2100-241(j) (2000 11) - bardhvac.com

Installation Instructions

Manual No.: 2100-241JSupersedes: 2100-241IFile: Volume I, Tab 4Date: 11-01-00

Bard Manufacturing CompanyBryan, Ohio 43506

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

© Copyright 2000

Split Air ConditionerOutdoor Section

Models: HAC181-AHAC241-AHAC301-AHAC361-AHAC421-AHAC481-AHAC481-BHAC601-AHAC601-B

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

Contents

i

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

Application and Location .................................... 4General .................................................................... 4Shipping Damage .................................................... 4Application ............................................................... 4Location ................................................................... 4Mounting Unit Outside on Slab ................................. 4Important Installer Note ............................................ 4Installing Refrigerant Tubing ..................................... 4Sweat Style Tubin Connections: SweatIndoor Unit and Sweat Outdoor Unit ........................ 5Field Fabricated Tubing Connections:Quick Connect Indoor Unit and SweatOutdoor Unit Using CTO Kit ..................................... 6

Wiring Instructions .............................................. 9General .................................................................... 9Control Circuit Wiring ............................................... 9Wall Thermostats ..................................................... 9Optional Controls ................................................... 12Installation Instructions – CMA-5 ............................ 12Installation Instructions – CMA-6 ............................ 12Installation Instructions – CMA-10A........................ 13Installation Instructions – CMA-13A........................ 14

Charging Instructions........................................ 15Pressure Service Ports .......................................... 15System Start-Up (Indoor Unitswithout Expansion Valves ....................................... 15

Service ................................................................ 17Service Hints .......................................................... 17Fan Blade Setting Dimensions ............................... 17Pressure Tables ................................................ 20-23

FIGURESFigure 1 .................................................................... 1Figure 2 .................................................................... 4Figure 3 .................................................................... 5Figure 4 .................................................................... 5Figure 5 .................................................................. 12Figure 6 .................................................................. 12Figure 7 .................................................................. 12Figure 8 .................................................................. 13Figure 9 .................................................................. 14

TABLESTable 1 ..................................................................... 1Table 2 ..................................................................... 2Table 3 ..................................................................... 3Table 4 ..................................................................... 6Table 6 ..................................................................... 9Table 7 ..................................................................... 9Table 8 ..................................................................... 9Table 9 ................................................................... 15Table 10 ................................................................. 15Table 11 ................................................................. 16Table 12 ................................................................. 17Table 13 ................................................................. 20Table 14 ................................................................. 20Table 15 ................................................................. 21Table 16 ................................................................. 21Table 17 ................................................................. 22Table 18 ................................................................. 22Table 19 ................................................................. 23

Manual 2100-241Page 1

SPLIT AIR CONDITIONER MODEL NOMENCLATURE

MIS-617

TABLE 1DIMENSIONS

.oNledoM"W"htdiW

"D"htpeD

"H"thgieH

181CAH142CAH

"04 "51 "62

103CAH163CAH

"54 "51 "62

124CAH184CAH106CAH

"05 "51 "23

Customized Unit Code

Electrical CharacteristicsA – 230/208-60-1B – 230/208-60-3

Modification Code

Capacity – 3 Ton or approx. 36,000 BTU

Basic Model Number

HAC 36 1 – A DXXX

FIGURE 1


� 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

.oNledoM MFCerusserP

HporD 2OdednemmoceRegnaRwolFriA

ecifirOmetsySderiuqeR

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

A142CAH A-SA03A 008 81. 019-007 550.

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

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

A-124CAHA-SA24AA-SA84A

004,1005,1

03.62.

055,1-072,1526,1-052,1

870.870.

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

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

Manual 2100-241

Page 3

TABLE 3

SPECIFICATIONS

SLEDOM A-181CAH A-142CAH A-103CAH A-163CAH A-124CAH A-184CAH B-184CAH A-106CAH B-106CAH

)HP/V/ZH06(gnitaRlacirtcelE 1-802/032 1-802/032 1-802/032 1-802/032 1-802/032 1-802/032 3-802/032 1-802/032 3-802/032

egnaRegatloVgnitarepO 352-791 352-791 352-791 352-791 352-791 352-791 352-781 352-791 352-781

yticapmAtiucriCmuminiM 51 51 91 02 52 62 71 53 12

� eziSeriWdleiF 41 41 21 21 01 01 21 8 01

� rekaerBtiucriCromumixaMesuFyaleD 02 02 03 03 04 54 52 06 53

802/032spmAtinUlatoT 6.8/9.7 4.11/2.01 0.41/4.31 8.51/5.41 6.91/1.91 0.12/4.91 4.31/8.21 7.62/7.22 2.71/3.51

ROSSERPMOC

802/032stloV 802/032 802/032 802/032 802/032 802/032 802/032 802/032 802/032 802/032

spmAdaoLdetaR 5.7/8.6 3.01/1.9 9.21/3.21 7.41/4.31 1.81/6.71 5.91/9.71 9.11/3.11 2.52/2.12 7.51/8.31

tnerruCnoitceleStiucriChcnarB 6.8 3.01 7.31 7.41 1.81 5.91 6.21 3.62 7.51

802/032spmArotoRkcoL 94/94 65/65 57/57 28/28 501/501 201/201 19/19 531/531 051/051

taeHesacknarC enoN enoN enoN enoN noisremmIepyT

noisremmIepyT

noisremmIepyT enoN enoN

RESNEDNOCdnaROTOMNAF

MPR/PHrotoMnaF 5286/1 5286/1 5286/1 5286/1 5284/1 5284/1 5284/1 5284/1 5284/1

spmArotoMnaF 1.1 1.1 1.1 1.1 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"42 006,2"42 006,2"42

METSYSTCENNOCTAEWS

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

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

.zO22-RegnahCyrotcaF .zo37 .zo97 .zo48 .zo69 .zo201 .zo551 .zo551 .zo351 .zo351

.SBLTHGIEWGNIPPIHS 551 551 081 081 052 052 052 552 552


APPLICATION and LOCATION

GENERAL

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

The condensing units are to be used in conjunction withthe matching evaporator coils or evaporator blower unitsfor comfort cooling applications as shown in thespecification sheet.

These instructions and any instructions packaged withany separate 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 checkedfor external signs of shipping damage. If damage isfound, the receiving part must contact the last carrierimmediately, preferably in writing, requesting inspectionby the carrier’s agent.

APPLICATION

Size of unit for a proposed installation should be basedon heat loss calculation and air duct sizing madeaccording to methods of Air Conditioning Contractors ofAmerica. The air duct should be installed in accordancewith the Standards of the National Fire ProtectionAssociation for the Installation of Air Conditioning andVentilating Systems of Other Than Residence Type,NFPA 90A, and Residence Type Warm Air Heating andAir Conditioning Systems, NFPA 90B. Where localregulations are at a variance with instructions, installershould adhere to local codes.

LOCATION

The condensing unit is designed to be located outsidewith free and unobstructed condenser air inlet anddischarge. It must also permit access for service andinstallation. Condenser air enters the coil from the rear ofthe unit as shown in Figure 2 with electrical serviceaccess.

MOUNTING UNIT OUTSIDE ON SLAB

A solid level base or platform, capable to support theunit’s weight, must be set at the outdoor unitpredetermined location. The base should be at least twoinches larger than the base dimensions of the unit and atleast two inches higher than surrounding grade level. Therequired unit minimum installed clearances must bemaintained as called out in Figure 2 when locating andsetting 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 refrigeranttubing and for changing the system orifice (if required)covers applications listed in the front of this installationinstruction only. Although other indoor units may be ofsimilar construction, the installation instructions for theseunits should be consulted for proper installation of thoseunits prior to installation.

This information is provided for the field servicepersonnel to install refrigerant tubing in compliance withSection 608 of Title VI National Recycling and EmissionReduction Program for the U.S. Clean Air Act effectiveJuly 1, 1992.

Consult manual 2100-002 on procedure for leak test –evacuation – charging before installation refrigeranttubing that requires any refrigerant recovery or systemevacuation. Manual 2100-002 is included with the unitinstallation instruction package when shipped from thefactory.

FIGURE 2INSTALLATION CLEARANCE

MIS-589


SWEAT STYLE TUBING CONNECTIONS:SWEAT INDOOR UNIT and SWEAT OUTDOORUNIT

Use only refrigeration grade (dehydrated and sealed)copper tubing. Care must be taken to insure that thetubing is kept clean and dry before and duringinstallation. Do not remove the plugs from the tubingends, coil connections or base valves until the connectionis ready to be brazed.

The suction line must be insulated with a minimum of3/8” 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 necessarybends in tubing. When necessary to bend theinsulated tube suction line, cut the insulation aroundits circumference at a distance far enough beyond thepoint of the bend so as to clear the tubing bender.Slip the insulation back together and vapor seal thejoint with tape. Coil any excess tubing in ahorizontal place with the slope of the tubing towardthe 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 Step8.

3. Disassemble Flow Control Assembly by turningbody hex.

4. If existing orifice has not dropped out of the bodywhen disassembled, remove by using a pin or paperclip. 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 insertedin body before connecting mating half. See chart inthe outdoor unit installation instructions for propersize.

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 linelengthwise from the union nut to the bulkhead. Thentighten an additional 1/6 turn (or 1 hex flat). Themisalignment of the line will show the amount theassembly has been tightened. This final 1/6 turn isnecessary to insure the formation of the leakproofjoint.

8. Wrap a wet rag around the copper stub beforebrazing.

9. Flux the copper tube and insert into the stub. Brazethe joint using an alloy of silver or copper andphosphorus with a melting temperature above 1,100°F for copper to copper joints. The phosphorus willact as a flux, therefore, no flux will be required.

FIGURE 3INSTALLING REFRIGERANT TUBING

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 itis round and free of burrs at the connecting ends.Clean the tubing to prevent contaminants fromentering the system.

FIGURE 4

FLOW CONTROL ASSEMBLYFIELD ORIFICE REPLACEMENT INSTRUCTIONS

pp5


A copper-silver alloy with a high silver contentshould be used when iron or steel material isinvolved in the joint. These alloys require the use ofsilver solder flux. Alloys containing phosphorusshould not be used with iron or steel. Phosphorusreacts with the iron forming iron phosphate which isextremely brittle.

To further prevent the formation of copper oxideinside the tubing, dry nitrogen may be purgedthrough the refrigerant system during brazing.

10. After brazing, quench with wet rag to cool the jointand remove 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 ininstallation instructions for details on setting propersystem charge.

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

Use only refrigeration grade (dehydrated and sealed)copper tubing. Care must be taken to insure that thetubing is kept clean and dry before and duringinstallation. Do not remove the plugs from the tubingends, coil connections or base valves until the connectionis 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 necessarybends in tubing. When necessary to bend theinsulated tube suction line, cut the insulation aroundits circumference at a distance far enough beyondthe point of the bend so as to clear the tubing bender.Slip the insulation back together and vapor seal thejoint with tape. Coil any excess tubing in ahorizontal place with the slope of the tubing towardthe 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. 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. CAUTION

1. 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.


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 jointand remove any flux residue.


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

If orifice does not have to be changed, skip theinstructions outlined further in Step 8 and proceed toStep 15.

8. Recover charge from the indoor unit.

A. Connect the suction line only to the indoor unitas outlined 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 turningbody hex.

10. If existing orifice has not dropped out of the bodywhen disassembled, remove by using a pin or paperclip. 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 insertedin body before connecting mating half. See chart inthe outdoor unit installation instructions for propersize.

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 beforebrazing.

4. Flux the copper tube and insert into the stub. Brazethe joint using an alloy of silver or copper andphosphorus with a melting temperature above 1,100°F for copper to copper joints. The phosphorus willact as a flux, therefore, no flux will be required.

A copper-silver alloy with a high silver contentshould be used when iron or steel material isinvolved in the joint. These alloys require the use ofsilver solder flux. Alloys containing phosphorusshould not be used with iron or steel. Phosphorusreacts with the iron forming iron phosphate which isextremely brittle.

To further prevent the formation of copper oxideinside the tubing, dry nitrogen may be purgedthrough the refrigerant system during brazing.

2. The tubing ends should be cut square. Make sure itis round and free of burrs at the connecting ends.Clean the tubing to prevent contaminants fromentering the system.

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 installationinstructions for details on setting the properrefrigerant charge.

15. Remove (remaining) protector caps and plugs (iforifice was changed). Inspect fittings and ifnecessary carefully wipe coupling seats and threadedsurfaces with a clean cloth to prevent the inclusion ofdirt or any foreign 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 linelengthwise from the union nut to the bulkhead. Thentighten an additional 1/6 turn (or 1 hex flat). Themisalignment of the line will show the amount theassembly has been tightened. This final 1/6 turn isnecessary to insure the formation of the leakproofjoint.


16. Lubricate male half diaphragm and synthetic rubberseal with refrigerant oil. Thread coupling halvestogether by hand to insure proper mating of threads.Be sure to hold the coupling firmly to preventmovement of the coupling and tubing. Failure to doso could tear out the diaphragm causing a blockageof the system. Use proper size wrenches (oncoupling body hex and on union nut) and tightenuntil coupling bodies ”bottom” or a definiteresistance 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 willresult in water damage to ceiling since the fitting will“sweat” and drop water on the ceiling.17. Using a marker or ink pen, mark a line lengthwise

from the coupling union nut to the bulkhead. Thentighten an additional 1/4 turn. The misalignment ofthe line will show the amount the coupling has beentightened. This final 1/4 turn is necessary to insurethe formation of leakproof joint. If a torque wrenchis used, the torque values shown in Table 5 arerecommended.

CAUTIONAfter starting to tighten up the fitting, never tryto back 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 theNational Electrical Code and local codes. In Canada, allwiring must be installed in accordance with the CanadianElectrical Code and in accordance with the regulations ofthe authorities having jurisdiction. Power supply voltagemust conform to the voltage shown on the unit serialplate. A wiring diagram of the unit is attached to theinside of the electrical cover. The power supply shall besized and fused according to the specification supplied.A ground lug is supplied in the control compartment forequipment ground.

The unit rating plate lists a “Maximum Time Delay Fuse”or HACR type” circuit breaker that is to be used with theequipment. The correct size must be used for propercircuit protection and also to assure that there will be nonuisance tripping due to the momentary high startingcurrent of the compressor motor.

CONTROL CIRCUIT WIRING

For split systems, the minimum control circuit wiringgauge needed to insure proper operation of all controls inboth indoor 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 usedin the control circuit wiring.

For control circuit transformers rated other than thoselisted, 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 SUBBASE COMBINATIONS

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


OPTIONAL CONTROLS

INSTALLATION INSTRUCTIONS — CMA-5

Disconnect all power to the unit. Remove control panelcover.

1. Mount compressor TDR in position shown in Figure5 with screw provided.

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

3. Connect yellow wire from terminal (Y) of the TDRto the (Y) terminal of the compressor contactor coil.This is the terminal that the wire was removed frominStep 2.

4. Recheck wiring. Refer to Figure 9. Energize unit.Compressor should start. Remove power andreapply. Compressor should not start until the 5minute time delay has expired.

5. Apply “This unit equipped with CMA-5 controlmodule” label to inside of the inner control panelcover above 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 leadfrom compressor contactor and reconnect to terminalblock.

3. Route low ambient control wires up through thebushing in the bottom of the control panel. Connectthe low ambient control wires between the terminalblock and T2 of the compressor contactor.

4. Remove service port cap on discharge line. Installthe low ambient control on the discharge line withthe flare tee adapter that is brazed to the low ambientcontrol. Check for pressure at the flare tee dill valveafter installation to insure that the dill valve in theunit service port was depressed by the flare teeconnector. Check for leaks at the flare teeconnectors. Replace service port cap on the flare teeservice 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 thehead pressure 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 5COMPONENT MOUNTING LOCATION

FIGURE 6INSTALLATION INSTRUCTIONS

FOR CMA-5 COMPRESSOR TIME DELAY RELAY

MIS-598

FIGURE 7INSTALLATION INSTRUCTIONS FOR

CMA-6 LOW AMBIENT FAN CYCLING CONTROL

MIS-594

MIS-1302

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 panelcover.

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

2. Disconnect yellow low voltage wire formcompressor contactor and reconnect to terminal “Y”of the compressor control module.

3. Connect the yellow wire from the compressor controlmodule to “Y” side of the compressors contactorcoil. This is the same terminal from which the wirewas removed 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 thecontrol panel. Connect the low pressure switch wireto terminals LPC of the compressor control module.

7. Remove service port caps on both the suction anddischarge lines. Install the high pressure switch onthe discharge line to the flare tee adapter that isbrazed to the controls. Install the low pressureswitch on the suction line. Check for pressure at theflare tee dill valves after installation to insure that thedill valve in the unit service port was depressed bythe flare tee connector. Check for leaks at the flaretee connectors. Replace service port caps on theflare tee service ports and tighten.

8. Adjust the compressor time delay relay to the desireddelay on break. Two minutes are recommended.This TDR 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 breakperiod. Run the unit for at least 5 minutes. The unitshould not go 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 panelcover.

1. Screw compressor control module and terminalblock into control panel as shown in Figure 5.

2. Disconnect yellow low voltage wire fromcompressor contactor and reconnect to terminal “Y”of the compressor control module.

3. Connect the yellow wire from the compressorcontrol module to “Y” side of the compressor’scontactor coil. This is the same terminal from whichthe wire was removed 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 thecontrol panel. Connect the low pressure switch wireto terminals 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 busingin the bottom of the control panel. Connect one wireto the terminal block and the other to “T2” of thecontactor. This will be the same terminal from

which the high voltage outdoor motor lead wasremoved in Step 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 withthe flare tee adapter that is brazed to the controls.Install the low pressure switch on the suction line.Check for pressure at the flare tee dill valves afterinstallation to insure that the dill valve in the unitservice port was depressed by the flare teeconnector. Check for leaks at the flare teeconnectors. Replace service port caps on the flaretee service ports and tighten.

10. Adjust the compressor time delay relay to the desireddelay on break. Two minutes are recommended.This TDR 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 breakperiod. Run the unit for at least 5 minutes. The unitshould not go into lockout. The condenser fan motorshould not run until the discharge pressure hasexceeded 300 PSI. Should the discharge pressurefall below 200 PSI while running the condenser fanmotor will de-energize until the head pressure buildsto 300 PSI.

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


MIS-1304

FIGURE 9

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

and COMPRESSOR TIME DELAY RELAY


PRESSURE SERVICE PORTS

High and low pressure service ports are installed on allunits so that the system operating pressures can beobserved. Pressure tables can be found later in themanual covering all models. It is imperative to match thecorrect pressure table to 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 runfor at least 10 minutes or until pressures are stable.Check pressures to the system pressure tableattached to the outdoor unit service panel. Foroptimum system performance, go to Step 4.

4. Install a thermometer on the suction lineapproximately 6" to 10" from the compressor.Optimum system performance will occur with arefrigerant charge resulting in a suction linesuperheat as determined from the followingcalculations.

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 10

SATURATED SUCTION TEMPERATURE R-22

GISPerusserPnoitcuSnoitcuSdetarutaS)F(erutarepmeT

053555

628203

851636

234363

567607

839314

376797

345474

2868

9415

TABLE 9SYSTEM SUPERHEAT

tneibmAroodtuOerutarepmeT)bluByrDF(

erutarepmeTriAnruteRbluBteWF

95 36 76 17

5015909580857

1113801

13794102

5)8(41915203

0262339324


TABLE 11

TOTAL SYSTEM OPERATING CHARGE(Includes charge for the basic outdoor unit,

indoor coil and 25’ of interconnecting tubing.)

noitceSroodtuO noitceSroodnI22-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

�

�

�

�

�

�

�

Installer Note: Stamp or mark the final systemcharge determined above on the outdoor unitserial plate.

SCHEDULE FOR TABLE 11

retemaiDeniLdiuqiL .tFreP22-R.zO

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

52.006.002.1

�

�

Includes 25’ of 1/4” diameter liquid line. For other than25’ and other tube sizes, adjust the total charge accord-ing to the following schedule.Includes 25’ of 3/8” diameter liquid line. For other than25’ and other tube sizes, adjust the total charge accord-ing to the following schedule.


SERVICE

TABLE 12

FAN BLADE SETTING

ledoM AnoisnemiD

181CAH142CAH103CAH163CAH124CAH184CAH106CAH

"4/1-3

FIGURE 10

FAN BLADE

MIS-1309

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, aswell as, increasing operating costs.

2. Check all power fuses or circuit breakers to be surethat they are the correct rating.

3. Periodic cleaning of the outdoor coil to permit fulland unrestricted 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 outdoorcoil.

Any service work requiring removal or adjustment in thefan and/or motor area will require that the dimensionsbelow be checked and blade adjusted in or out on themotor shaft accordingly.


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 13

PRESSURE TABLEHAC181-A

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 PSIGfrom values listed)

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

TABLE 14




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




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 16


TABLE 15


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 17

PRESSURE TABLEHAC 421-A



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



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



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

2100-241(j) (2000 11) - bardhvac.com

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