Bard WA381 Installation 2100-398

INSTALLATION INSTRUCTIONS

WALL MOUNTEDPACKAGE AIR CONDITIONERS

MODELSWA381WA423WA484WA491WA602

Manual : 2100-398Supersedes:File: Volume III Tab 16Date: 01-28-02

Bard Manufacturing CompanyBryan, Ohio 43506

Since 1914...Moving ahead just as planned.

© Copyright 2002

Contents

FiguresFigure 1 Unit Dimensions ...................................... 3Figure 2 Fresh Air Damper Assembly ................... 6Figure 3 Mounting Instructions .............................. 8Figure 4 Electric Heat Clearance .......................... 9Figure 5 Wall Mounting Instructions .................... 10Figure 6 Wall Mounting Instructions .................... 10Figure 7 Common Wall Mounting Installations..... 11Figure 8 Unit 24V Terminal Board ....................... 13Figure 9 Fan Blade Setting ................................. 16

TablesTable 1 Electric Heat Table .................................. 2Table 2 Electrical Specifications ................ 4 and 5Table 3 Thermostat Wire Size ........................... 12Table 4 Wall thermostat and Subbase

Combinations ........................................ 12Table 5 Fan Blade Dimensions .......................... 16Table 6 Refrigerant Charge ............................... 16Table 7 Indoor Blower Performance .................. 16Table 7A Indoor Blower Performance .................. 17Table 8 Recommended Air Flow ........................ 17Table 9 Maximum EXP Electric Heat Only ........ 17Table 9A Maximum EXP Electric Heat Only ........ 17Table 10 Pressure Table ...................................... 18Table 11 Optional Accessories ............................ 19

Getting Other Information and Publications 1

Wall Mount General InformationHeat Pump Wall Mount Model Nomenclature .......... 2Shipping Damage .................................................... 5General ................................................................ 5Duct Work ................................................................ 6Filters ................................................................ 6Fresh Air Intake ....................................................... 6Condensate Drain .................................................... 6

Installation InstructionsWall Mounting Information ....................................... 7Mounting the Unit .................................................... 7Wiring – Main Power ............................................. 12Wiring – Low Voltage Wiring ................................. 12

Start UpImportant Installer Note ......................................... 14High Pressure Switch ............................................ 14Three Phase Scroll Compressor Start Up ............. 14Phase Monitor ....................................................... 14Condenser Fan Operation ..................................... 14Service Hints ......................................................... 14Sequence of Operation .......................................... 15Compressor Control Module .................................. 15Adjustments ........................................................... 15Pressure Service Ports .......................................... 15

TroubleshootingFan Blade Setting Dimensions .............................. 16Removal of Fan Shroud ......................................... 16Refrigerant Charge ................................................ 16Pressure Table ....................................................... 18Optional Accessories ............................................. 19

Manual 2100-398Page 1

GETTING OTHER INFORMATION AND PUBLICATIONS

These publications can help you install the airconditioner or heat pump. You can usually find these atyour local library or purchase them directly from thepublisher. Be sure to consult current edition of eachstandard.

National Electrical Code ...................... ANSI/NFPA 70

Standard for the Installation .............. ANSI/NFPA 90Aof Air Conditioning andVentilating Systems

Standard for Warm Air ...................... ANSI/NFPA 90BHeating and AirConditioning Systems

Load Calculation for ............................ACCA Manual JResidential Winter andSummer Air Conditioning

Duct Design for Residential .............. ACCA Manual DWinter and Summer Air Conditioningand Equipment Selection

FOR MORE INFORMATION, CONTACTTHESE PUBLISHERS:

ACCA Air Conditioning Contractors of America1712 New Hampshire Ave. N.W.Washington, DC 20009Telephone: (202) 483-9370Fax: (202) 234-4721

ANSI American National Standards Institute11 West Street, 13th FloorNew York, NY 10036Telephone: (212) 642-4900Fax: (212) 302-1286

ASHRAE American Society of Heating, Refrigerationand Air Conditioning Engineers, Inc.1791 Tullie Circle, N.E.Atlanta, GA 30329-2305Telephone: (404) 636-8400Fax: (404) 321-5478

NFPA National Fire Protection AssociationBatterymarch ParkP.O. Box 9101Quincy, MA 02269-9901Telephone: (800) 344-3555Fax: (617) 984-7057

Manufactured under the followingU.S. Patent numbers:

5,485,878; 5,301,777; 5,002,116; 4,924,934;4,875,520; 4,825,936; 4,432,409


WALL MOUNT GENERAL INFORMATION

HEAT PUMP WALL MOUNT MODEL NOMENCLATURE

WA 42 3 – A 10 X N X X X A

NOTE: All vent options are without exhaust capability. May require separate field supplied barometric relief in building.

TABLE 1ELECTRIC HEAT TABLE

sledoM

A-183AWA-324AWA-484AWA-194AWA-206AW

B-183AWB-324AWB-484AWB-194AWB-206AW

C-183AWC-324AWC-484AWC-194AWC-206AW

1-032 1-802 3-032 3-802 3-064

WK A UTB A UTB A UTB A UTB A UTB

5 8.02 05071 1.81 00821 --- --- --- --- --- ---

6 --- --- --- --- 4.41 00502 5.21 06351 2.7 08402

8 3.33 08272 8.82 05402 --- --- --- --- --- ---

9 --- --- --- --- 7.12 00603 7.81 03032 8.01 00703

01 6.14 03143 2.63 00652 --- --- --- --- --- ---

51 5.26 00215 0.45 00483 2.63 00215 2.13 00483 3.71 00074

81 --- --- --- --- 3.34 03416 5.73 00164 --- ---

02 2.38 06286 1.27 00215 --- --- --- --- --- ---

KW

MODEL NUMBER CONTROLMODULES (See Chart Below)

VOLTS & PHASEA - 230/208/60/1B - 230/208/60/3C - 460/60/3

REVISIONS

VENTILATION OPTIONSX - Barometric Fresh Air Damper (Standard)B - Blank-off PlateM - Motorized Fresh Air DamperV - Commercial Ventilator -

Motorized with ExhaustE - Economizer (Internal) - Fully

Modulating with ExhaustR - Energy Recovery Ventilator -

Motorized with Exhaust

FILTER OPTIONSX - One Inch Throwaway (Standard)W - One Inch WashableP - Two Inch Pleated

COLOR OPTIONSX - Beige (Standard)1 - White2 - Mesa Tan4 - Buckeye Gray5 - Desert Brown6 - Dark Bronze

COIL OPTIONSX - Standard1 - Phenolic Coated Evaporator2 - Phenolic Coated Condenser3 - Phenolic Coated Evaporator

and Condenser

OUTLET OPTIONSX - Front (Standard)

CAPACITY38 - 3 Ton42 - 3 1/2 Ton48 - 4 Ton60 - 5 Ton

Manual 2100-398

Page 3

MIS-1262

FIGURE 1UNIT DIMENSIONS

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htpeD)D(

thgieH)H(

ylppuS nruteR

E F G I J K L M N O P Q R S TA B C B

83AW24AW84AW94AW06AW

570.24 234.22 578.48 88.9 88.92 88.51 88.92 88.34 01.91 66.13 00.03 86.23 49.62 96.43 34.23 73.3 88.24 88.32 00.01 44.1 00.61 88.1

FRONT VIEW BACK VIEWSIDE VIEW


� 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 theNational Electric Code (latest revision), article 310 for power conductor sizing. CAUTION: When more thanone field power conductor circuit is run through one conduit, the conductors must be derated. Pay specialattention to note 8 of table 310 regarding Ampacity Adjustment Factors when more than 3 conductors are ina raceway.

TABLE 2ELECTRICAL SPECIFICATIONS

ledoM

TIUCRICELGNIS TIUCRICLAUD

detaR&stloVesahP

.oNdleiFrewoPstiucriC

3

muminiMtiucriCyticapmA

1mumixaMlanretxEroesuFtiucriCrekaerB

2

dleiFrewoPeriWeziS

2

dnuorGeriWeziS

3


1mumixaMesuFlanretxEtiucriCrorekaerB

2

rewoPdleiFeziSeriW

2

dnuorGeziSeriW

ATKC BTKC ATKC BTKC ATKC BTKC ATKC BTKC

Z0A,00A-183AW50A80A01A

1-802/032

1111

52237485

53530506

8886

01010101

A/NA/NA/NA/N

A/NA/NA/NA/N

A/NA/NA/NA/N

A/NA/NA/NA/N

A/NA/NA/NA/N

A/NA/NA/NA/N

A/NA/NA/NA/N

A/NA/NA/NA/N

Z0B,00B-183AW60B90B

3-802/032111

024233

030353

01018

010101

A/NA/NA/N

A/NA/NA/N

A/NA/NA/N

A/NA/NA/N

A/NA/NA/N

A/NA/NA/N

A/NA/NA/N

A/NA/NA/N

Z0C,00C-183AW60C90C

3-064111

113171

515102

414121

414121

A/NA/NA/N

A/NA/NA/N

A/NA/NA/N

A/NA/NA/N

A/NA/NA/N

A/NA/NA/N

A/NA/NA/N

A/NA/NA/N

Z0A,00A-324AW50A01A51A02A

1-802/032

1112ro12ro1

53539558011

05050609011

88642

01010186

A/NA/NA/N6565

A/NA/NA/N6225

A/NA/NA/N0606

A/NA/NA/N0306

A/NA/NA/N66

A/NA/NA/N016

A/NA/NA/N0101

A/NA/NA/N0101

Z0B,00B-324AW90B51B81B

3-802/032

1111

42432506

53530506

8866

01010101

A/NA/NA/NA/N

A/NA/NA/NA/N

A/NA/NA/NA/N

A/NA/NA/NA/N

A/NA/NA/NA/N

A/NA/NA/NA/N

A/NA/NA/NA/N

A/NA/NA/NA/N

Z0C,00C-324AW90C51C

3-064111

317162

510203

412101

412101

A/NA/NA/N

A/NA/NA/N

A/NA/NA/N

A/NA/NA/N

A/NA/NA/N

A/NA/NA/N

A/NA/NA/N

A/NA/NA/N

Z0A,00A-484AW50A01A51A02A

1-802/032

1112ro12ro1

63639558011

05050609011

88642

01010186

A/NA/NA/N9595

A/NA/NA/N6225

A/NA/NA/N0606

A/NA/NA/N0306

A/NA/NA/N66

A/NA/NA/N016

A/NA/NA/N0101

A/NA/NA/N0101

Z0B,00B-484AW90B51B81B

3-802/032

1111

52432506

53530606

8866

01010101

A/NA/NA/NA/N

A/NA/NA/NA/N

A/NA/NA/NA/N

A/NA/NA/NA/N

A/NA/NA/NA/N

A/NA/NA/NA/N

A/NA/NA/NA/N

A/NA/NA/NA/N

Z0C,00C-484AW90C51C

3-064111

317162

510203

412101

412101

A/NA/NA/N

A/NA/NA/N

A/NA/NA/N

A/NA/NA/N

A/NA/NA/N

A/NA/NA/N

A/NA/NA/N

A/NA/NA/N

Z0A,00A-194AW50A80A01A

1-802/032

1111

33337485

05050506

8886

01010101

A/NA/NA/NA/N

A/NA/NA/NA/N

A/NA/NA/NA/N

A/NA/NA/NA/N

A/NA/NA/NA/N

A/NA/NA/NA/N

A/NA/NA/NA/N

A/NA/NA/NA/N

Z0B,00B-194AW60B90B

3-802/032111

727233

040404

888

010101

A/NA/NA/N

A/NA/NA/N

A/NA/NA/N

A/NA/NA/N

A/NA/NA/N

A/NA/NA/N

A/NA/NA/N

A/NA/NA/N

Z0C,00C-194AW60C01C

3-064111

313171

515102

414121

414121

A/NA/NA/N

A/NA/NA/N

A/NA/NA/N

A/NA/NA/N

A/NA/NA/N

A/NA/NA/N

A/NA/NA/N

A/NA/NA/N

5EGAPNODEUNITNOCELBAT


� 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 theNational Electric Code (latest revision), article 310 for power conductor sizing. CAUTION: When more thanone field power conductor circuit is run through one conduit, the conductors must be derated. Pay specialattention to note 8 of table 310 regarding Ampacity Adjustment Factors when more than 3 conductors are ina raceway.

SHIPPING DAMAGEUpon receipt of equipment, the carton should bechecked for external signs of shipping damage. Ifdamage is found, the receiving party must contact thelast carrier immediately, preferably in writing,requesting inspection by the carrier’s agent.

GENERALThe equipment covered in this manual is to be installedby trained, experienced service and installationtechnicians.

The refrigerant system is completely assembled andcharged. All internal wiring is complete.

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

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

These instructions and any instructions packaged withany separate equipment required to make up the entireair conditioning system should be carefully read beforebeginning the installation. Note particularly “StartingProcedure” and any tags and/or labels attached to theequipment.

While these instructions are intended as a generalrecommended guide, they do not supersede any nationaland/or local codes in any way. Authorities havingjurisdiction should be consulted before the installationis made. See Page 1 for information on codes andstandards.

Size of unit for a proposed installation should be basedon heat loss calculation made according to methods ofAir Conditioning Contractors of America (ACCA). Theair duct should be installed in accordance with theStandards of the National Fire Protection Associationfor the Installation of Air Conditioning and VentilatingSystems of Other Than Residence Type, NFPA No.90A, and Residence Type Warm Air Heating and AirConditioning Systems, NFPA No. 90B. Where localregulations are at a variance with instructions, installershould adhere to local codes.

4EGAPMORFDEUNITNOCELBAT

ledoM

TIUCRICELGNIS TIUCRICLAUD

detaR&stloVesahP

.oNdleiFrewoPstiucriC

3


1

mumixaMlanretxEroesuFtiucriCrekaerB

2

dleiFrewoPeriWeziS

2

dnuorGeriWeziS

3


1mumixaMesuFlanretxEtiucriCrorekaerB

2

rewoPdleiFeziSeriW

2

dnuorGeziSeriW

ATKC BTKC ATKC BTKC ATKC BTKC ATKC BTKC

Z0A,00A-206AW50A01A51A02A

1-802/032

1112ro12ro1

44445558011

06060609011

88642

01010186

A/NA/NA/N9595

A/NA/NA/N6225

A/NA/NA/N0606

A/NA/NA/N0306

A/NA/NA/N66

A/NA/NA/N016

A/NA/NA/N0101

A/NA/NA/N0101

Z0B,00B-206AW90B51B81B

3-802/032

1111

23432506

54540606

8866

01010101

A/NA/NA/NA/N

A/NA/NA/NA/N

A/NA/NA/NA/N

A/NA/NA/NA/N

A/NA/NA/NA/N

A/NA/NA/NA/N

A/NA/NA/NA/N

A/NA/NA/NA/N

Z0C,00C-206AW90C51C

3-064111

617162

020203

212101

212101

A/NA/NA/N

A/NA/NA/N

A/NA/NA/N

A/NA/NA/N

A/NA/NA/N

A/NA/NA/N

A/NA/NA/N

A/NA/NA/N


FILTERSA 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 removingthe service door. A one inch washable filter and twoinch pleated filter are also available as optionalaccessories. The internal filter brackets are adjustableto accommodate the two inch filter by loosening two (2)screws on each bracket assembly and sliding thebrackets apart to the required width and retightening thefour (4) screws.

FRESH AIR INTAKEAll units are built with fresh air inlet slots punched inthe 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. Toallow the damper to operate, the maximum andminimum blade position stops must be installed. SeeFigure 2.

All capacity, efficiency and cost of operationinformation as required for Department of Energy“Energyguide” Fact Sheets is based upon the fresh airblank-off plate in place and is recommended formaximum energy efficiency.

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

CONDENSATE DRAINA plastic drain hose extends from the drain pan at thetop of the unit down to the unit base. There areopenings in the unit base for the drain hose to passthrough. In the event the drain hose is connected to adrain system of some type, it must be an open or ventedtype system to assure proper drainage.

DUCT WORKAll duct work, supply and return, must be properlysized for the design air flow requirement of theequipment. Air Conditioning Contractors of America(ACCA) is an excellent guide to proper sizing. All ductwork or portions thereof not in the conditioned spaceshould be properly insulated in order to both conserveenergy and prevent condensation or moisture damage.

Refer to Table 10 for maximum static pressureavailable for duct design.

Design the duct work according to methods given by theAir Conditioning Contractors of America (ACCA).When duct runs through unheated spaces, it should beinsulated with a minimum of one inch of insulation.Use insulation with a vapor barrier on the outside of theinsulation. Flexible joints should be used to connect theduct work to the equipment in order to keep the noisetransmission to a minimum.

A 1/4 inch clearance to combustible material for thefirst three feet of duct attached to the outlet air frame isrequired. See Wall Mounting Instructions and Figures 3and 4 for further details.

Ducts through the walls must be insulated and all jointstaped or sealed to prevent air or moisture entering thewall cavity.

Some installations may not require any return air duct.A metallic return air grille is required with installationsnot requiring a return air duct. The spacing betweenlouvers on the grille shall not be larger than 5/8 inch.

Any grille that meets with 5/8 inch louver criteria maybe used. It is recommended that Bard Return Air GrilleKit RG2 through RG5 or RFG2 through RFG5 beinstalled when no return duct is used. Contactdistributor or factory for ordering information. If usinga return air filter grille, filters must be of sufficient sizeto allow a maximum velocity of 400 fpm.

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

MIS-938

FIGURE 2FRESH AIR DAMPER

BLADE IS LOCKEDCLOSED FORSHIPPING.


INSTALLATION INSTRUCTIONS

WARNINGFailure to provide the 1/4 inch clearancebetween the supply duct and a combustiblesurface for the first 3 feet of duct can result infire causing damage, injury or death.

WALL MOUNTING INFORMATION1. 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 bestrong and rigid enough to carry the weight of theunit without transmitting any unit vibration.

3. Concrete block walls must be thoroughly inspectedto insure that they are capable of carrying the weightof the installed unit.

MOUNTING THE UNIT1. These units are secured by wall mounting brackets

which secure the unit to the outside wall surface atboth sides. A bottom mounting bracket is providedfor ease of installation, but is not required.

2. The unit itself is suitable for 0 inch clearance, butthe supply air duct flange and the first 3 feet ofsupply air duct require a minimum of 1/4 inchclearance to combustible material. If a combustiblewall use a minimum of 30-1/2” x 10-1/2”dimensions for sizing. However it is generallyrecommended that a 1 inch clearance is used forease of installation and maintaining the requiredclearance to combustible material. The supply airopening would then be 32” x 12”. See Figures 3 and4 for details.

3. Locate and mark lag bolt locations and bottommounting bracket location. See Figure 3.

4. Mount bottom mounting bracket.

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

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

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

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

9. On side by side installations, maintain a minimumof 20 inches clearance on right side to allow accessto control panel and heat strips, and to allow properairflow to the outdoor coil. Additional clearancemay be required to meet local or national codes.

Manual 2100-398

Page 8

FIGURE 3MOUNTING INSTRUCTIONS

MIS-416


FIGURE 4ELECTRIC HEAT CLEARANCE

SIDE SECTION VIEW OF SUPPLY AIR DUCT FORWALL MOUNTED UNIT SHOWING 1/4 INCHCLEARANCE TO COMBUSTIBLE SURFACES.

MIS-277

WARNINGA minimum of 1/4 inch clearance must be maintained betweenthe supply air duct and combustible materials. This is required forthe first 3 feet of ducting.

It is important to insure that the 1/4 inch minimum spacing ismaintained at all points.

Failure to do this could result in overheating the combustiblematerial and may result in a fire causing damage, injury or death.


FIGURE 5WALL MOUNTING INSTRUCTIONS

FIGURE 6WALL MOUNTING INSTRUCTIONS

MIS-548

MIS-549

SEE FIGURE 3 – MOUNTING INSTRUCTIONS

SUPPLY AIR OPENING

RETURN AIR OPENING

RETURN AIR OPENING

SUPPLY AIR OPENING

BOTTOM MOUNTINGBRACKET. MOUNT ONWALL BEFOREINSTALLING UNIT.

RETURN AIR OPENING

SUPPLY AIR OPENING

WALL STRUCTURE

FACTORY SUPPLIED RAINFLASHING. MOUNT ON UNITBEFORE INSTALLATION

SEE UNIT DIMENSIONS, FIGURE1, FOR ACTUAL DIMENSIONS

ATTACH TO TOPPLATE OF WALL

1.000” CLEARANCEALL AROUND

INTERIOR FINISHED WALLOVER FRAME

1.000” CLEARANCEALL AROUND

EXTERIOR FINISHEDWALL OVER FRAME

ATTACH TO BOTTOMPLATE OF WALLFRAMING MATERIAL

2 X 4’S, 2 X 6’S AND/ORSTRUCTURAL STEEL

THIS STRUCTURAL MEMBER LOCATED TO MATCHSTUD SPACING FOR REST OF WALL. A SECONDMEMBER MAY BE REQUIRED FOR SOME WALLS.

RETURN DUCT OPENING

SUPPLY DUCT OPENING


FIGURE 7COMMON WALL MOUNTING INSTALLATIONS

FREE AIR FLOW NO DUCT DUCTED SUPPLY RETURN AT UNIT

FALSE WALL INSTALLATION CLOSET INSTALLATION

MIS-550


WIRING – MAIN POWERRefer to the unit rating plate for wire sizing informationand maximum fuse or “HACR” type circuit breakersize. Each outdoor unit is marked with a “MinimumCircuit Ampacity”. This means that the field wiringused must be sized to carry that amount of current.Depending on the installed KW of electric heat, theremay be two field power circuits required. If this is thecase, the unit serial plate will so indicate. All modelsare suitable only for connection with copper wire. Eachunit and/or wiring diagram will be marked “Use CopperConductors Only”. These instructions must be adheredto. Refer to the National Electrical Code (NEC) forcomplete current carrying capacity data on the variousinsulation grades of wiring material. All wiring museconform to NEC and all local codes.

The electrical data lists fuse and wire sizes (75° Ccopper) for all models including the most commonlyused heater sizes. Also shown are the number of fieldpower circuits required for the various models withheaters.

The unit rating plate lists a “Maximum Time DelayRelay Fuse” or “HACR” type circuit breaker that is tobe used with the equipment. The correct size must beused for proper circuit protection and also to assure thatthere will be no nuisance tripping due to the momentaryhigh starting current of the compressor motor.

The disconnect access door on this unit may be lockedto prevent unauthorized access to the disconnect. Toconvert for the locking capability bend the tab locatedin the bottom left hand corner of the disconnectopening under the disconnect access panel straight out.This tab will now line up with the slot in the door.When shut a padlock may be placed through the hole inthe tab preventing entry.

See “Start Up” section for important information onthree phase scroll compressor start ups.

WIRING – LOW VOLTAGE WIRING230 / 208V, 1 phase and 3 phase equipment dualprimary voltage transformers. All equipment leaves thefactory wired on 240V tap. For 208V operation,reconnect from 240V to 208V tap. The acceptableoperating voltage range for the 240 and 208V taps are:

TAP RANGE240 253 – 216208 220 – 187

NOTE: The voltage should be measured at the fieldpower connection point in the unit and while theunit is operating at full load (maximumamperage operating condition).

Five (5) wires should be run from thermostat subbase tothe 24V terminal board in the unit. A five conductor, 18gauge copper, color-coded thermostat cable isrecommended. The connection points are shown inFigure 8:

TABLE 3THERMOSTAT WIRE SIZE

remrofsnarTAV ALF eguaGeriW

mumixaMecnatsiDteeFnI

55 3.2

eguag02eguag81eguag61egaug41egaug21

5406001061052

TABLE 4WALL THERMOSTAT AND SUBBASE COMBINATIONS

tatsomrehT esabbuS serutaeFetanimoderP

200-30481113F78T

300-40480221A935Q

loocegats1,taehegats1looc-ffo-taeh:metsyS no-otua:naF

140-3048C4308T

--- loocegats1,taehegats1looc-ffo-taeh:metsyS no-otua:naF

910-30480671C478T

210-40481001A476Q

taehegats2,loocegats1looc-otua-taeh:metsyS no-otua:naF

120-30484391D478T

210-40481001A476Q

taehegats2,loocegats2looc-otua-taeh:metsyS no-otua:naF

940-3048083-39F1

--- taehegats2,loocegats2cinortcelE gnimmargorpyad7

340-3048002-MC --- loocegats1,taehegats1

looc-ffo-taeh:metsyS no-otua:naF

840-304831310048T --- loocegats1,taehegats1

cinortcelE


FIGURE 8UNIT 24V TERMINAL BOARD

MIS-1373A


START UP

IMPORTANT INSTALLER NOTEFor improved start up performance wash the indoor coilwith a dish washing detergent.

HIGH PRESSURE SWITCHThe WA381, WA484, WA491 and WA602 models aresupplied with a remote reset high pressure switch. Iftripped, this pressure switch may be reset by turning thethermostat off then back on again.

THREE PHASE SCROLL COMPRESSORSTART UP INFORMATIONScroll compressors, like several other types ofcompressors, will only compress in one rotationaldirection. Direction of rotation is not an issue withsingle phase compressors since they will always startand run in the proper direction.

However, three phase compressors will rotate in eitherdirection depending upon phasing of the power. Sincethere is a 50-50 chance of connecting power in such away as to cause rotation in the reverse direction,verification of proper rotation must be made.Verification of proper rotation direction is made byobserving that suction pressure drops and dischargepressure rises when the compressor is energized.Reverse rotation also results in an elevated sound levelover that with correct rotation, as well as, substantiallyreduced current draw compared to tabulated values.

Verification of proper rotation must be made at thetime the equipment is put into service. If improperrotation is corrected at this time there will be nonegative impact on the durability of the compressor.However, reverse operation for over one hour may havea negative impact on the bearing due to oil pump out.

NOTE: If compressor is allowed to run in reverserotation for several minutes, the compressor’sinternal protector will trip.

All three phase ZR compressors are wired identicallyinternally. As a result, once the correct phasing isdetermined for a specific system or installation,connecting properly phased power leads to the sameFusite terminal should maintain proper rotationdirection.

The direction of rotation of the compressor may bechanged by reversing any two line connections to theunit.

PHASE MONITORAll units with three phase scroll compressors areequipped with a 3 phase line monitor to preventcompressor damage due to phase reversal.

The phase monitor in this unit is equipped with twoLEDs. If the Y signal is present at the phase monitorand phases are correct the green LED will light.

If phases are reversed, the red fault LED will be lit andcompressor operation is inhibited.

If a fault condition occurs, reverse two of the supplyleads to the unit. Do not reverse any of the unit factorywires as damage may occur.

CONDENSER FAN OPERATIONThe condenser fan motor on 230/208 volt, one andthree phase, 60 HZ units is a two speed motor thatcomes factory wired on high speed for peakperformance. If ambient conditions permit, it can bereconnected to low speed (red wire) for lower soundlevel. See wiring diagram.

50 HZ models must have fan wired on low speed.These models are factory wired on low speed.

SERVICE HINTS1. Caution homeowner to maintain clean air filters at

all times. Also, not to needlessly close off supplyand return air registers. This reduces air flowthrough the system, which shortens equipmentservice life as well as increasing operating costs.

2. Switching to heating cycle at 75° F or higheroutside temperature may cause a nuisance trip ofthe remote reset high pressure switch. Turnthermostat off then on to reset the high pressureswitch.

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

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


SEQUENCE OF OPERATIONCOOLING – Circuit R-Y makes at thermostat pullingin compressor contactor, starting the compressor andoutdoor motor. The G (indoor motor) circuit isautomatically completed on any call for coolingoperation or can be energized by manual fan switch onsubbase of constant air circulation. On all 230 voltunits there is a one minute off delay on the blowermotor. 460 volt models do not have an off delay. On acall for heating, circuit R-W1 make at the thermostatpulling in heat contact for the strip heat and bloweroperation. On a call for second stage heat, R-W2 makesbringing on second heat contactor, if so equipped.

COMPRESSOR CONTROL MODULEThe compressor control module is standard on theWA391, WA484, WA491and WA602 models coveredby this manual and is optional on the WA423 model.The compressor control is an anti-short cycle/lockouttimer with high and low pressure switch monitoring andalarm relay output.

Adjustable Delay On Make And Break Timer

On initial power up or any time power is interrupted tothe unit the delay on make period begins which will be 2minutes plus 10% of the delay on break setting. Whenthe delay on make is complete and the high pressureswitch (and low pressure switch if employed) is closed,the compressor contactor is energized. Upon shutdownthe delay or break timer starts and prevents restart untilthe delay on break and delay on make periods haveexpired.

During routine operation of the unit with no powerinterruptions the compressor will operate on demandwith no delay.

High Pressure Switch and Lockout Sequence

If the high pressure switch opens, the compressorcontactor will de-energize immediately. The lockouttimer will go into a soft lockout and stay in soft lockoutuntil the high pressure switch closes and the delay onbreak time has expired. If the high pressure switchopens again in this same operating cycle the unit will gointo manual lockout condition and the alarm relaycircuit will energize. Recycling the wall thermostatresets the manual lockout.

Low Pressure Switch, Bypass, and LockoutSequence

If the low pressure switch opens for more than 120seconds, the compressor contactor will de-energize andgo into a soft lockout. Regardless the state of the low

pressure switch, the contactor will reenergize after thedelay on make time delay has expired. If the lowpressure switch remains open, or opens again for longerthan 120 seconds the unit will go into manual lockoutcondition and the alarm relay circuit will energize.Recycling the wall thermostat resets the manuallockout.

Alarm Relay Output

Alarm terminal is output connection for applicationswhere alarm relay is employed. This terminal ispowered whenever compressor is locked out due toHPC or LPC sequences as described.

NOTE: Both high and low pressure switch controls areinherently automatic reset devices. The highpressure switch and low pressure switch cut outand cut in settings are fixed by specific airconditioner or heat pump unit model. Thelockout features, both soft and manual, are afunction of the Compressor Control Module.

ADJUSTMENTS

Adjustable Delay on Make and Delay on BreakTimer

The potentiometer is used to select Delay on Break timefrom 30 seconds to 5 minutes. Delay on Make (DOM)timing on power-up and after power interruptions isequal to 2 minutes plus 10% of Delay on Break (DOB)setting:

0.5 minute (30 seconds) DOB = 123 second DOM1.0 minute (60 seconds) DOB = 126 second DOM2.0 minute (120 seconds) DOB = 132 second DOM3.0 minute (180 seconds) DOB = 138 second DOM4.0 minute (240 seconds) DOB = 144 second DOM5.0 minute (300 seconds) DOB = 150 second DOM

During routine operation of the unit with no powerinterruptions the compressor will operate on demandwith no delay.

Typical Settings for Dual Unit Installation:

Unit 1: DOB set at 2 minutes, and DOM is 132 seconds

Unit 2: DOB set at 4 minutes, and DOM is 144 seconds

PRESSURE SERVICE PORTSHigh and low pressure service ports are installed on allunits so that the system operating pressures can beobserved. A pressure table can be found later in themanual covering all models. It is imperative to matchthe correct pressure table to the unit by model number.


REMOVAL OF FAN SHROUD1. Disconnect all power to the unit.

2. Remove the screws holding both grilles, one on eachside of unit, and remove grilles.

3. Remove screws holding fan shroud to condenserand bottom. Nine (9) screws.

FIGURE 9FAN BLADE SETTING

TROUBLESHOOTING

4. Unwire condenser fan motor.

5. Slide complete motor, fan blade, and shroudassembly out the left side of the unit.

6. Service motor/fan as needed.

7. Reverse steps to reinstall.

REFRIGERANT CHARGEThe correct system R-22 charge is shown on the unitrating plate. Optimum unit performance will occur witha refrigerant charge resulting in a suction linetemperature (6” from compressor) as shown in Table 6.

Table 7A on for models WA381 and WA491

TABLE 5FAN BLADE DIMENSION

ledoMnoisnemiD

A

183AW324AW484AW194AW206AW

57.1

The suction line temperatures in table above are basedupon 80° F dry bulb / 67° F wet bulb (50% R.H.)temperature and rated airflow across the evaporatorduring cooling cycle.

TABLE 6REFRIGERANT CHARGE

ledoMdetaRwolfriA

DO59erutarepmeT

DO28erutarepmeT

183AW 0011 84-05 64-84

324AW 0041 45-25 66-46

484AW 0551 65-45 76-56

194AW 0521 64-84 54-74

206AW 0071 55-35 26-06

TABLE 7INDOOR BLOWER PERFORMANCE

CFM @ 230V

.P.S.EHnI 20

484AW,324AW 206AW

V032woL V032hgiH V032woL V032hgiH

lioCyrD teWlioC lioCyrD teW

lioC lioCyrD teWlioC lioCyrD teW

lioC

0.1.2.3.4.5.

05610551054105310031---

00610051004100315711---

588107715361005107310521

008156610451004158210511

00615251------------

05415731------------

002200120002578157710561

000200910081007100615741

FAN BLADE SETTING DIMENSIONSShown in Figure 10 is the correct fan blade settingdimension for proper air delivery across the outdoorcoil.

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


TABLE 7AINDOOR BLOWER PERFORMANCE

CFM @ 230V / 460V

.P.S.EnIH2O

183AW 194AW

deepShgiH deepSmuideM deepSwoL deepShgiH deepSmuideM

yrDlioC

teWlioC

yrDlioC

teWlioC

yrDlioC

teWlioC

yrDlioC

teWlioC

yrDlioC

teWlioC

0.1.2.3.4.

5261574105310511528

574105310511528057

5241523100215201---

52310021521578---

521100110001528---

00110001058576---

0071055100410521009

0551004105210011008

5741573105210011---

573105210011528---

TABLE 9MAXIMUM ESP OF OPERATION

ELECTRIC HEAT ONLY

Values shown are for units equipped with standard1 inch throwaway filter or 1 inch washable filter.Derate ESP by .15 for 2 inch pleated filters.

ledoM 324AW 484AW 206AW

WKhgiHdeepS

woLdeepS

hgiHdeepS

woLdeepS

hgiHdeepS

woLdeepS

50A-01A-51A-02A-

05.05.05.05.

05.05.05.54.

05.05.05.05.

05.05.05.54.

05.05.05.05.

05.05.05.04.

00B-90B-51B-81B-

05.05.05.05.

05.05.05.05.

05.05.05.05.

05.05.05.05.

05.05.05.05.

05.05.05.05.

90C-51C-

05.05.

05.05.

05.05.

05.05.

05.05.

05.05.

TABLE 9AMAXIMUM ESP OF OPERATION

ELECTRIC HEAT ONLY

Values shown are for units equipped withstandard 1 inch throwaway filter or 1 inchwashable filter. Derate ESP by .15 for 2 inchpleated filters.

ledoM 183AW 194AW

WKhgiHdeepS

deMdeepS

woLdeepS

hgiHdeepS

deMdeepS

50A-80A-01A-

03.03.03.

03.03.03.

03.03.02.

03.04.03.

03.04.03.

60B-90B-

04.04.

03.03.

03.03.

03.03.

03.03.

60C-90C-

03.03.

03.03.

03.03.

03.03.

03.03.

TABLE 8RECOMMENDED AIRFLOW

ledoMdetaR*MFC

detaR*PSE

dednemmoceRegnaRwolfriA

deepSyrotcaFnoitcennoC

183AW 0011 51. 058-0521 muideM

324AW 0041 03. 0511-0061 hgiH

484AW 0551 02. 5821-0571 hgiH

194AW 0521 02. 0011-5741 hgiH

206AW 0071 03. 5731-0591 hgiH


Low side pressure ± 2 PSIGHigh side pressure ± 5 PSIG

Tables are based upon rated CFM (airflow) across the evaporator coil. If there is any doubt as to correctoperating charge being in the system, the charge should be removed, system evacuated and rechargedto serial plate instructions.

NOTE: Pressure table based on high speed condenser fan operation. If condensing pressuresappear elevated check condenser fan wiring. See “Condenser Fan Operation” on Page 14.

TABLE 10PRESSURE TABLE

COOLINGAir Temperature Entering Outdoor Coil °F

ledoMriAnruteRerutarepmeT erusserP 57 08 58 09 59 001 501 011 511

183AW

BD.ged57BW.ged26

ediSwoLediShgiH

47571

47781

57202

67612

87232

97942

97562

08482

18203

BD.ged08BW.ged76

ediSwoLediShgiH

97971

97291

08702

18222

38832

48552

58272

68192

78013

BD.ged58BW.ged27

ediSwoLediShgiH

28581

28991

38412

48032

68642

78462

88252

98103

09123

324AW

BD.ged57BW.ged26

ediSwoLediShgiH

07702

27022

37532

57152

67662

77382

87003

97813

97733

BD.ged08BW.ged76

ediSwoLediShgiH

57212

77622

87142

08752

18372

28092

38803

48623

58643

BD.ged58BW.ged27

ediSwoLediShgiH

87912

08432

18942

38662

48382

58003

68913

78733

88853

484AW

BD.ged57BW.ged26

ediSwoLediShgiH

37402

47712

67232

87842

97562

08482

28403

38523

48843

BD.ged08BW.ged76

ediSwoLediShgiH

87012

97322

18832

28452

48272

68192

78213

98433

09753

BD.ged58BW.ged27

ediSwoLediShgiH

48712

58132

78742

88462

09282

29203

39323

59543

79963

194AW

BD.ged57BW.ged26

ediSwoLediShgiH

07991

17312

17722

27442

37062

57972

67892

77023

97143

BD.ged08BW.ged76

ediSwoLediShgiH

57402

67812

67332

77052

87762

08682

18603

28823

48053

BD.ged58BW.ged27

ediSwoLediShgiH

87112

97622

97142

08952

18672

38692

48713

58933

78263

206AW

BD.ged57BW.ged26

ediSwoLediShgiH

17332

27742

47262

57872

67592

77313

87133

87153

97173

BD.ged08BW.ged76

ediSwoLediShgiH

67732

87352

97962

08582

18303

28123

38043

48093

58183

BD.ged58BW.ged27

ediSwoLediShgiH

48542

58162

58872

68692

78413

88333

98353

09373

19493


TABLE 11OPTIONAL ACCESSORIES

WA

381-A

WA

381-B

WA

381-C

WA

423-A

WA

423-B

WA

423-C

WA

484-A

WA

484-B

WA

484-C

WA

491-A

WA

491-B

WA

491-C

WA

602-A

WA

602-B

WA

602-C

traPrebmuN noitpircseD

50A-50AWHE80A-50AWHE01A-50AWHE51A-50AWHE

segakcaPretaeHsegakcaPretaeHsegakcaPretaeHsegakcaPretaeH

XXXX

XXXX

XXXX

50A-83AWHE80A-83AWHE01A-83AWHE50A-94AWHE

segakcaPretaeHsegakcaPretaeHsegakcaPretaeHsegakcaPretaeH

XXX

XX

X

90B-50AWHE51B-50AWHE81B-50AWHE

segakcaPretaeHsegakcaPretaeHsegakcaPretaeH

XXX

XXX

XXX

60B-83AWHE90B-83AWHE60B-94AWHE

segakcaPretaeHsegakcaPretaeHsegakcaPretaeH

XX

X

A90C-50AWHE51C-50AWHE

segakcaPretaeHsegakcaPretaeH

X XX

XX

X XX

60C-83AWHE segakcaPretaeH X X

5-POB5-DAFB5-DAFM

etalPffOknalBrepmaDriAhserFcirtemoraBrepmaDriAhserFdezirotoM

XXX

XXX

XXX

XXX

XXX

XXX

XXX

XXX

XXX

XXX

XXX

XXX

XXX

XXX

XXX

5-VRC5-MFIE

B5A-VREWB5C-VREW

tsuahxEhtiwrotalitneVlaicremmoCtsuahxEhtiwrezimonocErotalitneVyrevoceRygrenErotalitneVyrevoceRygrenE

XXX

XXX

XX

X

XXX

XXX

XX

X

XXX

XXX

XX

X

XXX

XXX

XX

X

XXX

XXX

XX

X

6-AMC01-AMC

)CAL(lortnoCtneibmAwoLRDT+CPH+CPL

X X X XX

XX

XX

X X X X X X X X

31-AMC51-CMC61-AMC81-AMC

CAL+RDT+CPH+CPLtiKtratS

lortnoCeusserPwoLCAL+CPL

XXX

XX

XX

XX

XXXX

XX

XX

XXX

XX

XX

XXX

XX

X

B50-BCMWC10-DCMWA80-BCMWA90-BCMWB70-BCMWA50-BCMWB40-BCMWB60-BCMW

tiKrekaerBtiucriCtiKtcennocsiDlluP

rekaerBtiucriCrekaerBtiucriCrekaerBtiucriCrekaerBtiucriCrekaerBtiucriCrekaerBtiucriC

XX

XX

XX

X

XX

X

X

X

X

X

X

Bard WA381 Installation 2100-398

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Transcript of Bard WA381 Installation 2100-398