You are on page 1of 39

INSTALLATION INSTRUCTIONS

WALL MOUNTED PACKAGE AIR CONDITIONERS

Model:

W12A1

Bard Manufacturing Company, Inc. Bryan, Ohio 43506
Since 1914....Moving ahead just as planned.

Manual: Supersedes: File: Date:

2100-509D 2100-509C Volume III Tab 16 12-15-11 Manual Page 2100-509D 1 of 17

CONTENTS

Getting Other Informations and Publications

3

Wall Mount General Information Air Conditioner Wall Mount Model Nomenclature ..... 4 Shipping Damage ..................................................... 6 General ..................................................................... 6 Duct Work ................................................................. 7 Filters ........................................................................ 7 Fresh Air Intake ........................................................ 7 Condensate Drain ..................................................... 7 Installation Instructions Wall Mounting Information ........................................ 8 Mounting the Unit ..................................................... 8 Wiring – Main Power .............................................. 12 Wiring – Low Voltage Wiring .................................. 12

Start Up Requirements: R-410A ........................................... 13 Important Installer Note .......................................... 14 Service Hints .......................................................... 14 High Pressure Switch ............................................. 14 Sequence of Operation ........................................... 14 Compressor Control Module ................................... 14 Adjustments ............................................................ 15 Pressure Service Ports ........................................... 15 Troubleshooting Fan Blade Setting Dimension ................................. 16 Refrigerant Charge ................................................. 16 Pressure Table ........................................................ 17 Optional Field Installed Accessories ....................... 17

Figures Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7

Tables Unit Dimensions ...................................... 5 Blower Damper Assembly ....................... 7 Mounting Instructions .............................. 9 Wall Mounting Instructions ................... 10 Wall Mounting Instructions ................... 10 Common Wall Mounting Instructions ............................................ 11 Fan Blade Setting Dimensions ............. 16 Table 1 Table 2 Table 3 Table 4 Table 5 Table 6 Table 7 Table 8 Electric Heat Table .................................. 4 Electrical Specifications .......................... 6 Fan Blade Dimensions .......................... 16 Recommended Operating Ranges ....... 16 Indoor Blower Performance .................. 16 Maximum ESP of Operation Electric Heat Only ................................. 16 Pressure Table - Cooling ...................... 17 Optional Accessories ............................ 17

Manual 2100-509D Page 2 of 17

GETTING OTHER INFORMATION and PUBLICATIONS
These publications can help you install the air conditioner or heat pump. You can usually find these at your local library or purchase them directly from the publisher. Be sure to consult current edition of each standard. National Electrical Code ...................... ANSI/NFPA 70 Standard for the Installation of .......... ANSI/NFPA 90A Air Conditioning and Ventilating Systems Standard for Warm Air Heating ........ ANSI/NFPA 90B and Air Conditioning Systems Load Calculation for ............................ ACCA Manual J Residential Winter and Summer Air Conditioning Duct Design for ................................. ACCA Manual D Residential Winter and Summer Air Conditioning and Equipment Selection

For more information, contact these publishers:
ACCA Air Conditioning Contractors of America 1712 New Hampshire Avenue NW Washington, DC 20009 Telephone: (202) 483-9370 Fax: (202) 234-4721 American National Standards Institute 11 West Street, 13th Floor New York, NY 10036 Telephone: (212) 642-4900 Fax: (212) 302-1286

ANSI

ASHRAE American Society of Heating, Refrigerating and Air Conditioning Engineers, Inc. 1791 Tullie Circle, NE 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) 344-355 Fax: (617) 984-7057

Manufactured under the following U.S. patent numbers: 5,485,878 and 5,301,744

Manual Page

2100-509D 3 of 17

6 KW 05 .705 13.Telecommunication KW 00 .2-Inch Pleated TABLE 1 ELECTRIC HEAT TABLE Models 240V KW 02 03 05 15.Beige 4 .1 Ton AIR CONDITIONER 12 A 1 REVISIONS – A 00 X X X X X J CONTROL MODULES E .Buckeye Gray OUTLET OPTIONS X .WALL MOUNT GENERAL INFORMATION AIR CONDITIONER WALL MOUNT MODEL NOMENCLATURE W MODEL NUMBER CAPACITY 12 .0 18.Barometric Fresh Air Damper (Standard) B .Economizer (Internal) .5.0 20.0 KW COIL OPTIONS X .760 17.115/60/1 VENTILATION OPTIONS X .Standard Coils COLOR OPTIONS X .3.No KW 02 .1-Inch Throwaway (Standard) P .1 9.8 12.Low Ambient Control J .2.Fully Modulating with Exhaust V .230/208/60/1 K .Commercial Ventilator Motorized with Exhaust FILTER OPTIONS X .3 W12A1-K 120V 1 B TU 7.Blank-off Plate E .275 A 1 B TU A W12A1-A 208V 1 B TU A 18.Front VOLTS & PHASE A .2 KW 03 .540 13.985 1 With blower watts included Manual 2100-509D Page 4 of 17 .

00 5.50 Back View Return air opening is in upper field convertible position Back View Return air opening is in lower factory standard position 31.63 1.75 Side Wall Mounting Flanges (Built In) 23.72 Control Panel 46.00 Return Air Opening 10. Factory built at 5 inches.88 1.00* Return Air Opening 10.75 Front View Condenser Airflow is Blow Thru Right Side View MIS-2608 ( * ) Position of return air flanges are interchangeable between two positions. Manual Page 2100-509D 5 of 17 .00 5. Note: Maintain a minimum of 20 inches clearance on right side to allow access to control panel and allow proper airflow to outdoor condenser coil.25 Supply Air Opening 2.00 Top Rain Flashing Shipping Location Optional Electrical Entrance 20.50 19.00 2. (*) Position of return air flanges are interchangeable between two positions. NOTE: Maintain a minimum of 20 inches clearance on right side to allow access to control panel and allow proper airflow to outdoor condenser coil.00 30.25 26.06 Built-in Rain Hood 4° Pitch Electric Heat Heater and Filter Access Ventilation Air Electrical Entrance 14.72 18.00 19.00* 17. Allow 15 inches on left side.FIGURE 1 UNIT DIMENSIONS 32. Factory built at 5 inches.25 Low Voltage Entrance 19. Allow 15 inches on left side.00 Supply Air Opening 5.13 17.75 2.

GENERAL The equipment covered in this manual is to be installed by trained. installer should adhere to local codes.TABLE 2 ELECTRICAL HEAT SPECIFICATIONS SINGLE CIRCUIT 3 Rated Volts an d P h ase 230/208-1 No. 90B. article 310 for power conductor sizing. Authorities having jurisdiction should be consulted before the installation is made. the conductors must be derated. See Page 3 for information on codes and standards. and Residence Type Warm Air Heating and Air Conditioning Systems. If damage is found. NFPA No. These instructions explain the recommended method to install the air cooled self-contained unit and the electrical wiring connections to the unit. Field P o w er Circuits 1 1 1 1 1 Minimum Circuit Ampacity 9 20 28 20 29 1 Maximum External Fuse or Circuit Breaker 15 20 30 30 30 2 Field Pow er Wire Siz e 14 12 10 10 10 2 Ground Wire Siz e 14 12 10 10 10 Models W12A1-A00 A 03 A 05 W12A1-K00 K 02 115-1 1 Maximum size of the time delay fuse or HACR type circuit breaker for protection of field wiring conductors. requesting inspection by the carrier’s agent. The air duct should be installed in accordance with the Standards of the National Fire Protection Association for the Installation of Air Conditioning and Ventilating Systems of Other Than Residence Type. Manual 2100-509D Page 6 of 17 . These “Minimum Circuit Ampacity” values are to be used for sizing the field power conductors. Pay special attention to note 8 of table 310 regarding Ampacity Adjustment Factors when more than 3 conductors are in a raceway. experienced service and installation technicians. These instructions and any instructions packaged with any separate equipment required to make up the entire air conditioning system should be carefully read before beginning the installation. NFPA No. Where local regulations are at a variance with instructions. Size of unit for a proposed installation should be based on heat loss/gain calculation made according to methods of Air Conditioning Contractors of America (ACCA). the carton should be checked for external signs of shipping damage. SHIPPING DAMAGE Upon receipt of equipment. The unit is designed for use with or without duct work. The refrigerant system is completely assembled and charged. All internal wiring is complete. Refer to the National Electrical Code (latest revision). All wiring must conform to NEC and all local codes. While these instructions are intended as a general recommended guide. Note particularly “Starting Procedure” and any tags and/or labels attached to the equipment. Flanges are provided for attaching the supply and return air ducts. preferably in writing. 90A. they do not supersede any national and/or local codes in any way. the receiving party must contact the last carrier immediately. CAUTION: When more than one field power conductor circuit is run through one conduit. 2 3 Based on 75°C copper wire.

The blank-off plate is available upon request from the factory and is installed in place of the fresh air damper shipped with each unit. Ducts through the walls must be insulated and all joints taped or sealed to prevent air or moisture entering the wall cavity. drain valve and fan blade with slinger ring.DUCT WORK All duct work. The internal filter brackets are adjustable to accommodate the 2-inch filter by bending the metal tabs holding the 1-inch filter down. Flexible joints should be used to connect the duct work to the equipment in order to keep the noise transmission to a minimum. Refer to Table 6 for maximum static pressure available for duct design. Filters must be of sufficient size to allow a maximum velocity of 400 FPM. supply and return must be properly sized for the design air flow requirement of the equipment. All duct work or portions thereof not in the conditioned space should be properly insulated in order to both conserve energy and prevent condensation or moisture damage. If the unit is equipped with a fresh air damper assembly. To allow the damper to operate. The filter slides into position making it easy to service. the assembly is shipped already attached to the unit. At temperatures below 40°. This filter can be serviced from the outside by removing the service door. Use insulation with a vapor barrier on the outside of the insulation. CONDENSATE DRAIN This unit employs an automatic condensate disposal system consisting of a base drain pan. NOTE: If no return air duct is used. It is recommended that on this type of installation that a filter grille be located in the wall. efficiency and cost of operation information as required for Department of Energy “Energyguide” Fact Sheets is based upon the fresh air blank-off plate in place and is recommended for maximum energy efficiency. Design the duct work according to methods given by the Air Conditioning Contractors of America (ACCA). The damper blade is locked in the closed position. See Figure 2. applicable installation codes may limit this cabinet to installation only in a single story structure. The fan blade with slinger then rotates in this water and throws the water onto the condenser coil. When duct runs through unheated spaces. A plastic drain hose extends from the evaporator drain pain at the top of the unit to the base drain pan at the bottom. There are two tabs on each side of the filter. Some installations may not require any return air duct. the drain valve located between the condenser coil and fan shroud is closed allowing water to build up in the base to a height of 5/8" to 3/4". FILTERS A one inch throwaway filter is supplied with each unit. A 2-inch pleated filter is also available as an optional accessory. FIGURE 2 FRESH AIR DAMPER Manual Page 2100-509D 7 of 17 . the maximum and minimum blade position stops must be installed. At temperatures above 40°. This disposes of the water by evaporating it on the hot condenser. FRESH AIR INTAKE All units are built with fresh air inlet slots punched in the service panel. Air Conditioning Contractors of America (ACCA) is an excellent guide to proper sizing. All capacity. the drain valve opens draining the base pan and preventing freeze ups that could damage the coil or fan blade. it should be insulated with a minimum of one inch of insulation.

For additional mounting rigidity. Additional clearance may be required to meet local or national codes. Manual 2100-509D Page 8 of 17 . Top rain flashing is shipped attached to the back of the unit on the right side. MOUNTING THE UNIT 1. Locate and mark lag bolt locations. Concrete block walls must be thoroughly inspected to insure that they are capable of carrying the weight of the installed unit. for the supply and return air openings. the return air and supply air frames or collars can be drilled and screwed or welded to the structural wall itself (depending upon wall construction). must be cut through the wall as shown in Figure 3. 6. 3. 3. These units are secured by wall mounting brackets which secure the unit to the outside wall surface at both sides. Hook top rain flashing under back bend of top. 7. if desired. Secure rain flashing to wall and caulk across entire length of top. See Figure 3. 4. use 7/8 inch diameter flat washers on the lab bolts. 2. maintain a minimum of 20 inches clearance on right side to allow access to control panel and allow proper airflow to outdoor coil. Be sure to observe required clearance if combustible wall. See Figure 3. On side-by-side installations. Two holes. 2.INSTALLATION INSTRUCTIONS WALL MOUNTING INFORMATION 1. the wall construction must be strong and rigid enough to carry the weight of the unit without transmitting any unit vibration. 5. Position unit in opening and secure with 5/16 lag bolts. On wood frame walls.

FIGURE 3 MOUNTING INSTRUCTIONS Manual Page 2100-509D 9 of 17 .

MOUNTING INSTRUCTIONS FIGURE 5 WALL MOUNTING INSTRUCTIONS SEE UNIT DIMENSIONS. FOR ACTUAL DIMENSIONS Manual 2100-509D Page 10 of 17 . FIGURE 1.FIGURE 4 WALL MOUNTING INSTRUCTIONS SEE FIGURE 3 .

FIGURE 6 COMMON WALL-MOUNTING INSTALLATIONS Manual Page 2100-509D 11 of 17 .

the unit serial plate will so indicate. If this is the case. This means that the field wiring used must be sized to carry that amount of current. Depending on the installed KW of electric heat. Manual 2100-509D Page 12 of 17 . These instructions must be adhered to. 1 phase equipment use dual primary voltage transformers. refer to Wiring Manual 2100-507. For 208V operation. The unit rating plate lists a “Maximum Time Delay Relay Fuse” of “HACR” type circuit breaker that is to be used with the equipment.187 NOTE: The voltage should be measured at the field power connection point in the unit and while the unit is operating at full load (maximum amperage operating condition). The acceptable operating voltage range for the 240 and 208V taps are: TAP 240 208 RANGE 253 . All equipment leaves the factory wired on 240V tap. All wiring must conform to NEC and all local codes. The correct size must be used for proper circuit protection and also to assure that there will be no nuisance tripping due to the momentary high starting current of the compressor motor. Also shown are the number of field power circuits required for the various models with heaters. For wiring size and connections.216 220 . there may be two field power circuits required. The electrical data lists fuse and wire sizes (75°C copper) for all models. including the most commonly used heater sizes. WIRING – LOW VOLTAGE WIRING 230/208.WIRING – MAIN POWER Refer to the unit rating plate for wire sizing information and maximum fuse or “HACR” type circuit breaker size. Each outdoor unit is marked with a “Minimum Circuit Ampacity”. Refer to the National Electrical Code (NEC) for complete current carrying capacity data on the various insulation grades of wiring material. Each unit and/or wiring diagram will be marked “Use Copper Conductors Only”. All models are suitable only for connection with copper wire. reconnect from 240V to 208V tap.

If done correctly. R-410A refrigerant is close to being an azeotropic blend (it behaves like a pure compound or single component refrigerant). Cardiac irregularities. 8. Polyol Ester oil is hygroscopic. Never heat cylinders above 125°F. 7. any further rise in temperature will cause it to burst. out of direct sunlight. in the system. Once a cylinder or line is full of liquid. A liquid line dryer must be used . Polyol Ester oils can be irritating to the skin.similar to R-22 and R-12. TOPPING OFF SYSTEM CHARGE If a leak has occurred in the system. and liquid refrigerant will freeze the skin. there are no significant changes in the refrigerant composition during multiple leaks and recharges. 2. but must be reclaimed due to its global warming potential. R-410A is a binary blend of HFC-32 and HFC-125. 4. Although nearly azeotropic. Use only cylinders rated DOT4BA/4BW 400. Never fill cylinders over 80% of total capacity. 6. Do not burn R-410A. Never use air and R-410A to leak check. WARNING Failure to conform to these practices could lead to damage. R-410A compressors use Polyol Ester oil. the mixture may become flammable. 11. R-410A has an ozone depletion potential of zero. Store cylinders in a cool area. 12. gauge lines or cylinders. The remaining refrigerant charge. charge with liquid refrigerant. GENERAL: 1. 5. 7. Never mix R-410A with other refrigerants. Limit atmospheric exposure to 15 minutes.even a deep vacuum will not separate moisture from the oil. loss of coordination and slurred speech. Use gloves and safety glasses. 3. Purge with small amount of nitrogen when inserting plugs. Manual Page 2100-509D 13 of 17 . 9. 5. Evacuate the area if exposed. injury or death. Never trap liquid R-410A in manifold sets. 10. Use separate service equipment to avoid cross contamination of oil and refrigerants. it must come out of the charging cylinder/tank as a liquid to avoid any fractionation. evacuating (see criteria above). and systems designed for R-22 cannot withstand this higher pressure. 8. R-410A operates at 40-70% higher pressure than R-22. Do not inhale R-410A – the vapor attacks the nervous system. If compressor removal is necessary. topping off the system charge can be done without problems. Use recovery equipment rated for R-410A refrigerant.START UP THESE UNITS REQUIRE R-410A REFRIGERANT AND POLYOL ESTER OIL. it will rapidly absorb moisture and strongly hold this moisture in the oil. Bard Manufacturing recommends reclaiming. SAFETY PRACTICES: 1. R-410A is nearly azeotropic . 10. 3. With R-410A. and to insure optimal system performance. always plug compressor immediately after removal. Refer to instructions for the cylinder that is being utilized for proper method of liquid extraction. unconsciousness and ultimate death can result from breathing this concentration. 6. 4. 9. R-410A expands significantly at warmer temperatures. may be used after leaks have occurred and then “top-off” the charge by utilizing the pressure charts on the inner control panel cover as a guideline. REMEMBER: When adding R-410A refrigerant. This decomposition produces hazardous vapors. creating dizziness. Use manifold gauges rated for R-410A (800 psi/250 psi low). 2. and charging to the nameplate charge.

which will be 2 minutes plus 10% of the delay on break setting. The lockout features. Periodic cleaning of the outdoor coil to permit full and unrestricted airflow circulation is essential. HIGH & LOW PRESSURE SWITCH The W12A1 models are supplied with a remote reset high and low pressure switch. Check all power fuses or circuit breakers to be sure they are the correct rating. circuit R-W1 make at the thermostat pulling in heat contact for the strip heat and blower operation. The lockout timer will go into a soft lockout and stay in soft lockout until the high pressure switch closes and the delay on break time has expired. The high pressure switch and low pressure switch cut out and cut in settings are fixed by specific air conditioner or heat pump unit model. the contactor will reenergize after the delay on make time delay has expired. this pressure switch may be reset by turning the thermostat off then back on again. are a function of the Compressor Control Module. When the delay on make is complete and the high pressure switch (and low pressure switch if employed) is closed. The unit is equipped with a high pressure cut out switch. Manual 2100-509D Page 14 of 17 . The compressor control is an anti-short cycle/lockout timer with high and low pressure switch monitoring and alarm relay output. wash the indoor coil with a dishwasher detergent. COMPRESSOR CONTROL MODULE The compressor control module is optional on the models covered by this manual. Recycling the wall thermostat resets the manual lockout. High Pressure Switch and Lockout Sequence If the high pressure switch opens. During routine operation of the unit with no power interruptions the compressor will operate on demand with no delay. Recycling the wall thermostat resets the manual lockout. Also not to needlessly close off supply and return air registers.START UP IMPORTANT INSTALLER NOTE For improved start up performance. If the low pressure switch remains open. SEQUENCE OF OPERATION HEATING – Circuit R-Y makes at thermostat pulling in compressor contactor. Adjustable Delay on Make and Break Timer On initial power up or any time power is interrupted to the unit the delay on make period begins. the compressor contactor will de-energize immediately. If tripped. the compressor contactor will de-energize and go into a soft lockout. This terminal is powered whenever compressor is locked out due to HPC or LPC sequences as described. Regardless the state of the low pressure switch. the unit will go into manual lockout condition and the alarm relay circuit will energize. Low Pressure Switch. starting the compressor and outdoor motor. If the high pressure switch opens again in this same operating cycle the unit will go into manual lockout condition and the alarm relay circuit will energize. NOTE: Both high and low pressure switch controls are inherently automatic reset devices. The G (indoor motor) circuit is automatically completed on any call for cooling operation or can be energized by manual fan switch on subbase for constant air circulation. both soft and manual. the compressor contactor is energized. 3. Caution owner to maintain clean air filters at all times. Upon shutdown the delay on break time starts and prevents restart until the delay on break and delay on make periods have expired. SERVICE HINTS 1. This reduces airflow through the system which shortens equipment service life as well as increasing operation costs. On a call for heating. Bypass and Lockout Sequence If the low pressure switch opens for more than 120 seconds. Alarm Relay Output Alarm terminal is output connection for applications where alarm relay is employed. or opens again for longer that 120 seconds. 2. 4.

0 minute (120 seconds) 3.0 minute (180 seconds) 4.0 minute (60 seconds) 2.0 minute (300 seconds) DOB = 123 second DOB = 126 second DOB = 132 second DOB = 138 second DOB = 144 second DOB = 150 second DOM DOM DOM DOM DOM DOM PRESSURE SERVICE PORTS High and low pressure service ports are installed on all units so that the system operating pressures can be observed. Delay of Make (DOM) timing on power up and after power interruptions is equal to 2 minutes plus 10% of Delay of Break (DOB) setting: 0. It is imperative to match the correct pressure chart to the unit by model number. and DOM is 144 seconds.ADJUSTMENTS Adjustable Delay on Make and Delay on Break Timer The potentiometer is used to select Delay on Break time from 30 seconds to 5 minutes. During routine operation of the unit with no power interruptions the compressor will operate on demand with not delay. Pressure chart can be found later in the manual covering all models. 1: DOB set at 2 minutes.0 minute (240 seconds) 5. Unit No. Typical Settings for Dual Unit Installation: Unit No. and DOM is 132 seconds. Manual Page 2100-509D 15 of 17 .5 minute (30 seconds) 1. 2: DOB set at 4 minutes.

3 .35 .0 . If charge is in doubt. Derate ESP by .P.4 Dry / Wet High 530 485 440 390 325 / / / / / 500 460 425 375 300 Dry / Wet Low 465 415 365 315 270 / / / / / 425 400 350 300 265 TABLE 5 RATED CFM AND ESP RECOMMENDED AIRFLOW RANGE Model W12A1 Rated CFM* 400 Rated ESP* .1 . reclaim. this information should only be used by certified technicians as a guide for evaluating proper system performance.TROUBLESHOOTING FAN BLADE SETTING DIMENSIONS Shown in Figure 7 is the correct fan blade setting dimension for proper air delivery across the outdoor coil. AHRI capacity and efficiency ratings were determined by testing with this refrigerant charge quantity. evacuate and recharge the unit to the serial plate charge. TABLE 3 FAN BLADE DIMENSION Model W12A1 Dimension A 1/2" TABLE 6 MAXIMUM ESP OF OPERATION ELECTRIC HEAT ONLY Model W12A1-A00 A 03 A 05 W12A1-K00 K 02 ESP . Values shown are for units equipped with STD 1" throwaway filters.35 . Manual 2100-509D Page 16 of 17 . in H 2O .35 . Any service work requiring removal or adjustment in the fan and/or motor area will require that the dimension below be checked and blade adjusted in or out on the motor shaft accordingly. They shall not be used to adjust charge.15 for 2" pleated filters.35 R-410A REFRIGERANT CHARGE This unit was charged at the factory with the quantity of refrigerant listed on the serial plate.2 .S.300 * Rated CFM and ESP on low speed tap.10 Recommended Airflow Range 500 .35 . The following pressure tables show nominal pressures for the units. Since many installation specific situations can affect the pressure readings. FIGURE 7 FAN BLADE SETTING DIMENSION TABLE 4 INDOOR BLOWER PERFORMANCE CFM @ 230V / 115V W12A1 230V / 115V E.

WB W12A1 80 deg.TABLE 7 PRESSURE TABLE COOLING Return Air Temperature 75 deg.Spring Return W12A1 X X X X X TABLE 8 OPTIONAL FIELD INSTALLED ACCESSORIES Manual Page 2100-509D 17 of 17 . WB Low Side Pressure +4 PSIG High Side Pressure +10 PSIG Air Temperature Entering Outdoor Coil °F Pressure Low S i de High Side Low S i de High Side Low S i de High Side 75° 120 291 128 298 132 308 80° 124 310 133 318 138 329 85° 129 332 138 340 143 352 90° 133 355 142 364 147 377 95° 136 379 143 387 150 403 100° 105° 100° 115° 138 405 148 415 153 430 141 432 151 443 156 459 142 460 152 472 157 489 143 490 153 503 158 521 Model Model BOP-1A BFAD-1 EIFM-1 CMA-28 CRVS-1 Description Blank Off Plate Barometric Fresh Air Damper Economizer with Exhaust Low Ambient Control Commercial Ventilator . D B 72 deg. WB 85 deg. D B 62 deg. D B 67 deg.

Series Air Source Heat Pumps PA . F SUPERSEDES REV.Series Air Source Heat Pumps QW .Series Air Conditioners QH .Series Air Source Heat Pumps QA .Series Air Conditioners PH . I. E FILE VOL.Series Air Source Heat Pumps IH . TAB 6 .Series Air Conditioners WH & SH .USER’S GUIDE For all Packaged Systems (Air Conditioners and Heat Pumps) WA & WL .Series Water Source Heat Pumps DATE: 02-21-12 Page 1 of 9 MANUAL 2100-034 REV.

TABLE OF CONTENTS General Information Air Filters Outdoor Coil Routine Equipment Outdoor Maintenance Page 3 Page 3-4 Page 4 Basic Operating Principles Air Conditioners Heat Pump (Air-to-Air) Heat Pump (Water-to-Air) Ventilation Dehumidification Circuits Page 4-5 Page 5-6 Page 6 Page 7 Page 7 Automatic Control Systems Thermostats Humidistats (Humidity Controllers) Page 7 Page 7-8 Page 8 Page 8 Page 8 Page 8-9 Page 9 Insufficient Cooling or Heating Failure to Operate Lubrication Requirements Periodic Maintenance Helpful Hints & Operating Practices Page 2 of 9 .

and in extreme conditions can shorten the useful life of the equipment. DO NOT operate the system without the proper air filters. which can accumulate over time.GENERAL INFORMATION This manual is generic in nature and covers a wide range of heating and cooling products manufactured by Bard Manufacturing Company. Most equipment can have the filters inspected and serviced by the user with no problems. The useful life of an air filter can vary widely depending upon application and use of the equipment. It is important to make sure that the correct filter size and type for your system is always used. Otherwise. and it is critical to monitor filter condition and establish an acceptable maintenance schedule. to keep the system itself clean for peak efficiency and capacity. Have your installer or service company show you where the filter(s) are and demonstrate the service procedure or make arrangements for them to provide this service on an as needed basis. consult with your installing dealer or Service Company. it may be necessary to have this procedure done by a qualified service company. and replaced or cleaned (depending on type) as needed. In some instances. It is intended to be a general guide for care and operation of typical systems and covers the most important features you should be aware of and are responsible for as the user of the equipment. and also have them instruct you as to any routine maintenance procedures you are responsible for. Each type of system must be equipped with an air filter(s) in the indoor circulating air system to clean the air. AIR FILTERS Keeping clean air filter(s) is the single most important responsibility of the user of the equipment. and for a heat pump must also absorb heat during the heating mode. the airflow across the coil will be reduced causing poor performance. review the Installation Instructions for the specific equipment involved. and to prolong the useful life of the equipment. Page 3 of 9 . If the coil is dirty and matted with debris. and will then be separated into specific types of products to cover things unique to those product types. The air filters used may be a disposable (throwaway) type or may be a cleanable type that can be thoroughly cleaned. Because our product offerings are so varied and can be equipped with many features and options. rinsed and reused many times. materials shed from trees. decrease capacity and efficiency. The outdoor coil must dissipate heat during the cooling mode. dehumidification circuits. Failure to do so will increase operating and repair costs. If there is any question as to acceptable filter size or type. Therefore. if available. you should request a detailed operation sequence and explanation of any special features from your installer and/or Service Company. and shorten the service life of the equipment. while others may also incorporate various ventilation technologies. and airborne debris such as lint. Some systems may be quite simple in features to provide basic cooling and possibly heating. because of equipment design or specific installation conditions. Large volumes of air are circulated over the coil. and many different internal controls as well as room temperature controls. increased operating run time and associated utility bills. Filters should be inspected at least monthly. OUTDOOR COIL The outdoor coil must be kept clean and free of any airborne debris. A common symptom of a dirty filter in the cooling mode is a freeze-up of the indoor coil. dust. it is not possible to cover all aspects of what your specific system may be configured for. This manual will address the basic items that should apply to all systems. paper or other types of airborne material that can become airborne can collect on the entering coil surface.

The condenser (outdoor) coil where the heat that was absorbed from the indoor space is discharged to the outdoor environment. 2. which is a sealed pump that moves the refrigerant through the system. Other conditions that can cause reduction of airflow across the outdoor coil are flowers. using flashlight if necessary. A motor/blower assembly moves the indoor air through the system. 3. which circulates from the conditioned space. never do so without first having the installing dealer or Service Company instruct you in the proper procedure and technique. will be just as effective in blocking the airflow and create the same problems as will stacking things against the equipment. In coastal areas locate equipment the furthest distance away from the coastline as feasible. The compressor. and is returned to the space at a lower temperature and with some of the humidity (moisture) removed. These conditions can be easily managed and controlled by the user. actual cleaning of the outdoor coil should not be attempted under most circumstances. While the user of the equipment needs to be aware of the potential of clogging of the outdoor coil surface. which should only be done by qualified service technicians. 3.Depending on the specific equipment involved. especially as they mature and grow. and if the air inlet side of the coil is hidden. and instead will pull down the temperature slowly. try to observe the back (hidden) side by looking into the side grilles. The evaporator (indoor) coil where cold refrigerant absorbs heat from the air. 2. The moisture exits through a condensate drain system. A properly sized air conditioner cannot cool a structure off rapidly. If the user should attempt this procedure on their own. Closely review the machine when operating to see which direction or path that the airflow moves through the machine. ROUTINE EQUIPMENT OUTDOOR MAINTENANCE 1. removing heat from inside the conditioned space and rejects it outside of the space being controlled. Avoid having any lawn sprinkler spray directly on the equipment. BASIC OPERATING PRINCIPLES AIR CONDITIONERS COOLING MODE The cooling mode operates similar to a refrigerator. It also will remove a certain amount of moisture (humidity) from the circulating air Page 4 of 9 . There are three main parts of the system: 1. as they do not require actually entering into the equipment enclosure. especially if from a brackish water source. See section on Air-to-Air Heat Pumps for additional information concerning blockage due to heavy snow conditions. if applicable. Failure to do so can result in personal injury due to moving parts and/or electric shock hazard resulting in death. through the machine. Frequent cleaning and waxing of the cabinet using a good automobile polish will help extend its original appearance. A motor/fan system moves the outdoor air across the condenser coil. WARNING: Do not open or enter the equipment without first turning off the electrical service disconnect. shrubbery or other growth too near the outdoor coil air inlet and outlet openings. the surface that can accumulate debris can be on the opposite side that is exposed to view when standing in front of the machine. These living things.

the coil temperature will start to drop below 32°F. HEAT PUMP (Air-to-Air) A heat pump is a refrigerant-based system that has additional components and controls that both heats and cools using a compressor for both modes of operation. the outdoor coil will be colder than the outdoor air that is forced over it by the fan system. COOLING MODE The cooling mode of a heat pump is exactly the same as that described for an Air Conditioner in the above section. while operation of the air conditioning or heat pump system in the cooling mode will remove some amount of moisture as it reduces the air temperature. The unit continues to operate during the defrost cycle. Oversized equipment can easily control temperature but will have short run-times. and any other items that can generate moisture or affect its removal from the space. or anytime the system has been turned off for a long period of time. and frost or ice will begin to form on the coil.stream in the process. When the outdoor air temperature is above approximately 40°F. DEFROST CYCLE When operating in the heating mode. is not directly controlled and is a by-product of the unit operating to control temperature in response to the temperature (thermostat) control device. Even though it seems cold to humans. and there may be steam emit from the unit. It may take several hours to pull down a hot. and possibly also an outdoor thermostat. Therefore. showers. Page 5 of 9 . It is generally best to set the thermostat at a comfortable temperature and let it control the system as needed. but the outdoor fan motor will stop and the reversing valve will shift positions to flow hot refrigerant gas through the outdoor coil to melt the accumulated frost. meaning that it absorbs and moves heat from the outdoors and transfers it indoors to be rejected into the circulating air stream. rather than turning it on and off. there is usable heat that can be extracted efficiently from the outdoor air down to 0 degrees F. HEAT PUMP (HEATING MODE) The system operates in reverse cycle. although the colder the air is there is less heat to extract and the operating efficiency is diminished. precise humidity regulation in the conditioned space cannot be assured and additional equipment such as a dedicated dehumidifier may be required. Most heat pumps will also be equipped with some amount of electric heat to supplement the heating capacity of the compressor system on an as needed basis. thus reducing its ability to remove moisture from the circulating air stream. and will initiate a defrost cycle at the appropriate time. There are also many additional influences that can affect humidity levels within the conditioned space such as laundry appliances. cooking. moisture can accumulate on the coil and it will drain down and out the base of the unit. or heat pump when operating in the cooling mode. moist building or structure on initial startup. This operation is entirely automatic and is controlled by the indoor thermostat. As the air temperature gets below approximately 40°F. exhaust fans. An automatic defrost system keeps track of system run time when the outdoor coil temperature is in the freezing zone. Moisture (humidity) removal with a conventional air conditioner (cooling) unit. Water will start to drain freely from the unit.

Individual closed loop buried in a trench or vertical bore hole(s). Because of the design of water-to-air heat pumps and the water temperatures involved. For wall mounted or other equipment that is elevated. from heating to cooling mode. Individual loop submerged in a pond. it is important to keep heavy snow from accumulating around the machine to the point of blocking the inlet and outlet openings to the outdoor coil section. 2. When the heat pump shifts from cool to heating mode. For air source heat pumps. It could range from 1-2 minutes up to but not exceeding 10 minutes. meaning that it acquires and moves heat from the water supply flowing through the water to refrigerant coil. This is commonly described as a hissing noise and is a normal sound for this type equipment. this should not be a factor. WATER SUPPLY SYSTEMS Depending upon type and application of the water-to-air heat pump. Water supplied from a well and discharged into pond. HEAT PUMP (HEATING MODE) The system operates in reverse cycle. the water side of the system could be one of the following: 1. and especially during defrost cycles. they are refrigerant-based systems that both heats and cools using a compressor for both modes of operation. typically only in larger multi-unit installations. There is typically a large puff of steam emitted as the fan restarts. but for equipment installed on or near the ground. ditch or another well. The length of the defrost cycle will vary depending upon actual outdoor temperature. When the defrost cycle terminates. Page 6 of 9 . 4. Just like the air source heat pump. The air source heat pump cannot operate effectively and efficiently when snowbound just as a car cannot function well in heavy snow conditions. except that the outdoor coil uses water instead of air for the heat transfer medium. and transfers it indoors to be rejected into the circulating air stream. no defrost system is required as in air-to-air heat pumps. Water supplied from a boiler/tower system. This operation is entirely automatic and is controlled by the indoor thermostat. the reversing valve will shift back to heating mode and the outdoor fan will restart. HEAT PUMP (Water-to-Air) These types of heat pumps are also commonly referred to as water source or geothermal systems. The primary difference is that the system uses water or antifreeze protected water solution instead of an air-cooled outdoor heat transfer coil. COOLING MODE The cooling mode of a water-to-air heat pump is exactly the same as that described for an air conditioner in the above section for Air Conditioners. Most water-to-air heat pumps (but not all) will also be equipped with some amount of electric heat to supplement the heating capacity of the compressor system on an as needed basis. stream. humidity levels and amount of accumulated frost. 3. this can be an issue in areas prone to heavy and/or blowing snow. there will be a pressure transfer sound heard as the reversing valve redirects the flow of refrigerant. and there is no outdoor motor/fan system but instead a water pump to provide adequate water flow to the system.

Many installers also install thermostats other than those offered by Bard. Economizer 5. etc. have a dedicated dehumidification capability by having a special additional refrigeration circuit (factory installed option only) in addition to the basic system. sometimes also referred to as hot gas reheat. and must determine proper compatibility prior to installation. Motorized fresh air damper 3. it is not possible to adequately discuss them all in this User’s Guide. and if adjustable should only be adjusted by the person(s) responsible for overall building control conditions. many schools and similar institutions may utilize central energy management systems (EMS) or direct digital control (DDC) systems. and for any instructions or maintenance requirements you should be aware of as the user.) that may be installed. are different and are used for different reasons. In all circumstances have your installer. DEHUMIDIFICATION CIRCUITS Many Bard systems. These systems can be described as follows: 1. typically those used in schools or other commercial applications. and for any instructions or maintenance requirements you should be aware of as the user. Consult your installer and/or Service Company to determine if your installation has any of these devices. and since these can vary in numerous features and functions. if installed. They may also have different control strategies. The devices may or may not be adjustable.VENTILATION Many Bard systems have the capability of various ventilation packages available (either factory or field installed) directly into the basic system. Service Company or building administrator or maintenance department personnel instruct you as to proper operation of your specific thermostat or temperature control system. are designed to control humidity on demand from a humidity controller much the same as the basic cooling and/or heating system is controlled by a wall thermostat. Consult your installer and/or Service Company to determine if your installation has any of these devices. Commercial room ventilator 4. and these can vary in features and some functions depending upon the type of system (air conditioner. Barometric fresh air damper 2. etc. HUMIDISTATS (HUMIDITY CONTROLLERS) All systems with dedicated dehumidification (hot gas reheat) circuits also require a humidity controller (also called humidistat or de-humidistat) in addition to a thermostat for proper control. AUTOMATIC CONTROL SYSTEMS THERMOSTATS There are many types of thermostats available to properly control your system. Approved compatible thermostats are available from Bard Manufacturing Company for all applications. supplemental heat. heat pump. Energy recovery ventilator All of these ventilation systems. These special systems.) installed and any special options (ventilation. Normal settings would be somewhere between Page 7 of 9 . In addition.

either all or at least in part. 1. and gas or water supplies if applicable. 3. and replace or clean if dirty. typically either an internal drain or outdoor location. and that all supply registers and return air grilles are not blocked. 4. check the following before calling your Service Company: 1. These are user responsibilities. 2. and this must be kept open and free to convey the condensate generated by the operation of the equipment to a suitable location. and under no circumstances should be set lower than 40% as overcooling of the conditioned space and/or freeze-ups of the indoor coil may occur. especially during peak operating periods and conditions. and if they cannot be fulfilled by the user. 4. Be sure the thermostat setting is correct. the user would at least be aware of the dram mechanism and know what to expect.50 and 60% Relative Humidity (RH) and typically affords acceptable human comfort conditions for most individuals. Make sure that the power supply. Depending upon the specific installation. Keeping the air filters clean and recognizing the importance of a clean outdoor coil are key elements. arrangements should be made with your Service Company. If any questions. have your Service Company inspect annually and perform maintenance as outlined in the ERV Installation and Operating Instructions. If an Energy Recovery Ventilator (ERV) is installed in your system. Check the air filters. LUBRICATION REQUIREMENTS All indoor and outdoor air-moving motors are permanently lubricated. Be sure the thermostat setting is correct. Make sure that the outdoor coil is not blocked with any foreign matter. There is a condensate drain system for all air conditioners and heat pumps. FAILURE TO OPERATE Check the following before calling your Service Company: 1. 2. and replace or clean if dirty. Check the air filters. Make sure that air can circulate freely throughout the conditioned space. 5. Make sure that the outdoor coil is not blocked with any foreign matter. are “On”. or otherwise restricted with any growth or other items. PERIODIC MAINTENANCE Periodic maintenance must be conducted on your system to insure maximum performance. Page 8 of 9 . 3. 2. and require no re-oiling. If the unit operates but fails to provide sufficient comfort. or otherwise restricted with any growth or other items. Make sure that air can circulate freely throughout the conditioned space. INSUFFICIENT COOLING OR HEATING In extremely hot or cold weather your system will continue to deliver its normal supply of conditioned air. and that all supply registers and return air grilles are not blocked. it should be reviewed and discussed with your installer and/or Service Company.

type of building or facility. and can vary depending upon what type of heating/cooling system you may have. It is not recommended to turn the system “Off” and then back “On” when you need it. Setting the thermostat very high does not make the system heat faster. The thermostat automatically controls everything. the inside conditions will not be totally out of control. 7. and delivers the most efficient heat. If the building is to be unoccupied for a lengthy period. For most efficient operation. All heating and cooling systems should have periodic inspections made by a trained professional. The heat pump (compressor) mode is controlled by the 1st stage of the thermostat. Have your installer or Service Company explain and demonstrate proper operation of the heating and cooling system. Rapid changes either up or down should not be done. and setting it very low does not make it cool faster. Upon return. could reduce airflow below acceptable levels and should not be done without review by your Service Company who can access the overall situation and advise you accordingly. Therefore. Page 9 of 9 . The heating and cooling system is designed to have a certain amount of airflow for proper operation. so it is very important to have a thorough understanding of how it works and how to use it properly. Always keep the equipment in peak operating condition with routine scheduled maintenance. set the thermostat at the temperature you prefer. HELPFUL HINTS AND GOOD OPERATING PRACTICES The following information will help you enjoy the full comfort and benefits of your Bard cooling and heating system. 6. they should be made in small adjustments and the system be allowed time to respond. the heat pump mode heat will also diminish (because there is less heat in the outdoor air to absorb). especially air-to-air heat pumps. and then let it take control. and other factors that can impact how often a machine must be serviced. closing off registers. and help extend the life of your system: 1. and this is normal. As the outdoor temperature drops off. knowledge. especially for the air filters and to assure clean outdoor coil. Since there are many different types of controls available. Have your installer or Service Company explain and demonstrate proper operation of the controls. 4. and the backup electric heat will only operate on demand as needed to maintain the desired temperature. training. which is not as efficient as the heat pump. may have the system (compressor) run continuously at lower outdoor temperatures. 3. This can allow temperature and humidity to build up in warm weather conditions and force the system to run continuously to try and catch up. Make sure you thoroughly understand how the heating and cooling system itself is intended to operate and what to expect from it. and also help ward off more extensive and expensive repairs. and the necessary tools and equipment required to do these tasks properly and in accordance with approved or mandated procedures. 2. licensing. who has the experience. Proper and routine maintenance and service will protect your investment and help extend the service life of the product. The thermostat is the user’s primary connection to the system. 5. maximize the performance and efficiency. If any changes to the settings are required. in unused rooms as an example. 3. and recovery time to desired conditions would be much shorter. 8. 4. 5. Keep all supply registers open and all returns free and unrestricted. Heat pumps. The maintenance procedures and frequency of routine service can vary depending upon actual type of equipment in use. and must be supplemented by the 2nd stage electric heat. it is best to adjust the thermostat to a reasonable higher (or lower depending upon the season) setting rather than turning it completely off. certifications.

Ohio 43506 Since 1914. Tab 1 03-08-07 © Copyright 2007 Manual 2100-479 Page 1 of 11 ..: Supersedes: File: Date: 2100-479 NEW Volume I. just as planned. Bryan.SERVICING PROCEDURE R-410A LEAK TEST EVACUATION CHARGING Bard Manufacturing Company. Manual No.Moving ahead.. Inc.

. 3 Attaching Manifold Hose to Schrader Valve ............................... 9 Heat Pump ............................................... 9 High Suction — Low Head Pressure ... 6 Figure 2: Typical HP System Cooling Cycle ............................ 4 & 5 Charging .......... 5 Troubleshooting the Mechanical System Air Conditioning & Heat Pump ......................................... 4 Evacuation ............. 8 Charts Troubleshooting Chart for Air Conditioners ... 7 Figure 3: Heating Cycle ............................ 9 High Suction — High Head Pressure .......................................................................... 9 Low Suction — Low Head Pressure . 9 Low Suction — High Head Pressure .............................. 9 High Suction — Low Head Pressure ........................................... 10 Troubleshooting Chart for Air-to-Air Heat Pumps .......... 4 Leak Test .................Heating ............... 3 Leak Detectors .................. 9 Figures Figure 1: Typical AC System Cooling Cycle .................. 9 Low Suction — High Head Pressure ................................ 11 Manual 2100-479 Page 2 of 11 ............................................... 9 High Suction — High Head Pressure .....CONTENTS General Recovery Equipment Rated for R-410A .................... 3 Gauge Manifold .........................................................Cooling ............................ 5 Preliminary Charging Steps ..... 3 Attaching Gauge Manifold ......... 5 Charging the System by Weight .................................................. 9 Low Suction — Low Head Pressure .............................................

the gauge ports are still open to the gauges. charging liquid or evacuating. (This information will be indicated on the hoses. purging. Its purpose is to determine the operating refrigerant pressures in order for the serviceman to analyze the condition of the system. but must be reclaimed due to its global warming potential. If the system has been open for more than 5 minutes. The valving on the manifold is so arranged that when the valves are closed (front-seated) the center port on the manifold is closed to the gauges and gauge ports. change the filter dryer immediately before evacuation. checking charge. Connect suction side of gauge manifold to Schrader valve on suction line. connect high pressure side of gauge manifold to Schrader valve on liquid or discharge line. Opening either valve opens the center port to that side of the manifold and system. On heat pumps the suction line is between compressor and reversing valve.) Vacuum Pump and micron gauge must be used when evacuating a system to 500 microns. permitting the gauges to register system pressures.GENERAL GAUGE MANIFOLD WARNING The oils used with R-410A refrigerant are hydroscopic and absorb water from the atmosphere readily. Do not leave systems open to the atmosphere for more than 5 minutes. A necessary instrument in checking and serving air conditioning and heat pump equipment is the gauge manifold. ATTACHING GAUGE MANIFOLD For leak testing. Then recharge the system to the factory specified charge. All hoses must have a service rating of 800 psig. Manual Page 2100-479 3 of 11 . Recovery equipment rated for R-410A refrigerant R-410A has an ozone depletion potential of zero. The gauge manifold set is specially designed to withstand the higher pressure associated with R-410A. Manifold sets are required to range up to 800 psig on the high side and 250 psig on the low side with a 250 psig low side retard. Leak Detectors An electronic leak detector capable of detecting HFC refrigerant can be used with R-410A refrigerant. WARNING Gauge manifold must be suitable for use with R-410A refrigerant and POE oils. With the valves in the closed position.

Operate the pump below 500 microns for 60 minutes and then close valve to the vacuum pump. 2. Disconnect charging line at vacuum pump and connect to refrigerant supply. the liquid line filter dryer (R-410A compatible) must be replaced any time the system is open. Crack the cylinder valve and purge charging line at center on manifold. will not separate moisture from Polyol Ester oil (POE) in R-410A systems. use a tubing cutter to avoid releasing moisture back into the system. Never use air and R-410A to leak check. push end of hose tight against end of Schrader valve and hold in place while quickly unscrewing coupler nut from Schrader valve. If hose does not have an unseating pin. Relieve all pressure from the system down to 0 psig. Close manifold high pressure gauge valve. Release nitrogen or CO2 into the atmosphere through suction line of gauge manifold. Replace caps on valve. (Unit should be running. A 500 micron evacuation. 7. (Unit should not be running. Remember: Always use a pressure regulator with nitrogen and a safety valve down stream . A system can be safely leak-checked by using nitrogen or a trace gas of R-410A and nitrogen. it is wise to detach refrigerant hoses at the lowest pressure readings on the system. EVACUATION Evacuation An evacuation to 500 microns is usually sufficient to remove moisture from a system using R-22 and mineral oil lubricant. Screw coupler on to valve. do not use a torch. Be sure all leaks are located and marked before bleeding pressure from system. Open refrigerant drum valve and manifold high pressure gauge valve to pressurize system to a positive pressure with refrigerant vapor. 3. 1. 2. system is ready to be evacuated and charged. Check all soldered joints. if any. 6. Correct any leaks and recheck. When leaks. Evacuate system to less than 500 microns. Put low pressure hose “A” on second. WARNING At no time use the compressor to evacuate the system or any part of it. Pressurize the complete system with dry nitrogen.) 1. WARNING As a safety measure. The system is now ready for the correct operating charge of Refrigerant R-410A. Change the filter dryer. Remove cap from valve.) B.ATTACHING MANIFOLD HOSE TO SCHRADER VALVE 3. Do not exceed 250 psig. Close drum valve and disconnect from center port. 3. 2. Remove gauge port cap from suction and liquid service valve ports and attach manifold gauge hoses. using a good vacuum pump and an accurate high vacuum gauge. however. When leaks. Manual 2100-479 Page 4 of 11 . Allow the system to stand for 30 additional minutes to be sure a 500 micron vacuum or less is maintained.. 4. as well as halide torch leak detectors. system is ready to be evacuated and charged. pressure in the system must be bled off since it is impossible to solder with unit pressurized.set at no more than 150 psig. Put high pressure hose “B” on first. 8. Older R-22 leak detectors. If a leak is found which requires soldering. including those on the evaporator coil with an Electronic Leak Detector suitable for use with HFC refrigerants or R-410A. 4. Make sure coupler is lined up straight with Schrader valve. a number 395 Superior or equivalent unseating coupler must be used. 5. Then close cylinder valve. Read the suction pressure on compound gauge and heat pressure on pressure gauge. Connect an upright R-410A drum to center port of gauge manifold. 5. Relieve all pressure from the system down to 0 psig. have been repaired. Make sure gauge manifold valves are closed. When removing a filter dryer from a system. To remove. if any. In addition to a 500 micron evacuation. To do this: A. have been repaired. will not detect leaks in R-410A systems. Open gauge manifold valve slightly and purge air from hose with refrigerant. as the mixture may become flammable at pressures above 1 atmosphere. Remove coupler from Schrader valve. or CO2 until the pressure reaches 200 psig. Leak Test 1.

Loosely attach the suction gauge hose to the line valve. which allow liquid refrigerant to be removed from the cylinder when it is in the upright position. Remove the cap from the suction line valve. 4. 5. When liquid stops flowing. Start compressor by setting thermostat. the filter dryer should be replaced and then evacuated. Attach a second charging hose to the suction gauge (low pressure) side of the gauge manifold. 4. Some cylinders supplied by manufacturers have dip tubes. Repeat steps 3 and 4 above. never start the compressor with less than 55 psig of suction pressure. 5. A throttling valve can be used to insure that liquid is converted to vapor prior to entering the system. Place refrigerant drum upright on scale and determine exact weight of the refrigerant and cylinder. CHARGING THE SYSTEM BY WEIGHT 1. Refer to Start-Up Procedure and Check List for further start-up details. To avoid fractionation. 2. Front seat gauge manifold valves. The high side will hold 80-100% of the total charge. Connect the gauge manifold to the high and low side. 7. Then proceed as follows: 1. Keep in mind two issues: first. CHARGING 1. PRELIMINARY CHARGING STEPS If the system has been open to the atmosphere. 3. Manual Page 2100-479 5 of 11 . Finish charging with liquid by cracking the suction valve. Cylinders without dip tubes have to be tipped upside down in order for liquid to be removed. 8. Proper manipulation (restricting) of the manifold gauge set can also act as a throttling device to insure liquid is not entering the compressor. open refrigerant cylinder liquid valve and allow pressure in system to balance with pressure of cylinder or 80% of charge is in the unit whichever comes first. To insure that the proper blend composition is charged into the system. Secondly. Single Package Units — Refer to the unit serial plate for the full operating charge. The remainder of the charge will be added to the low side. it is important that liquid only be removed from the charging cylinder. Throttle the manifold valve to keep pressure about 100 psig for R-410A. Open the manifold low pressure valve to allow refrigerant to flow into the system. Connect manifold as instructed. 2. it cannot be ignored completely when charging. close refrigerant cylinder valve and allow unit to run for 30 minutes. disconnect charging and gauge hoses and replace all valve caps. charging of an air conditioner or heat pump system incorporating R-410A shall be done with “liquid” to maintain optimum system performance. front seat (close) the discharge manifold valve and let the system stabilize for about five minutes. Attach a drum of proper. make sure the liquid is throttled. thus vaporized into the low side of the system to avoid compressor damage. Open the valve on the refrigerant drum and the suction valve on the charging manifold slightly to purge the air from the manifold and hoses before tightening the fitting. Attach the third hose to the high pressure side of the manifold and the liquid line valve.R-410A System Charging Even though R-410A has a very small fractionation potential. When the correct weight of refrigerant has been added to the unit. close high side port. 6. 3. When there is approximately an 80% charge. The Service Technician must differentiate between which type of charging cylinder they are using to avoid removing vapor refrigerant instead of liquid refrigerant to avoid fractionation and for safety concerns. clean refrigerant to the center port of the charging manifold with one of the charging hoses. Allow liquid to enter the high side only. With manifold suction valve closed and manifold discharge valve open.

FIGURE 1 TYPICAL AIR CONDITIONING SYSTEM COOLING CYCLE MIS-369 Manual 2100-479 Page 6 of 11 .

FIGURE 2 TYPICAL HEAT PUMP SYSTEM COOLING CYCLE MIS-368 Manual Page 2100-479 7 of 11 .

Remember to either consider the total weight of the pan of water or remove the drum for weighing frequently to keep track of the charging process. it may be necessary to place refrigerant drum in a pan of warm water (not greater than 130º F). FIGURE 3 HEATING CYCLE MIS-369 Manual 2100-479 Page 8 of 11 .WARNING To speed refrigerant flow.

(Low water flow. 6. Overcharged. dryer. Low indoor temperature 4. Defective reversing valve. Restricted airflow over indoor coil. IPR valve open. Defective reversing valve. Restricted airflow through outdoor coil. Partial restriction and then overcharged. etc. 5. 6. 3. (High entering water temperature. Defective indoor fan motor. Restricted liquid line. Frozen outdoor coil. 5. ) LOW SUCTION — HIGH HEAD PRESSURE 1. (Frozen water coil. LOW SUCTION — HIGH HEAD PRESSURE 1. HIGH SUCTION — HIGH HEAD PRESSURE 1. Partial restriction and then overcharged. ) 4. Low ambient entering air temperature. Iced indoor coil. ) 2. High indoor air temperature. etc.TROUBLESHOOTING THE MECHANICAL SYSTEM AIR CONDITIONING AND HEAT PUMP — COOLING LOW SUCTION — LOW HEAD PRESSURE 1. Low outdoor air temperature. Low indoor air temperature. ) 2. Air in system. Low airflow outdoor coil. (Defective water pump. Restricted liquid line. 4. HIGH SUCTION — LOW HEAD PRESSURE 1. (Restricted water coil. 3. High entering outdoor air temperature. metering device. ) 2. (Low water temperature. (Low entering water temperature to water coil. Defective or broken valves. Air in system. 2. ) 3. Defective or broken valves. High entering outdoor air temperature. 7. 5. Overcharged. HIGH SUCTION — HIGH HEAD PRESSURE 1. ) 5. ) 3. ) 6. HIGH SUCTION — LOW HEAD PRESSURE 1. 7. dryer. (Restricted water flow through water coil. Low charge. 2. High indoor air temperature. HEAT PUMP — HEATING LOW SUCTION — LOW HEAD PRESSURE 1. Manual Page 2100-479 9 of 11 . 3. 6. Defective outdoor motor. Restricted outdoor coil. Low charge. Restricted air coil. Low indoor airflow. Water source heat pump. metering device. IPRV valve open. 3. (High entering water temperature. 4. 2. Water source heat pump.

Make this check only if previous checks fail to locate trouble. Always make these checks first. Compressor runs continuously—no cooling Rarely the cause. Meter to Line Side of Contactor Power Supply High Pressure Side of System Low S i de General Load Side of Contactor to Motor Terminal Control Circuit Motors Compressor System Operation Condenser Air Evaporator Air .) Excessive Load in Space Liquid Valve Partially Closed Condenser Fins Dirty or Plugged Condenser Fan Belt Slipping Condenser Air Short Circuiting Low Condenser Air Volume Condenser Air Temperature Low Plugged or Restricted Metering Device TROUBLESHOOTING CHART FOR AIR CONDITIONERS Evaporator Fins Dirty or Plugged Evaporator Belt Slipping Low Evaporator Air Volume Dirty Filters Ductwork Small or Restricted Restrictions Thermostat Setting Thermostat Location Stratified Air in Space Incorrect Refrigerant Piping System Too Small Manual 2100-479 Page 10 of 11 Compressor noisy Suction pressure too high Evaporator frosting Condenser fan motor will not start Compressor loses oil Compressor "hums" but will not start Head pressure too high Head pressure too low Compressor short cycles on low pressure Compressor and condenser fan motor will not start Compressor will not start but condenser fan will run Liquid line frosting or sweating Suction pressure too low Compressor cycles on overload Suction line frosting or sweating Evaporator blower will not start Compressor runs continuously —cooling Condenser fan motor runs contactor not pulled in Liquid refrigerant flooding back to compressor— cap tube system Space temperature too high Generally the cause. etc. Make these checks only if first checks fail to locate trouble. Occasionally the cause.Power Failure Blown Fuses or Tripped Circuit Breakers Faulty Wiring Loose Terminals Low Voltage Single 1PH Failure of 3PH Unbalanced Power Supply 3PH Voltage Too High Open Disconnect Switch Faulty Wiring Loose Terminal Low Voltage Defective Contacts in Contactor Compressor Overload Potential Relay Fails to Open Potential Relay Fails to Close Run Capacitor Start Capacitor Faulty Wiring Loose Terminals Control Transformer Low Voltage Thermostat Contactor Coil Pressure Control Condenser Fan Relay Evaporator Fan Relay Compressor Motor Condenser Motor Evaporator Motor Compressor Off on Internal Overload Hold Down Bolts Defective Compressor Bearings Seized Compressor Defective Compressor Valves Compressor Oil Level Open or Short Motor Windings Refrigerant Charge Low Overcharge of Refrigerant High Head Pressure High Suction Pressure Low Suction Pressure Temperatures Non-Condensables (Air.

blower off Excessive ice on O.D. Ice build up on lower part of O. coil frosting or icingHigh compressor amps Compressor runs continuously—no cooling Suction pressure too low Compressor runs continuously—no heating Liquid refrigerant flooding back to compressor Defrost cycle initiates no ice on coil 2100-479 11 of 11 Excessive operating costs Heating or Cooling Cycles Suction pressure too high Compressor noisy Denotes common cause. Timer or Relay Leaking Defective Valve or Coil Sticking Closed Leaking or Defective Plugged or Restricted Meter Device (Htg) Check Valve Fins Dirty or Plugged Motor Winding Defective Recirculation or Air Air Volume Low (Cooling) Low Temperature Coil Air (Cooling) Plugged or Restricted Metering Device (Clg) Outdoor Fan Motor and Coil Fins Dirty or Plugged Motor Winding Defective Air Volume Low Air Filters Dirty Undersized or Restricted Ductwork Indoor Blower Motor and Coil Indoor Section Sticking Closed Leaking or Defective Auxiliary Heat Upstream of Coil TROUBLESHOOTING CHART FOR AIR TO AIR HEAT PUMPS Check Aux. blower will not start I. coil Liquid refrigerant flooding back to compressor Compressor and O.D. fan motor runs Compressor off on high pressure control Head pressure too low Head pressure too high Compressor "hums" but will not start Reversing valve does not shift Denotes occasional cause.Heating Cycle Auxiliary heat on I.D. Heat .D.D.D. coil Manual Page Cooling Cycle I. Compressor will not run O. fan motor do not operate Compressor cycles on overload Power Failure Blown Fuse or Tripped Breaker Faulty Wiring Loose Terminals Low Voltage Line Voltage Single 1PH Failure of 3PH Unbalanced 3PH Defective Contacts in Contactor Compressor Overload Potential Relay Run Capacitor Start Capacitor Faulty Wiring Loose Terminals Control Transformer Low Voltage Thermostat Contactor Coil Pressure Control or Impedance Relay Power Supply Control Circuit Indoor Fan Relay Discharge Line Hitting Inside of Shell Bearings Defective Seized Valve Defective Motor Windings Defective Refrigerant Charge Low Refrigerant Overcharge High Head Pressure Low Head Pressure High Suction Pressure Low Suction Pressure Non-Condensables Unequalized Pressures Sensing Bulb Loose-Poorly Located Compressor Refrigerant System Outdoor Section Defrost Control Rev.D. Valve Cycle Too Long (Clock timer) Defective Control.