Bard WA Series Wall Mount Air Conditioner Instruction Manual
- June 12, 2024
- Bard
Table of Contents
Bard WA Series Wall Mount Air Conditioner
Specifications
- Product: 11EER WA Series Wall Mount Air Conditioner
- Models: W42AY-A, W48AY-A, W60AY-A, W72AY-A, W42AY-B, W48AY-B, W60AY-B, W72AY-B, W42AY-C, W48AY-C, W60AY-C, W72AY-C, W42AYRC, W48AYRC, W60AYRC, W72AYRC, W42AYDA, W48AYDA, W60AYDA, W72AYDA, W42AYDB, W48AYDB, W60AYDB, W72AYDB, W42AYDC, W48AYDC, W60AYDC, W72AYDC
- Manufacturer: Bard Manufacturing Company, Inc.
- Website: www.bardhvac.com
- Manual: 2100-787A
- Supersedes: 2100-787
Product Usage Instructions
Safety Instructions
Read all safety instructions before using the product. Your safety and the safety of others are crucial. Follow all safety messages provided in the manual and on the appliance.
General Information
- Shipping Damage: Check for any shipping damage before installation.
- Air Conditioner Wall Mount Model Nomenclature: Refer to the model nomenclature for specific model details.
Duct Work
- Ensure proper duct work is in place for efficient operation.
Filters
- Filter Removal/Installation: Follow the instructions provided to remove and install filters.
- Switching Filter Sizes: If needed, switch between different filter sizes as per instructions.
Fresh Air Intake
- Follow the guidelines for fresh air intake to maintain optimal air quality.
FAQ
- Q: How do I check for shipping damage?
- A: Before installation, carefully inspect the product for any signs of shipping damage such as dents or scratches.
- Q: Can I switch between different filter sizes?
- A: Yes, you can switch between different filter sizes following the provided instructions in the manual.
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IMPORTANT SAFETY INSTRUCTIONS
READ ALL INSTRUCTIONS BEFORE USE Your safety and the safety of others are very
important.
We have provided many important safety messages in this manual and on your
appliance. Always read and follow all safety messages.
ANSI Z535.5 Definitions:
DANGER: Indicate[s] a hazardous situation which, if not avoided, will
result in death or serious injury. The signal word “DANGER” is to be limited
to the most extreme situations. DANGER [signs] should not be used for property
damage hazards unless personal injury risk appropriate to these levels is also
involved. WARNING: Indicate[s] a hazardous situation which, if not avoided,
could result in death or serious injury.
WARNING: [signs] should not be used for property damage hazards unless
personal injury risk appropriate to this level is also involved.
CAUTION: Indicate[s] a hazardous situation which, if not avoided, could
result in minor or moderate injury. CAUTION [signs] without a safety alert
symbol may be used to alert against unsafe practices that can result in
property damage only.
NOTICE: [this header is] preferred to address practices not related to
personal injury. The safety alert symbol shall not be used with this signal
word. As an alternative to “NOTICE” the word “CAUTION” without the safety
alert symbol may be used to indicate a message not related to personal injury.
IMPORTANT SAFETY INSTRUCTIONS
WARNING
To reduce the risk of explosion, fire, death, electric shock, scalding or injury to persons when using this product, follow basic precautions, including the following:
GENERAL
· The equipment covered in this manual is to be installed by trained,
experienced service and installation technicians.
· This appliance is not intended for use by persons (including children) with
reduced physical, sensory or mental capabilities, or lack of experience and
knowledge, unless they have been given supervision or instruction concerning
use of the appliance by a person responsible for their safety.
· 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
Additional Publications 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.
INSTALLATION
· This product is not intended for use at altitudes exceeding 2,000 meters
(6,561 feet). For appliances intended for use at altitudes exceeding 2 000 m
(6,561 feet), the maximum altitude of use shall be stated.
· Before use, the appliance must be properly installed as described in this
manual. · Contact the authorized service technician for repair or maintenance
of this unit. · Contact the installer for installation of this unit. · The air
conditioner is not intended for use by young children or invalids without
supervision. · Young children should be supervised to ensure that they do not
play with the air conditioner. · Installation work must be performed in
accordance with the National Electric Code by qualified and authorized
personnel only. · Connect to a properly rated, protected, and sized power
circuit to avoid electrical overload. · Adhere to all industry recommended
safety procedures including the use of long-sleeved gloves and safety glasses.
· Use care when unpacking and installing. The edges of the product may be
sharp. · Keep packaging materials out of the reach of children. These
materials can pose a suffocation risk to children.
OPERATION
· This appliance is not intended for use by persons (including children) with
reduced physical, sensory, or mental capabilities, or lack of experience and
knowledge, unless they have been given supervision or instruction concerning
use of the appliance by a person responsible for their safety.
· Use this appliance only for its intended purpose. · Never attempt to operate
this appliance if it is damaged, malfunctioning, partially disassembled, or
has missing or broken parts. · Do not tamper with controls.
General
The equipment covered in this manual is to be installed by trained,
experienced service and installation technicians.
This appliance is not intended for use by persons (including children) with
reduced physical, sensory or mental capabilities, or lack of experience and
knowledge, unless they have been given supervision or instruction concerning
use of the appliance by a person responsible for their safety.
Children should be supervised to ensure that they do not play with the
appliance.
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
following section 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.
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.
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.
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″ 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.
All model series require a 1/4″ clearance to combustible material for the
first 3′ of duct attached to the outlet air frame is required.
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 a 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″.
Any grille that meets with 5/8″ louver criteria may be used. It is recommended
that Bard Return Air Grille Kits RG5 or 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.
INSTALLATION
Basic Installation Design and Application Planning
Successful unit installations require proper planning and site inspection before installation begins. Before installing the wall mount unit, make sure that all service and airflow clearances are met and that the unit can meet all applicable code and regulation requirements. Provide an inspection of both the inside and outside of the structure by reviewing floorplans and/or visiting the installation site.
Wall Construction
The wall must be inspected to ensure that the weight of the unit can be supported. Be sure to review all applicable construction codes and regulations including seismic requirements. When inspecting wood frame walls, the wall construction must be strong and rigid enough to carry the weight of the unit without transmitting any unit vibration. It is important that the side unit wall mounting lags and optional bottom bracket are supported by structural members inside the wall cavity. Concrete block and brick walls must be thoroughly inspected to ensure that they are capable of carrying the weight of the installed unit. Metal buildings must contain structural components to support the unit weight. If heavily corrugated siding is present, it may need to be trimmed and flashed similar to a window to provide a flat, even surface to attach and seal the unit to the wall. Heavy gauge corrugations that would be present on shipping containers and blast-proof structures may require the installation of a metal plate over the corrugated area. It is important that the unit area is weatherized and sealed to avoid air and water infiltration into the area between the unit and the wall.
Outdoor Area Inspection
Inspect the outdoor area of the jobsite or review construction plans and locate the area where the wall mount is to be installed. The outdoor area must be free from obstructions including fences, bushes and walls that will hinder unit operation regarding outdoor condenser airflow and unit serviceability. Do not install units in enclosed areas that limit the amount of ambient temperature airflow. Warm air will exit the front condenser section of the unit, and outdoor ambient temperature air must be able to enter side intake condenser openings of the unit. Portable or modular building placement must be in a way that the wall mount units have a constant supply of outdoor air for proper unit operation. Make sure that the service panels of the unit are accessible. Inspect wall surfaces for obstructions that could hinder unit installation and servicing including outdoor electrical conduits, junction boxes, wall drains, vent hoods, windows, doors, overhangs and posts.
Condensate Water Drainage
Review all codes and requirements for unit condensate drainage. A clear,
flexible PVC drain hose (3/4″ ID, 1″ OD) extends from the drain pan in the
upper section of the unit and extends down to the unit base. An opening is
supplied towards the back of the unit base for the drain hose to pass through,
and the hose extends 1″ to 2″ below the unit base. Water removed from the
indoor air (condensate) will be expelled from the unit in large amounts during
cooling operation through the hose. Units running in cooling operation in cold
outdoor below freezing conditions can cause the condensate to freeze after
leaving the drain hose. 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 ensure proper
drainage throughout seasonal use.
Indoor Ducted and Non-Ducted Applications
Air distribution inside the structure being conditioned plays an important
role in making sure the area is a consistent temperature. Improper air
distribution can result in areas being cooler or warmer, electrical equipment
not receiving sufficient airflow or occupancy discomfort felt inside an area.
Thermostat or indoor temperature sensor placement inside the area being
conditioned also plays an important role in indoor climate control.
Indoor Supply Airflow
Indoor installation areas must provide a non-restrictive path for the
conditioned supply air to leave supply grilles and registers. Inspect the area
to ensure that all indoor portions of the room or rooms will have access to
supply air. Ductwork may be used to ensure proper air circulation and all
provided ductwork guidelines and clearances must be followed. Non-ducted
applications must use a supply louver grille installed over the supply opening
inside the room. Be sure to adjust supply deflectors to properly disperse the
conditioned supply air to all parts of the room. Avoid closing sections of the
supply grilles which would cause unneeded supply duct pressurization.
Indoor Return Airflow
A non-restrictive path for room air returning to the center section of the
unit must be provided inside the room. Avoid placing objects including
furniture, electronics equipment, equipment racks and cabinets directly in
front of the unit return grilles and registers. Bard recommends at least 2′
between solid objects and return grilles or registers. Ductwork may be used to
ensure proper air circulation and all provided ductwork guidelines and
clearances must be followed. Nonducted applications must use a return louver
grille installed over the return opening inside the room.
Ducted Applications
Field fabricated supply and return duct work may be installed inside the
structure being conditioned. A short supply and/or return stub duct may be
connected to the unit supply and return flanges before unit installation to
help with duct connections inside the structure. Supply and return ducts 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 conserve energy, reduce heat conductivity,
and prevent condensation or moisture damage. Refer to Maximum External Static
Pressure (ESP) of Operation Table. Design the duct work according to methods
given by the Air Conditioning Contractors of America (ACCA). When duct work is
installed in unheated spaces, it should be insulated with a minimum of 1″ 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 from entering the wall cavity.
All model series require a 1/4″ clearance to combustible material for the
first 3′ of duct attached to the outlet air frame is required.
WARNING
Fire hazard.
Maintain minimum 1/4″ clearance between the supply air duct and combustible
materials in the first 3′ of ducting.
Failure to do so could result in fire causing damage, injury or death.
Free Blow Applications
Some installations may not require extensive supply duct work throughout the
structure and are referred to as free blow applications. A short field-
fabricated supply duct must be used in the wall cavity to transition between
the supply collar on the unit and the supply louver grille in the room. The
duct must be properly insulated in order to conserve energy, reduce heat
conductivity and prevent condensation or moisture damage. All joints must be
taped or sealed to prevent air or moisture entering the wall cavity. Follow
all clearances including distances to combustible materials and all
instructions provided in this manual.
A non-restrictive metallic supply air grille with deflectors is required for
free blow applications. Contact the local Bard distributor or visit
www.bardhvac.com for ordering information.
A metallic return air grille is required for non-ducted applications. The
spacing between louvers on the grille shall not be larger than 5/8″. It is
recommended that a Bard Return Air Grille Kit is installed that is designed
specifically for the wall mount product. Contact the local Bard distributor or
visit www.bardhvac.com for ordering information. A
field-supplied return grille that meets the 5/8″ louver criteria and does not
cause the unit to exceed the maximum specified external static pressure (ESP)
may be used. If using a return air filter grille, filters must be of
sufficient size to allow a maximum velocity of 400 fpm. Filter return air
grilles do not filter air being brought into the structure through ventilation
options including fresh air dampers, ventilators, economizers and energy
recovery ventilators. Be sure to install the return grille with the louvers
pointed downward towards the floor. This will help ensure return air is drawn
upward from the floor and improve air circulation in the room.
NOTE: If no return air duct is used, applicable installation codes may limit this cabinet to installation only in a single story structure.
Thermostat or Indoor Temperature Sensor Placement
The location and installation of the thermostat or temperature sensor that monitors indoor temperature is very important regarding unit operation. Avoid placing the thermostat in an area exposed to direct sunlight or air from doorways leading outdoors. Use a piece of insulating material to close off conduit openings or holes in the wall surface for wire entry into the thermostat or temperature sensor. This will help avoid non-conditioned air from entering the thermostat and effecting temperature and/or humidity readings. As common practice, the thermostat or temperature sensor should measure the temperature of the air being returned to the unit, and not the conditioned air being supplied by the unit. Placing the thermostat or temperature sensor near a return air opening will normally result in optimal unit performance.
Unit Installation
Make sure to have the proper tools at the work site that are needed for unit installation. The following steps are provided to ensure the unit is installed properly to the wall surface, and that the unit will provide years of service with minimal service requirements.
Materials/Tools List
Additional hardware and miscellaneous supplies are needed for installation. These items are field supplied and must be sourced before installation. This list also includes tools needed for installation.
Wall Preparation
1. Two holes for the supply and return air openings must be cut through the
wall as shown in Figure 14. Be sure the openings are square and level. Follow
all clearances including distances to combustible materials and all
instructions provided in this manual.
2. Review all electrical requirements provided in this manual and plan out
electrical entrances into the building. Also plan electrical conduit routing
and thermostat placement, if necessary.
3. Install necessary duct work and prepare the openings for unit
installation.
4. Clean the exterior wall where the unit is to be installed and make sure it
is able to provide a smooth, level, debris-free surface. Remove all
construction debris from the supply, return and electrical hole cutting
process.
Wall Mount Installation to Wall Surface
1. Remove packaging from unit and make sure the unit is not damaged before
installation. A top rain flashing is supplied for field use and is mounted to
the back of the unit for shipping. Remove the rain flashing before locating
the unit against the wall. Top rain flashing is required to avoid water
entering the area behind the unit that is against the wall. A bottom mounting
bracket, attached to the skid for shipping, is provided for ease of
installation but is not required. Review all requirements listed on unit
labels and on serial plate located on the side of the unit.
2. Locate and mark bolt hole locations and bottom mounting bracket location.
Install bottom mounting bracket with field-supplied fasteners to wall if it is
to be used (optional). Bracket must be level and installed in the correct
location to help support the unit during the installation process (see Figure
14).
3. Position the wall mount unit close to the wall surface where it will be
installed. Install rain flashing at the top of the unit facing the wall by
hooking the hem bend into the rear bend of the unit top (see Figure 14).
4. Apply a liberal amount of caulk on left and right cabinet side wall mount
brackets and back of top rain flashing. Place unit back surface flush against
wall. Unit must be level to ensure proper condensate drainage. Optional bottom
bracket may be used to help support the unit.
5. Units are secured to the wall by using fieldsupplied fasteners along each
side of the wall mount through the built-in wall mounting brackets. It is the
responsibility of the installer to select the proper fastener to secure the
unit to the wall based on wall construction and applicable building codes.
Typical installations may include 5/16″ fasteners with 7/8″ diameter flat
washers. Be sure unit is securely mounted and all weight-bearing fasteners are
attached to the weight supporting structural members of the wall.
6. Apply a bead of caulk between the back of the unit top and the front
surface of the top rain flashing (see Figure 14).
7. Connect unit duct work from the inside of the building following all
clearances and instructions provided. 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 use code approved duct tape or other sealing materials to seal the
duct work to the unit.
8. On side-by-side installations, maintain a minimum of 20″ clearance on both
sides to allow access to heat strips and to provide proper airflow to the
outdoor coil. Additional clearance may be required to meet local or national
codes.
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 polyol ester 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 ensure optimal system performance. Refer to instructions for the cylinder that is being utilized for proper method of liquid extraction.
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.
Important Installer Note
For improved start up performance, wash the indoor coil with a dishwashing
detergent.
High Pressure Switch
All WAY wall-mounted air conditioner series models are supplied with a remote
reset for the high pressure switch. If tripped, the pressure switch may be
reset by turning the thermostat off then back on again. High pressure switch
settings: Opens 650 +/ 15 PSI, Closes 520 +/ 15 PSI.
Three Phase Scroll Compresser 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 1 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 an extended
period of time, the compressor’s internal protector will trip.
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.
Phase Monitor
All units with three phase scroll compressors are equipped with a three phase
line monitor to prevent compressor damage due to phase reversal.
The phase monitor in this unit is equipped with two LEDs. If the Y signal
(call for cooling) 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.
Condenser Fan Operation
NOTE: Certain models may be equipped with a low ambient control (LAC), and if
so, the condenser fan motor will have a delayed start until system refrigerant
operating pressure builds up. After starting, the fan motor may or may not
cycle depending upon ambient conditions. This is normal operation.
50 Hz models must have fan wired on low speed. These models are factory wired
on low speed.
Service Hints
1. Caution owner/operator to maintain clean air filters at all times and 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.
Sequence of Operation
Circuit R-Y1 makes at thermostat pulling in compressor contactor, starting the
compressor and outdoor motor. (See NOTE under Condenser Fan Operation
concerning models equipped with low ambient control.) The G (indoor motor)
circuit is automatically completed by the thermostat 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 makes at the thermostat
pulling in heat contactor for the strip heat and blower operation. On a call
for second stage heat, R-W2 makes bringing on second heat contactor, if so
equipped.
Balanced ClimateTM Mode
Balanced ClimateTM is a great comfort feature that can easily be applied under
any normal circumstances. If the Bard air conditioning system is being set up
in a typical environment where 72°F is the lowest cooling setpoint, remove the
Y1/Y2 jumper and install a 2-stage cooling thermostat. This will increase the
humidity removal up to 35% and provide a much more comfortable environment.
NOTE: Units with mechanical dehumidification require an additional connection
to be made when enabling Balanced Climate. Refer to dehumidification
supplemental instructions for this step.
If the application is likely to require air conditioning operation below 60°F
outdoor conditions, a low ambient control (LAC) kit must be installed. The LAC
kit is equipped with an outdoor temperature switch that disables Balanced
Climate mode when the outdoor temperature drops below 50°F. This prevents
potential evaporator coil freeze up issues. The LAC kit also comes with an
evaporator freeze protection thermostat that cuts out the compressor if the
evaporator begins to freeze up.
If the unit is being installed with any ventilation package, a Bard LAC kit
must be installed. Failure to utilize an LAC with any air conditioner can
cause coil freeze up.
Balanced Climate can readily be applied to duct-free (supply and return air
grille) applications. It may also be applied to ducted applications with
limited static of 0.20″ ESP (total including both supply and return statics).
Consult Bard Application Engineering for details prior to implementation.
CAUTION: Balanced Climate is not a replacement for a dehumidification (hot gas
reheat) unit for extreme applications, but rather an enhancement feature for
limited climates and applications.
Vent Connection Plug
All units are equipped with a vent connection plug in the side of the control
panel for the different ventilation packages to plug in to. If the compressor
will not start and there is no “Y1” at the compressor control module, first
check to make sure that either the optional vent is plugged into the vent
connection plug or the supplied jumper plug is in place. The unit will not
operate without anything plugged in. This plug is located on the side of the
control panel behind the front vent door (behind the filter access door). If
the unit is supplied with a factory-installed vent package, it will be plugged
in but the jumper plug will also be tethered next to the connection for
troubleshooting purposes, if necessary.
Compressor Control Module
The compressor control module (CCM) is standard on all models covered by this
manual.
Features
Delay-on-Make Timer Short Cycle Protection/Delay-on-Break Low Pressure
Detection High Pressure Detection LPC and HPC Status LEDs Test Mode Brownout
Protection with Adjustment
Delay-on-Make Timer
A delay-on-make timer is included to be able to delay startup of the
compressor. This is desired when more than one unit is on a structure so that
all of the units do not start at the same time which could happen after a
power loss or building shutdown. The delayon-make time period is 2 minutes
plus 10% of the delay-on-break time period. To ensure that all of the units do
not start at the same time, adjust the delayon-break timer on each unit to a
slightly different delay time.
Short Cycle Protection/Delay-on-Break
An anti-short cycle timer is included to prevent short cycling the compressor.
This is adjustable from 30 seconds to 5 minutes via the adjustment knob (see
Figure 22). Once a compressor call is lost, the time period must expire before
a new call will be initiated.
Low Pressure Detection
Low pressure switch monitoring allows for a lockout condition in a situation
where the switch is open. If the low pressure switch remains open for more
than 2 minutes, the CCM will de-energize the compressor for the delay-on-break
time. If the switch closes again, it will then restart the compressor. If the
switch trips again during the same Y call, the compressor will be de-energized
and the alarm terminal will be energized indicating an alarm. The blue LED
will light and stay on until power is cycled to the control or a loss of
voltage is present at Y terminal for more than ½ second.
High Pressure Detection
High pressure switch monitoring allows for a lockout condition in a situation
where the switch is open. If the high pressure switch opens, the CCM will
deenergize the compressor. If the switch closes again, it will then restart
the compressor after the delayon-break setting has expired on the device. If
the switch trips again during the same thermostat call, the compressor will be
de-energized and the alarm terminal will be energized indicating an alarm. The
red LED will light and stay on until power is cycled to the control or a loss
of voltage is present at Y terminal for more than ½ second.
Test Mode
By rapidly rotating the potentiometer (POT) clockwise (see Figure 22), all
timing functions will be removed for testing.
The conditions needed for the unit to enter test mode are as follows: POT must
start at a time less than or equal to the 40 second mark. The POT must then be
rapidly rotated to a position greater than or equal to the 280 second mark in
less than ¼ second. Normal operation will resume after power is reset or after
the unit has been in test mode for at least 5 minutes.
Brownout Protection with Adjustment
Brownout protection may be necessary if the utility power or generator power
has inadequate power to prevent the voltage from dropping when the compressor
starts. This is rare but can happen if the generator is undersized at the site
or if the site is in a remote location far from the main power grid. Under
normal circumstances, allowing the brownout to be ignored for a time period
should not be needed. The CCM is shipped with all the DIP switches in the
‘off’ or ‘do not ignore’ position (see Figure 22).
If ignoring the brownout is needed because of the above conditions, three
preset timers can be set by DIP switches in order to delay signaling a power
brownout for a specific length of time after compressor contactor is
energized. This allows the compressor a time period to start even if the
voltage has dropped and allows the voltage to recover. This delay only happens
when the CC terminal energizes. The delay can be set to 1 second (“A” DIP
switch), 5 seconds (“B” DIP switch) or 10 seconds (“C” DIP switch); time is
not cumulative–only the longest setting will apply. If the voltage recovers
during the brownout delay period, the compressor will continue running.
Troubleshooting
Troubleshooting Light
Delay-on-Break Time Adjustment Potentiometer
Low Pressure Switch
Brownout “Ignore Time” DIP Switches*
- Turn on only one switch for that specific “Ignore Time” setting. 10 seconds is the maximum brownout “Ignore Time”. If all switches are “off”, the control is in “do not ignore”.
If a brownout condition is detected by the CCM at any point while there is a
cooling call or power is on at Y, the troubleshooting light will flash blue.
The light will continue to flash until the cooling call is satisfied or power
is removed from the Y terminal. This condition does not prevent operation; it
only indicates that a brownout condition was present at some point during the
call. If a brownout condition is detected while CC has an output, CC will be
de-energized and will retry after the delay-on-break timer is satisfied,
honoring any DIP switch timer chosen when the CC output is re-energized; this
process will continue until call is satisfied.
If inadequate utility or generator power continues after the delay-on-make or
delay-on-break timer is fulfilled, the CC output will not energize. This could
lead to the compressor never starting. The control will see the brownout
immediately and not start.
A common scenario and one that has been seen in the field is when a unit or
units switch from utility power to generator power. With slower transfer
switches, the time delay between the utility power and generator power
didn’t cause a problem. The units lost power, shut off and came back on line
normally. With the introduction of almost instantaneous transfer switches, the
power glitch may be enough that the compressor will start to run backwards.
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 covering all
models can be found. It is imperative to match the correct pressure table to
the unit by model number.
This unit employs high-flow Coremax valves instead of the typical Schrader
type valves.
WARNING! Do NOT use a Schrader valve core removal tool with these valves. Use
of such a tool could result in eye injuries or refrigerant burns!
To change a Coremax valve without first removing the refrigerant, a special
tool is required which can be obtained at
www.fastestinc.com/en/SCCA07H. See the
replacement parts manual for replacement core part numbers.
Troubleshooting Nidec SelecTech Series ECM Motors
If the Motor Is Running
1. It is normal for the motor to rock back and forth on start up. Do not
replace the motor if this is the only problem identified.
2. If the system is excessively noisy, does not appear to change speeds in
response to a demand (Heat, Cool, Other) or is having symptoms during the
cycle such as tripping limit or freezing coil, check the following:
A. Wait for programmed delays to time out.
B. Ensure that the motors control inputs are wired as shown in the factory-
supplied wiring diagram to ensure motor is getting proper control signals and
sequencing.
C. Remove the filter and check that all dampers, registers and grilles are
open and free flowing. If removing the filters corrects the problem, clean or
replace with a less restrictive filter. Also check and clean the blower wheel
or coil as necessary.
D. Check the external static pressure (total of both supply and return) to
ensure it is within the range as listed on the unit serial plate. If higher
than allowed, additional duct work is needed.
E. If the motor does not shut off at the end of the cycle, wait for any
programmed delays to time out (no more than 90 seconds). Also make sure that
there is no call for “Continuous Fan” on the G terminal.
F. If the above diagnostics do not solve the problem, confirm the voltage
checks in the next section below, then continue with the Model SelecTech
Communication Diagnostics.
If the Motor Is Not Running
1. Check for proper high voltage and ground at the L/ L1, G, N/L2 connections
at the motor (see Figure 23). Correct any voltage issues before proceeding to
the next step. The SelecTech motor is voltage specific. Only the correct
voltage should be applied to the proper motor. Input voltage within plus or
minus 10% of the nominal line power VAC is acceptable.
2. If the motor has proper high voltage and ground at the L/L1, G, N/L2
connections, then continue with the Model SelecTech Communication Diagnostics.
Model SelecTech Communication Diagnostics
The SelecTech motor is communicated through 24 VAC low voltage (thermostat
control circuit wiring).
1. Start with unit wiring diagram to confirm proper connections and voltage
(see Figure 24).
2. Initiate a demand from the thermostat and check the voltage between the
common and the appropriate motor terminal (1-5). (G input is typically on
terminal #1, but always refer to wiring diagram.)
A. If the low voltage communication is not present, check the demand from the
thermostat. Also check the output terminal and wire(s) from the terminal strip
or control relay(s) to the motor.
B. If the motor has proper high voltage (verified in Step 1 of If the Motor Is
Not Running), proper low voltage to a programmed terminal and is not
operating, the motor is failed and will require replacement.
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 pressure table on the
following page shows 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.
Removal of Fan Shroud
1. Disconnect all power to the unit before servicing. 2. To access the
condenser coil for cleaning or to
service the outdoor fan, first remove the side grilles. 3. The fan shroud
sides can then be removed for ease of access to the coil and the back side of
the shroud by removing the seven (7) screws as shown in Figure 26. 4. The fan
or coil can now be serviced. 5. Reverse the steps to reassemble.
FIGURE 26 Fan Shroud Removal
Return Air Temp (DB/WB)
TABLE 10 Cooling Pressure Standard Airflow
Air Temperature Entering Outdoor Coil °F
Pressure 75 80 85 90 95 100 105 110 115 120 125
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 and system evacuated and recharged to serial plate charge
weight.
NOTE: Pressure table based on high speed condenser fan operation. If
condensing pressures appear elevated check condenser fan wiring.
60
90
57
26
60
30
30 30 35 60
15 20 25
15 20 25
40
40
60
90
59
26
60
30
30 30 35 60
15 20 30
15 20 30
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. 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 three (3) current carrying conductors are in a raceway.
Maximum size of the time delay fuse or circuit breaker for protection of field
wiring conductors.
NOTE: The Maximum Overcurrent Protection (MOCP) value listed is the maximum value as per UL 60335 calculations for MOCP (branch-circuit conductor sizes in this chart are based on this MOCP). The actual factory-installed overcurrent protective device (circuit breaker) in this model may be lower than the maximum UL 60335 allowable MOCP value, but still above the UL 60335 minimum calculated value or Minimum Circuit Ampacity (MCA) listed.
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.
Single Circuit
Multiple Circuit
Model
Rated Volts & Phase
W60AY-A0Z A05 A10 A15
W60AY-B0Z B09 B15
W60AY-C0Z C09 C15
W60AYRC0Z RC09 RC15
W72AY-A0Z A05 A10 A15
W72AY-B0Z B09 B15
W72AY-C0Z C09 C15
W72AYRC0Z RC09 RC15
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. 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 three (3) current carrying conductors are in a raceway.
Maximum size of the time delay fuse or circuit breaker for protection of field
wiring conductors.
NOTE: The Maximum Overcurrent Protection (MOCP) value listed is the maximum
value as per UL 60335 calculations for MOCP (branch-circuit conductor sizes in
this chart are based on this MOCP). The actual factory-installed overcurrent
protective device (circuit breaker) in this model may be lower than the
maximum UL 60335 allowable MOCP value, but still above the UL 60335 minimum
calculated value or Minimum Circuit Ampacity (MCA) listed.
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.
Setting Unit Airflow
The unit is set from the factory at the default speed. Most units have three
selectable cooling speed taps that can be utilized. The default speed is the
lowest cooling speed. The two higher speed taps can be used for higher duct
static applications so that the unit can maintain the recommended airflow as
shown in Table 12. The higher speeds can also be used when higher sensible
cooling is desired. To change to the higher speed taps, move the orange/black
wire on the blower speed terminal block to either MED or HI. Set the unit duct
static based on the highest airflow that the unit will run at.
TABLE 12 Recommended Airflow
call for ventilation, electric heat or 2nd stage cooling from a 2-stage
thermostat. At that time, the unit will automatically activate a higher speed
tap.
Blower Speeds
Five factory programmed speed taps (torque settings) are available for the
motor, and are selected through different unit modes of operation. These modes
are energized by 24VAC signals from the low voltage terminal block located
inside the control panel by a thermostat or other controlling device. Each
speed tap is programmed by Bard at the factory to different motor torque
settings (see Figure 27).
FIGURE 27 Speed Taps
Rated point
Max Speed Tap (HI)
Hi Speed Tap (MED)
Default Rated Speed Tap (LO)
Balanced Climate Speed
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
0.45
0.5
E.S.P.
GRAPH 2 W48AY Indoor Airflow Performance Wet Coil
1850
1750
CFM
1650 1550 1450 1350 1250
Rated point
Max Speed Tap (HI) Hi Speed
Tap (MED)
Default Rated Speed Tap (LO)
1150
1050 0
Balanced Climate Speed
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
0.45
0.5
2100 2000 1900 1800 1700 1600 1500 1400 1300 1200 1100
0
2200 2100 2000 1900 1800 1700 1600 1500 1400 1300 1200
0
GRAPH 3 W60AY Indoor Airflow Performance Wet Coil
Rated point
Max Speed Tap (HI)
Hi Speed Tap (MED)
Default Rated Speed Tap (LO)
Balanced Climate Speed
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
0.45
0.5
E.S.P.
GRAPH 4 W72AY Indoor Airflow Performance Wet Coil
Rated point
Max Speed Tap (HI)
Hi Speed Tap (MED) Default Rated Speed Tap (LO)
Balanced Climate Speed
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
0.45
0.5
E.S.P.
TABLE 14 Maximum ESP of Operation
Electric Heat Only
Model
W42AY/D W48AY/D W60AY/D W72AY/D
-A05
.50
.50
.50
.50
-A10
.50
.50
.50
.50
-A15
.50
.50
.50
.50
-B05
.50
.50
-B09
.50
.50
.50
.50
-B15
.50
.50
.50
.50
-C05
.50
.50
-C09
.50
.50
.50
.50
-C15
.50
.50
.50
.50
Values shown are for units equipped with a 2″ pleated MERV 13 filter.
TABLE 15 Electric Heat
Electric Heat Nomenclature
05 09 10 15
Nominal KW
5.0 9.0 10.0 15.0
KW
4.6 8.3 9.2 13.8
Total KW and BTUH @ Field-Supplied Voltage
@ 230V
@ 208V
@ 460V
1-PH Amps
3-PH Amps
BTUH
KW
1-PH Amps
3-PH Amps
BTUH
KW
3-PH Amps
BTUH
20.0 —
40.0 60.0
11.5 20.8
-34.6
15,700 28,300 31,400 47,100
3.8 6.8 7.5 11.3
18.0 —
36.1 54.1
10.4 18.7
-31.2
12,800 23,000 25,600 38,400
4.6 8.3 -13.8
5.8 10.4
-17.3
15,700 28,300
230V Units 460V Units
Vent and Control Options
Part Number CMC-32 CMC-33 CMC-35 CMC-38 CMC-39 CMC-41 CMA-39 CMA-41 CMA-43 CMA-44 BOP5 FAD-NE5 FAD-BE5 CRV-F5 CRV-V5 ECON-NC5 ECON-WD5 ECON-DB5 ERV-FA5 ERV-FC5
Description Start Kit (230V 1-Phase) Dirty Filter Switch Kit Alarm Relay Crankcase Heater (230V 1-Phase) Crankcase Heater (460V 3-Phase) Crankcase Heater (230V 3-Phase) LAC – On/Off LAC – On/Off (W72AY Units Only) ODT DDC Blank Off Plate Fresh Air Damper – No Exhaust Fresh Air Damper – Barometric Exhaust Commercial Ventilator – On/Off, Spring Return Commercial Ventilator – 0-10V, Spring Return Economizer – Bldg. Equipment, 0-10V, No Controls Economizer – Bldg. Equipment, Enthalpy Economizer – Bldg. Equipment, Temperature Energy Recovery Ventilator (230V) Energy Recovery Ventilator (460V)
X XX XX X
X X XX XX XX XX XX XX XX XX XX XX XX XX X
X
W42AY-A W42AY-B W42AY-C, RC W42AYDA W42AYDB W42AYDC W48AY-A W48AY-B W48AY-C, RC W48AYDA W48AYDB W48AYDC W60AY-A W60AY-B W60AY-C, RC W60AYDA W60AYDB W60AYDC W72AY-A W72AY-B W72AY-C, RC W72AYDA W72AYDB W72AYDC
Optional Accessories
Heater Kits
Circuit Breaker (WMCBC)
EHWA042A-A05 EHWA042A-A10 EHWA042A-A15 EHWA042A-B05 EHWA042A-B09 EHWA042A-B15 EHWA042A-C09 EHWA042A-C15 EHWA042ADA10 EHWA042ADC05 EHWA048A-A05 EHWA048A-A10 EHWA048A-A15 EHWA048A-B05 EHWA048A-B09 EHWA048A-B15 EHWA048A-C09 EHWA048A-C15 EHWA048ADA05 EHWA048ADC05 EHWA060A-A05 EHWA060A-A10 EHWA060A-A15 EHWA060A-B15 EHWA072A-A05 EHWA072A-A10 EHWA072A-A15 EHWA072A-B09 WMCBC-04B WMCBC-05B WMCBC- 06A WMCBC-06C WMCBC-07A WMCBC-07B WMCBC-08A WMCBC-09A
GRAPH 5 W42AY FAD-NE5 W/O Exhaust Ventilation Delivery
References
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