237413-01 (BARD AC) (1).pdf

MATERIAL APPROVAL SUBMITTAL

(See Instructions on Reverse)

TO: (Contracting Officer) FROM: (Contractor) DATE

CONTRACT NUMBER SUBMISSION NUMBER SUBMITTAL

NEW RESUBMITTAL

PREVIOUS SUBMISSION NUMBER PROJECT NUMBER

TO BE COMPLETED BY CONTRACTOR FOR GOVERNMENT USE ONLY

ITEM

NO.

SPECIFICATION SECTION/

PARA NO./DRAWING NO.

DESCRIPTION OF MATERIAL

(Include Type, Model Number, Mfg., etc. & file name of attachments)

AP-

PROVED

DISAP-

PROVED

SEE

REVERSE INITIAL

BY COMPLETING THIS FORM, THE UNDERSIGNED CONTRACTOR CERTIFIES THAT

THE MATERIAL COMPLIES WITH ALL SPECIFICATIONS OF SUBJECT CONTRACT.

DATE TYPE OR PRINT NAME AND TITLE SIGNATURE

FOR GOVERNMENT USE ONLY

TO: (A/E)

For Evaluation and Action

DATE TYPE OR PRINT NAME AND GRADE SIGNATURE

TO: (VA Engineer / COR)

RECOMMEND APPROVAL DISAPPROVAL AS INDICATED ABOVE AND SUBJECT TO ANY APPLICABLE COMMENTS ON THE REVERSE

DATE TYPE OR PRINT NAME AND GRADE SIGNATURE

TO: (Contracting)

APPROVED DISAPROVED AS INDICATED ABOVE AND SUBJECT TO ANY APPLICABLE COMMENTS ON THE REVERSE SIDE. REQUEST

RESUBMITTAL ON DISAPPROVED ITEMS WITHIN DAYS OF DATE SHOWN BELOW.

DATE TYPE OR PRINT NAME AND GRADE SIGNATURE

COMMENTS

(Number to correspond with applicable Item Number on reverse)

INSTRUCTIONS TO CONTRACTORS

1. The term "material" is defined as articles, supplies, raw materials, equipment, parts, components, and completed end items that are to be incorporated into the work required by the contract.

2. This form is to be used by Contractors for submitting Shop Drawings (*.DWG or *.PDF format), Manufacturer's Literature and Certificates (scanned as * .PDF) to the Government for approval in accordance with the provisions of this contract. Unless otherwise specified, it is to be prepared, signed, and E-mailed to the Contracting Officer with appropriate attachments. One paper format copy shall be submitted as well.

3. Item(s) to be approved will be clearly tabbed or identified. Data pertaining to item(s) to be approved will be clearly identified or tabbed, particularly where documents are voluminous, in order to properly evaluate the materials or articles to be incorporated in the work. Each attachment will be numbered to correspond with the item number shown on the face of this form.

4. Requests submitted shall be numbered consecutively, by contract, in the space entitled "Submission No.". This number, in addition to the Contract No., will be used to identify each Material Approval Submittal. Resubmissions will be indicated in the appropriate block and the insertion of previous submission number and data in addition to a new submission number. A single submission should be used for all work of a section of the specifications, but in NO instance should the submission include work for more than one (1) contract. Allow reasonable time in accordance with the project specifications for review of the submittal(s) by the A/E and Government. Submittals requiring priority handling will be submitted by separate submittal using the form and so marked across the face of the form.

5. This Material Approval Submittal is not valid unless it is signed by the Contracting Officer. This approval is required as called for by the Contracting Officer under the terms of this contract. One paper copy of the submittal is to be hand signed for Contracting Officers records.

6. The A/E and Government review is limited to checking for conformance with the information given and the design concept expressed in the contract documents. The Contractor and/or Construction Manager remains totally responsible for confirming all dimensions, quantities, fabrication, construction means and methods, techniques, sequences in the work, procedures, and coordination of the work for all trades.

7. This review does not relieve the Contractor of full responsibility for strict compliance with all requirements of contract plans and specifications. Provide and install all supplementary or miscellaneous items, appurtenances, devices and their available options incidental to or necessary for a functionally, sound, secure, complete, compatible and code compliant system.

11EER WA Series Wall Mount Air Conditioner

Models:

INSTALLATION INSTRUCTIONS

W42AC-A

W42AC-B

W42AC-C

W42ACRC

W48AC-A

W48AC-B

W48AC-C

W48ACRC

Bard Manufacturing Company, Inc.

Bryan, Ohio 43506 www.bardhvac.com

Manual: 2100-692G

Supersedes: 2100-692F

Date: 5-14-21

W60AC-A

W60AC-B

W60AC-C

W60ACRC

W72AC-A

W72AC-B

W72AC-C

W72ACRC

W42ACDA

W42ACDB

W42ACDC

W48ACDA

W48ACDB

W48ACDC

W60ACDA

W60ACDB

W60ACDC

W72ACDA

W72ACDB

W72ACDC

Manual 2100-692G

CONTENTS

Getting Other Information and Publications Wall Mount General Information

Air Conditioner Wall Mount Model Nomenclature

Shipping Damage

General

Duct Work

Filters

Filter Removal/Installation

Switching Filter Sizes

Fresh Air Intake

Condensate Drain

Installation Basic Installation Design and Application Planning .. 8

Wall Construction

Outdoor Area Inspection

Condensate Water Drainage

Indoor Ducted and Non-Ducted Applications

Indoor Supply Airflow

Indoor Return Airflow

Ducted Applications

Free Blow Applications

Thermostat or Indoor Temperature Sensor

Placement

Unit Installation

Materials/Tool List

Wall Preparation

Wall Mount Installation to Wall Surface

Wiring – Main Power

High Voltage Connections

Wiring – Low Voltage

Low Voltage (24VAC) Connections

Unit Shutdown Feature

Balanced ClimateTM Feature

Dehumidification Feature

Ventilation Features

Low Ambient Control (LAC)

Outdoor Temperature Switch and Freeze

Protection Thermostat

Alarm Relay Feature

DDC Controls Feature

Dirty Filter Switch Indicator (DFS)

Discharge Air Sensor

Airflow Switch

Compressor Current Sensor

Start Up General

Topping Off System Charge

Safety Practices

Important Installer Note

High Pressure Switch

Three Phase Scroll Compressor Start Up

Information

Phase Monitor

Condenser Fan Operation

Service Hints

Sequence of Operation

Balanced ClimateTM Mode

Vent Connection Plug

Compressor Control Module

Features

Delay-on-Make Timer

Short Cycle/Delay-on-Break

Low Pressure Detection

High Pressure Detection

Test Mode

Brownout Protection with Adjustment

Pressure Service Ports

Service Troubleshooting Nidec SelecTech Series ECM

Motors

If the Motor is Running

If the Motor is Not Running

Model SelecTech Communication Diagnostics ... 28

Fan Blade Setting Dimensions

R-410A Refrigerant Charge

Removal of Fan Shroud

Setting Unit Airflow

Blower Speeds

Speed Tap 1 – Vent/Blower Only

Speed Tap 2 – Balanced Climate

Speed Tap 3 – Default LO Cooling &

Heating

Speed Tap 4 – Optional MED Cooling &

Heating

Speed Tap 5 – Optional HI Cooling &

Heating

Dirty Filter Switch

Dirty Filter Switch Adjustment

FIGURES

Figure 1 Front Control Panel Cover

Figure 2 Removing Left Filter

Figure 3 Removing Second Filter

Figure 4 Filter Tabs in Up Position

Figure 5 Bend FIlter Tabs Down

Figure 6 Remove Four Screws

Figure 7 Re-Install Filter Support Brackets into

Lower Slots

Figure 8 Re-Install Screws and Bend Tabs Up

Figure 9 Install Right 2" Filter

Figure 10 Install Left 2" Filter

Figure 11 Fresh Air Damper

Figure 12 Vent Installation/Removal Clearance

Required

Figure 13 Unit Dimensions

Figure 14 Mounting Instructions

Figure 15 Electric Heat Clearance

Figure 16 Wall Mounting Instructions

Figure 17 Wall Mounting Instructions

Figure 18 Common Wall Mounting Installations

Figure 19 High Voltage Connections

Figure 20 Programmable Thermostat

Connections

GETTING OTHER INFORMATION AND PUBLICATIONS

These publications can help when installing the air conditioner. They can usually be found at the local library or purchased directly from the publisher. Be sure to consult the current edition of each standard.

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

Standard for the Installation of Air Conditioning and

Ventilating Systems

.......................................................ANSI/NFPA 90A

Standard for Warm Air Heating and Air Conditioning

Systems

.......................................................ANSI/NFPA 90B

Load Calculation for Winter and Summer Air

Conditioning

....................................... ACCA Manual J Residential

Duct Design for Residential Winter and Summer Air

Conditioning and Equipment Selection

....................................................... ACCA Manual D

For more information, contact these publishers:

ACCA Air Conditioning Contractors of America

1712 New Hampshire Ave. N.W.

Washington, DC 20009

Telephone: (202) 483-9370

Fax: (202) 234-4721

ANSI American National Standards Institute

11 West Street, 13th Floor

New York, NY 10036

Telephone: (212) 642-4900

Fax: (212) 302-1286

ASHRAE American Society of Heating, Refrigeration and Air Conditioning Engineers, Inc.

1791 Tullie Circle, N.E.

Atlanta, GA 30329-2305

Telephone: (404) 636-8400

Fax: (404) 321-5478

NFPA National Fire Protection Association

Batterymarch Park

P.O. Box 9101

Quincy, MA 02269-9901

Telephone: (800) 344-3555

Fax: (617) 984-7057

Figure 21 Non-Programmable Thermostat

Connections

Figure 22 8201-169 Compressor Control Module ...26

Figure 23 Motor Connections

Figure 24 Motor Connections

Figure 25 Fan Blade Setting

Figure 26 Fan Shroud Removal

Figure 27 Speed Taps

Figure 28 Speed Taps

Figure 29 Dirty Filter Switch and Dirty Filter

Indicator Light/Reset Switch

Figure 30 Adjusting Filter Switch

TABLES

Table 1 Clearance Required for Service Access and Adequate Condenser Airflow

Table 2 Minimum Clearances Required to

Combustible Materials

Table 3 Additional Low Voltage Connections

(if applicable)

Table 4 Low Voltage Connections for

DDC Control

Table 5 Wall Thermostats

Table 6 Humidity Controls

Table 7 CO2 Controllers

Table 8 Thermostat Wire Size

Table 9 Fan Blade Dimensions

Table 10 Cooling Pressure – Standard Airflow

Table 11 Cooling Pressure – Balanced Climate

Airflow

Table 12A Electrical Specs W42AC, W48AC

Table 12B Electrical Specs W60AC, W72AC

Table 13 Recommended Airflow

Table 14 Blower Speeds for Unit Operational

Modes

Table 15 Indoor Blower Performance

Table 16 Maximum ESP Electric Heat Only

Table 17 Electric Heat

Table 18 Vent and Control Options

Table 19 Optional Accessories

GRAPHS

Graph 1 W42AC FAD-NE5 W/O Exhaust

Ventilation Delivery

Graph 2 W48AC FAD-NE5 W/O Exhaust

Ventilation Delivery

Graph 3 W60AC FAD-NE5 W/O Exhaust

Ventilation Delivery

Graph 4 W72AC FAD-NE5 W/O Exhaust

Ventilation Delivery

WALL MOUNT GENERAL INFORMATION

AIR CONDITIONER WALL MOUNT MODEL NOMENCLATURE

NOTE: Vent options X and B are without exhaust capability. May require separate field-supplied barometric relief in building.

Shipping Damage

Upon receipt of equipment, the carton should be checked for external signs of shipping damage. If damage is found, the receiving party must contact the last carrier immediately, preferably in writing, requesting inspection by the carrier’s agent.

General

The equipment covered in this manual is to be installed by trained, experienced service and installation technicians.

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 page 3 for information on codes and standards.

Insert “D” for dehumidification with hot gas reheat. Reference Form 7960-811 for complete details. Insert "R" for units with isolation transformer for high resistance ground applications.

CONTROL MODULES

(See Spec. Sheet S3583)

COIL OPTIONS

X – Standard

1 – Phenolic Coated Evaporator

2 – Phenolic Coated Condenser

3 – Phenolic Coated Evaporator and Condenser

4 – Coated Coils and Condenser

Section

5 – Coated Coils, Inside and

Outside of UnitSPECIALTY PRODUCTS (Non-Standard)

W 42 A C – A 0Z X X X X X X

MODEL SERIES

REVISION

KW

A – Air Conditioner

PLACEHOLDER

X – Future Use

COLOR OPTIONS

X – Beige (Standard)

1 – White

4 – Buckeye Gray

5 – Desert Brown

8 – Dark Bronze

A – Aluminum

S – Stainless Steel

CAPACITY

42 – 3½ Ton

48 – 4 Ton

60 – 5 Ton

72 – 6 Ton

VENTILATION OPTIONS

X – Fresh Air Damper - No Exhaust (Standard)

A – Fresh Air Damper - With Barometric Exhaust

B – Blank-off Plate

D – DDC, 0-10V Economizer

M – Commercial Ventilator - ON/OFF Operation Only

R – Energy Recovery Ventilator - Motorized with Exhaust

V – Commercial Ventilator - No Hood with Exhaust

Y – Economizer - DB Full Flow

Z – Economizer - DB & WB, Full Flow

VOLTS & PHASE

A – 230/208/60/1

B – 230/208/60/3

C – 460/60/3

FILTER OPTIONS

X – 1" Throwaway (Standard) N – 2" MERV 13

W – 1" Washable B – NPBI TECH + 2" MERV 13

P – 2" Pleated A – UV-C + 2" MERV 13

M – 2" MERV 11

Size of unit for a proposed installation should be based on heat loss calculation made according to methods of

Air Conditioning Contractors of America (ACCA). The air duct should be installed in accordance with the

Standards of the National Fire Protection Association for the Installation of Air Conditioning and Ventilating

Systems of Other Than Residence Type, NFPA No.

90A, and Residence Type Warm Air Heating and Air

Conditioning Systems, NFPA No. 90B. Where local regulations are at a variance with instructions, installer should adhere to local codes.

Duct Work

All duct work, supply and return, must be properly sized for the design 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 on page 39.

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. See instructions on page 10 and Figures 14 − 18 (pages 13 – 16) for further details.

Ducts through the walls must be insulated and all joints taped or sealed to prevent air or moisture entering the wall cavity.

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.

Filters

The filters can be serviced from the outside by removing the front control panel cover (see Figure 1).

Two (2) 20" x 20" x 1" throwaway filters come standard with each unit. Additional 1" and 2" filter options are available as optional accessories. To be notified when filters need changed, a dirty filter switch option is available. See page 40 for the dirty filter switch kit.

2. Slide second filter to the left around the wires and pull the filter out (see Figure 3 on page 6).

FIGURE 1

Front Control Panel Cover

Front Control Panel

Cover

Filter Removal/Installation

1. Remove left filter first by pulling on filter removal slide (see Figure 2).

FIGURE 2

Removing Left Filter

Filter Removal

Slide

2. Locate the filter support brackets and remove the four (4) screws holding them to the top of the control panel (see Figure 6).

FIGURE 4

Filter Tabs in Up Position

FIGURE 5

Bend Filter Tabs Down

3. Pull the brackets out towards the front of the unit.

The back of the bracket will slip out of the upper slots at the back of the filter tray.

4. Re-install the filter support brackets into the lower slots at the back of the filter tray (see Figure 7).

FIGURE 6

Remove Four Screws

5. Re-install the four (4) screws into the upper screw holes on the filter support brackets. Then bend the tab up out of the way (see Figure 8).

FIGURE 7

Re-Install Filter Support Brackets into Lower Slots

FIGURE 8

Re-Install Screws and Bend Tabs Up

FIGURE 3

Removing Second Filter

3. Reverse the order for new filter installation.

NOTE: When installing new filters, make sure that airflow arrows on filters point up.

Switching Filter Sizes

1. To switch from 1" to 2" filters, start by removing the filter slide and bend the tabs down out of the way (see Figures 4 and 5).

Upper slots for

1" filters

Lower slots for

2" filters

6. Install the right 2" filter first followed by the left filter (see Figures 9 and 10).

NOTE: When installing new filters, make sure that airflow arrows on filters point up.

7. Reverse the steps above to switch from 2" to 1" filters.

Fresh Air Intake

All units are built with fresh air inlet louvers punched in the side grilles.

If the unit is equipped with a fresh air damper assembly, the assembly is shipped already attached to the unit.

The damper blade is locked in the closed position. To allow the damper to operate, remove the two (2) screws in the bottom of the blade (see Figure 11). Remove right side grille to access the damper blade.

FIGURE 9

Install Right 2" Filter

FIGURE 10

Install Left 2" Filter

There is an adjustable slide on the side of the fresh air intake that can be adjusted to limit how far the damper opens so that the amount of fresh air that enters the structure is regulated.

Graphs found on pages 42 and 43 give approximate fresh air amounts based on the slide adjustment setting.

All capacity, efficiency and cost of operation information is based upon the fresh air blank-off plate in place.

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

MIS-3977

LOSED

OVE (2)

INTAKE

RATION.

Blade is screwed closed for shipping. Remove two (2) screws for fresh air intake during unit operation.

FIGURE 11

Fresh Air Damper

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. Non-ducted 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 16 on page 39. 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. See instructions on page 10 and Figures 14 − 18 (pages 13 – 16) for further details.

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.

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.

! WARNI NG

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.

• Appropriate safety gear including gloves and safety glasses

• 5/16" hex bit with drill driver

• Phillips head screwdriver

• Small straight (thermostat) screwdriver

• Tape measure

• Leveling device

• Two (2) tubes of caulk and caulk gun

• Utility knife

• Tools for cutting holes in the wall surface (if needed)

• Electrical components and wiring along with electrical tools

• Multimeter

• Wall fasteners for side flanges, bottom mounting bracket and top rain flashing

• Duct tape and/or other duct sealing materials

Wall Preparation

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

14 on page 13. 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 field-supplied 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.

* For vent installation and removal, one side of the unit requires 45" clearance in the vent area. See Figure

12 for clarity.

See Specifications Sheet S3583.

TABLE 1

Clearance Required for Service Access and

Adequate Condenser Airflow

Model Left

Side

Right

Side

Discharge –

Front

W42AC

W48AC

W60AC

W72AC

20" 20" 10'

TABLE 2

Minimum Clearances Required to Combustible Materials

Model Supply Air Duct (1st 3') Cabinet

W42AC

W48AC

W60AC

W72AC

1/4" 0"

FIGURE 12

Vent Installation/Removal Clearance Required

4"

2"

4"

4"

45"

MIS-4042

KEEP AREA

CLEAR FOR 45"

IN FRONT OF

SIDE PANEL

OBJECT OR WALL

IN THIS SECTION OR ANY

OTHER OBSTRUCTION

OF UNIT

OR RIGHT SIDE OF UNIT

CLEARANCE NEEDED ON LEFT

VENT ASSEMBLY

SHOWN OUTSIDE

AVOID LOCATING UNIT DISCONNECT

VENTS CAN BE INSTALLED

FROM EITHER SIDE OF UNIT.

45"

Width

(W)

Depth

(D)

Height

(H)

Supply Return

A B C B E F G I J K L M N O R S T

W42AC

W48AC

42.00 25.52 84.75 9.88 29.88 15.88 29.88 43.88 12.63 39.06 30.06 43.25 26.94 55.59 52.59 8.82 43.00 1.44 16.00 1.88

W60AC

W72AC

42.00 25.52 92.88 9.88 29.88 15.88 29.88 43.88 12.63 45.00 30.06 49.25 35.06 61.72 58.72 8.82 43.00 1.44 16.00 10.00

FIGURE 13

Unit Dimensions

2.000

Return Air Opening

Supply Air Opening

MIS-3978 A

Condenser Air Outlet

Ventilation Air

Inlet

Cond. Air

Exhaust Air

Brackets

(Built In)

Mounting

Side Wall

Location

Shipping

Flashing

Top Rain

DO NOT PLACE ELECTRICAL

ENTRANCES IN SHADED AREAS

ABOVE DUE TO POTENTIAL

INTERFERENCE WITH COPPER TUBING

L

O

B

E

.375

M

N

T

S

S

S

S

S

R

.375

TYP.

Access Panel

(Lockable)

Disconnect

C. Breaker/

Filter Behind Control Panel Door

Optional

Electrical

Entrance

Drain

W

G

F

4° Pitch

Rain Hood

Electrical

Panel

High Voltage

Built In

Entrance

Heater Access

Electric Heat

Low Voltage

Electrical

Entrance

1.375

A

K

H

D

C

I

2.250

J

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

FIGURE 14

Mounting Instructions

D

16"

16"

16"

16"

16"

2 " 6

2 "

4"

1"

3"

4" Typ.

4" Typ.

2 " 30"

E

F

G

CC

4 "

B

A

SEAL WITH BEAD

OF CAULKING ALONG

ENTIRE LENGTH OF

TOP.

WALL

WALL STRUCTURE

1/4" CLEARANCE ON ALL

FOUR SIDES OF SUPPLY

AIR DUCT IS REQUIRED

FROM COMBUSTABLE

MATERIALSHEATER ACCESS

PANEL

FOAM AIR SEAL

RAIN FLASHING

SUPPLIED

TOP

Right Side ViewWall Opening and Hole Location View

Supply Opening

Return Opening

UNITS REQUIRED DIMESIONS A B C D E F G

W42AC-W48AC

UNITS

REQUIRED DIMESIONS TO

MAINTAIN 1/4" MIN. CLEARANCE

FROM COMBUSTIBLE

MATERIALS

30 1/2 10 1/2 6 1/4 1 1/4 29 3/4 16 1 7/8

REQUIRED DIMENSIONS TO

MAINTAIN RECOMMENDED 1"

CLEARANCE FROM

COMBUSTIBLE MATERIALS

32 12 5 1/2 2 29 16 1 7/8

W60AC-W72AC

UNITS

REQUIRED DIMESIONS TO

MAINTAIN 1/4" MIN. CLEARANCE

FROM COMBUSTIBLE

MATERIALS

30 1/2 10 1/2 6 1/4 1 1/4 29 3/4 16 10

REQUIRED DIMENSIONS TO

MAINTAIN RECOMMENDED 1"

CLEARANCE FROM

COMBUSTIBLE MATERIALS

32 12 5 1/2 2 29 16 10

MIS-3980 B

FIGURE 15

Electric Heat Clearance

NOTE 1: SIDE SECTION VIEW OF SUPPLY AIR

DUCT FOR WALL MOUNTED UNIT SHOWING 1/4"

CLEARANCE TO COMBUSTIBLE SURFACES.

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.

! WARNI NG

FIGURE 16

Wall Mounting Instructions

FIGURE 17

Wall Mounting Instructions

I

C

K

E + 1.000

B

1.000

A

2 x 4'S, 2 x 6'S &/OR

FRAMING MATERIAL

STRUCTURAL STEEL

1.000" CLEARANCE

INTERIOR FINISHED WALL

OVER FRAME

EXTERIOR FINISH WALL

OVER FRAME

ATTACH TO BOTTOM

PLATE OF WALL

1.000" CLEARANCE

ALL AROUND DUCT

ATTACH TO TOP

PLATE OF WALL

ALL AROUND DUCT

MIS-3982 A

THIS STRUCTURAL MEMBER

LOCATED TO MATCH STUD

SPACING FOR REST OF WALL.

A SECOND MEMBER MAY BE

REQUIRED FOR SOME WALLS.

SUPPY DUCT

OPENING

RETURN DUCT

OPENING

See Figure 14 Mounting Instructions

WALL BEFORE

CONCRETE BLOCK WALL INSTALLATION

OPENING

RETURN AIR

WALL STRUCTURE

INSTALLING UNIT.

OPENING

WOOD OR STEEL SIDING

MOUNT ON UNIT

BOTTOM MOUNTING

WOOD FRAME WALL INSTALLATION

BRACKET. MOUNT ON

BEFORE INSTALLATION

SIDE VIEW

FACTORY SUPPLIED

RAIN FLASHING.

SUPPLY AIR

MIS-3981 A

FIGURE 18

Common Wall Mounting Installations

FLASHING

RECOMMEND WALL SLEEVE

WALL

RAIN

SUPPLY DUCT MAYBE LOCATED IN AN ATTIC

SUPPLY AIR DUCT

FINISHED CEILING

RAFTERS

WALL

OPENING WITH

CEILING SURFACE

OUTSIDE

WALLWALL

WALL SLEEVE

SUPPLY DUCT MAY BE LOCATED IN AN ATTIC

FINISHED CEILING SURFACE

RAIN

CLOSET WALL

FINISHED CEILING SURFACE

RAIN

RECOMMEND WALL SLEEVE

RAFTERS

GRILLE

FLASHING

OR BELOW CEILING RAFTERS AS SHOWN

OR BELOW CEILING RAFTERS AS SHOWN

FLASHING

OUTSIDE

SURFACE

RAIN

FLASHING

SLEEVE

FINISHED

SUPPLY DUCT MAYBE LOCATED IN AN ATTIC

GRILLE

OUTSIDE

OR BELOW CEILING RAFTERS AS SHOWN

SUPPLY AIR DUCT

RAFTERS

RETURN AIR

RETURN AIR

RETURN AIR

OPENING WITH

GRILLE

FALSE WALL

SUPPLY AIR DUCT

OPENING WITH GRILLE

FALSE WALL INSTALLATION

CLOSET INSTALLATION

DUCTED SUPPLY

RETURN AT UNIT

FREE AIR

NO DUCT

MIS-4043 A

RAISED FLOOR

RETURN AIR

RETURN AIR

GRILLE

SUPPLY AIR

GRILLE

SUPPLY AIR DUCT

LOWERD

CEILING

OUTSIDE

WALL

RAFTERS

RETURN AIR

SPACE

Wiring – Main Power field wiring used must be sized to carry that amount of current. Depending on the installed KW of electric heat, there may be two field power circuits required. If this is the case, the unit serial plate will so indicate.

All models are suitable only for connection with copper wire. Each unit and/or wiring diagram will be marked

“Use Copper Conductors Only”. These instructions must be adhered to. Refer to the National Electrical

Code (NEC) for complete current carrying capacity data on the various insulation grades of wiring material. All wiring must conform to NEC and all local codes.

The electrical data on the serial plate, in the unit specifications and also in Table 12 on page 32 list fuse and wire sizes (75°C copper) for all models including the most commonly used heater sizes. Also shown are the number of field power circuits required for the various models with heaters. The unit rating plate lists a “Maximum Time Delay Relay Fuse” or circuit breaker that is to be used with the equipment. The correct type and size must be used for proper circuit protection and also to ensure that there will be no nuisance tripping due to the momentary high starting current of the compressor motor.

Three phase models must have proper phasing. A phase monitor is included in all three phase models, and will indicate improper phasing during a call for cooling

(24VAC at Y1 terminal). See provided information included in this document regarding the phase monitor.

High Voltage Connections

Route field wires under the field wire shield shown in

Figure 19. (The field wire shield can be removed for

WIRE SHIELD

FIELD HIGH OR LOW

VOLTAGE WIRE SHIELD

FRONT VIEW

FIGURE 19

High Voltage Connections

USE CONDUIT

WHEN FIELD WIRES

COME IN THROUGH

THE BACK

RIGHT SIDE VIEW

MIS-4044

Electrical shock hazard.

Do not operate this equipment without an earth ground attached and always disconnect the remote electric power supplies before servicing.

Electrical shock can result in serious injury or death.

! WARNI NG

Main electrical power must be supplied to the unit from a clean, reliable power source. Verify voltage being supplied to the unit is consistent during all times of the day and within the range specified for the unit in the unit specifications and on the unit serial plate. Voltage must be measured at the field power connection point in the unit and while the unit is operating at full load

(maximum amperage operating condition).

NOTE: In applications where a field-supplied transformer is used to step down a higher incoming voltage, the center leg must be grounded when high resistance grounding is used.

Refer to the unit serial plate and unit specifications for wire sizing information and maximum fuse or circuit breaker size. Each outdoor unit is marked with a “Minimum Circuit Ampacity”. This means that the wire installation.) If field power is supplied to the left side of the unit, run the high voltage wires under the shield and to the right of the wire shield next to the compressor contactor and up into the upper control panel where the connections are made. If field power is supplied to the right of side of the unit, the low voltage wires can be run under the field wire shield to access the low voltage terminal strip.

When field wires are supplied through the back of the unit, flexible conduit must be extended through the back of the unit and terminate into the knock-outs on the upper control panel (see Figure 19).

Wiring – Low Voltage

All 230/208V 1 phase and 3 phase equipment have dual primary voltage transformers. All equipment leaves the factory wired on 240V tap. For 208V operation, reconnect from 240V to 208V tap. The acceptable operating voltage range for the 240 and 208V taps are:

Tap: 240 Range: 253 – 216

Tap: 208 Range: 220 – 187

NOTE: The voltage should be measured at the field power connection point in the unit and while the unit is operating at full load (maximum amperage operating condition).

For low voltage wiring, an 18 gauge copper, color-coded cable is recommended. See Table 8 on page 20 for more information.

Low Voltage (24VAC) Connections

These units use a 24-volt AC low voltage circuit.

C terminal is the 24VAC common and is grounded.

G terminal is the indoor blower input.

Y1 terminal is the 1st Stage input for cooling.

Y2 terminal is the 2nd Stage compressor input for cooling (if equipped with an economizer) or Y2 disables

Balanced Climate mode if the Y1-Y2 jumper is removed

(see page 24).

B/W1 terminal is the 1st stage electric heat.

W2 terminal is the 2nd stage heat (if equipped).

A terminal is the ventilation input. This terminal energizes any factory-installed ventilation option and indoor blower.

D terminal is the dehumidification input. If installed, this terminal energizes any factory-installed dehumidification option.

L terminal is 24 volt alarm active output.

For units equipped with an alarm relay:

1 terminal is the normally closed contact on the relay.

2 terminal is the normally open contact on the relay.

3 terminal is the common contact on the relay.

See Table 3 for additional low voltage connections on auxiliary terminal strip.

Unit Shutdown Feature (Standard on All Models)

The RT terminal is the 24VAC transformer output, and the R terminal is the 24VAC hot terminal for the operation of the equipment. RT and R are connected with a brass jumper bar which can be removed and RT and R connected to an external NC (normally closed) contact such as a fire/smoke detector that will cause shutdown of the equipment upon activation.

Balanced Climate™ Feature (Standard on All Models)

All units are equipped with the capability of running in Balanced Climate mode. This mode is designed to enhance the comfort level by reducing the indoor airflow amount and extending the run time to help extract more humidity during cooling operation. The Y1 terminal is the 24VAC input for Balanced Climate compressor cooling operation. The Y2 terminal is the 24VAC input for compressor cooling standard operation. Y1 and Y2 are connected with a brass jumper bar which can be removed to enable Balanced Climate mode. Units with an economizer will not have the brass jumper installed.

Refer to vent manuals for instructions on how Balanced

Climate works with each vent.

NOTE: Units with mechanical dehumidification require an additional connection to be made when enabling Balanced Climate. Refer to dehumidification supplemental instructions for this step.

To operate in Balanced Climate mode, a 2-stage cooling thermostat is required. The lower indoor airflow operation is overridden by utilizing a 2-stage thermostat. If the call for cooling is not satisfied within a given time frame or temperature differential

(specified by the thermostat), the thermostat will send a signal to Y2 which then increases the blower speed

TABLE 3

Additional Low Voltage Connections (if applicable)

Terminal Unit Description

V Control

Option Only

Discharge Air Sensor, 10K Ohm

V Control

Option Only

Discharge Air Sensor, 10K Ohm

F, V Control

Options

Filter Switch, Normally Open Contact

F, V Control

Options

Filter Switch, Normally Open Contact

V Control

Option Only

Blower Airflow Switch, Normally Open Contact

V Control

Option Only

Blower Airflow Switch, Normally Open Contact

V Control

Option Only

Compressor Current Sensor, Normally Open Contact

V Control

Option Only

Compressor Current Sensor, Normally Open Contact back to the selected speed. See pages 33 – 35 for blower speed selection options.

Refer to page 24 for additional Balanced Climate requirements and limitations.

Dehumidification Feature (Optional)

The D terminal is the 24VAC input for dehumidification operation on dehumidification hot gas reheat equipped units. When 24VAC is applied to the D terminal, a

3-way valve solenoid is energized. The reheat coil located behind the evaporator coil is then active to reheat the supply air during cooling mode. This allows humidity to be removed from the air entering the unit without a large amount of sensible cooling capacity.

During dehumidification, the indoor blower speed is reduced to help with the humidity removal. A humidity sensing thermostat or humidistat is required to control dehumidification operation.

Ventilation Features (Optional)

See ventilation instructions provided with unit for low voltage wiring.

Low Ambient Control (LAC)

The low ambient control is a pressure switch that is attached to the liquid line of the system and monitors high side pressure. Operation of the LAC occurs as outdoor temperatures drop below 60°F. LAC operation cycles the condenser fan on/off based on pressure changes caused by outdoor temperature changes.

Outdoor Temperature Switch and Freeze Protection

Thermostat

An outdoor temperature switch and an evaporator freeze protection thermostat is supplied with all units that have a low ambient control. The outdoor switch disables Balanced Climate mode (if enabled) when the temperature drops below 50°F. This prevents potential evaporator coil freeze up issues. For units with mechanical dehumidification, this switch must remain disconnected when Balanced Climate mode is not being used. Refer to unit wiring diagram. The freeze thermostat cuts out compressor operation if the evaporator begins to freeze up.

Alarm Relay Feature (Controls Option)

The alarm relay provides a set of NO (normally open) and NC (normally closed) pilot duty contacts that operate when the compressor control module locks out compressor operation because of a high or low system refrigerant pressure event.

DDC Controls Feature (Controls Option)

The DDC controls option provides additional sensors that can be used with a field-supplied advanced logic controller. The DDC controls option contains the following installed components:

Dirty Filter Switch Indicator (DFS)

The switch is adjustable and measures pressure drop across the unit filter surface. When pressure drop is higher than the switch setting, NO contacts are provided to indicate the filter needs to be serviced.

Refer to page 34 for instructions on making switch adjustments.

Discharge Air Sensor

The discharge air sensor provides a temperature reading of the supply air leaving the unit. The sensor is a 10K OHM @ 77°F measuring device. It is installed in the supply airstream in the heater bracket.

Airflow Switch

The airflow switch measures the pressure differential between the blower inlet and outlet. It is located directly above the blower partition. Relay contacts (NO) are provided for the DDC controls option that indicates the indoor blower assembly needs to be serviced.

Compressor Current Sensor

The compressor current sensor indicates when the compressor is operational by measuring amp draw. It is located inside the unit control panel. Relay contacts

(NO) are provided to indicate the compressor is not operating.

See Table 4 for low voltage connections for DDC control.

Standard Units Units w/

Economizers

Fan Only Energize G Energize G

1st Stage

Cooling Mode/

Balanced Climate

Energize Y1, G Energize Y1, G

2nd Stage

Cooling Mode

Energize Y2 to overide Balanced

Climate mode when Y1-Y2 jumper is removed

Energize Y1, Y2, G

1st Stage Heating Energize B/W1 Energize B/W1

2nd Stage Heating (if employed) Energize B/W1, W2 Energize B/W1, W2

Ventilation Energize A Energize A

Dehumidification (if employed) Energize D Energize D

TABLE 4

Low Voltage Connections for DDC Control

TABLE 6

Humidity Controls

Part Number Predominate Features

8403-038

(H600A1014)

SPDT switching, pilot duty 50VA @ 24V;

Humidity range 20-80% RH

8403-047

(H200-10-21-10)

Electronic dehumidstat SPST closes-on-rise; Humidity range 10-90% with adjustable stops

TABLE 7

CO2 Controllers

Part Number Predominate Features

8403-096

Normally Open SPST relay closes-on-rise

24V dual wave length sensor. Default setting

950ppm, adjustable to 0-2000ppm

Default off setting 1000ppm, adjustable to

0-200 ppm can be calibrated

TABLE 8

Thermostat Wire Size

Transformer

VA

FLA Wire Gauge

Maximum

Distance

In Feet

55 2.3

18 gauge

16 gauge

14 gauge

12 gauge

TABLE 5

Wall Thermostats

Part Number Predominate Features

8403-060

(1120-445)

3 stage Cool; 3 stage Heat; Electronic Programmable/Non-Programmable; HP or Conventional; Auto or Manual changeover; Dehumidification Output

8403-089

(T4 Pro)

1 stage Cool, 1 stage Heat – Heat Pump; 1 stage Cool, 1 stage Heat – Conventional; Programmable/Non-

Programmable Electronic; Auto or Manual changeover

8403-090

(T6 Pro)

2 stage…