INSTALLATION INSTRUCTIONS

Getting Other Information and Publications

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

• National Electrical Code: ANSI/NFPA 70
• Standard for the Installation of Air Conditioning and Ventilating Systems: ANSI/NFPA 90A
• Standard for Warm Air Heating and Air Conditioning Systems: ANSI/NFPA 90B
• Load Calculation for Winter and Summer Air Conditioning: ACCA Manual J Residential
• Duct Design for Residential Winter and Summer Air Conditioning and Equipment Selection: ACCA Manual D

For more information, contact these publishers:

ACCA (Air Conditioning Contractors of America)
1712 New Hampshire Ave. N.W.
Washington, DC 20009
Telephone: (202) 483-9370
Fax: (202) 234-4721

ANSI (American National Standards Institute)
11 West Street, 13th Floor
New York, NY 10036
Telephone: (212) 642-4900
Fax: (212) 302-1286

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

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

Wall Mount General Information

Air Conditioner Wall Mount Model Nomenclature

The model nomenclature provides details about the unit's configuration. For example, 'W12AB-A0Z' breaks down as:

• Model Series: W
• Capacity: 12 (1 Ton)
• Revision: A (Air Conditioner)
• Volts & Phase: A (230/208/60/1), D (240/220/50/1), K (115/60/1)
• KW: (Kilowatts)
• Ventilation Options: X (Barometric Fresh Air Damper - Standard), B (Blank-off Plate), E (Economizer - Internal, Fully Modulating with Exhaust), V (Commercial Ventilator - Motorized with Exhaust)
• Filter Options: X (1" Throwaway - Standard), W (1" Washable), P (2" Pleated)
• Control Modules: X (Standard), E (Low Ambient Control), J (Low Ambient Control and Alarm Relay)
• Coil Options: X (Standard), 1 (Phenolic Coated Evaporator), 2 (Phenolic Coated Condenser), 3 (Phenolic Coated Evaporator and Condenser)
• Placeholder: X (Future Use)
• Color Options: X (Beige - Standard), 1 (White), 4 (Buckeye Gray), 5 (Desert Brown), 8 (Dark Bronze)

Note: Vent options X and B do not include exhaust capability and may require a separate field-supplied barometric relief.

Shipping Damage

Upon receipt, inspect the carton for external shipping damage. If damage is found, contact the carrier immediately, preferably in writing, to request an inspection by their agent.

General

This equipment is intended for installation by trained, experienced service and installation technicians. It is not intended for use by persons with reduced physical, sensory, or mental capabilities, or lack of experience and knowledge, unless supervised. Children should be supervised to ensure they do not play with the appliance.

The refrigerant system is fully assembled and charged. Internal wiring is complete. The unit is designed for use with or without ductwork, with flanges provided for supply and return ducts.

These instructions detail the recommended method for installing the self-contained unit and its electrical connections. Read all instructions, including those packaged with separate equipment, before beginning installation. Pay attention to "Starting Procedure" and any tags or labels on the equipment.

These instructions are a general guide and do not supersede national or local codes. Consult authorities having jurisdiction. Unit sizing should be based on ACCA heat loss calculations. Air duct installation must comply with NFPA No. 90A and NFPA No. 90B. Adhere to local codes where they differ.

Duct Work

All supply and return ductwork must be properly sized for the design airflow requirement, following ACCA guidelines. Ductwork not in the conditioned space should be insulated (minimum 1" with vapor barrier) to conserve energy and prevent condensation. Flexible joints should be used to minimize noise transmission. Ducts through walls must be insulated and sealed. Some installations may not require a return air duct; in such cases, a filter grille is recommended, with filters sized for a maximum velocity of 400 fpm. Applicable codes may limit installation without a return air duct to single-story structures.

Filters

A standard 1" throwaway filter is included, accessible from the outside via the service door. A 2" pleated filter is available as an optional accessory; internal filter brackets can be adjusted.

Fresh Air Intake

Units have fresh air inlet slots. If equipped with a fresh air damper assembly, it is shipped attached and locked closed. Maximum and minimum blade position stops must be installed for operation (see Figure 1). An adjustable slide regulates the amount of fresh air. Capacity, efficiency, and cost of operation information are based on the fresh air blank-off plate being in place. A blank-off plate is available upon request from the factory.

Figure 1: Fresh Air Damper depicts the fresh air damper, noting the blade is locked closed for shipping.

Installation

Basic Installation Design and Application Planning

Proper planning and site inspection are crucial for successful installation. Ensure all service and airflow clearances are met and applicable codes are followed. Inspect both the inside and outside of the structure.

Wall Construction

Verify the wall can support the unit's weight and review construction codes, including seismic requirements. For wood frame walls, ensure structural members support mounting lags and brackets. Concrete block, brick, and metal buildings must have adequate structural components. Trim and flash corrugated siding to provide a flat surface for sealing. Heavy gauge corrugations may require a metal plate. Ensure the unit area is weatherized and sealed to prevent air and water infiltration.

Outdoor Area Inspection

Inspect the outdoor area for obstructions that could hinder condenser airflow or unit serviceability. Avoid enclosed areas that limit ambient airflow. Warm air exits the front condenser section, and outdoor air enters the side intake openings. Ensure adequate airflow for proper unit operation. Check wall surfaces for obstructions like conduits, junction boxes, drains, windows, doors, or overhangs.

Condensate Water Drainage

Review condensate drainage requirements. A clear, flexible PVC drain hose (3/4" ID, 1" OD) extends from the drain pan to the unit base and protrudes 1" to 2" below. Units operating in freezing outdoor temperatures may cause condensate to freeze. If connected to a drain system, it must be open or vented.

Indoor Ducted and Non-Ducted Applications

Proper air distribution is key for consistent temperature. Improper distribution can lead to uneven temperatures or discomfort. Thermostat placement also impacts climate control. Ensure supply air paths are non-restrictive, using grilles or ductwork. For non-ducted applications, use a supply louver grille and adjust deflectors. Avoid closing grille sections to prevent duct pressurization.

Ensure a non-restrictive path for return air. Avoid placing furniture or equipment near return grilles. Bard recommends at least 2 feet clearance from solid objects to return grilles. For non-ducted applications, use a return grille with louvers pointing downward to draw air from the floor.

Ducted Applications

Field-fabricated ductwork may be installed inside the structure. Stub ducts can connect to unit flanges. Ducts must be properly sized per ACCA guidelines. Ductwork in unheated spaces requires insulation (minimum 1" with vapor barrier). Flexible joints minimize noise. Ducts through walls need insulation and sealing.

Free Blow Applications

These installations may not require extensive ductwork. A short field-fabricated supply duct transitions to a supply louver grille. Ductwork must be insulated and sealed. A non-restrictive metallic supply air grille with deflectors is required. For return air, a metallic grille with louvers no larger than 5/8" is required. A Bard Return Air Grille Kit is recommended. Return air grilles do not filter air from ventilation options.

Thermostat or Indoor Temperature Sensor Placement

Proper placement is critical for unit operation. Avoid direct sunlight or drafts from doorways. Use insulating material for wire entry holes. The thermostat should measure return air temperature, not supply air. Placement near a return air opening typically yields optimal performance.

Unit Installation

Ensure proper tools are on-site. Follow these steps for correct wall surface installation and minimal service requirements.

Materials/Tools List

Additional field-supplied hardware and miscellaneous supplies are needed. Tools required include:

• Safety gear (gloves, safety glasses)
• 5/16" hex bit with drill driver
• Phillips head screwdriver
• Small straight (thermostat) screwdriver
• Tape measure
• Leveling device
• Caulk and caulk gun
• Utility knife
• Tools for cutting wall holes
• Electrical components, wiring, and electrical tools
• Multimeter
• Wall fasteners for side flanges and top rain flashing
• Duct tape and/or other duct sealing materials

Wall Preparation

1. Cut two holes for supply and return air openings (refer to Figure 3). Ensure openings are square and level. Follow all clearances and manual instructions.
2. Review electrical requirements and plan electrical entrances, conduit routing, and thermostat placement.
3. Install necessary ductwork and prepare openings.
4. Clean the exterior wall surface to be smooth, level, and debris-free. Remove all construction debris from hole cutting.

Wall Mount Installation to Wall Surface

1. Remove unit packaging and inspect for damage. Remove the factory-supplied top rain flashing (mounted for shipping). Review unit labels and serial plate for requirements.
2. Position the unit close to the wall. Install the top rain flashing by hooking its hem bend into the rear bend of the unit top (see Figure 3).
3. Apply caulk to side wall mount brackets and the back of the top rain flashing. Place the unit back surface flush against the wall. Ensure the unit is level for proper condensate drainage.
4. Secure the unit using field-supplied fasteners through the built-in wall mounting brackets. Select fasteners based on wall construction and codes. Typical fasteners include 5/16" with 7/8" diameter flat washers. Ensure fasteners attach to structural members.
5. Apply a bead of caulk between the unit top and the front surface of the top rain flashing (see Figure 3).
6. Connect unit ductwork from inside the building, following clearances and instructions. For rigidity, return/supply air frames can be secured to the structural wall. Seal ductwork to the unit with approved duct tape or sealing materials.
7. For side-by-side installations, maintain a minimum 20" clearance on the right side for control panel access and airflow to the outdoor coil. Additional clearance may be needed per local codes.

Table 1: Clearance Required for Service Access and Adequate Condenser Airflow

Figure 2: Unit Dimensions provides detailed measurements for the front, back, and right side views of the unit.

Figure 3: Mounting Instructions illustrates the wall opening and hole location, including details on sealing with caulking and foam air seal. It also shows the placement of the rain flashing.

Figure 4: Wall Mounting Instructions shows installations for concrete block walls and wood frame walls, along with a side view detail of the factory-supplied rain flashing.

Figure 5: Wall Mounting Instructions details structural support requirements for wall mounting, showing attachment points to wall plates and framing materials.

Figure 6: Common Wall Mounting Installations illustrates four scenarios: Non-Ducted Installations, Ducted Installations, Outdoor Wall Curb Installations, and WAPR11 Indoor Sound Plenum Installations, showing airflow paths and installation context.

Wiring – Main Power

Supply main electrical power from a clean, reliable source. Verify voltage consistency and range specified for the unit. Voltage must be measured at the field power connection point while the unit operates at full load. Refer to the unit serial plate and specifications for wire sizing and fuse/circuit breaker size. Field wiring must be sized for the "Minimum Circuit Ampacity." Use only copper conductors. Wiring must conform to NEC and local codes. The unit rating plate specifies the "Maximum Time Delay Relay Fuse" or circuit breaker for proper protection and to prevent nuisance tripping.

Wiring – Low Voltage

Units with 230/208V 1 phase and 3 phase have dual primary voltage transformers. They are factory wired on the 240V tap. For 208V operation, reconnect to the 208V tap. Acceptable voltage ranges are 253-216V for 240V tap and 220-187V for 208V tap. Low voltage wiring typically uses an 18-gauge copper, color-coded cable (see Table 4).

Low Voltage (24VAC) Connections

The unit uses a 24-volt AC low voltage circuit with terminals for:

• C: 24VAC common (grounded)
• G: Indoor blower input
• Y1: 1st Stage cooling input
• Y2: 2nd Stage compressor input for cooling (disables Balanced Climate mode if Y1-Y2 jumper is removed)
• B/W1: 1st stage electric heat
• A: Ventilation input (energizes ventilation option and indoor blower)
• L: 24 volt alarm active output

For units with an alarm relay:

• 1: Normally closed contact
• 2: Normally open contact
• 3: Common contact

Unit Shutdown Feature

The RT terminal is the 24VAC transformer output, and R is the 24VAC hot terminal. A jumper connects RT and R. This jumper can be removed and RT/R connected to an external NC (normally closed) contact, such as a fire/smoke detector, for emergency shutdown.

Balanced Climate™ Feature

This feature reduces indoor airflow and extends run time to enhance comfort and humidity removal. Y1 terminal is for Balanced Climate cooling; Y2 is for standard cooling. A jumper connects Y1 and Y2; removing it enables Balanced Climate mode. Units with an economizer do not have this jumper. A 2-stage cooling thermostat is required. If cooling is not satisfied, the thermostat signals Y2, increasing blower speed. Refer to page 18 for limitations.

Ventilation Features (Optional)

Refer to provided ventilation instructions for low voltage wiring.

Alarm Relay Feature

The alarm relay provides NO and NC contacts that activate when the compressor control module locks out operation due to high or low refrigerant pressure.

Table 2: Wall Thermostats lists various thermostat part numbers and their predominant features.

Table 3: CO2 Controllers lists part numbers and predominant features for CO2 controllers.

Table 4: Thermostat Wire Size provides wire gauge recommendations based on transformer VA and FLA, and maximum distance.

Start Up

General

These units require R-410A refrigerant and polyol ester oil.

Safety Practices

• Use separate service equipment for R-410A.
• Use recovery equipment rated for R-410A.
• Use manifold gauges rated for R-410A.
• R-410A is a binary blend (HFC-32/HFC-125) and is nearly azeotropic; charge with liquid refrigerant.
• R-410A operates at higher pressure than R-22.
• R-410A has zero ozone depletion potential but has global warming potential.
• R-410A compressors use polyol ester oil, which is hygroscopic.
• Use a liquid line dryer. Limit atmospheric exposure to 15 minutes.
• Plug compressors immediately after removal.
• Never mix R-410A with other refrigerants.
• Wear gloves and safety glasses; polyol ester oil can irritate skin, and liquid refrigerant can freeze skin.
• Never use air and R-410A for leak checks.
• Do not inhale R-410A vapor; it can cause dizziness, loss of coordination, and potentially death.
• Do not burn R-410A; decomposition produces hazardous vapors.
• Use only DOT4BA/4BW 400 rated cylinders.
• Never fill cylinders over 80% capacity.
• Store cylinders in a cool area, out of direct sunlight.
• Never heat cylinders above 125°F.
• Never trap liquid R-410A in lines or cylinders.

REMEMBER: Add R-410A refrigerant as a liquid from the charging cylinder/tank for optimal performance.

Topping Off System Charge

If a leak occurs, Bard recommends reclaiming, evacuating, and recharging to the nameplate charge. For topping off, R-410A composition does not change significantly with leaks. Use pressure charts on the control panel cover as a guideline.

Important Installer Note

Wash the indoor coil with dishwashing detergent for improved start-up performance.

High Pressure Switch

Models have a remote reset for high/low pressure switches. Reset by turning the thermostat off and then back on. High pressure switch settings: Opens 575 ± 15 PSI, Closes 425 ± 15 PSI.

Condenser Fan Operation

Some models have a low ambient control (LAC) that delays condenser fan start until system refrigerant pressure builds. Fan cycling may occur depending on ambient conditions. 50 Hz models must have the fan wired on low speed.

Service Hints

1. Advise owners to maintain clean air filters and not to close off supply/return registers unnecessarily, as this reduces airflow and equipment life.
2. Check fuses/circuit breakers for correct rating.
3. Periodically clean the outdoor coil for unrestricted airflow.

Sequence of Operation

Cooling: R-Y1 at thermostat energizes compressor contactor, starting compressor and outdoor motor. The G circuit (indoor motor) is completed by the thermostat or manual fan switch. Heating: R-W1 at thermostat energizes heat contactor for strip heat and blower operation.

Balanced Climate™ Mode

This feature reduces indoor airflow and extends run time to enhance comfort and humidity removal. Y1 terminal is for Balanced Climate cooling; Y2 is for standard cooling. A jumper connects Y1 and Y2; removing it enables Balanced Climate mode. Units with an economizer do not have this jumper. A 2-stage cooling thermostat is required. If cooling is not satisfied, the thermostat signals Y2, increasing blower speed. Refer to page 18 for limitations.

Vent Connection Plug

A vent connection plug is located in the control panel for ventilation packages. Ensure either the optional vent or the supplied jumper plug is connected; the unit will not operate otherwise. This plug is behind the filter access door.

Compressor Control Module (CCM)

The CCM is standard on all models. Features include:

• 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 2-minute delay prevents multiple units from starting simultaneously after a power loss. Adjust the delay-on-break timer on each unit to slightly different times.

Short Cycle Protection/Delay-on-Break

An anti-short cycle timer prevents compressor short cycling. It is adjustable from 30 seconds to 5 minutes via an adjustment knob (see Figure 9). A new call will not initiate until the timer expires after the previous call is lost.

Low Pressure Detection

Monitors low pressure switch. If open for >2 minutes, the CCM de-energizes the compressor for the delay-on-break time. If the switch closes, the compressor restarts. If it trips again during the same call, the compressor is de-energized, and the alarm terminal is energized. A blue LED indicates this condition.

High Pressure Detection

Monitors high pressure switch. If open, the CCM de-energizes the compressor. If it closes again, the compressor restarts after the delay-on-break setting. If it trips again during the same call, the compressor is de-energized, and the alarm terminal is energized. A red LED indicates this condition.

Test Mode

All timing functions are removed for testing by rapidly rotating the potentiometer (POT) clockwise (see Figure 9). Conditions: POT starts at or below 40 seconds, then rotated to or above 280 seconds in < 1/4 second. Normal operation resumes after power reset or 5 minutes in test mode.

Brownout Protection with Adjustment

May be necessary if utility or generator power is inadequate. The 8201-169 has DIP switches for brownout ignore time (1, 5, or 10 seconds). This allows the compressor time to start and voltage to recover. If a brownout is detected, the troubleshooting light flashes blue. The condition does not prevent operation but indicates a brownout occurred. If the 'do not ignore' position is selected with inadequate power, the compressor may not start.

Figure 9: 8201-169 Compressor Control Module shows the layout and connections of the control module, including DIP switches for brownout ignore time and the delay-on-break adjustment potentiometer.

Pressure Service Ports

High and low pressure service ports allow observation of system operating pressures. Refer to pressure tables (page 22) matching the unit model. This unit uses high-flow Coremax valves. WARNING: Do NOT use a Schrader valve core removal tool. A special tool is required for changing Coremax valves without refrigerant removal (available at www.fastestinc.com/en/SCCA07H).

Service

Fan Blade Setting Dimensions

Figure 10 shows the correct fan blade setting for proper air delivery. Refer to Table 5 for specific dimensions. Adjust blade position on the motor shaft as needed.

Figure 10: Fan Blade Setting illustrates the fan blade position 'A' relative to airflow.

Table 5: Fan Blade Dimensions

R-410A Refrigerant Charge

The unit is factory charged with the quantity listed on the serial plate. AHRI ratings are based on this charge. Pressure tables provide nominal pressures for evaluation by certified technicians; they are not for adjusting charge. If charge is in doubt, reclaim, evacuate, and recharge to the serial plate charge.

Setting Unit Airflow

The unit is factory set to a default speed. Two selectable cooling speed taps are available: the default (lowest) and a higher speed for higher duct static applications or increased sensible cooling. To change to the higher speed, replace the blue wire on the blower relay with the black wire. Refer to Table 11 for airflow at each tap. Set unit duct static based on the highest airflow.

Note: Adjust system static or blower speed to maintain airflows above minimum recommendations to prevent freeze-up with Balanced Climate mode. Do not operate in Balanced Climate mode with high static applications.

Blower Speeds

The ECM motor has three speed taps selected via 24VAC signals. Multiple taps can be energized simultaneously; the highest number takes priority. See Table 10 for blower speeds by operational mode.

• Speed Tap 1 – Balanced Climate: Lower than rated speed. Requires Y1/Y2 jumper removal. Airflow is lower than default. Overridden by taps 2 or 3.
• Speed Tap 2 – Default Cooling & Heating: Rated speed. Default for Y1 cooling. Unit ships with Y1/Y2 jumper installed (remove for Balanced Climate).
• Speed Tap 3 – Optional HI Cooling & Heating: Highest speed. Provides highest rated airflow. Used for cooling if blue wire on blower relay is replaced with black wire.

Table 9: Recommended Airflow provides nominal rated CFM, ESP, recommended airflow range, and factory speed connection for the W12AB model.

Table 10: Blower Speeds for Unit Operational Modes details thermostat inputs (G, Y1, Y2, W1, A, D) and corresponding speed taps (1, 2-3) for different unit operations (Blower Only, Balanced Climate Cooling, Full Load Cool, 1st Stage Heat), and compressor operation.

Table 11: Indoor Blower Performance provides airflow (CFM) for different ESP values, Balanced Climate Speed, Rated/Ventilation Speed, and Optional HI Cooling & Heating Speed for models W12AB-B, W12AB-D, and W12AB-K.

Table 12: Electric Heat lists KW, Amps, and BTU for different voltage options for models W12AB-A, W12AB-K, and W12AB-D.

Table 13: Maximum ESP of Operation – Electric Heat Only shows ESP values for different outlet speeds (High/Low) for the W12AB model.

Table 14: Vent and Control Options lists part numbers and descriptions for optional controls and ventilation features.