Bard WA3S1, WA4S1, WA5S1 Installation Instructions Manual

INSTALLATION

WALL MOUNTED PACKAGED
AIR CONDITIONER

INSTRUCTIONS

Models:

WA3S1
WA4S1
WA5S1

THIS IS AN R-410A

REFRIGERANT SYSTEM

Bard Manufacturing Company, Inc.
Bryan, Ohio 43506

Since 1914...Moving ahead, just as planned.

NOTE

HIGH PRESSURE

Manual No.: 2100-451E
Supersedes: 2100-451D
File: Volume III, Tab 16
Date: 09-02-08

Manual 2100-451E
Page 1 of 24

CONTENTS

Getting Other Information and Publications

For more information contact these publishers........ 3

Wall Mount General Information

Air Conditioner Wall Mount Model Nomenclature.... 4

Shipping Damage .................................................... 7

General ............................................................... 7

Duct Work ............................................................... 7

Filters ............................................................... 7

Condensate Drain.................................................... 7

Installation Instructions

Wall Mounting Information....................................... 8

Mounting the Unit .................................................... 8

Typical Installations ................................................. 8

Wiring – Main Power ....................................... 8 & 9

Wiring – Low Voltage Wiring ............................... 12

Start Up

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

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

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

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

Crankcase Heaters................................................ 15

High & Low Pressure Switch ................................. 15

Three Phase Scroll Compressor Start Up

Information............................................................. 15

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

Sequence of Operation.......................................... 16

Blower Time Delay Disable.................................... 16

Compressor Control Module.................................. 16

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

Phase Monitor ....................................................... 17

Motor Start Device ................................................. 17

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

Troubleshooting

Compressor Solenoid ............................................ 18

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

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

R-410A Refrigerant Charge ................................... 19

Pressure Chart ...................................................... 22

GE ECM™Motors................................................... 21

GE ECM™Motors................................................... 22

Optional Accessories ............................................. 24

Figures

Figure 1 Unit Dimensions..................................... 5

Figure 2 Mounting Instructions............................. 9

Figure 3 Wall-Mounting Instructions .................. 10

Figure 4 Wall-Mounting Instructions .................. 10

Figure 5 Common Wall-Mounting Instructions ....11

Figure 6 Electric Heat Clearance ....................... 12

Figure 7 Low Voltage Wiring.............................. 13

Figure 8 Start-Up Label...................................... 15

Figure 9 Fan Blade Setting ................................ 18

Figure 10 Control Disassembly............................ 22

Figure 11 Winding Test ........................................ 22

Figure 12 Drip Loop ............................................. 22

Tables

Table 1 Electric Heat Table ................................. 4

Table 2 Dimensions of Basic Unit....................... 5

Table 3 Electrical Specifications ......................... 6

Table 4 Operating Voltage Range .................... 12

Table 5 Thermostat Wire Size .......................... 12

Table 6 Wall Thermostats................................. 12

Thermostatic Control - Dual Unit.......... 12

Table 7 Fan Blade Dimensions......................... 18

Table 8 Liquid Line Temperatures .................... 19

Table 9 Cooling Pressure ................................. 20

Table 10 Indoor Blower Performance ................. 23

Table 11 Maximum ESP of Operation

Electric Heat Only ................................ 23

Table 12 Optional Accessories ........................... 24

Manual 2100-451E
Page 2 of 24

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 or

Residential Winter and Manual N
Summer Air Conditioning

Low Pressure, Low Velocity..........ACCA Manual D or

Duct System Design for Winter Manual Q
and Summer Air Conditioning

FOR MORE INFORMATION, CONTACT
THESE PUBLISHERS:

ACCA Air Conditioning Contractors of America

1712 New Hampshire Ave. N.W.
Washington, DC 20009
Telephone: [phone]
Fax: [phone]

ANSI American National Standards Institute

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

ASHRAE American Society of Heating Refrigerating,

and Air Conditioning Engineers, Inc.

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

NFPA National Fire Protection Association

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

Manual 2100-451E
Page 3 of 24

WALL MOUNT GENERAL INFORMATION

AIR CONDITIONER WALL MOUNT MODEL NOMENCLATURE

WA 4S 1 – B 09 B P X X X X

MODEL NUMBER

CAPACITY

3S – 3 Ton
4S – 4 Ton
5S – 5 Ton

VOLTS & PHASE

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

KW

0Z – No KW

05 – 5 KW
06 – 6 KW
08 – 8 KW
09 – 9 KW
10 – 10 KW
15 – 15 KW
20 – 20 KW

REVISION

w/Circuit Breaker
or Pull Disconnect

VENTILATION OPTIONS

B – Blank-off Plate(Standard)
V – Commercial Room Ventilator -

Motorized with Exhaust
(3-Position)

E – Economizer (Internal) - Fully

Modulating with Exhaust

R – Energy Recovery Ventilator -

with Exhaust

CONTROL MODULES

COIL OPTIONS

X – Standard

OUTLET OPTIONS

X – Front (Standard)

COLOR OPTIONS

X – Beige

(Standard)
4 – Buckeye Gray
5 – Desert Brown
8 – Dark Bronze

FILTER OPTIONS

P – Two Inch Pleated

NOTE: For 0KW and circuit breakers (230/208 V) or pull disconnects (460 V) applications, insert 0Z in the KW field of model number.

TABLE 1

ELECTRIC HEAT TABLE

lanimoN

WK

wKspmAhP-1spmAhP-3hutBwKspmAhP-1spmAhP-3hutBwKspmAhP-3hutBwKspmAhP-3hutB

0.50.58.02560,7157.30.81997,21

0.60.64.41874,0205.45.21953,510.62.7874,0225.59.6048,81

0.80.83.33403,7200.68.82874,02

0.90.97.12717,0357.67.81830,320.98.01717,0382.84.01062,82

0.010.017.14031,4305.71.63895,52

0.510.515.261.63591,1552.111.452.13693,830.510.81591,158.313.71990,74

0.020.023.38062,8600.511.27591,15

)1(V042tA)1(V802tA)2(V084tA)2(V064tA

.ylnostinuV802/032nielbaliavaerasretaehcirtceleesehT)1(

.ylnostinuV084nielbaliavaerasretaehcirtceleesehT)2(

See Table 3 for Heater Availability by Model

Manual 2100-451E
Page 4 of 24

88.11S4AW

00.61

00.01

88.32

73.388.24

86.2349.6296.4334.23

00.03

66.13

TABLE 2

FIGURE 1

UNIT DIMENSIONS

EFGI JKLMNOPQSTABCB

ylppuSnruteR

88.988.9288.5188.9288.3401.91

thgieH

578.48

H

htpeD

DIMENSIONS OF BASIC UNIT FOR ARCHITECTURAL AND INSTALLATION REQUIREMENTS (NOMINAL)

D

578.4966.1486.2449.6396.4434.2488.3300.12

htdiW

W

tinU

570.24234.22

1S3AW

1S5AW

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

Manual 2100-451E

Page 5 of 24

eriW

2 dnuorG

eziSeriW

rewoP

2 dleiF

01010101

010101

01

6

01010101

010101

601

01

6

601

01010101

010101

01

6

601

888

esuFlanretxE

.rkrB.tkCro

03060603

1 mumixaM

545454

yticapmA

tiucriC

3 muminiM

A.tkC B.tkC C.tkC A.tkC B.tkC C.tkC A.tkC B.tkC C.tkC A.tkC B.tkC C.tkC

TABLE 3

ELECTRICAL SPECIFICATIONS

eriW

2 dnuorG

eziSeriW

rewoP

tiucriCelgniS tiucriCelpitluM

2 dleiF

esuFlanretxE

.rkrB.tkCro

1 mumixaM

62252562

535353

010101

886

88663

060709

54

54

2

511

010101

01

01

03

030406

888

03060603

545454

62252562

737373

01

41

41

21

01

010101

41

41

21

8

6

01

88643

51

51

02

03

060709

54

54

886

2

021

010101

01

01

040404

01

212101

01

212101

020252

01

03

8

6

06

888

03060603

050505

62252562

444444

010101

886

88663

0505060709

2

021

010101

888

040404

01

6

06

010101

010101

525252

01

01

03

yticapmA

tiucriC

3 muminiM

dleiF.oN

stiucriC

rewoP

esahPdna

detaR

stloV

ledoM

Manual 2100-451E
Page 6 of 24

135315

111

Z0A-1S3AW

50A-

311

16

327263

78

2ro1

2ro1

3ro1

111

1-802/032

Z0B-1S3AW

80A-

01A-

60B-

02A-

51A-

5.31

21

91

55

1

3-802/032

90B-

51B-

111

3-064

Z0C-1S3AW

60C-

82

1

90C-

51C-

8383353698

111

Z0A-1S4AW

50A-

511

829283

2ro1

2ro1

3ro1

111

1-802/032

80A-

01A-

3-802/032

Z0B-1S4AW

02A-

60B-

51A-

90B-

65

1

51B-

51

61

111

3-064

Z0C-1S4AW

60C-

12

03

44

44

1

111

Z0A-1S5AW

90C-

51C-

50A-

353698

2ro1

1-802/032

80A-

01A-

511

43

43

83

2ro1

3ro1

111

3-802/032

Z0B-1S5AW

02A-

60B-

51A-

90B-

65

1

51B-

71

71

111

3-064

Z0C-1S5AW

60C-

12

03

1

CAUTION: When more than one filed power conductor circuit is run through one conduit, the conductors must be derated.

90C-

51C-

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 the National Electric Code (NEC) and all local codes.

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

conductor sizing.

Pay special attention to Note * of Table 310 regarding Ampacity Adjustment Factors when more than 3 conductors are in a raceway.

123

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.

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 1-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.

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.

CAUTION

Some installations may not require any return
air duct. A 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 inches.

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.

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.

Any grille that meets the 5/8 inch louver criteria, may be
used. It is recommended that Bard Return Air Grille Kit
RG-5 or RFG-5 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 2-inch pleated 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. The internal filter brackets are adjustable
to accommodate the 1-inch filter by bending up the tabs
to allow spacing for the 1-inch filters.

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.

Manual 2100-451E

Page 7 of 24

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. See
Figures 4 and 5.

WARNING

Fire hazard can result if 1/4 inch clearance to
combustible materials for supply air duct is
not maintained. See Figure 3.

3. Concrete block walls must be thoroughly inspected
to insure that they are capable of carrying the weight
of the installing unit. See Figure 4.

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 is provided
for ease of installation.

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. If a combustible
wall, use a minimum of 30-1/2" x 10-1/2"
dimensions for sizing. However, it is generally
recommended that a 1-inch clearance is used for ease
of installation and maintaining the required
clearance to combustible material. The supply air
opening would then be 32" x 12". See Figures 2, 3
and 6 for details.

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.

3. Locate and mark lag bolt locations and bottom
mounting bracket location. See Figure 4.

4. Mount bottom mounting bracket.

5. Hook top rain flashing under back bend of top. Top
rain flashing is shipped secured to the right side of
the back.

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 2.

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 heat strips and control panel and to allow proper
airflow to the outdoor coil. Additional clearance
may be required to meet local or national codes.

TYPICAL INSTALLATIONS

See Figure 5 for common ways to install the wall mount
unit.

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 (75ºC
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.

Manual 2100-451E
Page 8 of 24