh Air Damper	X
EIFM-1	Economizer with Exhaust	X
CMA-6	Low Ambient Control	X
CMA-20	LPC + TDR + LAC	X

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