Bard HAC181-AD040 User manual

SPLIT AIR CONDITIONER
OUTDOOR SECTION
Models: HAC181-AD040
HAC241-AD040
HAC301-AD040
HAC361-AD040
HAC421-AD040
HAC481-AD040
HAC481-BD040
HAC601-AD040
HAC601-BD040
FOR USE WITH:
MATCHING INDOOR
BLOWER COIL UNITS
AND MATCHING ADD
ON COIL UNITS ONLY
INSTALLATION INSTRUCTIONS
Manual No.: 2100-346C
Supersedes: 2100-346B
File: Volume 1, Tab 4
Date: 09-04-02
Bard Manufacturing Company
Bryan, Ohio 43506
Since 1914 . . . Moving ahead just as planned.
© Copyright2002

CONTENTS
Split Air Conditioner General Information.........1
Split Air Conditioner Model Nomenclature ............... 1
Application and Location ....................................4
General .................................................................... 4
Shipping Damage .................................................... 4
Application ............................................................... 4
Location ................................................................... 4
Mounting Unit Outside on Slab................................. 4
ImportantInstallerNote............................................ 4
InstallingRefrigerant Tubing..................................... 4
Sweat Style Tubin Connections: Sweat
Indoor Unit and Sweat Outdoor Unit ........................ 5
FieldFabricated Tubing Connections:
Quick Connect Indoor Unit and Sweat
Outdoor Unit Using CTO Kit..................................... 6
Wiring Instructions ..............................................9
General .................................................................... 9
Control Circuit Wiring ............................................... 9
Wall Thermostats ..................................................... 9
OptionalControls ................................................... 12
InstallationInstructions –CMA-5 ............................ 12
InstallationInstructions –CMA-6 ............................ 12
InstallationInstructions – CMA-10A........................ 13
InstallationInstructions – CMA-13A........................ 14
Charging Instructions........................................15
Pressure Service Ports .......................................... 15
System Start-Up (Indoor Units
withoutExpansion Valves....................................... 15
Service ................................................................17
ServiceHints.......................................................... 17
Fan Blade Setting Dimensions ............................... 17
PressureTables ................................................ 20-23
FIGURES
Figure 1.................................................................... 1
Figure 2.................................................................... 4
Figure 3.................................................................... 5
Figure 4.................................................................... 5
Figure 5.................................................................. 12
Figure 6.................................................................. 12
Figure 7.................................................................. 12
Figure 8.................................................................. 13
Figure 9.................................................................. 14
TABLES
Table 1 ..................................................................... 1
Table 2 ..................................................................... 2
Table 3 ..................................................................... 3
Table 4 ..................................................................... 6
Table 6 ..................................................................... 9
Table 7 ..................................................................... 9
Table 8 ..................................................................... 9
Table 9 ................................................................... 15
Table 10 ................................................................. 15
Table 11 ................................................................. 16
Table 12 ................................................................. 17
Table 13 ................................................................. 20
Table 14 ................................................................. 20
Table 15 ................................................................. 21
Table 16 ................................................................. 21
Table 17 ................................................................. 22
Table 18 ................................................................. 22
Table 19 ................................................................. 23

Manual 2100-346
Page 1
SPLIT AIR CONDITIONER MODEL NOMENCLATURE
TABLE 1
UNIT DIMENSIONS
.oNledoM
"W"
htdiW
"D"
htpeD
"H"
thgieHABCEF
181CAH
142CAH 00.0400.5100.62521.5881.0200.4521.7881.42
103CAH
163CAH 00.5400.5100.62521.5881.5200.4521.7881.92
124CAH
184CAH
106CAH
00.0500.5100.23526.6886.8200.4526.8886.23
W
H
C
BF
E
A
D
HIGH VOLTAGE
ENTRANCE
LOW VOLTAGE
ENTRANCE
ALTERNATE
ELECTRICAL
ENTRANCES
ON BACK
REFRIGERANT
SHUTOFF
VALVES
MIS-1789
Customized Unit Code
ElectricalCharacteristics
A–230/208-60-1
B–230/208-60-3
Modification Code
Capacity –3 Ton or
approx. 36,000 BTU
Basic Model Number
HAC 36 1 – A DXXX
FIGURE 1
UNITDIMENSIONALDRAWING

Manual 2100-346
Page 2
wolfriAdetaR
gnisnednoC tinU .oNledoM rotaropavE lioC .oNledoM MFC erusserP HporD
2
OdetaR .P.S.E
rotoM deepS paT
dednemmoceR egnaRwolFriA
metsyS ecifirO deriuqeR
A-181CAH A-SA03A A-SA42S B42CB
056 056 056 51. 42. 53.deM 517-055 517-055 517-055 250. 250. 250.
*
*
*
A142CAH A-SA03A A-SA42S B42CB
008 087 057 81. 03. 02.hgiH 019-007 098-086 019-007 550. 550. 550.
*
*
A-103CAH A-SA63A B63CB 000,1 000,1 02. 03.woL 571,1-058 571,1-058 360. 360.
*
*
A-163CAH A-SA73A B63CB 001,1 001,1 81. 72.hgiH 022,1-029 022,1-029 960. 960.
*
*
A-124CAH
A-SA24A A-SA84A B63CB B06CB 004,1 005,1 002,1 005,1 03. 62. 51. 83. hgiH woL 055,1-072,1 526,1-052,1 023,1-020,1 526,1-052,1 870. 870. 870. 870.
*
*
*
B-,A-184CAH B-SA16A B06CB 007,1 007,1 82. 52.woL 578,1-054,1 578,1-054,1 180. 180.
*
*
B-,A-106CAH B-SA16A B06CB 067,1 008,1 03. 82.hgiH 059,1-005,1 579,1-525,1 290. 290.
TABLE 2
RATED CFM AND AIR FLOW DATA
(WET COIL – COOLING)
QMeasuredacross theevaporatorcoil assembly, includingdrain pan.
RExternalstatic pressureavailable forthe ductsystem --supply andreturn. Allblowercoilshave multispeed
motors,and valueshown isat therecommended ratedspeed. Consult specificationair flowchartswith the
blowercoil unitsfor completeinformationatotherspeeds.
*IMPORTANTINFORMATION
Propersized orificeis notfactoryinstalled inindoor section. Properorifice sizeis shippedwith outdoorunit
packagedwith itsinstallation instructionsfor indoorsections listedon thispage. The orificemust bereplaced
withthe proper systemorifice shownabove inTable 2.
Forother evaporatorcoil modelsnotlisted,seeindoor coilinstallation instructionsfor properorificeinformation.

Manual 2100-346 Page 3
TABLE 3
SPECIFICATIONS
SLEDOMA-181CAHA-142CAHA-103CAHA-163CAHA-124CAHA-184CAHB-184CAHA-106CAHB-106CAH
)HP/V/ZH06(gnitaRlacirtcelE1-802/0321-802/0321-802/0321-802/0321-802/0321-802/0323-802/0321-802/0323-802/032
egnaRegatloVgnitarepO352-791352-791352-791352-791352-791352-791352-781352-791352-781
yticapmAtiucriCmuminiM515191025262715312
¬eziSeriWdleiF41412121010121801
!rekaerBtiucriCromumixaMesuFyaleD020203030454520653
802/032spmAtinUlatoT6.8/9.74.11/2.010.41/4.318.51/5.416.91/1.910.12/4.914.31/8.217.62/7.222.71/3.51
ROSSERPMOC
802/032stloV802/032802/032802/032802/032802/032802/032802/032802/032802/032
spmAdaoLdetaR5.7/8.63.01/1.99.21/3.217.41/4.311.81/6.715.91/9.719.11/3.112.52/2.127.51/8.31
tnerruCnoitceleStiucriChcnarB6.83.017.317.411.815.916.213.627.51
802/032spmArotoRkcoL94/9465/6557/5728/28501/501201/20119/19531/531051/051
taeHesacknarCenoNenoNenoNenoN noisremmI
epyT
noisremmI
epyT
noisremmI
epyT enoNenoN
RESNEDNOCdnaROTOMNAF
MPR/PH–rotoMnaF528–6/1528–6/1528–6/1528–6/1528–4/1528–4/1528–4/1528–4/1528–4/1
spmA–rotoMnaF1.11.11.11.15.15.15.15.15.1
retemaiD–naF000,2–"02000,2–"02000,2–"02000,2–"02006,2–"42006,2–"42006,2–"42006,2–"42006,2–"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
.SBL–THGIEWGNIPPIHS 551551081081052052052552552

Manual 2100-346
Page 4
APPLICATION and LOCATION
GENERAL
These instructions explain the recommended method to
install the air cooled remote type condensing unit, the
interconnecting refrigerant tubing and the electrical wiring
connections to the unit.
The condensing units are to be used in conjunction with the
matching evaporator coils or evaporator blower units for
comfort cooling applications as shown in the specification
sheet.
These instructions and any instructions packaged with any
separate equipment required to make up the entire air
conditioning system should be carefully read before
beginning the installation. Note particularly “Starting
Procedure” and any tags and/or labels attached to the
equipment.
SHIPPING DAMAGE
Upon receipt of equipment, the carton should be checked for
external signs of shipping damage. If damage is found, the
receiving part must contact the last carrier immediately,
preferably in writing, requesting inspection by the carrier’s
agent.
APPLICATION
Size of unit for a proposed installation should be based on
heat loss calculation and air duct sizing made according to
methods of Air Conditioning Contractors of America. The
air duct should be installed in accordance with the Standards
of the National Fire Protection Association for the
Installation of Air Conditioning and Ventilating Systems of
Other Than Residence Type, NFPA 90A, and Residence
Type Warm Air Heating and Air Conditioning Systems,
NFPA 90B. Where local regulations are at a variance with
instructions, installer should adhere to local codes.
FIGURE 2
INSTALLATION CLEARANCE
LOCATION
The condensing unit is designed to be located outside with
free and unobstructed condenser air inlet and discharge. It
must also permit access for service and installation.
Condenser air enters the coil from the rear of the unit as
shown in Figure 2 with electrical service access.
MOUNTING UNIT OUTSIDE ON SLAB
A solid level base or platform, capable to support the unit’s
weight, must be set at the outdoor unit predetermined
location. The base should be at least two inches larger than
the base dimensions of the unit and at least two inches
higher than surrounding grade level. The required unit
minimum installed clearances must be maintained as called
out in Figure 2 when locating and setting the base.
Remove the unit from its shipping carton and position the
unit on the prepared base or platform.
NOTE: These units employ internally sprung
compressors; therefore, it is not necessary to
remove or loosen the base mounting bolts on the
compressor prior to operation.
Consideration should be given to the electrical and tubing
connections when placing the unit to avoid unnecessary
bends or length of material.
IMPORTANT INSTALLER NOTE
For improved start up performance, wash the indoor coil
with a dishwashing detergent.
INSTALLATION REFRIGERANT TUBING
The information that follows on installing refrigerant tubing
and for changing the system orifice (if required) covers
applications listed in the front of this installation instruction
only. Although other indoor units may be of similar
construction, the installation instructions for these units
should be consulted for proper installation of those units
prior to installation.
This information is provided for the field service personnel
to install refrigerant tubing in compliance with Section 608
of Title VI National Recycling and Emission Reduction
Program for the U.S. Clean Air Act effective July 1, 1992.
Consult manual 2100-002 on procedure for leak test –
evacuation – charging before installation refrigerant tubing
that requires any refrigerant recovery or system evacuation.
Manual 2100-002 is included with the unit installation
instruction package when shipped from the factory.
MIS-589

Manual 2100-346
Page 5
SWEAT STYLE TUBING CONNECTIONS: SWEAT
INDOOR UNIT and SWEAT OUTDOOR UNIT
Use only refrigeration grade (dehydrated and sealed) copper
tubing. Care must be taken to insure that the tubing is kept
clean and dry before and during installation. Do not remove
the plugs from the tubing ends, coil connections or base
valves until the connection is ready to be brazed.
The suction line must be insulated with a minimum of 3/8”
Armaflex or equivalent before cutting and making
connections.
1. Being careful not to kink, route both the suction line
and liquid line between the indoor unit and outdoor
unit. Use a tubing bender to make any necessary bends
in tubing. When necessary to bend the insulated tube
suction line, cut the insulation around its circumference
at a distance far enough beyond the point of the bend so
as to clear the tubing bender. Slip the insulation back
together and vapor seal the joint with tape. Coil any
excess tubing in a horizontal place with the slope of the
tubing toward the condensing unit. See Figure 3.
NOTE: Do not braze line to units! If orifice needs to be
changed, change out orifice first.
If the orifice does not have to be changed, skip the
instructions outlined further in Step 3 and proceed to Step 8.
3. Disassemble Flow Control Assembly by turning body
hex.
4. If existing orifice has not dropped out of the body when
disassembled, remove by using a pin or paper clip.
Discard this original orifice.
5. Insert proper sized orifice fully into the flow control
body with rounded “bullet” nose towards the unit as
shown in Figure 4. Insure the orifice stays inserted in
body before connecting mating half. See chart in the
outdoor unit installation instructions for proper size.
6. Thread assembly halves together by hand to insure
proper mating of threads and tighten until bodies
“bottom” or a definite resistance is felt.
7. Using a marker pen or ink pen, mark a line lengthwise
from the union nut to the bulkhead. Then tighten an
additional 1/6 turn (or 1 hex flat). The misalignment of
the line will show the amount the assembly has been
tightened. This final 1/6 turn is necessary to insure the
formation of the leakproof joint.
8. Wrap a wet rag around the copper stub before brazing.
9. Flux the copper tube and insert into the stub. Braze the
joint using an alloy of silver or copper and phosphorus
with a melting temperature above 1,100° F for copper
to copper joints. The phosphorus will act as a flux,
therefore, no flux will be required.
FIGURE 3
INSTALLINGREFRIGERANT TUBING
FIGURE 4
FLOW CONTROL ASSEMBLY
FIELD ORIFICE REPLACEMENT INSTRUCTIONS
pp5
CAUTION
1. Be careful not to tear the insulation when
pushing it through hole in masonry or frame
walls. 2. When sealing the tube opening in
house wall, use a soft material to prevent tube
damage and vibration transmission. 3. Avoid
excessive bending in any one place to avoid
kinking.
CAUTION
Be sure there is no dirt introduced into the flow
control - orifice assembly. Be sure to install the
orifice with the bullet nose pointing in the proper
direction as shown in Figure 4. Failure to do so
will result in improper operation.
2. The tubing ends should be cut square. Make sure it is
round and free of burrs at the connecting ends. Clean
the tubing to prevent contaminants from entering the
system.
pp5

Manual 2100-346
Page 6
A copper-silver alloy with a high silver content should
be used when iron or steel material is involved in the
joint. These alloys require the use of silver solder flux.
Alloys containing phosphorus should not be used with
iron or steel. Phosphorus reacts with the iron forming
iron phosphate which is extremely brittle.
CAUTION
1. Brazing alloys with a melting temperature
below 700°F should not be used. 2. Lead-
tin or tin-antimony solders should not be used
due to their low melting point and necessity for
corrosivefluxes.
To further prevent the formation of copper oxide inside
the tubing, dry nitrogen may be purged through the
refrigerant system during brazing.
WARNING
Never purge or pressurize a system with
oxygen. An explosion and fire will result.
10. After brazing, quench with wet rag to cool the joint and
remove any flux residue.
11. Leak test all connections using an electronic leak
detector or a halide torch.
12. Evacuate suction line, liquid line and indoor unit
through outdoor unit base valves.
13. Open both the suction and liquid base valves to the
fully open position. Refer to section later in installation
instructions for details on setting proper system charge.
FIELD FABRICATED TUBING CONNECTIONS:
QUICK CONNECT INDOOR UNIT and SWEAT
OUTDOOR UNIT USING CTO KIT
Use only refrigeration grade (dehydrated and sealed) copper
tubing. Care must be taken to insure that the tubing is kept
clean and dry before and during installation. Do not remove
the plugs from the tubing ends, coil connections or base
valves until the connection is ready to be brazed.
The suction line must be insulated with a minimum of 3/8”
Armaflex or equivalent before cutting and making
connections.
1. Being careful not to kink, route both the suction line and
liquid line between the indoor unit and outdoor unit. Use
a tubing bender to make any necessary bends in tubing.
When necessary to bend the insulated tube suction line,
cut the insulation around its circumference at a distance
far enough beyond the point of the bend so as to clear the
tubing bender. Slip the insulation back together and
vapor seal the joint with tape. Coil any excess tubing in
a horizontal place with the slope of the tubing toward the
condensing unit. See Figure 3.
TABLE 4
TUBINGCHART
cisaB gnisnednoC ledoMtinU
).tF(htgneLeniLtnaregirfeR
02-006-12001-16
diuqiLnoitcuSdiuqiLnoitcuSdiuqiLnoitcuS
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"4/32/1"8/7
124CAH"8/3"4/3"8/3"8/72/1"8/7
184CAH"8/3"8/7"8/3"8/72/1"8/1-1
106CAH"8/3"8/7"8/3"8/72/1"8/1-1
CAUTION
1. Be careful not to tear the insulation when
pushing it through hole in masonry or frame
walls. 2. When sealing the tube opening in
house wall, use a soft material to prevent tube
damage and vibration transmission. 3. Avoid
excessive bending in any one place to avoid
kinking.

Manual 2100-346
Page 7
NOTE: Do not make any tubing connection at indoor unit
at this time. Make all brazing of joints and
evacuate both suction and liquid line first.
3. Wrap a wet rag around the copper stub before brazing.
4. Flux the copper tube and insert into the stub. Braze the
joint using an alloy of silver or copper and phosphorus
with a melting temperature above 1,100° F for copper
to copper joints. The phosphorus will act as a flux,
therefore, no flux will be required.
A copper-silver alloy with a high silver content should
be used when iron or steel material is involved in the
joint. These alloys require the use of silver solder flux.
Alloys containing phosphorus should not be used with
iron or steel. Phosphorus reacts with the iron forming
iron phosphate which is extremely brittle.
To further prevent the formation of copper oxide inside
the tubing, dry nitrogen may be purged through the
refrigerant system during brazing.
2. The tubing ends should be cut square. Make sure it is
round and free of burrs at the connecting ends. Clean
the tubing to prevent contaminants from entering the
system.
CAUTION
1. Brazing alloys with a melting temperature
below 700°F should not be used. 2. Lead-tin
or tin-antimony solders should not be used due
to their low melting point and necessity for
corrosivefluxes.
WARNING
Never purge or pressurize a system with
oxygen. An explosion and fire will result.
5. After brazing, quench with wet rag to cool the joint and
remove any flux residue.
6. Leak test all connections using an electronic leak
detector or a halide torch.
7. Evacuate suction line and liquid line through outdoor
unit base valves.
If orifice does not have to be changed, skip the instructions
outlined further in Step 8 and proceed to Step 15.
8. Recover charge from the indoor unit.
A. Connect the suction line only to the indoor unit as
outlined in Steps 15, 16, and 17.
B. Recover indoor unit and suction line unit charge
through service port located on outdoor unit base
valve.
9. Disassemble Flow Control Assembly by turning body
hex.
10. If existing orifice has not dropped out of the body when
disassembled, remove by using a pin or paper clip.
Discard this original orifice.
11. Insert proper sized orifice fully into the flow control
body with rounded “bullet” nose towards the unit as
shown in Figure 4. Insure the orifice stays inserted in
body before connecting mating half. See chart in the
outdoor unit installation instructions for proper size.
CAUTION
Be sure there is no dirt introduced into the flow
control –orifice assembly. Be sure to install the
orifice with the bullet nose pointing in the proper
direction as shown in Figure 4. Failure to do so
will result in improper operation.
14. Evacuate the suction line and indoor unit through the
outdoor unit base valve before connecting all other
tubing. Refer to section later in installation instructions
for details on setting the proper refrigerant charge.
15. Remove (remaining) protector caps and plugs (if orifice
was changed). Inspect fittings and if necessary
carefully wipe coupling seats and threaded surfaces
with a clean cloth to prevent the inclusion of dirt or any
foreign material in the system.
12. Thread assembly halves together by hand to insure
proper mating of threads and tighten until bodies
“bottom” or a definite resistance is felt.
13. Using a marker pen or ink pen, mark a line lengthwise
from the union nut to the bulkhead. Then tighten an
additional 1/6 turn (or 1 hex flat). The misalignment of
the line will show the amount the assembly has been
tightened. This final 1/6 turn is necessary to insure the
formation of the leakproof joint.

Manual 2100-346
Page 8
16. Lubricate male half diaphragm and synthetic rubber
seal with refrigerant oil. Thread coupling halves
together by hand to insure proper mating of threads. Be
sure to hold the coupling firmly to prevent movement of
the coupling and tubing. Failure to do so could tear out
the diaphragm causing a blockage of the system. Use
proper size wrenches (on coupling body hex and on
union nut) and tighten until coupling bodies ”bottom”
or a definite resistance is felt.
18. Leak test all connections using an electronic leak
detector or a halide torch.
19. When tubing is installed in attics or drop ceilings,
insulate the couplings on the larger tube thoroughly
with 3/8” wall thickness, closed cell sponge tube
insulation or equivalent. Failure to insulate will result
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. Then tighten
an additional 1/4 turn. The misalignment of the line
will show the amount the coupling has been tightened.
This final 1/4 turn is necessary to insure the formation
of leakproof joint. If a torque wrench is used, the
torque values shown in Table 5 are recommended.
CAUTION
After starting to tighten up the fitting, never try to
back it off or take it apart.
TABLE 5
COUPLINGS
eziSgnilpuoCsdnuoPteeF
6-21-01
01-54-53
11-54-53
21-56-05

Manual 2100-346
Page 9
WIRING INSTRUCTIONS
GENERAL
All wiring must be installed in accordance with the National
Electrical Code and local codes. In Canada, all wiring must
be installed in accordance with the Canadian Electrical
Code and in accordance with the regulations of the
authorities having jurisdiction. Power supply voltage must
conform to the voltage shown on the unit serial plate. A
wiring diagram of the unit is attached to the inside of the
electrical cover. The power supply shall be sized and fused
according to the specification supplied. A ground lug is
supplied in the control compartment for equipment ground.
The unit rating plate lists a “Maximum Time Delay Fuse” or
HACR type” circuit breaker that is to be used with the
equipment. 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.
CONTROL CIRCUIT WIRING
For split systems, the minimum control circuit wiring gauge
needed to insure proper operation of all controls in both
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 circuit
wiring. (This is the distance between the wall
thermostat to the indoor unit plus the distance
between the indoor unit to the outdoor unit.)
The following table should be used to determine proper
gauge of control circuit wiring required.
Example: 1. Control circuit transformer rated at 40 VA
2. Maximum total distance of control circuit
wiring 85 feet.
From Table 6, minimum of 18 gauge wire should be used in
the control circuit wiring.
For control circuit transformers rated other than those listed,
use the next lower rated transformer listed.
Example: 1. Control circuit transformer rated at 55 VA
From table use 50VA transformer.
There are two (2) separate control diagrams for fossil fuel
furnaces with air conditioners.
Control diagrams for the various circuit which could be
encountered with blower coils can be found in the
installation instructions of the blower coil.
WALL THERMOSTATS
The following wall thermostats and subbases should be
used as indicated, depending on the application.
TABLE 7
CONTROLDIAGRAMS
metsyS ecanruFsaG margaiDlortnoC ecanruFliO margaiDlortnoC
sledoMllA001-1904101-1904
TABLE 8
WALL THERMOSTAT and SUBBASE
COMBINATIONS
tatsomrehTesabbuSserutaeFetanimoderP
200-3048 113F78T 300-4048 0221A925Q yrucreM;loocegats1,taehegats1 otua-no:naFlooc-ffo-taeh:metsyS
140-3048 C-4308T --- yrucreM;loocegats1,taehegats1 otua-no:naFlooc-ffo-taeh:metsyS
530-3048 08-59F1 --- loocegats2,taehegats2 elbammargorP cinortcelE
240-3048 G1158T --- loocegats1,taehegats2 looc-otua-ffo-taeh:metsyS cinortcelEotua-no:naF
340-3048 002MC --- loocegats1,taehegats1 otua-no:naFlooc-ffo-taeh:metsyS noitcApanS
720-3048 17-29F1
---
loocegats2,taehegats3 elbammargorP cinortcelE
TABLE 6
CONTROL CIRCUIT WIRING
foAVdetaR tiucriClortnoC remrofsnarT remrofsnarT yradnoceS V42@ALF
latoTmumixM foecnatsiD tiucriClortnoC teeFnigniriW
046.1
56eguag02 09eguag81 541eguag61 032eguag41
051.2
54eguag02 06eguag81 001eguag61 061eguag41 052eguag21
567.2
04eguag02 55eguag81 58eguag61 531eguag41 012eguag21

Manual 2100-346
Page 10

Manual 2100-346
Page 11

Manual 2100-346
Page 12
FIGURE 5
COMPONENTMOUNTINGLOCATION
OPTIONAL CONTROLS
MIS-1302
INSTALLATION INSTRUCTIONS — CMA-5
Disconnect all power to the unit. Remove control panel
cover.
1. Mount compressor TDR in position shown in Figure 5
with screw provided.
2. Disconnect yellow low voltage (Y) wire at the
compressor contactor coil and reconnect to the Y1 or #3
terminal of the TDR.
3. Connect yellow wire from terminal (Y) of the TDR to
the (Y) terminal of the compressor contactor coil. This
is the terminal that the wire was removed from in
Step 2.
4. Recheck wiring. Refer to Figure 9. Energize unit.
Compressor should start. Remove power and reapply.
Compressor should not start until the 5 minute time
delay has expired.
5. Apply “This unit equipped with CMA-5 control
module” label to inside of the inner control panel cover
above wiring diagram.
6. Replace all panels and covers. This completes
installation.
INSTALLATION INSTRUCTIONS — CMA-6
Disconnect all power to unit. Remove control panel inner
and outer cover.
1. Mount terminal block in position shown in Figure 5.
2. Disconnect black high voltage outdoor motor lead from
compressor contactor and reconnect to terminal block.
3. Route low ambient control wires up through the
bushing in the bottom of the control panel. Connect the
low ambient control wires between the terminal block
and T2 of the compressor contactor.
4. Remove service port cap on discharge line. Install the
low ambient control on the discharge line with the flare
tee adapter that is brazed to the low ambient control.
Check for pressure at the flare tee dill valve after
installation to insure that the dill valve in the unit
service port was depressed by the flare tee connector.
Check for leaks at the flare tee connectors. Replace
service port cap on the flare tee service port and tighten.
5. Recheck wiring. See Figure 10. Check for proper
operation of the unit by energizing in cooling mode.
The condenser fan motor should not run until the
discharge pressure has exceeded 300 PSI. Should the
discharge pressure fall below 200 PSI while running,
the condenser fan motor will de-energize until the head
pressure builds to 300 PSI.
6. Apply “This unit equipped with CMA-6 control
module” label to the inside of the control panel cover
above the wiring diagrams.
7. Replace all panels and covers. This completes
installation.
FIGURE 6
INSTALLATION INSTRUCTIONS
FOR CMA-5 COMPRESSOR TIME DELAY RELAY
MIS-598
FIGURE 7
INSTALLATIONINSTRUCTIONSFOR
CMA-6 LOW AMBIENT FAN CYCLING CONTROL
MIS-594
CMA-5 & CMA-13A LOW
AMBIENTFANCYCLING
CONTROL TERMINAL BLOCK
CMA-5 COMPRESSOR
TIMEDELAYRELAY
SK109 LOW VOLTAGE
START KIT CMA-10A& CMA-13A
COMPRESSOR
CONTROL

Manual 2100-346
Page 13
INSTALLATIONINSTRUCTIONS–CMA-10A
Disconnect all power to unit. Remove control panel cover.
1. Screw compressor control module and terminal block
into control panel as shown in Figure 5.
2. Disconnect yellow low voltage wire form compressor
contactor and reconnect to terminal “Y” of the
compressor control module.
3. Connect the yellow wire from the compressor control
module to “Y” side of the compressors contactor coil.
This is the same terminal from which the wire was
removed in Step 2.
4. Connect the black wire form the compressor control
module to common “C” side of the compressor
contactorcoil.
5. Connect a field supplied wire from “R” of the indoor
unit to “R” on the compressor control module.
6. Route the high (red) and low (blue) pressure switch
wires through the bushing in the bottom of the control
panel. Connect the low pressure switch wire to
terminals LPC of the compressor control module.
7.Remove service port caps on both the suction and
discharge lines. Install the high pressure switch on the
discharge line to the 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 after installation to insure that the dill valve in
the unit service port was depressed by the flare tee
connector. Check for leaks at the flare tee connectors.
Replace service port caps on the flare tee service ports
and tighten.
8. Adjust the compressor time delay relay to the desired
delay 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 has
expired. This will be 10% of the delay on break period.
Run the unit for at least 5 minutes. The unit should not
go into lockout.
10. Apply “This unit equipped with CMA-10A control
module.” label to the inside of the inner control panel
cover above the wiring diagram.
11. Replace all panels and covers. This completes
installation.
FIGURE 8
INSTALLATION INSTRUCTIONS FOR
CMA-10A DUAL PRESSURE CONTROL and
COMPRESSOR TIME DELAY RELAY
MIS-1303

Manual 2100-346
Page 14
INSTALLATIONINSTRUCTIONS–CMA-13A
Disconnect all power to unit. Remove control panel cover.
1. Screw compressor control module and terminal block
into control panel as shown in Figure 5.
2. Disconnect yellow low voltage wire from compressor
contactor and reconnect to terminal “Y” of the
compressor control module.
3. Connect the yellow wire from the compressor control
module to “Y” side of the compressor’s contactor coil.
This is the same terminal from which the wire was
removed in Step 2.
4. Connect the black wire from the compressor control
module to common “C” side of the compressor
contactorcoil.
5. Connect a field supplied wire from “R” of the indoor
unit to “R” on the compressor control module.
6. Route the high (red) and low (blue) pressure switch
wires through the bushing in the bottom of the control
panel. Connect the low pressure switch wire to
terminals LPC of the compressor control module.
Connect the high pressure switch wires to terminals
HPC of the compressor control module.
7. Disconnect the high voltage outdoor motor lead and
reconnect to the terminal block installed in Step 1.
8. Route the LAC (black) wires up through the busing in
the bottom of the control panel. Connect one wire to
the terminal block and the other to “T2” of the
contactor. This will be the same terminal from which
the high voltage outdoor motor lead was removed in
Step 7.
9. Remove service port caps on both the suction and
discharge lines. Install the high pressure switch and
the low ambient control on the discharge line with the
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 after installation to
insure that the dill valve in the unit service port was
depressed by the flare tee connector. Check for leaks at
the flare tee connectors. Replace service port caps on
the flare tee service ports and tighten.
10. Adjust the compressor time delay relay to the desired
delay 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 has
expired. This will be 10% of the delay on break period.
Run the unit for at least 5 minutes. The unit should not
go into lockout. The condenser fan motor should not
run until the discharge pressure has exceeded 300 PSI.
Should the discharge pressure fall below 200 PSI while
running the condenser fan motor will de-energize until
the head pressure builds to 300 PSI.
12. Apply “This unit equipped with CMA-13A control
module.” label to the inside of the inner control panel
cover above the wiring diagram.
13. Replace all panels and covers. This completes
installation.
FIGURE 9
INSTALLATION INSTRUCTIONS FOR
CMA-13A DUAL PRESSURE CONTROL, LOW AMBIENT FAN CYCLING CONTROL
and COMPRESSOR TIME DELAY RELAY
MIS-1304

Manual 2100-346
Page 15
PRESSURE SERVICE PORTS
High and low pressure service ports are installed on all units
so that the system operating pressures can be observed.
Pressure tables can be found later in the manual covering all
models. It is imperative to match the correct pressure table
to the unit by model number.
SYSTEM START-UP (INDOOR UNITS
WITHOUT EXPANSION VALVES)
1. Close disconnect switch(es) and set the thermostat to
cool and the temperature to the highest setting.
2. Check for proper airflow across the indoor coil by
referring to indoor unit installation.
3. Connect the service gauges and allow the unit to run for
at least 10 minutes or until pressures are stable. Check
pressures to the system pressure table attached to the
outdoor unit service panel. For optimum system
performance, go to Step 4.
4. Install a thermometer on the suction line approximately
6" to 10" from the compressor. Optimum system
performance will occur with a refrigerant charge
resulting in a suction line superheat as determined from
the following calculations.
A. Measure outdoor air dry bulb temperature
________ ºF
B. Measure indoor air wet bulb temperature
________ ºF
C. Measure suction pressure ______PSIG
D. Measure suction line temperature ________ ºF
E. Determine optimum system superheat
from Table 9 using outdoor air dry bulb
(Step B) and indoor air wet bulb (Step A)
________ ºF
F. Determine saturated suction temperature
from 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 the
optimum system superheat (Step E) by adding
charge to lower the superheat or removing
charge to raise the superheat.
I. Check final system operating pressures to the
system pressure tables as was done in Step 3.
CHARGING INSTRUCTIONS
TABLE 9
SYSTEMSUPERHEAT
tneibmAroodtuO F(erutarepmeT )bluByrD
erutarepmeTriAnruteR bluBteWF
95367617
501 5909580857 1
1
1
3
8
01
1
3
7
9
4102
5)8( 41915203
0262339324
TABLE 10
SATURATED SUCTION TEMPERATURE R-22
GISPerusserPnoitcuS noitcuSdetarutaS )F(erutarepmeT
053555 628203
851636 234363
567607 839314
376797 345474
2868 9415

Manual 2100-346
Page 16
noitceSroodtuOnoitceSroodnI 22-RlatoT ).zO(egrahC
A-181CAH A-SA03A A-SA42S B42CB
.zo37 .zo37 .zo87
A-142CAH A-SA03A A-SA42S B42CB
.zo08 .zo08 .zo97
A-103CAH A-SA63A B63CB .zo48 .zo59
A-163CAH A-SA73A B63CB .zo89 .zo69
A-124CAH
A-SA24A A-SA84A B63CB B06CB .zo201 .zo711 .zo501 .zo241
B-,A-184CAH A-SA16A B06CB .zo551 .zo571
B-,A-106CAH A-SA16A B06CB .zo351 .zo561
TABLE 11
TOTALSYSTEM OPERATING CHARGE
(Includes charge for the basic outdoor unit,
indoor coil and 25’ of interconnecting tubing.)
Q
R
Includes25’of 1/4”diameterliquid line. Forother than25’and
othertube sizes,adjust thetotal chargeaccording tothe
followingschedule.
Includes25’of 3/8”diameterliquid line. Forother than25’and
othertube sizes,adjust thetotal chargeaccording tothe
followingschedule.
Q
R
R
R
R
R
R
Installer Note: Stamp or mark the final system charge
determinedabove onthe outdoorunit serialplate.
SCHEDULE FOR TABLE 11
retemaiDeniLdiuqiL.tFreP22-R.zO
"4/1 "8/3 "2/1 52.0 06.0 02.1

Manual 2100-346
Page 17
SERVICE
SERVICE HINTS
1. Caution homeowner to maintain clean air filters at all
times. Also, not to needlessly close off supply and
return air registers. This reduces air flow through the
system, which shortens equipment service life, as well
as, increasing operating costs.
2. Check all power fuses or circuit breakers to be sure that
they are the correct rating.
3. Periodic cleaning of the outdoor coil to permit full and
unrestricted air flow circulation is essential.
FAN BLADE SETTING DIMENSIONS
Shown in Figure 10 are the correct fan blade setting
dimensions for proper air delivery across the outdoor coil.
Any service work requiring removal or adjustment in the fan
and/or motor area will require that the dimensions below be
checked and blade adjusted in or out on the motor shaft
accordingly.
TABLE 12
FAN BLADE SETTING
ledoMAnoisnemiDsnoitacoLbuHnaF
181CAH 142CAH 103CAH 163CAH
"5B
124CAH 184CAH 106CAH "4/3-4C
FIGURE 10
FAN BLADE
C
B
A
7960-337

Manual 2100-346
Page 18