Bard WA Series Wall Mount Air Conditioner Instruction Manual

Instruction Manual for Bard models including: 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, WA Series Wall Mount Air Conditioner, WA Series, Wall Mount Air Conditioner, Mount Air Conditioner, Air Conditioner, Conditioner

2100-787(A) (2023 08)

W42AY-A, W42AY-B, W42AY-C, W42AYRC, W48AY-A, W48AY-B, W48AY-C, W48AYRC, W60AY-A, W60AY-B, W60AY-C, W60AYRC, W72AY-A, W72AY-B, W72AY-C, W72AYRC, W42AYDA, W42AYDB, W42AYDC, W48AYDA, W48AYDB, W48AYDC, W60AYDA, W60AYDB, W60AYDC, W72AYDA, W72AYDB, W72AYDC

INSTALLATION INSTRUCTIONS

File Info : application/pdf, 50 Pages, 2.47MB

2100-787

INSTALLATION INSTRUCTIONS
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

Bard Manufacturing Company, Inc. Bryan, Ohio 43506
www.bardhvac.com

Manual: 2100-787A

Supersedes: 2100-787

Date:

8-14-23

Page

1 of 50

CONTENTS

Safety Instructions ................................................. 4 General Information ............................................. 10
General ............................................................. 10 Shipping Damage ............................................... 10 Additional Publications ....................................... 10 Air Conditioner Wall Mount Model Nomenclature... 11 Duct Work ......................................................... 12 Filters ............................................................... 12
Filter Removal/Installation............................... 12 Switching Filter Sizes ..................................... 13 Fresh Air Intake ................................................. 14
Installation ............................................................. 15 Basic Installation Design and Application Planning 15 Wall Construction ........................................... 15 Outdoor Area Inspection.................................. 15 Condensate Water Drainage ............................. 15 Indoor Ducted and Non-Ducted Applications......... 15 Indoor Supply Airflow...................................... 15 Indoor Return Airflow ...................................... 15 Ducted Applications ....................................... 16 Free Blow Applications.................................... 16 Thermostat or Indoor Temperature Sensor Placement ..................................................... 16 Unit Installation ................................................. 16 Materials/Tool List .......................................... 16 Wall Preparation............................................. 17 Wall Mount Installation to Wall Surface ............ 17 Wiring Main Power........................................... 24 High Voltage Connections................................ 24 Wiring Low Voltage........................................... 25 Low Voltage (24VAC) Connections .................... 25 Unit Shutdown Feature ................................... 25 Balanced ClimateTM Feature............................. 25 Dehumidification Feature ................................ 26 Ventilation Features ........................................ 26 Low Ambient Control (LAC) ............................. 26 Outdoor Temperature Switch and Freeze Protection Thermostat................................. 26 Alarm Relay Feature ....................................... 26 DDC Controls Feature...................................... 26 Dirty Filter Switch Indicator (DFS) ............... 26 Discharge Air Sensor .................................. 26 Airflow Switch ............................................ 26 Compressor Current Sensor ......................... 26

Start Up ................................................................... 30 General ............................................................. 30 Topping Off System Charge ................................. 30 Safety Practices ................................................. 30 Important Installer Note...................................... 30 High Pressure Switch.......................................... 30 Three Phase Scroll Compressor Start Up Information........................................................ 30 Phase Monitor.................................................... 31 Condenser Fan Operation .................................... 31 Service Hints ..................................................... 31 Sequence of Operation........................................ 31 Balanced ClimateTM Mode................................ 31 Vent Connection Plug.......................................... 32 Compressor Control Module ................................. 32 Features ........................................................ 32 Delay-on-Make Timer ...................................... 32 Short Cycle/Delay-on-Break ............................. 32 Low Pressure Detection................................... 32 High Pressure Detection.................................. 32 Test Mode...................................................... 32 Brownout Protection with Adjustment ............... 32 Pressure Service Ports ........................................ 33
Service ..................................................................... 34 Troubleshooting Nidec SelecTech Series ECM Motors............................................................... 34 If the Motor is Running ................................... 34 If the Motor is Not Running ............................. 34 Model SelecTech Communication Diagnostics ... 35 Fan Blade Setting Dimensions ............................. 36 R-410A Refrigerant Charge ................................. 36 Removal of Fan Shroud....................................... 36 Setting Unit Airflow ............................................ 40 Blower Speeds ............................................... 40 Speed Tap 1 Vent/Blower Only .................. 41 Speed Tap 2 Balanced Climate ................. 41 Speed Tap 3 Default LO Cooling & Heating ............................... 41 Speed Tap 4 Optional MED Cooling & Heating ............................... 41 Speed Tap 5 Optional HI Cooling & Heating ............................... 41 Dirty Filter Switch ............................................. 41 Dirty Filter Switch Adjustment ......................... 41

Manual 2100-787A Page 2 of 50

FIGURES
Figure 1 Front Control Panel Cover .................... 12 Figure 2 Removing Left Filter............................ 12 Figure 3 Removing Second Filter ....................... 13 Figure 4 Filter Tabs in Up Position..................... 13 Figure 5 Bend FIlter Tabs Down......................... 13 Figure 6 Remove Four Screws ........................... 13 Figure 7 Re-Install Filter Support Brackets into
Lower Slots ........................................ 13 Figure 8 Re-Install Screws and Bend Tabs Up..... 13 Figure 9 Install Right 2" Filter........................... 14 Figure 10 Install Left 2" Filter............................. 14 Figure 11 Fresh Air Damper ................................ 14 Figure 12 Vent Installation/Removal Clearance
Required ............................................ 18 Figure 13 Unit Dimensions ................................. 19 Figure 14 Mounting Instructions.......................... 20 Figure 15 Electric Heat Clearance ....................... 21 Figure 16 Wall Mounting Instructions .................. 22 Figure 17 Wall Mounting Instructions .................. 22 Figure 18 Common Wall Mounting Installations .... 23 Figure 19 High Voltage Connections .................... 24 Figure 20 Programmable Thermostat
Connections ....................................... 28 Figure 21 Non-Programmable Thermostat
Connections ....................................... 29 Figure 22 Compressor Control Module.....................33 Figure 23 Motor Connections .............................. 34 Figure 24 Motor Connections .............................. 35 Figure 25 Fan Blade Setting ............................... 36 Figure 26 Fan Shroud Removal ........................... 36 Figure 27 Speed Taps......................................... 40 Figure 28 Speed Taps......................................... 41 Figure 29 Dirty Filter Switch and Dirty Filter
Indicator Light/Reset Switch ................ 42 Figure 30 Adjusting Filter Switch ........................ 43

TABLES
Table 1 Clearance Required for Service Access and Adequate Condenser Airflow........... 18
Table 2 Minimum Clearances Required to Combustible Materials ......................... 18
Table 3 Additional Low Voltage Connections (if applicable) ..................................... 25
Table 4 Low Voltage Connections for DDC Control ....................................... 26
Table 5 Wall Thermostats ................................ 27 Table 6 Humidity Controls ............................... 27 Table 7 CO2 Controllers ................................... 27 Table 8 Thermostat Wire Size........................... 27 Table 9 Fan Blade Dimensions ......................... 36 Table 10 Cooling Pressure Standard Airflow ...... 37 Table 11A Electrical Specs W42AY, W48AY .......... 38 Table 11B Electrical Specs W60AY, W72AY .......... 39 Table 12 Recommended Airflow ......................... 40 Table 13 Blower Speeds for Unit Operational
Modes................................................ 40 Table 14 Maximum ESP Electric Heat Only......... 46 Table 15 Electric Heat ...................................... 46 Table 16 Vent and Control Options ..................... 47 Table 17 Optional Accessories ........................... 48

GRAPHS

Graph 1 Graph 2 Graph 3 Graph 4 Graph 5 Graph 6 Graph 7 Graph 8

W42AY Indoor Airflow Performance Wet Coil .......................................... 44 W48AY Indoor Airflow Performance Wet Coil .......................................... 44 W60AY Indoor Airflow Performance Wet Coil .......................................... 45 W72AY Indoor Airflow Performance Wet Coil .......................................... 45 W42AY FAD-NE5 W/O Exhaust Ventilation Delivery ............................. 49 W48AY FAD-NE5 W/O Exhaust Ventilation Delivery ............................. 49 W60AY FAD-NE5 W/O Exhaust Ventilation Delivery ............................. 50 W72AY FAD-NE5 W/O Exhaust Ventilation Delivery ............................. 50

NOTICE
APPLIANCE ACCESSIBLE TO THE GENERAL PUBLIC.

Manual 2100-787A

Page

3 of 50

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.

NOTICE
APPLIANCE ACCESSIBLE TO THE GENERAL PUBLIC.

! WARNI NG
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
Fire hazard. Maintain minimum 1/4" clearance between the supply air duct and combustible materials in the first 3' feet of ducting. Failure to do so could result in fire causing damage, injury or death.
! WARNI NG
Heavy item hazard. Use more than one person to handle unit. Failure to do so could result in unit damage or serious injury.

Manual 2100-787A Page 4 of 50

! WARNI NG
Electrical shock hazard. Have a properly trained individual perform these tasks. Failure to do so could result in electric shock or death.
The following symbols are displayed on units.

! CAUTI ON
Sharp metallic edges. Take care and wear appropriate protective devices to avoid accidental contact with sharp edges. Failure to do so can result in personal injury.

This symbol indicates that the Operation Manual should be read carefully.
This symbol indicates that a service personnel should be handling this equipment with reference to the Installation Manual.
This symbol indicates that information is available such as the Operation Manual or Installation Manual.

Manual 2100-787A

Page

5 of 50

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.
Manual 2100-787A Page 6 of 50

INSTRUCTIONS DE SÉCURITÉ

LIRE TOUTES LES INSTRUCTIONS AVANT UTILISATION
Votre sécurité et celle des autres sont très importantes.
Nous avons fourni de nombreux messages de sécurité importants dans ce manuel et sur votre appareil. Lisez et suivez toujours tous les messages de sécurité.

Définitions ANSI Z535.5 :

DANGER : Indique une situation dangereuse qui, si elle n'est pas évitée, entraînera certainement la mort ou des blessures graves. Le mot « DANGER » doit être limité aux situations extrêmes. Les indications « DANGER » ne doivent pas être utilisées pour les risques de dégâts matériels, à moins qu'il n'existe un risque concomitant de blessures corporelles.

AVERTISSEMENT : Indique une situation dangereuse qui, si elle n'est pas évitée, peut entraîner la mort ou des blessures graves. Les indications « AVERTISSEMENT » ne doivent pas être utilisées pour les risques de dégâts matériels, à moins qu'il n'existe un risque concomitant de blessures corporelles.

ATTENTION : Indique une situation dangereuse qui, si elle n'est pas évitée, peut entraîner des blessures mineures à modérées. Les indications « ATTENTION », sans symbole d'avertissement, peuvent être utilisées pour alerter sur des pratiques dangereuses pouvant entraîner des dégâts matériels uniquement.

REMARQUE : cet avis concerne les pratiques n'entraînant aucune blessure corporelle. Le symbole d'avertissement ne doit

will

result

deaputathislisêétrepouutriliisnédiaqvueecr

ce mot. Comme un message non

alternative à « AVIS », le mot « lié à des blessures corporelles.

ATTENTION

sans

symbole

d'avertissement

peut

être

ADANGER o, wthilel rmesousltt ienxtdreemateh

ADANGER dddttao,aoinwmmttvhhioalaelelggvrmemeeesdohohu.sasalttztzaieaenrxrxddtdtrrsseeemamthee

ADANGER REMARQUE oddai,nmcvooaulgvlededrh.easzualrtdins

£ dodfi,oncrvoopulrvoledpdre.erstyult in £ heddidissff,oollcereropvpvueerrolloldpipissreeeararsttlylysusolot in £ dh,iscoleuvldelriessaullst oin
AATTENTION ! de, rctosuymldbreosl multaiynbe AATTENTION eedllerere,ttdyryrcttoddtssoauayymplmmmdeabarbresgogoseolel munmoolatnanalilynlyyy.bb. ee AREAMTATREQNTUIEON netaertldywdtooarpmde.arAsgsoenaoannl ly.
!RREEMMAARRQQUUEE nnytyaeaaadllllwewetororottrprssddeyy..mmrAAsssbboonoaalalnnmml aayy
ty alert symbol may

AVERTISSEMENT AVERTISSEMENT AVERTISSEMENT
AVERTI SSEMENT

APPAREIL ACCESSIBLE AU GRAND PUBLIC.
AVERTI SSEMENT
Risque d'incendie. Conserver un dégagement minimal de 6,35 mm/1/4 po entre le conduit d'air soufflé et les matériaux combustibles sur les 900 premiers millimètres (3 pi) du conduit. Le non-respect de cette consigne entraîne des risques de dégâts matériels, de blessures corporelles ou de décès.

mmediate hazard Risque de choc électrique.

mngmeer dtaiagtseshhaazallrbde

Ne pas faire fonctionner cet équipement sans qu'il soit relié à la terre et toujours débrancher

mngmeer dtaiagtse

shhaazallrbde

les alimentations électriques aux opérations d'entretien.

avant

procéder

cnaguetriotang· sansdhall be Une électrisation peut entraîner des blessures

I WARNING I cthaeuytihoanv·eaandsignal graves ou la mort.

I WARNING I cwtwthhaiieessuyyeetihhommaanveve·eeeaetantattdhhsseeiiggnnaall

I WARNING I rwise meet the

! AVERTI SSEMENT
Risque lié aux objets lourds. Plusieurs personnes sont nécessaires à la manipulation de l'unité. Le non-respect de cette consigne peut entraîner dégâts à l'unité ou des blessures graves.

Manual 2100-787A

Page

7 of 50

! AVERTI SSEMENT
Risque de choc électrique. Ces tâches doivent être réalisées par une personne parfaitement qualifiée et formée. Le non-respect de cette consigne peut entraîner des chocs électriques ou la mort.
Les symboles suivants sont affichés sur les unités.

! ATTENTI ON
Arêtes métalliques vives. Faites attention et portez des dispositifs de protection appropriés pour éviter tout contact accidentel avec des arêtes vives. Le non-respect de cette consigne peut entraîner des blessures corporelles.

Ce symbole indique que le manuel d'utilisation doit être lu attentivement.
Ce symbole indique qu'un membre du personnel de service devrait manipuler cet équipement en se référant au manuel d'installation.
Ce symbole indique que des informations sont disponibles telles que le manuel d'utilisation ou le manuel d'installation.

Manual 2100-787A Page 8 of 50

INSTRUCTIONS DE SÉCURITÉ IMPORTANTES

! AVERTISSEMENT
Pour réduire le risque d'explosion, d'incendie, de décès, de choc électrique, d'échaudure ou de blessures pour les personnes lors de l'utilisation de ce produit, suivez les précautions de base, notamment les suivantes :
GÉNÉRALITÉS · L'équipement couvert dans ce manuel doit être installé par des techniciens de service et d'installation formés et
expérimentés. · Cet appareil n'est pas destiné à être utilisé par des personnes (y compris des enfants) ayant des capacités physiques,
sensorielles ou mentales réduites, ou un manque d'expérience et de connaissances, à moins qu'elles n'aient reçu la supervision ou l'instruction concernant l'utilisation de l'appareil par une personne responsable de leur sécurité. · Le système de réfrigérant est complètement assemblé et chargé. Tout le câblage interne est complet. · L'unité est conçue pour être utilisée avec ou sans conduits. Des brides sont prévues pour fixer les conduits d'alimentation et de retour. · Ces instructions expliquent la méthode recommandée pour installer l'unité autonome refroidie à l'air et les connexions de câblage électrique à l'unité. · Ces instructions et toutes les instructions emballées avec tout équipement distinct requis pour constituer l'ensemble du système de climatisation doivent être lues attentivement avant de commencer l'installation. Notez en particulier « Procédure de démarrage » et les étiquettes et / ou étiquettes attachées à l'équipement. · Bien que ces instructions soient conçues comme un guide général recommandé, elles ne remplacent en aucune façon les codes nationaux et/ou locaux. Les autorités compétentes devraient être consultées avant que l'installation ne soit effectuée. Voir d'autres publications pour obtenir des renseignements sur les codes et les normes. · La taille de l'unité pour une installation proposée devrait être basée sur le calcul de la perte de chaleur effectué selon les méthodes de Air Conditioning Contractors of America (ACCA). Le conduit d'air devrait être installé conformément aux Normes de la National Fire Protection Association for the Installation of Air Conditioning and Ventilating Systems of Other Than Residence Type, NFPA No. 90A, et aux Systèmes de chauffage et de climatisation d'air chaud de type résidence, NFPA No. 90B. Lorsque les réglementations locales sont en contradiction avec les instructions, l'installateur doit respecter les codes locaux.
L'INSTALLATION · Ce produit n'est pas destiné à être utilisé à des altitudes supérieures à 2 000 mètres (6 561 pieds). Pour les
appareils destinés à être utilisés à des altitudes supérieures à 2 000 m (6 561 pieds), l'altitude maximale d'utilisation doit être indiquée. · Avant utilisation, l'appliance doit être correctement installée comme décrit dans ce manuel. · Communiquez avec le technicien d'entretien autorisé pour la réparation ou l'entretien de cette unité. · Contactez le programme d'installation pour l'installation de cet appareil. · Le climatiseur n'est pas destiné à être utilisé par de jeunes enfants ou des invalides sans surveillance. · Les jeunes enfants devraient être surveillés pour s'assurer qu'ils ne jouent pas avec le climatiseur. · Les travaux d'installation doivent être effectués conformément au Code national de l'électricité par du personnel qualifié et autorisé uniquement. · Connectez-vous à un circuit d'alimentation correctement évalué, protégé et dimensionné pour éviter les surcharges électriques. · Respectez toutes les procédures de sécurité recommandées par l'industrie, y compris l'utilisation de gants à manches longues et de lunettes de sécurité. · Faites attention lors du déballage et de l'installation. Les bords du produit peuvent être tranchants. · Gardez les matériaux d'emballage hors de la portée des enfants. Ces matériaux peuvent poser un risque d'étouffement pour les enfants.
OPÉRATION
· Cet appareil n'est pas destiné à être utilisé par des personnes (y compris des enfants) ayant des capacités physiques, sensorielles ou mentales réduites, ou un manque d'expérience et de connaissances, à moins qu'elles n'aient reçu une supervision ou une instruction concernant l'utilisation de l'appareil par une personne responsable de leur sécurité.
· Utilisez cet appareil uniquement aux fins prévues. · N'essayez jamais de faire fonctionner cet appareil s'il est endommagé, défectueux, partiellement démonté ou s'il
a des pièces manquantes ou cassées. · Ne pas altérer les contrôles.

Manual 2100-787A

Page

9 of 50

GENERAL INFORMATION

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.

Additional 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

Manual 2100-787A Page 10 of 50

Air Conditioner Wall Mount Model Nomenclature

W 42 A Y A 0Z X X X X X X

MODEL SERIES
CAPACITY 42 3½ Ton
48 4 Ton 60 5 Ton 72 6 Ton
A Air Conditioner
REVISION
SPECIAL CONFIGURATION () Standard System D Dehumidification
R Motor Isolation (460V Only for High Resistance Ground)
ELECTRICAL A 230/208/60/1 B 230/208/60/3 C 460/60/3 E 220/220/50/3 F 415/380/60/3
ELECTRIC HEAT 00 No Electric Heat, No Circuit Breaker
0Z No Electric Heat, w/Circuit Breaker 05 5KW Electric Heat 06 6KW Electric Heat 09 9KW Electric Heat
10 10KW Electric Heat 12 12KW Electric Heat 15 15KW Electric Heat
VENT X Fresh Air Damper, No Exhaust A Fresh Air Damper, w/Exhaust
B Blank-Off Plate D DDC/BrightStat, 0-10V Economizer M Commercial Room Ventilator, ON/OFF Operation Only
R Energy Recovery Ventilator V Commercial Ventilator, Modulating Operation w/Board
Y Full Flow Economizer w/JADE, Dry Bulb Z Economizer, DB & WB, Full Flow

CONTROL X None (Standard) E Low Ambient Control F Filter Replacement Pressure
Switch, Alarm Relay & Low Ambient Control J Alarm Relay & Low Ambient Control K Start Kit & Low Ambient Control M Start Kit, Low Ambient Control & Alarm Relay V DDC Controls
COIL OPTIONS X Standard 1 Phenolic Coated Evaporator 2 Phenolic Coated Condenser 3 Phenolic Coated Evaporator and
Condenser 4 3rd Party Unit Coating: Condenser 5 3rd Party Unit Coating: Entire Unit
PLACEHOLDER X Standard Front Outlet J Recessed Cabinet Top, Blow Thru
COLOR OPTIONS X Beige 1 White 4 Gray 5 Desert Brown 8 Dark Bronze A Aluminum S Stainless Steel
FILTER X 1" Throwaway (Standard) W 1" Washable P 2" MERV 8 M 2" MERV 11 N 2" MERV 13 A 2" MERV 13 with UVC-LED Light B 2" MERV 13 with NPBI TECH

Manual 2100-787A

Page

11 of 50

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 46.
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 17 and Figures 14 - 18 (pages 20 23) 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 47 for the dirty filter switch kit.
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

Manual 2100-787A Page 12 of 50

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

FIGURE 3 Removing Second Filter

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 6 Remove Four Screws

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).
FIGURE 4 Filter Tabs in Up Position

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 7 Re-Install Filter Support Brackets into Lower Slots
Upper slots for 1" filters

FIGURE 5 Bend Filter Tabs Down

Lower slots for 2" filters
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 8 Re-Install Screws and Bend Tabs Up

Manual 2100-787A

Page

13 of 50

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.
FIGURE 9 Install Right 2" Filter

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 11 Fresh Air Damper

FIGURE 10 Install Left 2" Filter

LOSED
Blade is screwed closedOVfEo(r2) shipping. Remove two AN(TT2IAOK)NE. screws for fresh air intake
during unit operation.

MIS-3977

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 49 and 50 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.

Manual 2100-787A Page 14 of 50

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.

Manual 2100-787A

Page

15 of 50

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 14 on page 46. 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 17 and Figures 14 - 18 (pages 20 23) for further details.
! WARNI NG
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.

Manual 2100-787A Page 16 of 50

· 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 20. 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.

Manual 2100-787A

Page

17 of 50

TABLE 1 Clearance Required for Service Access and
Adequate Condenser Airflow

Model
W42AY W48AY W60AY W72AY

Left Side

Right Side

Discharge Front

20"

10'

* 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 S3642.

TABLE 2 Minimum Clearances Required
to Combustible Materials

Model

Supply Air Duct (1st 3')

Cabinet

W42AY

W48AY W60AY

1/4"

W72AY

FIGURE 12 Vent Installation/Removal Clearance Required

2034"

OBJECT OR WALL
AVOID LOCATING UNIT DISCONNECT IN THIS SECTION OR ANY OTHER OBSTRUCTION
45" CLEARANCE NEEDED ON LEFT
OR RIGHT SIDE OF UNIT

VENTS CAN BE INSTALLED FROM EITHER SIDE OF UNIT.

45"

VENT ASSEMBLY SHOWN OUTSIDE OF UNIT
KEEP AREA CLEAR FOR 45"
IN FRONT OF SIDE PANEL

1734" 3714"

Manual 2100-787A Page 18 of 50

MIS-4042 A

FIGURE 13 Unit Dimensions

Width Depth Height Supply

Return

(W) (D) (H) A B

K L MNO R S T U V

W42AY W48AY 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 10.50 12.00

W60AY W72AY 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 13.88 15.43

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

C. Breaker/ Disconnect Access Panel (Lockable)
W

3.000 Recessed front cover
VU

High Voltage

Electrical

Entrance

Filter Behind Control Panel Door

2.250

Exhaust Air

Low Voltage Electrical Entrance

J G
Condenser Air Outlet

Built In Rain Hood
4° Pitch D
1.375

Electric Heat Heater Access Panel R 2.000
A S

Ventilation Air
Cond. Air Inlet

S H
C

LS M

E O Supply Air Opening B
Return Air Opening

.375
Top Rain Flashing Shipping Location Optional Electrical Entrance
Side Wall Mounting Brackets (Built In)
.375 TYP.

Drain

T N

MIS-3978 D

DO NOT PLACE ELECTRICAL ENTRANCES IN SHADED AREAS ABOVE DUE TO POTENTIAL INTERFERENCE WITH COPPER TUBING

Manual 2100-787A

Page

19 of 50

FIGURE 14 Mounting Instructions

UNITS

REQUIRED DIMESIONS

B C D E FG

REQUIRED DIMESIONS TO

MAINTAIN 1/4" MIN. CLEARANCE FROM COMBUSTIBLE

30 1/2

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

16 1 7/8

W42ACY-W48AACY UUNNITS

MATERIALS REQUIRED DIMENSIONS TO

TOP

MAINTAIN RECOMMENDED 1" CLEARANCE FROM

12 5 1/2 2

29 16 1 7/8

COMBUSTIBLE MATERIALS

W60AACY-W722AACY UNITS

REQUIRED DIMESIONS TO

MAINTAIN 1/4" MIN. CLEARANCE FROM COMBUSTIBLE

30 1/2

MATERIALS

REQUIRED DIMENSIONS TO

MAINTAIN RECOMMENDED 1" CLEARANCE FROM

COMBUSTIBLE MATERIALS

10 1/2 6 1/4 1 1/4 29 3/4 12 5 1/2 2 29

16 9 7/8 16 9 7/8

Supply Opening

16"

HEATER ACCESS PANEL
WALL

16"

Return Opening

16"

1 2

30"

16"
3" 1" G

Typ.

1 2

4" Typ.

3 4

1 2

Wall Opening and Hole Location View

SEAL WITH BEAD OF CAULKING ALONG
ENTIRE LENGTH OF TOP.
RAIN FLASHING SUPPLIED
FOAM AIR SEAL
WALL STRUCTURE
1/4" CLEARANCE ON ALL FOUR SIDES OF SUPPLY AIR DUCT IS REQUIRED FROM COMBUSTABLE MATERIALS

Right Side View

MIS-3980 C

Manual 2100-787A Page 20 of 50

FIGURE 15 Electric Heat Clearance

Typical Building Outside Sheeting
Unit
Supply Air Duct Flange of Wall

Wall Frame
Inside Sheeting Supply Air Duct
1/4" Min. See Note Below

Note: Side section view of supply air duct for wall mounted unit showing 1/4" clearance to combustible surfaces.
MIS-277 A
! WARNI NG
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.

Manual 2100-787A

Page

21 of 50

See Figure 14 Mounting Instructions

FIGURE 16 Wall Mounting Instructions

FACTORY SUPPLIED RAIN FLASHING. MOUNT ON UNIT
BEFORE INSTALLATION

WALL STRUCTURE

SUPPLY AIR OPENING

RETURN AIR OPENING

CONCRETE BLOCK WALL INSTALLATION

WOOD OR STEEL SIDING
WOOD FRAME WALL INSTALLATION
FIGURE 17 Wall Mounting Instructions
ATTACH TO TOP PLATE OF WALL

BOTTOM MOUNTING BRACKET. MOUNT ON
WALL BEFORE INSTALLING UNIT.
SIDE VIEW

MIS-3981 B

E + 1.000 B

SEE UNIT DIMENSIONS, FIGURE 13, FOR ACTUAL DIMENSIONS

1.000" CLEARANCE ALL AROUND DUCT
INTERIOR FINISHED WALL OVER FRAME
1.000" CLEARANCE ALL AROUND DUCT
EXTERIOR FINISH WALL OVER FRAME

SUPPY DUCT OPENING
RETURN DUCT OPENING

1.000 A I C K

MIS-3982 B
Manual 2100-787A Page 22 of 50

FRAMING MATERIAL 2 x 4'S, 2 x 6'S &/OR
STRUCTURAL STEEL

ATTACH TO BOTTOM PLATE OF WALL

THIS STRUCTURAL MEMBER LOCATED TO MATCH STUD SPACING FOR REST OF WALL. A SECOND MEMBER MAY BE REQUIRED FOR SOME WALLS.

RAIN FLASHING
OUTSIDE WALL

FIGURE 18 Common Wall Mounting Installations

SUPPLY DUCT MAY BE LOCATED IN AN ATTIC OR BELOW CEILING RAFTERS AS SHOWN

RAFTERS

RAIN FLASHING

FINISHED CEILING SURFACE
SUPPLY AIR DUCT OPENING WITH GRILLE

RETURN AIR OPENING WITH GRILLE

RECOMMEND WALL SLEEVE
FREE AIR NO DUCT

OUTSIDE WALL

RAFTERS SUPPLY AIR DUCT
FINISHED CEILING SURFACE RETURN AIR OPENING WITH GRILLE
RECOMMEND WALL SLEEVE
DUCTED SUPPLY RETURN AT UNIT

SUPPLY DUCT MAYBE LOCATED IN AN ATTIC OR BELOW CEILING RAFTERS AS SHOWN

RAIN FLASHING

RAFTERS

SUPPLY AIR DUCT

RAIN FLASHING

OUTSIDE WALL

FINISHED CEILING SURFACE

WALL SLEEVE
RETURN AIR SPACE
FALSE WALL

RETURN AIR GRILLE

OUTSIDE WALL

FALSE WALL INSTALLATION

SUPPLY DUCT MAYBE LOCATED IN AN ATTIC OR BELOW CEILING RAFTERS AS SHOWN

RAFTERS

SUPPLY AIR DUCT LOWERD CEILING
CLOSET WALL

SUPPLY AIR GRILLE
FINISHED CEILING SURFACE

WALL SLEEVE
RAISED FLOOR RETURN AIR

RETURN AIR GRILLE

CLOSET INSTALLATION

MIS-4043 B

Manual 2100-787A

Page

23 of 50

Wiring Main Power
! WARNI NG
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.
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

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 Tables 11A and 11B on pages 38 and 39 list fuse sizes 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

FIGURE 19 High Voltage Connections

FIELD HIGH OR LOW VOLTAGE WIRE SHIELD

FRONT VIEW

WIRE SHIELD

USE CONDUIT WHEN FIELD WIRES COME IN THROUGH THE BACK

Manual 2100-787A Page 24 of 50

RIGHT SIDE VIEW

MIS-4044A

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 Tap: 208

Range: 253 216 Range: 215 197

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 27 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 Balanced Climate Feature).
B/W1 terminal is the 1st stage electric heat (if equipped).
W2 terminal is the 2nd stage heat (if equipped).
A terminal is the ventilation input. This terminal energizes any powered 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.

TABLE 3 Additional Low Voltage Connections (if applicable)

Terminal 9 10 11 12 13 14 15 16

Unit
V Control Option Only
V Control Option Only
F, V Control Options
F, V Control Options
V Control Option Only
V Control Option Only
V Control Option Only
V Control Option Only

Description
Discharge Air Sensor, 10K Ohm
Discharge Air Sensor, 10K Ohm
Filter Switch, Normally Open Contact
Filter Switch, Normally Open Contact
Blower Airflow Switch, Normally Open Contact
Blower Airflow Switch, Normally Open Contact
Compressor Current Sensor, Normally Open Contact
Compressor Current Sensor, Normally Open Contact

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 ClimateTM 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

Manual 2100-787A

Page

25 of 50

back to the selected speed. See pages 40 41 for blower speed selection options.
Refer to page 31 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 41 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.
TABLE 4 Low Voltage Connections for DDC Control

Fan Only
1st Stage Cooling Mode/ Balanced Climate

Standard Units Energize G Energize Y1, G

Units w/ Economizers Energize 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

Ventilation
Dehumidification (if employed)

Energize A Energize D

Manual 2100-787A Page 26 of 50

Part Number

TABLE 5 Wall Thermostats
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/NonProgrammable Electronic; Auto or Manual changeover

8403-090 (T6 Pro)

2 stage Cool, 3 stage Heat Heat Pump; 2 stage Cool, 2 stage Heat Conventional; Programmable/NonProgrammable Electronic; Auto or Manual changeover

8403-091

1 stage Cool, 1 stage Heat; Non-Programmable; FEMA use

8403-092 (T6 Pro Wi-Fi)

2 stage Cool, 3 stage Heat Heat Pump; 2 stage Cool, 2 stage Heat Conventional; Programmable/NonProgrammable Electronic; Auto or Manual changeover; Wi-Fi

TABLE 6 Humidity Controls

Part Number

Predominate Features

8403-100* (H6062A1000)

Electronic humidistat DPST Humidity range 10-90% with adjustable stops

8403-047 (H200-10-21-10)

Electronic dehumidistat SPST, closes-on-rise Humidity range 10-90% with adjustable stops

* If using Honeywell HumidiPRO (H6062A1000) 8403-100 humidistat, it must be configured for dehumidification in the menu.

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

18 gauge

2.3

16 gauge 14 gauge

12 gauge

Maximum Distance In Feet
60 100 160 250

Manual 2100-787A

Page

27 of 50

FIGURE 20 Programmable Thermostat Connections

SC SC SC Completestat Model #CS9B-THOA or Model #CS9BE-THOA
24V COM G Y1 Y2 O/B W2 W1/E L A D GND

6
Thermostat Bard #8403-060

R C G Y1 Y2 O/B W2 W1/E L A YO/D

Optional CO2 Controller

Bard Part #8403-096

1 24VAC
2

3 CO2 OUT

Unit Low

Voltage

R RT C G Y1 Y2 B/W1 W2 W3 L A D 1 2 3 4 5 6

Term. Strip

4 TEMP-OUT 5 6

12-Pin 9 Vent Plug

6 3 2 5 11

ALL VENT OPTIONS PLUG IN HERE
If not equipped with a ventilation option to plug in, a jumper plug must be installed.

4 12 10

MIS-3974 D

Factory installed jumper. Remove jumper and connect to N.C fire alarm circuit if emergency shutdown required.

2 Wire not needed below 15KW.

3 Wire required for dehumidification models only.

4 Do not connect "A" from thermostat if optional CO2 controller is used

0-10 VDC modulating C02 control signal for modulating ventilation control (optional for ECON only - see vent instruction manuals)

Change model configuration from heat pump to heat/cool. Must be configured to programmable

and fan set to be programmed fan for the "A" output to function during scheduled occupied periods. Must be configured for multi-stage for Y1 output to be active 1st stage cooling. For

dehumidification, must be configured for "No Economizer" for YO/D to be active for humidity

control.

7 Install jumper for 1 stage electric heat on units with more than 10KW

8 Do not add these wires if setting up for modulating control. See note 5.

Factory installed jumper. Remove jumper to activate Balanced ClimateTM mode. A 2-stage thermostat is recommended for Balanced Climate mode.

Manual 2100-787A Page 28 of 50

FIGURE 21 Non-Programmable Thermostat Connections

8 T4 Pro 8403-089 R Rc C

WOB

T6 Pro 8403-090 8403-092

Y2 W W2

Units With Dehumidification
8403-038 Mechanical Humidistat

8403-047

ELECTRONIC HUMIDISTAT

U/DEH

U/DEH 8403-100

ELECTRONIC HUMIDISTAT

Optional CO2 Controller

Bard Part #8403-096

1 2 24VAC

3 CO2 OUT

Unit Low Voltage

R RT C

G Y1 Y2 B/W1 W2 W3 L

Term. Strip

5 4

4 TEMP-OUT 5 6

12-Pin 9

6 3 2 5 11

Vent Plug

4 12 10

MIS-3975 F

ALL VENT OPTIONS PLUG IN HERE
If not equipped with a ventilation option to plug in, a jumper plug must be installed.

FACTORY INSTALLED JUMPER. REMOVE JUMPER AND CONNECT TO N.C FIRE ALARM CIRCUIT IF EMERGENCY SHUTDOWN REQUIRED.

2A WIRE NOT NEEDED BELOW 15KW.

INSTALL JUMPER FOR 1 STAGE ELECTRIC HEAT ON UNITS WITH MORE THAN 10KW.

3 WIRE REQUIRED FOR DEHUMIDIFICATION MODELS ONLY.
FOR VENT OPERATION, ADD JUMPER IF OPTIONAL CO2 CONTROLLER IS NOT USED. 4 VENT WILL RUN WHILE BLOWER IS ENERGIZED.
FOR ECON & CRV-V AN ADDITIONAL WIRE CHANGE IS REQUIRED SEE INSTALL MANUAL.

6 0-10 VDC MODULATING CO2 CONTROL SIGNAL FOR MODULATING VENTILATION CONTROL (OPTIONAL FOR ECON ONLY) - SEE VENT INSTALLATION MANUAL.
7 JUMPER NEEDS ADDED.
8 THERMOSTAT WILL NOT WORK WITH UNITS EQUIPPED WITH ECONOMIZERS.
FACTORY INSTALLED JUMPER. REMOVE JUMPER TO ACTIVATE BALANCED CLIMATETM MODE. 9 A 2-STAGE THERMOSTAT IS RECOMMENDED FOR BALANCED CLIMATE MODE. Y1 Y2 JUMPER
NOT PRESENT IF ECONOMIZER IS FACTORY INSTALLED. UNITS WITH ECONOMIZERS HAVE BALANCED CLIMATE JUMPER IN ECONOMIZER, REFER TO ECONOMIZER MANUAL.

5 DO NOT ADD THESE WIRES IF SETTING UP FOR MODULATING CONTROL. SEE NOTE 6.

10 HUMIDISTAT 8403-100 WILL NEED TO BE CONFIGURED FOR DEHUMIDIFICATION IN THE MENU. SEE USER'S MANUAL.

Manual 2100-787A

Page

29 of 50

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.
Manual 2100-787A Page 30 of 50

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 W**AY 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

Manual 2100-787A

Page

31 of 50

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.

Manual 2100-787A Page 32 of 50

High Pressure Switch
18-30 VAC Input
Y Input from Thermostat and High Pressure Switch

FIGURE 22 Compressor Control Module
Compressor Contactor Output Alarm Output
Common

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 on page 37. 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.

Manual 2100-787A

Page

33 of 50

SERVICE

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.

FIGURE 23 Motor Connections

LINE POWER
GROUND
LINE POWER

L2 LINE EARTH POWER GROUND

L1 LINE POWER

NOTE: MOTOR IS CONSTANTLY POWERED BY LINE VOLTAGE

Manual 2100-787A Page 34 of 50

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.

FIGURE 24 Motor Connections

24VAC Common
24VAC "R" Signal through thermostat output.
Speed Tap 1: Vent Speed Speed Tap 2: Balanced Climate Speed Speed Tap 3: Default Speed Speed Tap 4: Medium Speed Speed Tap 5: High Speed
24VAC Common
24VAC "R" Signal through thermostat output.

Manual 2100-787A

Page

35 of 50

Fan Blade Setting Dimensions
Shown in Figure 25 is the correct fan blade setting for proper air delivery across the outdoor coil. Refer to Table 9 for unit specific dimension. Any service work requiring removal or adjustment in the fan and/or motor area will require that the dimensions below be checked and blade adjusted in or out on the motor shaft accordingly.
FIGURE 25 Fan Blade Setting

AIRFLOW

"A"
MIS-1724

TABLE 9 Fan Blade Dimensions

Model

Dimension A

W42AY

W48AY

1.5"

W60AY

W72AY

1.75"

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
REMOVE (7) SCREWS TO REMOVE THE FAN
RemSHRoOvUDeACsCcESrSeCwOVsER ON EITHER SIDE TO GET
anTdO THfEaCnONsDEhNrSoORuCdOIL to accOeRsFsANfBaLAnDE. or coil

Manual 2100-787A Page 36 of 50

PARTS HIDDEN FOR CLARITY
Parts hidden for clarity

MIS-4045

Model

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

W42AY W48AY W60AY W72AY

75/62 80/67 85/72 75/62 80/67 85/72 75/62 80/67 85/72 75/62 80/67 85/72

Low Side High Side
Low Side High Side
Low Side High Side
Low Side High Side
Low Side High Side
Low Side High Side
Low Side High Side
Low Side High Side
Low Side High Side
Low Side High Side
Low Side High Side
Low Side High Side

122 124 126 128 130 132 134 136 137 140 142 314 336 360 383 409 434 460 488 517 546 576
130 133 135 137 139 141 143 145 147 150 152 322 345 369 393 419 445 472 501 530 560 591
135 138 140 142 144 146 148 150 152 155 157 333 357 382 407 434 461 489 519 549 580 612
128 131 133 135 137 138 140 142 144 146 148 331 352 374 398 422 448 474 502 530 561 592
137 140 142 144 146 148 150 152 154 156 158 339 361 384 408 433 459 486 515 544 575 607
142 145 147 149 151 153 155 157 159 161 164 351 374 397 422 448 475 503 533 563 595 628
127 129 131 133 134 136 137 139 140 142 143 326 348 371 395 420 446 472 499 527 556 586
136 138 140 142 143 145 147 149 150 152 153 334 357 381 405 431 457 484 512 540 570 601
141 143 145 147 148 150 152 154 155 157 158 346 369 394 419 446 473 501 530 559 590 622
119 121 122 123 125 127 129 131 133 134 136 334 356 379 403 428 453 481 509 538 567 599
127 129 131 132 134 136 138 140 142 143 145 343 365 389 413 439 465 493 522 552 582 614
131 134 136 137 139 141 143 145 147 148 150 355 378 403 427 454 481 510 540 571 602 635

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. See Condenser Fan Operation on page 31.

Manual 2100-787A

Page

37 of 50

TABLE 11A Electrical Specifications - W42AY, W48AY Series

Single Circuit

Multiple Circuit

Model

Rated Volts & Phase

No. Field Power Circuits

Minimum
Circuit Ampacity

Maximum External Fuse or Circuit Breaker

Minimum
Circuit Ampacity

Ckt.

Maximum External Fuse or Ckt. Breaker

Ckt.

W42AY-A0Z

A05 A10

230/208-1

1 1

31 57

A15

1 or 2

W42AY-B0Z

B05 B09

230/208-3

1 1

23 33

B15

W42AY-C0Z

C09

460-3

C15

W42AYRC0Z

RC09

460-3

RC15

W48YC-A0Z

A05 A10

230/208-1

1 1

35 59

A15

1 or 2

W48YC-B0Z

B05 B09

230/208-3

1 1

25 34

B15

W48YC-C0Z

C09

460-3

C15

W48AYRC0Z

RC09

460-3

RC15

30 30 35 60

15 20 25

30 30 35 60

15 20 30

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.

Manual 2100-787A Page 38 of 50

TABLE 11B Electrical Specifications - W60AY, W72AY Series

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

230/208-1 230/208-3
460-3 460-3 230/208-1 230/208-3 460-3 460-3

No. Field Power Circuits

Minimum Circuit
Ampacity

Maximum External Fuse or Circuit Breaker

1 or 2

Minimum
Circuit Ampacity

Ckt.

Maximum External Fuse or Ckt. Breaker

Ckt.

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.

Manual 2100-787A

Page

39 of 50

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. Refer to the graphs on pages 44 and 45 for the corresponding airflow of each tap. 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

Model
W42AY W48AY W60AY W72AY

Nominal Rated CFM*
1350
1550
1750
1900

Nominal Rated ESP*
.15
.20
.20
.25

Recommended Airflow Range
1250 - 1600 1450 - 1750 1650 - 2000 1800 - 2100

Factory Speed Connection
Default

* Rated CFM and ESP on factory speed connection.

NOTE: Be sure to adjust the system static or blower speed to maintain airflows above the minimum recommendations to prevent freeze up conditions if Balanced Climate mode is activated.
Do not operate the unit in Balanced Climate mode if running high static applications as indicated in the blower performance table. If Balanced Climate mode is activated as described on page 25, the unit will run in this mode at all times unless there is a

24VAC Common
24VAC "R" signal through thermostat output
Speed Tap 1: Vent Speed Speed Tap 2: Balanced Climate Speed Speed Tap 3: Default Speed Speed Tap 4: Medium Speed Speed Tap 5: High Speed
Multiple motor speed taps may be energized simultaneously by 24VAC power during different modes of operation. The highest number speed tap energized takes priority with 5 being the highest and 1 being the lowest. See Table 13 for the corresponding blower speeds with the different modes of operation.

TABLE 13 Blower Speeds for Unit Operational Modes

Unit Operation

Thermostat Inputs 24VAC

Speed Taps

G Y1 Y2 W1 W2 A D 1 2 3-4-51

Blower Speed

Compressor Operation

Blower Only Balanced Climate Cooling Full Load Cool 1st Stage Heat 2nd Stage Heat Dehumidify2

X XX XXX
X XX

Vent/Blower Only

Off

Balanced Climate

X Lo/Med/Hi

Off

X Lo/Med/Hi

Off

XXX

Balanced Climate

¹ Fan speed is selectable through the blower speed control terminal block. LO (default), MED or HI speeds can be used. 2 Dehumidification operation is disabled when a call for heating or cooling occurs. Unit runs at Balanced Climate speed
during dehumidification operation.

Manual 2100-787A Page 40 of 50

Programmed blower speed taps are as follows (see also Figure 28): Speed Tap 1: Vent/blower only speed Speed Tap 2: Balanced Climate speed Speed Tap 3: Default LO cooling & heating speed. Energized by default for cooling operation through the blower speed tap selection and is labeled as LO. Speed Tap 4: Optional MED Cooling & heating speed. Selected manually through the blower speed tap selection and is labeled as MED. Speed Tap 5: Optional HI cooling & heating speed. Selected manually through the blower speed tap selection and is labeled as HI.
FIGURE 28 Speed Taps
Orange Wire w/Black Stripe
Speed Tap 1 Vent/Blower Only Speed taps 1 and 3 are programmed to identical torque settings in the ECM motor. This means that if speed tap 1 is energized, the airflow amount will be the same as default airflow. Tap 1 is used when a vent is installed and ventilation is called for by energizing the A terminal of the low voltage terminal block with 24VAC. Speed tap 1 is the lowest priority; if any of the other speed taps are energized, they will override speed tap 1. Speed Tap 2 Balanced Climate Speed tap 2 is programmed to a lower than rated speed in the ECM motor. In order for Balanced Climate speed to be used during compressor cooling mode, the jumper between Y1 and Y2 must be removed. This means that if speed tap 2 is energized, the airflow amount will be lower than default airflow. Tap 2 is used when Balanced Climate is called for by energizing the Y1 terminal of the low voltage terminal block with 24VAC. Speed tap 2 is overridden if taps 3, 4, or 5 are energized.

Speed Tap 3 Default LO Cooling & Heating
Speed tap 3 is programmed for rated speed in the SelecTech motor. This means that if speed tap 3 is energized, the airflow amount will be the default airflow. Tap 3 is used by default when cooling is called for by energizing the Y1 terminal of the low voltage terminal block with 24VAC. The unit is shipped with the jumper between Y1 and Y2 installed and it must be removed to use Balanced Climate mode. The unit is shipped with the orange/black wire connected to terminal LO (rated speed) on the blower selection speed terminal block. Speed tap 3 can be overridden if taps 4 or 5 are energized by changing the position of the orange/black wire on the blower selection speed terminal block to MED (4) or HI (5) positions.
Speed Tap 4 Optional MED Cooling & Heating
Speed tap 4 is programmed to a higher than rated speed in the ECM motor. This is a user-selectable airflow amount that will be higher than rated airflow. Tap 4 is used for cooling operation if the orange/black wire on the blower speed selection terminal block is moved to MED. Speed tap 4 can be overridden if tap 5 is energized.
Speed Tap 5 Optional HI Cooling & Heating
Speed tap 5 is programmed to the highest speed in the ECM motor. This is a user-selectable airflow amount that will provide the highest rated airflow. Tap 5 is used for cooling operation if the orange/black wire on the blower speed selection terminal block is moved to HI.
Dirty Filter Switch (Optional)
1. Disconnect all power to the unit. Remove control panel outer cover and upper front panel.
2. The dirty filter switch is located on top of the filter partition between the blower wheels (see Figure 29 on page 42). The dirty filter indicator light and reset switch is located on the right side of the filter access opening above the control panel. Remove the cover on the dirty filter switch and ensure the knob is set at 0.4" W.C. (see Figure 30 on page 43). This is only a recommended starting point prior to making switch adjustments. Switch setting is highly dependent on filter type used, blower speed, unit ducting and other unit installation characteristics. See Dirty Filter Switch Adjustment instructions on how to make proper switch adjustments.
3. Re-install upper front panel.
Dirty Filter Switch Adjustment
1. Apply power to the unit.
2. Turn the unit indoor blower on (energize R-G on low voltage terminal board).
3. With air filters installed and switch initially set at 0.4" W.C. (see Step 2 under Dirty Filter

Manual 2100-787A

Page

41 of 50

Switch), begin restricting the air filter of the unit using a piece of cardboard under the filters until the switch trips and the light comes on. If the filter is restricted by 75% (or desired restriction amount), skip to Step 6.
4. If switch setting adjustment is required, disconnect power to the unit. Remove the upper front panel and the cover on the airflow switch so that adjustment can be made. If the switch tripped before 75% restriction was reached, turn the knob slightly clockwise. If the switch tripped after 75%, turn the knob counter-clockwise (see Figure 30).

5. Replace the upper front panel and repeat Steps 1-3. Continue to make adjustments described in Step 4 until the desired restriction is obtained.
6. Remove the restriction and reset the filter switch. Replace the switch cover once adjustment is complete.
7. Install the outer control panel cover. This completes the adjustment.

FIGURE 29 Dirty Filter Switch and Dirty Filter Indicator Light/Reset Switch

Dirty Filter Switch
Manual 2100-787A Page 42 of 50

Dirty Filter Indicator Light and Reset Switch

FIGURE 30 Adjusting Dirty Filter Switch
TURN CLOCKWISE TO INCREASE RESTRICTION AMOUNT REQUIRED TO ACTIVATE THE SWITCH AND COUNTER-CLOCKWISE TO DECREASE RESTRICTION AMOUNT

MIS-4086 B

Manual 2100-787A

Page

43 of 50

CFM

1800 1700 1600 1500 1400 1300 1200 1100 1000
900 800
0
1950

GRAPH 1 W42AY 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 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

E.S.P.

Manual 2100-787A Page 44 of 50

CFM

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.

Manual 2100-787A

Page

45 of 50

TABLE 14 Maximum ESP of Operation
Electric Heat Only

Model

W42AY/D W48AY/D W60AY/D W72AY/D

-A05

.50

-A10

.50

-A15

.50

-B05

.50

-B09

.50

-B15

.50

-C05

.50

-C09

.50

-C15

.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

1-PH Amps

3-PH Amps

BTUH

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
-47,100

Manual 2100-787A Page 46 of 50

230V Units 460V Units

TABLE 16 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

Manual 2100-787A

Page

47 of 50

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

TABLE 17 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

Manual 2100-787A Page 48 of 50

GRAPH 5 W42AY FAD-NE5 W/O Exhaust Ventilation Delivery

GRAPH 6 W48AY FAD-NE5 W/O Exhaust Ventilation Delivery

Manual 2100-787A

Page

49 of 50

GRAPH 7 W60AY FAD-NE5 W/O Exhaust Ventilation Delivery
GRAPH 8 W72AY FAD-NE5 W/O Exhaust Ventilation Delivery
Manual 2100-787A Page 50 of 50

References

Adobe PDF Library 17.0