Bard WA121 User Manual

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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

Page

1 of 17

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

Manual

2100-234I

Page

2 of 17

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: (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, Refrigerating

and Air Conditioning Engineers, Inc.

1791 Tullie Circle, NE

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) 344-355

 

Fax: (617) 984-7057

Manufactured under the following U.S. patent numbers:

5,485,878; and 5,301,744

Manual 2100-234I

Page

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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

Manual 2100-234I

Page 4 of 17

UNIT DIMENSIONS

FIGURE 1

FACTORY BUILT AT 5 INCHES

Manual 2100-234I

Page

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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.

Manual 2100-234I

Page 6 of 17

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

Manual 2100-234I

Page

7 of 17

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.

Manual 2100-234I

Page 8 of 17

FIGURE 3

MOUNTING INSTRUCTIONS

Manual 2100-234I

Page

9 of 17

FIGURE 4

WALL MOUNTING INSTRUCTIONS

SEE FIGURE 3 - MOUNTING INSTRUCTIONS

FIGURE 5

WALL MOUNTING INSTRUCTIONS

SEE UNIT DIMENSIONS, FIGURE 1,

FOR ACTUAL DIMENSIONS

Manual 2100-234I

Page 10 of 17

FIGURE 6

COMMON WALL-MOUNTING INSTALLATIONS

Manual 2100-234I

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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

 

 

Manual 2100-234I

Page 12 of 17

FIGURE 7

LOW VOLTAGE WIRING

Manual 2100-234I

Page

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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.

Manual 2100-234I

Page 14 of 17

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.

Manual 2100-234I

Page

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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.

Manual 2100-234I

Page 16 of 17

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

 

 

 

Manual 2100-234I

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