2100-269(g) (2002 10) - bardhvac.com

SPLIT AIR CONDITIONEROUTDOOR SECTION50HZ Models

HAC181-DHAC241-DHAC301-DHAC361-GHAC421-GHAC421-EHAC421-FHAC481-GHAC481-EHAC481-FHAC601-GHAC601-EHAC601-F

For Use With:Matching IndoorBlower Coil Unitsand Matching AddOn Coil Units Only

INSTALLATION INSTRUCTIONS

Manual No.: 2100-269GSupersedes: 2100-269FFile: Tab 4Date: 10-01-02

Bard Manufacturing CompanyBryan, Ohio 43506

Since 1914...Moving ahead, just as planned.

© Copyright 2002

CONTENTS

i

Split Air Conditioner General Information ......... 1Split Air Conditioner Model Nomenclature ............... 1

Application and Location .................................... 5General .................................................................... 5Shipping Damage .................................................... 5Application ............................................................... 5Location ................................................................... 5Mounting Unit Outside on Slab ................................. 5Important Installer Note ............................................ 5Installing Refrigerant Tubing ..................................... 5Sweat Style Tubin Connections: SweatIndoor Unit and Sweat Outdoor Unit ........................ 6Field Fabricated Tubing Connections:Quick Connect Indoor Unit and SweatOutdoor Unit Using CTO Kit ..................................... 7

Wiring Instructions ............................................ 10General .................................................................. 10Control Circuit Wiring ............................................. 10Wall Thermostats ................................................... 10Optional Controls ................................................... 13Installation Instructions – CMA-5 ............................ 13Installation Instructions – CMA-6 ............................ 13Installation Instructions – CMA-10A........................ 14Installation Instructions – CMA-13A........................ 15

Charging Instructions........................................ 16Pressure Service Ports .......................................... 16System Start-Up (Indoor Unitswithout Expansion Valves ....................................... 16

Service ................................................................ 18Service Hints .......................................................... 18Fan Blade Setting Dimensions ............................... 18Pressure Tables ................................................ 22-25

FIGURESFigure 1 .................................................................... 1Figure 2 .................................................................... 5Figure 3 .................................................................... 6Figure 4 .................................................................... 6Figure 5 .................................................................. 13Figure 6 .................................................................. 13Figure 7 .................................................................. 13Figure 8 .................................................................. 14Figure 9 .................................................................. 15

TABLESTable 1 ..................................................................... 1Table 2 ..................................................................... 2Table 3 ............................................................... 3 & 4Table 4 ..................................................................... 7Table 5 ..................................................................... 9Table 6 ................................................................... 10Table 7 ................................................................... 10Table 8 ................................................................... 10Table 9 ................................................................... 16Table 10 ................................................................. 16Table 11 ................................................................. 17Table 12 ................................................................. 18Table 13 ................................................................. 22Table 14 ................................................................. 22Table 15 ................................................................. 23Table 16 ................................................................. 23Table 17 ................................................................. 24Table 18 ................................................................. 24Table 19 ................................................................. 25

Manual 2100-269Page 1

SPLIT AIR CONDITIONER MODEL NOMENCLATURE

TABLE 1UNIT DIMENSIONS (INCHES)

.oNledoM"W"htdiW

"D"htpeD

"H"thgieH A B C E F

181CAH142CAH 00.04 00.51 00.62 521.5 881.02 00.4 521.7 881.42

103CAH163CAH 00.54 00.51 00.62 521.5 881.52 00.4 521.7 881.92

124CAH184CAH106CAH

00.05 00.51 00.23 526.6 886.82 00.4 526.8 886.23

W

H

C

BF

E

A

D

HIGH VOLTAGEENTRANCE

LOW VOLTAGEENTRANCE

ALTERNATEELECTRICALENTRANCES

ON BACK

REFRIGERANTSHUTOFFVALVES

MIS-1789

Customized Unit Code

Electrical CharacteristicsD - 240-220-50-1E - 220-200-50-3F - 415-380-50-3G - 220-200-50-1

Modification Code

Capacity – 3 Ton or approx. 36,000 BTU

Basic Model Number

HAC 36 1 – G DXXX

FIGURE 1

DIMENSIONAL DRAWING


� Measured across the evaporator coil assembly, including drain pan.� External static pressure available for the duct system -- supply and return. All blower coils have

multispeed motors, and value shown is at the recommended rated speed. Consult specificationair flow charts with the blower coil units for complete information at other speeds.

* IMPORTANT INFORMATIONProper sized orifice is not factory installed in indoor section. Proper orifice size is shipped withindoor coil packaged with its installation instructions for indoor sections listed on this page. Theorifice must be replaced with the proper system orifice shown above in Table 2.

For other evaporator coil models not listed, see indoor coil installation instructions for proper orificeinformation.

TABLE 2

RATED CFM AND AIR FLOW DATA(WET COIL – COOLING)

wolfriAdetaR

gnisnednoCtinU

.oNledoM

rotaropavElioC

.oNledoMMFC

erusserPHporD 2O

dednemmoceRwolFriAegnaR

metsySecifirO

deriuqeR

181CAH A-SA03A 056 51. 517-055 250. *

142CAH A-SA03A 008 81. 019-007 550.

103CAH A-SA63A 000,1 02. 571,1-058 360.

163CAH A-SA73A 001,1 81. 022,1-029 960.

124CAHA-SA24AA-SA84A

004,1 03.055,1-072,1526,1-052,1

870.870.

184CAH B-SA16A 007,1 82. 578,1-054,1 180. *

106CAH B-SA16A 067,1 03. 059,1-005,1 290.

Manual 2100-269

Page 3

SLEDOM D-181CAH D-142CAH D-103CAH G-163CAH G-124CAH E-124CAH F-124CAH

)HP/V/ZH06(gnitaRlacirtcelE 1-022/042 1-022/042 1-022/042 1-002/022 1-002/022 3-002/022 3-083/514

egnaRegatloVgnitarepO 452-891 452-891 452-891 242-081 242-081 242-081 654-243

yticapmAtiucriCmuminiM 21 61 71 82 23 02 11

� eziSeriWdleiF 41 41 21 01 8 21 41

� rekaerBtiucriCromumixaMesuFyaleD 51 52 03 54 05 03 51

802/032spmAtinUlatoT 6.9 8.21 9.41 2.12 0.32 8.41 1.8

ROSSERPMOC

802/032stloV 022/042 022/42 022/042 002/022 002/022 002/022 083-514

spmAdaoLdetaR 1.8 3.11 4.31 7.91 5.12 3.31 6.6

tnerruCnoitceleStiucriChcnarB 1.8 3.11 7.31 1.12 7.32 7.41 0.7

802/032spmArotoRkcoL 0.54 0.56 7.08 0.801 0.611 0.29 0.64

taeHesacknarC epyTnoisremmI

RESNEDNOCdnaROTOMNAF

MPR/PHrotoMnaF 528-4/1 528-4/1 528-4/1 528-4/1 528-4/1 528-4/1 528-4/1

spmArotoMnaF 5.1 5.1 5.1 5.1 5.1 5.1 5.1

retemaiDnaF 000,2-"02 000,2-"02 000,2-"02 000,2-"02 006,2-"42 006,2-"42 006,2-"42

METSYSTCENNOCTAEWS

DIeziSeniLnoitcuS "8/5 "4/3 "4/3 "4/3 "8/7 "8/7 "8/7

DIeziSeniLdiuqiL "4/1 "8/3 "8/3 "8/3 "8/3 "8/3 "8/3

.zO22-RegnahCyrotcaF .zo37 .zo97 .zo48 .zo69 .zo201 .zo201 .zo201

.SBLTHGIEWGNIPPIHS 551 551 081 081 052 052 052

TABLE 3

SPECIFICATIONS

Manual 2100-269

Page 4

TABLE 3

SPECIFICATIONS (CONTINUED)

SLEDOM G-184CAH E-184CAH F-184CAH G-184CAH E-106CAH F-106CAH

)HP/V/ZH06(gnitaRlacirtcelE 1-002/022 3-002/022 3-083/514 1-002-022 3-002/022 3-083/514

egnaRegatloVgnitarepO 022-081 242-081 654-243 022-081 242-081 654-243

yticapmAtiucriCmuminiM 83 32 31 04 72 51

� eziSeriWdleiF 8 01 41 8 8 41

� rekaerBtiucriCromumixaMesuFyaleD 06 04 02 06 54 02

802/032spmAtinUlatoT 9.52 0.61 0.9 7.92 5.81 3.01

ROSSERPMOC

802/032stloV 002/022 002/022 083-514 002/022 002/022 083-514

spmAdaoLdetaR 4.42 5.41 5.7 2.82 0.71 8.8

tnerruCnoitceleStiucriChcnarB 8.82 3.71 0.9 1.03 5.02 2.01

802/032spmArotoRkcoL 831 601 35 871 421 26

taeHesacknarC epyTnoisremmI

RESNEDNOCdnaROTOMNAF

MPR/PHrotoMnaF 528-4/1 528-4/1 528-4/1 528-4/1 528-4/1 528-4/1

spmArotoMnaF 5.1 5.1 5.1 5.1 5.1 5.1

retemaiDnaF 006,2-"42 006,2-"42 006,2-"42 006,2-"42 006,2-"42 006,2-"42

METSYSTCENNOCTAEWS

DIeziSeniLnoitcuS "8/7 "8/7 "8/7 "8/7 "8/7 "8/7

DIeziSeniLdiuqiL "8/3 "8/3 "8/3 "8/3 "8/3 "8/3

.zO22-RegnahCyrotcaF .zo551 .zo551 .zo551 .zo351 .zo351 .zo351

.SBLTHGIEWGNIPPIHS 052 052 052 552 552 552


APPLICATION and LOCATION

GENERAL

These instructions explain the recommended method toinstall the air cooled remote type condensing unit, theinterconnecting refrigerant tubing and the electrical wiringconnections to the unit.

The condensing units are to be used in conjunction with thematching evaporator coils or evaporator blower units forcomfort cooling applications as shown in the specificationsheet.

These instructions and any instructions packaged with anyseparate equipment required to make up the entire airconditioning system should be carefully read beforebeginning the installation. Note particularly “StartingProcedure” and any tags and/or labels attached to theequipment.

SHIPPING DAMAGE

Upon receipt of equipment, the carton should be checked forexternal signs of shipping damage. If damage is found, thereceiving part must contact the last carrier immediately,preferably in writing, requesting inspection by the carrier’sagent.

APPLICATION

Size of unit for a proposed installation should be based onheat loss calculation and air duct sizing made according tomethods of Air Conditioning Contractors of America. Theair duct should be installed in accordance with the Standardsof the National Fire Protection Association for theInstallation of Air Conditioning and Ventilating Systems ofOther Than Residence Type, NFPA 90A, and ResidenceType Warm Air Heating and Air Conditioning Systems,NFPA 90B. Where local regulations are at a variance withinstructions, installer should adhere to local codes.

LOCATION

The condensing unit is designed to be located outside withfree and unobstructed condenser air inlet and discharge. Itmust also permit access for service and installation.Condenser air enters the coil and discharges. Refrigerantand electrical connections are made from the rear of the unitas shown in Figure 2 with electrical service access.

MOUNTING UNIT OUTSIDE ON SLAB

A solid level base or platform, capable to support the unit’sweight, must be set at the outdoor unit predeterminedlocation. The base should be at least two inches larger thanthe base dimensions of the unit and at least two incheshigher than surrounding grade level. The required unitminimum installed clearances must be maintained as calledout in Figure 2 when locating and setting the base.

Remove the unit from its shipping carton and position theunit on the prepared base or platform.

NOTE: These units employ internally sprungcompressors; therefore, it is not necessary toremove or loosen the base mounting bolts on thecompressor prior to operation.

Consideration should be given to the electrical and tubingconnections when placing the unit to avoid unnecessarybends or length of material.

IMPORTANT INSTALLER NOTE

For improved start up performance, wash the indoor coilwith a dishwashing detergent.

INSTALLATION REFRIGERANT TUBING

The information that follows on installing refrigerant tubingand for changing the system orifice (if required) coversapplications listed in the front of this installation instructiononly. Although other indoor units may be of similarconstruction, the installation instructions for these unitsshould be consulted for proper installation of those unitsprior to installation.

This information is provided for the field service personnelto install refrigerant tubing in compliance with Section 608of Title VI National Recycling and Emission ReductionProgram for the U.S. Clean Air Act effective July 1, 1992.

Consult manual 2100-002 on procedure for leak test –evacuation – charging before installation refrigerant tubingthat requires any refrigerant recovery or system evacuation.Manual 2100-002 is included with the unit installationinstruction package when shipped from the factory.

FIGURE 2

INSTALLATION CLEARANCE

MIS-589


SWEAT STYLE TUBING CONNECTIONS: SWEATINDOOR UNIT and SWEAT OUTDOOR UNIT

Use only refrigeration grade (dehydrated and sealed) coppertubing. Care must be taken to insure that the tubing is keptclean and dry before and during installation. Do not removethe plugs from the tubing ends, coil connections or basevalves until the connection is ready to be brazed.

The suction line must be insulated with a minimum of 3/8”Armaflex or equivalent before cutting and makingconnections.

1. Being careful not to kink, route both the suction lineand liquid line between the indoor unit and outdoorunit. Use a tubing bender to make any necessary bendsin tubing. When necessary to bend the insulated tubesuction line, cut the insulation around its circumferenceat a distance far enough beyond the point of the bend soas to clear the tubing bender. Slip the insulation backtogether and vapor seal the joint with tape. Coil anyexcess tubing in a horizontal place with the slope of thetubing toward the condensing unit. See Figure 3.

NOTE: Do not braze line to units! If orifice needs to bechanged, change out orifice first.

If the orifice does not have to be changed, skip theinstructions outlined further in Step 3 and proceed to Step 8.

3. Disassemble Flow Control Assembly by turning bodyhex.

4. If existing orifice has not dropped out of the body whendisassembled, remove by using a pin or paper clip.Discard this original orifice.

5. Insert proper sized orifice fully into the flow controlbody with rounded “bullet” nose towards the unit asshown in Figure 4. Insure the orifice stays inserted inbody before connecting mating half. See chart in theoutdoor unit installation instructions for proper size.

6. Thread assembly halves together by hand to insureproper mating of threads and tighten until bodies“bottom” or a definite resistance is felt.

7. Using a marker pen or ink pen, mark a line lengthwisefrom the union nut to the bulkhead. Then tighten anadditional 1/6 turn (or 1 hex flat). The misalignment ofthe line will show the amount the assembly has beentightened. This final 1/6 turn is necessary to insure theformation of the leakproof joint.

8. Wrap a wet rag around the copper stub before brazing.

9. Flux the copper tube and insert into the stub. Braze thejoint using an alloy of silver or copper and phosphoruswith a melting temperature above 1,100° F for copperto copper joints. The phosphorus will act as a flux,therefore, no flux will be required.

FIGURE 3

INSTALLING REFRIGERANT TUBING

FIGURE 4

FLOW CONTROL ASSEMBLYFIELD ORIFICE REPLACEMENT INSTRUCTIONS

PP5

CAUTION1. Be careful not to tear the insulation whenpushing it through hole in masonry or framewalls. 2. When sealing the tube opening inhouse wall, use a soft material to prevent tubedamage and vibration transmission. 3. Avoidexcessive bending in any one place to avoidkinking.

CAUTIONBe sure there is no dirt introduced into the flowcontrol - orifice assembly. Be sure to install theorifice with the bullet nose pointing in the properdirection as shown in Figure 4. Failure to do sowill result in improper operation.

2. The tubing ends should be cut square. Make sure it isround and free of burrs at the connecting ends. Cleanthe tubing to prevent contaminants from entering thesystem.

PP5


A copper-silver alloy with a high silver content shouldbe used when iron or steel material is involved in thejoint. These alloys require the use of silver solder flux.Alloys containing phosphorus should not be used withiron or steel. Phosphorus reacts with the iron formingiron phosphate which is extremely brittle.

CAUTION1. Brazing alloys with a melting temperaturebelow 700° F should not be used. 2. Lead-tinor tin-antimony solders should not be used dueto their low melting point and necessity forcorrosive fluxes.

To further prevent the formation of copper oxide insidethe tubing, dry nitrogen may be purged through therefrigerant system during brazing.

WARNINGNever purge or pressurize a system withoxygen. An explosion and fire will result.

10. After brazing, quench with wet rag to cool the joint andremove any flux residue.

11. Leak test all connections using an electronic leakdetector or a halide torch.

12. Evacuate suction line, liquid line and indoor unitthrough outdoor unit base valves.

13. Open both the suction and liquid base valves to thefully open position. Refer to section later in installationinstructions for details on setting proper system charge.

FIELD FABRICATED TUBING CONNECTIONS:QUICK CONNECT INDOOR UNIT and SWEATOUTDOOR UNIT USING CTO KIT

Use only refrigeration grade (dehydrated and sealed) coppertubing. Care must be taken to insure that the tubing is keptclean and dry before and during installation. Do not removethe plugs from the tubing ends, coil connections or basevalves until the connection is ready to be brazed.

The suction line must be insulated with a minimum of 3/8”Armaflex or equivalent before cutting and makingconnections.

1. Being careful not to kink, route both the suction lineand liquid line between the indoor unit and outdoorunit. Use a tubing bender to make any necessary bendsin tubing. When necessary to bend the insulated tubesuction line, cut the insulation around its circumferenceat a distance far enough beyond the point of the bend soas to clear the tubing bender. Slip the insulation backtogether and vapor seal the joint with tape. Coil anyexcess tubing in a horizontal place with the slope of thetubing toward the condensing unit. See Figure 3.

TABLE 4

TUBING CHART

cisaBgnisnednoCledoMtinU

).tF(htgneLeniLtnaregirfeR

02-0 06-12 001-16

diuqiL noitcuS diuqiL noitcuS diuqiL noitcuS

181CAH "4/1 "8/5 "4/1 "8/5 "8/3 "4/3

142CAH "8/3 "8/5 "8/3 "4/3 "8/3 "4/3

103CAH "8/3 "8/5 "8/3 "4/3 "8/3 "4/3

163CAH "8/3 "8/5 "8/3 "4/3 "2/1 "8/7

124CAH "8/3 "4/3 "8/3 "8/7 "2/1 "8/7

184CAH "8/3 "8/7 "8/3 "8/7 "2/1 "8/1-1

106CAH "8/3 "8/7 "8/3 "8/7 "2/1 "8/1-1

CAUTION1. Be careful not to tear the insulation whenpushing it through hole in masonry or framewalls. 2. When sealing the tube opening inhouse wall, use a soft material to prevent tubedamage and vibration transmission. 3. Avoidexcessive bending in any one place to avoidkinking.


NOTE: Do not make any tubing connection at indoor unitat this time. Make all brazing of joints andevacuate both suction and liquid line first.

3. Wrap a wet rag around the copper stub before brazing.

4. Flux the copper tube and insert into the stub. Braze thejoint using an alloy of silver or copper and phosphoruswith a melting temperature above 1,100° F for copperto copper joints. The phosphorus will act as a flux,therefore, no flux will be required.

A copper-silver alloy with a high silver content shouldbe used when iron or steel material is involved in thejoint. These alloys require the use of silver solder flux.Alloys containing phosphorus should not be used withiron or steel. Phosphorus reacts with the iron formingiron phosphate which is extremely brittle.

To further prevent the formation of copper oxide insidethe tubing, dry nitrogen may be purged through therefrigerant system during brazing.

2. The tubing ends should be cut square. Make sure it isround and free of burrs at the connecting ends. Cleanthe tubing to prevent contaminants from entering thesystem.

CAUTION1. Brazing alloys with a melting temperaturebelow 700° F should not be used. 2. Lead-tinor tin-antimony solders should not be used dueto their low melting point and necessity forcorrosive fluxes.

WARNINGNever purge or pressurize a system withoxygen. An explosion and fire will result.

5. After brazing, quench with wet rag to cool the joint andremove any flux residue.


7. Evacuate suction line and liquid line through outdoorunit base valves.

If orifice does not have to be changed, skip the instructionsoutlined further in Step 8 and proceed to Step 15.

8. Recover charge from the indoor unit.

A. Connect the suction line only to the indoor unit asoutlined in Steps 15, 16, and 17.

B. Recover indoor unit and suction line unit chargethrough service port located on outdoor unit basevalve.

9. Disassemble Flow Control Assembly by turning bodyhex.

10. If existing orifice has not dropped out of the body whendisassembled, remove by using a pin or paper clip.Discard this original orifice.

11. Insert proper sized orifice fully into the flow controlbody with rounded “bullet” nose towards the unit asshown in Figure 4. Insure the orifice stays inserted inbody before connecting mating half. See chart in theoutdoor unit installation instructions for proper size.

CAUTIONBe sure there is no dirt introduced into the flowcontrol – orifice assembly. Be sure to install theorifice with the bullet nose pointing in the properdirection as shown in Figure 4. Failure to do sowill result in improper operation.

14. Evacuate the suction line and indoor unit through theoutdoor unit base valve before connecting all othertubing. Refer to section later in installation instructionsfor details on setting the proper refrigerant charge.

15. Remove (remaining) protector caps and plugs (if orificewas changed). Inspect fittings and if necessarycarefully wipe coupling seats and threaded surfaceswith a clean cloth to prevent the inclusion of dirt or anyforeign material in the system.

12. Thread assembly halves together by hand to insureproper mating of threads and tighten until bodies“bottom” or a definite resistance is felt.

13. Using a marker pen or ink pen, mark a line lengthwisefrom the union nut to the bulkhead. Then tighten anadditional 1/6 turn (or 1 hex flat). The misalignment ofthe line will show the amount the assembly has beentightened. This final 1/6 turn is necessary to insure theformation of the leakproof joint.


16. Lubricate male half diaphragm and synthetic rubberseal with refrigerant oil. Thread coupling halvestogether by hand to insure proper mating of threads. Besure to hold the coupling firmly to prevent movement ofthe coupling and tubing. Failure to do so could tear outthe diaphragm causing a blockage of the system. Useproper size wrenches (on coupling body hex and onunion nut) and tighten until coupling bodies ”bottom”or a definite resistance is felt.


19. When tubing is installed in attics or drop ceilings,insulate the couplings on the larger tube thoroughlywith 3/8” wall thickness, closed cell sponge tubeinsulation or equivalent. Failure to insulate will resultin water damage to ceiling since the fitting will “sweat”and drop water on the ceiling.

20. Open both the suction and liquid base valves to thefully open position. Refer to section later in installationinstructions for details on setting proper system charge.

17. Using a marker or ink pen, mark a line lengthwise fromthe coupling union nut to the bulkhead. Then tightenan additional 1/4 turn. The misalignment of the linewill show the amount the coupling has been tightened.This final 1/4 turn is necessary to insure the formationof leakproof joint. If a torque wrench is used, thetorque values shown in Table 5 are recommended.

CAUTIONAfter starting to tighten up the fitting, never try toback it off or take it apart.

TABLE 5

COUPLINGS

eziSgnilpuoC sdnuoPteeF

6- 21-01

01- 54-53

11- 54-53

21- 56-05


WIRING INSTRUCTIONS

GENERAL

All wiring must be installed in accordance with the NationalElectrical Code and local codes. In Canada, all wiring mustbe installed in accordance with the Canadian ElectricalCode and in accordance with the regulations of theauthorities having jurisdiction. Power supply voltage mustconform to the voltage shown on the unit serial plate. Awiring diagram of the unit is attached to the inside of theelectrical cover. The power supply shall be sized and fusedaccording to the specification supplied. A ground lug issupplied in the control compartment for equipment ground.

The unit rating plate lists a “Maximum Time Delay Fuse” orHACR type” circuit breaker that is to be used with theequipment. The correct size must be used for proper circuitprotection and also to assure that there will be no nuisancetripping due to the momentary high starting current of thecompressor motor.

CONTROL CIRCUIT WIRING

For split systems, the minimum control circuit wiring gaugeneeded to insure proper operation of all controls in bothindoor and outdoor units will depend on two factors:

1. The rated VA of the control circuit transformer.

2. The maximum total distance of the control circuitwiring. (This is the distance between the wallthermostat to the indoor unit plus the distancebetween the indoor unit to the outdoor unit.)

The following table should be used to determine propergauge of control circuit wiring required.

Example: 1. Control circuit transformer rated at 40 VA2. Maximum total distance of control circuit

wiring 85 feet.

From Table 6, minimum of 18 gauge wire should be used inthe control circuit wiring.

For control circuit transformers rated other than those listed,use the next lower rated transformer listed.

Example: 1. Control circuit transformer rated at 55 VA

From table use 50VA transformer.

There are two (2) separate control diagrams for fossil fuelfurnaces with air conditioners.

Control diagrams for the various circuit which could beencountered with blower coils can be found in theinstallation instructions of the blower coil.

WALL THERMOSTATS

The following wall thermostats and subbases should beused as indicated, depending on the application.

TABLE 6

CONTROL CIRCUIT WIRING

foAVdetaRtiucriClortnoC

remrofsnarT

remrofsnarTyradnoceS

ALF @ V42

latoTmumixMfoecnatsiD

tiucriClortnoCteeFnigniriW

04 6.1

56eguag0209eguag81541eguag61032eguag41

05 1.2

54eguag0206eguag81001eguag61061eguag41052eguag21

56 7.2

04eguag0255eguag8158eguag61531eguag41012eguag21

TABLE 7

CONTROL DIAGRAMS

metsySecanruFsaGmargaiDlortnoC

ecanruFliOmargaiDlortnoC

sledoMllA 001-1904 101-1904

TABLE 8

WALL THERMOSTAT AND SUBBASECOMBINATIONS

tatsomrehT esabbuS serutaeFetanimoderP

200-3048113F78T

300-40480221A925Q

yrucreM;loocegats1,taehegats1otua-no:naFlooc-ffo-taeh:metsyS

140-3048C-4308T

---yrucreM;loocegats1,taehegats1otua-no:naFlooc-ffo-taeh:metsyS

530-304808-59F1

---loocegats2,taehegats2

elbammargorPcinortcelE

240-3048G1158T

---loocegats1,taehegats2looc-otua-ffo-taeh:metsyS

cinortcelEotua-no:naF

340-3048002MC


otua-no:naFlooc-ffo-taeh:metsySnoitcApanS

720-304817-29F1


elbammargorPcinortcelE


FIGURE 5

COMPONENT MOUNTING LOCATION

OPTIONAL CONTROLS

MIS-1302

INSTALLATION INSTRUCTIONS — CMA-5

Disconnect all power to the unit. Remove control panelcover.

1. Mount compressor TDR in position shown in Figure 5with screw provided.

2. Disconnect yellow low voltage (Y) wire at thecompressor contactor coil and reconnect to the Y1 or #3terminal of the TDR.

3. Connect yellow wire from terminal (Y) of the TDR tothe (Y) terminal of the compressor contactor coil. Thisis the terminal that the wire was removed from inStep 2.

4. Recheck wiring. Refer to Figure 9. Energize unit.Compressor should start. Remove power and reapply.Compressor should not start until the 5 minute timedelay has expired.

5. Apply “This unit equipped with CMA-5 controlmodule” label to inside of the inner control panel coverabove wiring diagram.

6. Replace all panels and covers. This completesinstallation.

INSTALLATION INSTRUCTIONS — CMA-6

Disconnect all power to unit. Remove control panel innerand outer cover.

1. Mount terminal block in position shown in Figure 5.

2. Disconnect black high voltage outdoor motor lead fromcompressor contactor and reconnect to terminal block.

3. Route low ambient control wires up through thebushing in the bottom of the control panel. Connect thelow ambient control wires between the terminal blockand T2 of the compressor contactor.

4. Remove service port cap on discharge line. Install thelow ambient control on the discharge line with the flaretee adapter that is brazed to the low ambient control.Check for pressure at the flare tee dill valve afterinstallation to insure that the dill valve in the unitservice port was depressed by the flare tee connector.Check for leaks at the flare tee connectors. Replaceservice port cap on the flare tee service port and tighten.

5. Recheck wiring. See Figure 10. Check for properoperation of the unit by energizing in cooling mode.The condenser fan motor should not run until thedischarge pressure has exceeded 300 PSI. Should thedischarge pressure fall below 200 PSI while running,the condenser fan motor will de-energize until the headpressure builds to 300 PSI.

6. Apply “This unit equipped with CMA-6 controlmodule” label to the inside of the control panel coverabove the wiring diagrams.


FIGURE 6

INSTALLATION INSTRUCTIONSFOR CMA-5 COMPRESSOR TIME DELAY RELAY

MIS-598

FIGURE 7

INSTALLATION INSTRUCTIONS FORCMA-6 LOW AMBIENT FAN CYCLING CONTROL

MIS-594

CMA-5 & CMA-13A LOWAMBIENT FAN CYCLINGCONTROL TERMINAL BLOCK

CMA-5 COMPRESSORTIME DELAY RELAY

SK109 LOW VOLTAGESTART KIT

CMA-10A & CMA-13ACOMPRESSORCONTROL


INSTALLATION INSTRUCTIONS – CMA-10A

Disconnect all power to unit. Remove control panel cover.

1. Screw compressor control module and terminal blockinto control panel as shown in Figure 5.

2. Disconnect yellow low voltage wire form compressorcontactor and reconnect to terminal “Y” of thecompressor control module.

3. Connect the yellow wire from the compressor controlmodule to “Y” side of the compressors contactor coil.This is the same terminal from which the wire wasremoved in Step 2.

4. Connect the black wire form the compressor controlmodule to common “C” side of the compressorcontactor coil.

5. Connect a field supplied wire from “R” of the indoorunit to “R” on the compressor control module.

6. Route the high (red) and low (blue) pressure switchwires through the bushing in the bottom of the controlpanel. Connect the low pressure switch wire toterminals LPC of the compressor control module.

7. Remove service port caps on both the suction anddischarge lines. Install the high pressure switch on thedischarge line to the flare tee adapter that is brazed tothe controls. Install the low pressure switch on thesuction line. Check for pressure at the flare tee dillvalves after installation to insure that the dill valve inthe unit service port was depressed by the flare teeconnector. Check for leaks at the flare tee connectors.Replace service port caps on the flare tee service portsand tighten.

8. Adjust the compressor time delay relay to the desireddelay on break. Two minutes are recommended. ThisTDR is variable form 30 seconds to 5 minutes.

9. Recheck wiring. Energize unit is first stage cooling.Compressor should not start until the time delay hasexpired. This will be 10% of the delay on break period.Run the unit for at least 5 minutes. The unit should notgo into lockout.

10. Apply “This unit equipped with CMA-10A controlmodule.” label to the inside of the inner control panelcover above the wiring diagram.


FIGURE 8

INSTALLATION INSTRUCTIONS FORCMA-10A DUAL PRESSURE CONTROL AND

COMPRESSOR TIME DELAY RELAY

MIS-1303


INSTALLATION INSTRUCTIONS – CMA-13A

Disconnect all power to unit. Remove control panel cover.

1. Screw compressor control module and terminal blockinto control panel as shown in Figure 5.

2. Disconnect yellow low voltage wire from compressorcontactor and reconnect to terminal “Y” of thecompressor control module.

3. Connect the yellow wire from the compressor controlmodule to “Y” side of the compressor’s contactor coil.This is the same terminal from which the wire wasremoved in Step 2.

4. Connect the black wire from the compressor controlmodule to common “C” side of the compressorcontactor coil.

5. Connect a field supplied wire from “R” of the indoorunit to “R” on the compressor control module.

6. Route the high (red) and low (blue) pressure switchwires through the bushing in the bottom of the controlpanel. Connect the low pressure switch wire toterminals LPC of the compressor control module.Connect the high pressure switch wires to terminalsHPC of the compressor control module.

7. Disconnect the high voltage outdoor motor lead andreconnect to the terminal block installed in Step 1.

8. Route the LAC (black) wires up through the busing inthe bottom of the control panel. Connect one wire tothe terminal block and the other to “T2” of thecontactor. This will be the same terminal from which

the high voltage outdoor motor lead was removed inStep 7.

9. Remove service port caps on both the suction anddischarge lines. Install the high pressure switch andthe low ambient control on the discharge line with theflare tee adapter that is brazed to the controls. Installthe low pressure switch on the suction line. Check forpressure at the flare tee dill valves after installation toinsure that the dill valve in the unit service port wasdepressed by the flare tee connector. Check for leaks atthe flare tee connectors. Replace service port caps onthe flare tee service ports and tighten.

10. Adjust the compressor time delay relay to the desireddelay on break. Two minutes are recommended. ThisTDR is variable from 30 seconds to 5 minutes.

11. Recheck wiring. Energize unit in first stage cooling.Compressor should not start until the time delay hasexpired. This will be 10% of the delay on break period.Run the unit for at least 5 minutes. The unit should notgo into lockout. The condenser fan motor should notrun until the discharge pressure has exceeded 300 PSI.Should the discharge pressure fall below 200 PSI whilerunning the condenser fan motor will de-energize untilthe head pressure builds to 300 PSI.

12. Apply “This unit equipped with CMA-13A controlmodule.” label to the inside of the inner control panelcover above the wiring diagram.


FIGURE 9

INSTALLATION INSTRUCTIONS FORCMA-13A DUAL PRESSURE CONTROL, LOW AMBIENT FAN CYCLING CONTROL

AND COMPRESSOR TIME DELAY RELAY

MIS-1304


PRESSURE SERVICE PORTS

High and low pressure service ports are installed on all unitsso that the system operating pressures can be observed.Pressure tables can be found later in the manual covering allmodels. It is imperative to match the correct pressure tableto the unit by model number.

SYSTEM START-UP (INDOOR UNITSWITHOUT EXPANSION VALVES)

1. Close disconnect switch(es) and set the thermostat tocool and the temperature to the highest setting.

2. Check for proper airflow across the indoor coil byreferring to indoor unit installation.

3. Connect the service gauges and allow the unit to run forat least 10 minutes or until pressures are stable. Checkpressures to the system pressure table attached to theoutdoor unit service panel. For optimum systemperformance, go to Step 4.

4. Install a thermometer on the suction line approximately6" to 10" from the compressor. Optimum systemperformance will occur with a refrigerant chargeresulting in a suction line superheat as determined fromthe following calculations.

A. Measure outdoor air dry bulb temperature________ ºF

B. Measure indoor air wet bulb temperature________ ºF

C. Measure suction pressure ______ PSIG

D. Measure suction line temperature ________ ºF

E. Determine optimum system superheatfrom Table 9 using outdoor air dry bulb(Step B) and indoor air wet bulb (Step A)

________ ºF

F. Determine saturated suction temperaturefrom suction pressure using Table 10 ________ ºF

G. Determine system superheat:Suction line temperature (Step D) ________ ºF- Saturated suction temperature (Step F)

- ________ ºF= System superheat

= ________ ºF

H. Adjust the system superheat (Step G) to theoptimum system superheat (Step E) by addingcharge to lower the superheat or removingcharge to raise the superheat.

I. Check final system operating pressures to thesystem pressure tables as was done in Step 3.

CHARGING INSTRUCTIONS

TABLE 9SYSTEM SUPERHEAT

tneibmAroodtuOerutarepmeT)bluByrDF(

erutarepmeTriAnruteRbluBteWF

95 36 76 17

5015909580857

1113801

13794102

5)8(41915203

0262339324

TABLE 10

SATURATED SUCTION TEMPERATURE R-22

GISPerusserPnoitcuSnoitcuSdetarutaS)F(erutarepmeT

053555

628203

851636

234363

567607

839314

376797

345474

2868

9415


TABLE 11

TOTAL SYSTEM OPERATING CHARGE(INCLUDES CHARGE FOR THE BASIC OUTDOOR

UNIT,INDOOR COIL AND 25’ OF INTERCONNECTING

TUBING.)noitceSroodtuO noitceSroodnI

22-RlatoT).zO(egrahC

A-181CAHA-SA03AA-SA42S

C42CB

.zo37

.zo37

.zo87

A-142CAHA-SA03AA-SA42S

C42CB

.zo08

.zo08

.zo97

A-103CAHA-SA63A

C63CB.zo48.zo59

A-163CAHA-SA73A

C63CB.zo89.zo69

A-124CAH

A-SA24AA-SA84A

C63CBC06CB

.zo201

.zo711

.zo501

.zo241

B-,A-184CAHB-SA16A

C06CB.zo551.zo571

B-,A-106CAHB-SA16A

C06CB.zo351.zo561

�

�

Includes 25’ of 1/4” diameter liquid line. For other than 25’ andother tube sizes, adjust the total charge according to thefollowing schedule.

Includes 25’ of 3/8” diameter liquid line. For other than 25’ andother tube sizes, adjust the total charge according to thefollowing schedule.

�

�

�

�

�

�

�

Installer Note: Stamp or mark the final system chargedetermined above on the outdoor unit serial plate.

SCHEDULE FOR TABLE 11

retemaiDeniLdiuqiL .tFreP22-R.zO

"4/1"8/3"2/1

52.006.002.1


SERVICE

SERVICE HINTS

1. Caution homeowner to maintain clean air filters at alltimes. Also, not to needlessly close off supply andreturn air registers. This reduces air flow through thesystem, which shortens equipment service life, as wellas, increasing operating costs.

2. Check all power fuses or circuit breakers to be sure thatthey are the correct rating.

3. Periodic cleaning of the outdoor coil to permit full andunrestricted air flow circulation is essential.

FAN BLADE SETTING DIMENSIONS

Shown in Figure 10 are the correct fan blade settingdimensions for proper air delivery across the outdoor coil.

Any service work requiring removal or adjustment in the fanand/or motor area will require that the dimensions below bechecked and blade adjusted in or out on the motor shaftaccordingly.

FIGURE 10

FAN BLADE

MIS-1309

TABLE 12

FAN BLADE SETTING

ledoM AnoisnemiD

181CAH142CAH103CAH163CAH124CAH184CAH106CAH

"4/1-3


Low side pressure ± 2 PSIG (suction line 8 inches from compressor)High side pressure ± 5 PSIG (discharge line 8 inches from compressor, liquid at base valve approximately -20 PSIG from

values listed)

Tests are based upon rated CFM (airflow) across the evaporator coil. If there is any doubt as to correct operating change being inthe system. The charge should be removed, system evacuated and recharged to serial plate instructions.

TABLE 13

PRESSURE TABLEHAC181-A

roodnInoitceS

riAnruteR.pmeT erusserP

lioCroodtuOgniretnEerutarepmeTriA

56 07 57 08 58 09 59 001 501 011 511

A-SA03SAA-SA42S

BD57BW26

ediSwoLediShgiH

86051

07071

27781

47302

67622

87442

08452

28852

48552

58642

78023

BD08BW76

ediSwoLediShgiH

07961

37381

67891

97312

18822

48442

68062

88672

09392

29013

39823

BD58BW27

ediSwoLediShgiH

67771

97191

28602

58122

78632

09252

29962

49682

69403

89223

99043

42CB C

BD57BW26

ediSwoLediShgiH

55261

26871

86391

37902

87422

18042

48652

68272

78882

78403

78023

BD08BW76

ediSwoLediShgiH

77461

87081

87891

08312

18032

28642

48362

68082

88692

09313

39923

BD58BW27

ediSwoLediShgiH

67771

97191

28602

58122

78632

09252

29962

49682

69403

89223

99043

TABLE 14



values listed)


roodnInoitceS



56 07 57 08 58 09 59 001 501 011 511

A-SA03SAA-SA42S

BD57BW26

ediSwoLediShgiH

06271

46091

86702

17422

47142

67852

87572

08292

18803

28523

28143

BD08BW76

ediSwoLediShgiH

66771

07591

37312

67032

97742

18562

38282

58992

68613

78333

88053

BD58BW27

ediSwoLediShgiH

37581

67302

97022

28832

58752

78372

98192

19903

29623

49443

59263

42CB C

BD57BW26

ediSwoLediShgiH

56971

96491

37902

77522

08142

28752

38372

48092

58603

68423

78143

BD08BW76

ediSwoLediShgiH

07401

37251

57291

77522

97152

18962

38082

58482

68182

88072

98252

BD58BW27

ediSwoLediShgiH

37581

67302

97022

28832

58652

78372

98192

19903

29623

49443

59263


TABLE 15



values listed)


roodnInoitceS



56 07 57 08 58 09 59 001 501 011 511

A-SA63A

BD57BW26

ediSwoLediShgiH

26261

56381

76402

96422

17442

37262

57082

77792

87313

08923

18443

BD08BW76

ediSwoLediShgiH

86761

07881

27012

47032

67052

87962

08782

28503

48123

58833

78353

BD58BW27

ediSwoLediShgiH

57171

77491

87612

08832

28852

48872

68792

88513

09333

29943

49563

C63CB

BD57BW26

ediSwoLediShgiH

16581

56102

96712

27432

57052

77662

97282

18892

28413

38133

48743

BD08BW76

ediSwoLediShgiH

76091

17702

47322

77932

08652

28272

48982

68603

78223

88933

98653

BD58BW27

ediSwoLediShgiH

47891

77512

08232

38842

68562

88282

09992

29613

39333

59153

69863

TABLE 16



values listed)


roodnInoitceS



56 07 57 08 58 09 59 001 501 011 511

A-SA73A

BD57BW26

ediSwoLediShgiH

66181

86791

07312

27032

47642

67262

87872

08492

28013

48623

68343

BD08BW76

ediSwoLediShgiH

17681

37202

57912

77532

97252

18862

38582

58203

78813

98533

19153

BD58BW27

ediSwoLediShgiH

77191

97802

18622

38342

58062

78872

98592

19213

39033

59743

79463

C63CB

BD57BW26

ediSwoLediShgiH

36871

66591

86212

07822

27542

47262

67972

87692

97313

18133

28843

BD08BW76

ediSwoLediShgiH

66481

96002

27712

57432

87152

08962

28682

48403

58123

78933

88753

BD58BW27

ediSwoLediShgiH

27881

57602

87422

18242

38062

68872

88692

09413

29233

49153

59963


TABLE 17

PRESSURE TABLEHAC 421-A


values listed)

Tests are based upon rated CFM (airflow) across the evaporator coil. If there is any doubt as to correct operating changebeing in the system. The charge should be removed, system evacuated and recharged to serial plate instructions.

roodnInoitceS



57 08 58 09 59 001 501 011 511

A-SA24A63CB C

BD57BW26

ediSwoLediShgiH

46302

76812

07332

27052

47662

67382

77003

87813

97633

BD08BW76

ediSwoLediShgiH

96802

27422

57042

77652

97372

28092

28803

48623

58543

BD58BW27

ediSwoLediShgiH

37612

77232

08842

38562

58282

78003

98813

09733

19953

A-SA84A06CB C

BD57BW26

ediSwoLediShgiH

37212

47822

67442

77062

97772

18492

28213

48033

68943

BD08BW76

ediSwoLediShgiH

77812

97432

18052

38762

58482

78203

98023

09933

29853

BD58BW27

ediSwoLediShgiH

38422

58142

78852

98672

19492

39492

59133

79053

99073

TABLE 18

PRESSURE TABLEHAC481-A, HAC481-B


values listed)


roodnInoitceS



57 08 58 09 59 001 501 011 511

B-SA16A

BD57BW26

ediSwoLediShgiH

47802

57322

77832

87452

08172

28882

38603

58423

78343

BD08BW76

ediSwoLediShgiH

87412

08922

28542

48162

68872

88692

09413

19333

39253

BD58BW27

ediSwoLediShgiH

48022

68632

88352

09072

29882

49603

69523

79443

99463

06CB C

BD57BW26

ediSwoLediShgiH

86242

07052

27062

47272

67582

87003

97713

08633

18653

BD08BW76

ediSwoLediShgiH

67842

77652

87662

08872

18292

28803

48523

58443

78563

BD58BW27

ediSwoLediShgiH

28752

38562

48672

68882

78203

88813

09633

19653

39873


TABLE 19

PRESSURE TABLEHAC601-A, HAC601-B


values listed)


roodnInoitceS



57 08 58 09 59 001 501 011 511

B-SA16A

BD57BW26

ediSwoLediShgiH

76722

96342

17062

37672

57392

67013

87623

97343

97953

BD08BW76

ediSwoLediShgiH

27232

47942

67662

87482

08103

28813

48633

68353

88073

BD58BW27

ediSwoLediShgiH

87042

08852

28672

48392

68113

88923

09643

29463

49283

C06CB

BD57BW26

ediSwoLediShgiH

46322

76932

07752

27572

47592

67613

77933

87363

87883

BD08BW76

ediSwoLediShgiH

96032

27642

57462

77382

97303

18523

28843

38273

48893

BD58BW27

ediSwoLediShgiH

67732

87552

08372

28392

58413

58633

78063

98583

09114

2100-269(g) (2002 10) - bardhvac.com

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