Bard K36A2-A User manual

Page 1 of 24
WALL-MOUNTED PACKAGED
AIR CONDITIONER
Models:
K36A2-A
K36A2-N
K42A2-A
K42A2-N
K48A2-A
K48A2-N
INSTALLATION INSTRUCTIONS
Bard Manufacturing Company, Inc.
Bryan, Ohio 43506
www.bardhvac.com
Manual: 2100-628
Supersedes: NEW
Date: 12-1-14
K60A2-A
K60A2-N
K36L2-A
K36L2-N
K42L2-A
K42L2-N
K48L2-A
K48L2-N
K60L2-A
K60L2-N

Manual 2100-628
Page 2 of 24
Contents
Figures
Figure 1 Unit Dimensions ................................... 7
Figure 2
Mounting Instructions – K36, 42, 48, 60 ...... 8
Figure 3 Electric Heat Clearance ......................... 9
Figure 4 Wall Mounting Instructions .................. 10
Figure 5 Wall Mounting Instructions .................. 10
Figure 6 Common Wall Mounting Installations .... 11
Figure 7 Thermostat Connections ...................... 14
Figure 8 MV4001K-B Controller Connections...... 15
Figure 9 Fan Blade Setting ............................... 19
Figure 10 Motor High Voltage Connections ........... 20
Figure 11 Motor Low Voltage Connections ............ 21
Tables
Table 1 Low Voltage Connections DDC Control ... 12
Table 2 Wall Thermostat.................................. 12
Table 3 Thermostat Wire SIze .......................... 12
Table 4 Fan Blade Dimension .......................... 19
Table 5 Cooling Pressure Table......................... 22
Table 6 Electric Specifications ......................... 23
Table 7 Recommended Airflow ......................... 24
Table 8 Indoor Blower Performance .................. 24
Table 9 Maximum ESP Electric Heat Only......... 24
Table 10 Electric Heat ...................................... 24
Getting Other Information and Publications 3
Wall Mount General Information ......................... 4
Wall Mount Model Nomenclature ........................... 4
Shipping Damage ................................................. 4
General ............................................................... 4
Duct Work ........................................................... 5
Filters ................................................................. 5
Condensate Drain ................................................ 5
Installation ............................................................... 6
Wall Mounting Information .................................... 6
Mounting the Unit ................................................ 6
Clearances Required............................................. 6
Minimum Clearances ............................................ 6
Wiring – Main Power........................................... 12
Wiring – Low Voltage Wiring................................. 12
Humidity Control Option ..................................... 13
Start Up ................................................................... 16
General ............................................................. 16
Topping Off System Charge ................................. 16
Safety Practices ................................................. 16
Important Installer Note...................................... 17
High Pressure Switch.......................................... 17
Three Phase Scroll Compressor............................ 17
Phase Monitor.................................................... 17
Condenser Fan Operation .................................... 17
Service Hints ..................................................... 17
Sequence of Operation........................................ 18
Compressor Control Module................................. 18
Adjustments ...................................................... 18
Pressure Service Ports ........................................ 18
Service ..................................................................... 19
Fan Blade Setting Dimensions ............................. 19
R-410A Refrigerant Charge ................................. 19
Removal of Fan Shroud....................................... 19
Troubleshooting Constant Torque ECM Motors ....... 19

Manual 2100628
Page 3 of 24
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 ..............ANSI/NFPA 90A
of Air Conditioning and Ventilating Systems
Standard for Warm Air.......................ANSI/NFPA 90B
Heating and Air Conditioning Systems
Load Calculation for ......................... ACCA Manual J
Residential Winter and Summer Air Conditioning
Duct Design for Residential ............... ACCA Manual D
Winter and Summer Air Conditioning and Equipment
Selection
FOR MORE INFORMATION, CONTACT
THESE PUBLISHERS:
ACCA Air Conditioning Contractors of America
1712 New Hampshire Ave. N.W.
Washington, DC 20009
Telephone: [phone]
Fax: [phone]
ANSI American National Standards Institute
11 West Street, 13th Floor
New York, NY 10036
Telephone: [phone]
Fax: [phone]
ASHRAE American Society of Heating, Refrigeration
and Air Conditioning Engineers, Inc.
1791 Tullie Circle, N.E.
Atlanta, GA 30329-2305
Telephone: [phone]
Fax: [phone]
NFPA National Fire Protection Association
Batterymarch Park
P.O. Box 9101
Quincy, MA 02269-9901
Telephone: [phone]
Fax: [phone]

Manual 2100-628
Page 4 of 24
WALL-MOUNT GENERAL INFORMATION
AIR CONDITIONER WALL-MOUNT MODEL NOMENCLATURE
K 42 A 2 – A 05 N P X X X J
SHIPPING DAMAGE
Upon receipt of equipment, the carton should be
checked for external signs of shipping damage. If
damage is found, the receiving party must contact
the last carrier immediately, preferably in writing,
requesting inspection by the carrier’s agent.
GENERAL
The equipment covered in this manual is to be installed
by trained, experienced service and installation
technicians.
This appliance is not intended for use by persons
(including children) with reduced physical, sensory
or mental capabilities, or lack of experience and
knowledge, unless they have been given supervision or
instruction concerning use of the appliance by a person
responsible for their safety.
Children should be supervised to ensure that they do
not play with the appliance.
The refrigerant system is completely assembled and
charged. All internal wiring is complete.
The unit is designed for use with or without duct work.
Flanges are provided for attaching the supply and
return ducts.
These instructions explain the recommended method
to install the air cooled self-contained unit and the
electrical wiring connections to the unit.
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.
While these instructions are intended as a general
recommended guide, they do not supersede any
national and/or local codes in any way. Authorities
having jurisdiction should be consulted before the
installation is made. See Page 3 for information on
codes and standards.
Size of unit for a proposed installation should be based
on heat loss calculation made according to methods of
Air Conditioning Contractors of America (ACCA). 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 No.
90A, and Residence Type Warm Air Heating and Air
Conditioning Systems, NFPA No. 90B. Where local
regulations are at a variance with instructions, installer
should adhere to local codes.
KW
0Z
05 (1 PH)
06 (3 PH)
MODEL SERIES CONTROL
J – Low Ambient Control
and Alarm Relay (Standard)
VOLTS & PHASE
A – 230/208/60/1
N – 400/60/3
REVISION
VENTILATION OPTIONS
N – No vent, no vent exhaust,
solid service door
FILTER OPTIONS
P – 2" Pleated MERV 8
COLOR OPTIONS
X – Beige (Standard)
1 – White
S – Stainless
COIL OPTIONS
1 – Standard
3 – Phenolic Coated Evaporator
and Condenser
CONTROL PANEL COVER
X – Desert Duty Door (Standard)
M – Moderate Duty Door (Rev 2 Cover)
CAPACITY
36 – 3 Ton
42 – 3½ Ton
48 – 4 Ton
60 – 5 Ton
A – Right Hand Air Conditioner
L – Left Hand Air Conditioner

Manual 2100628
Page 5 of 24
DUCT WORK
All duct work, supply and return, must be properly
sized for the design airflow requirement of the
equipment. Air Conditioning Contractors of America
(ACCA) is an excellent guide to proper sizing. 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.
Refer to Table 9 Maximum ESP of Operation – Electric
Heat Only on page 24.
Design the duct work according to methods given by
the Air Conditioning Contractors of America (ACCA).
When duct runs through unheated spaces, it should be
insulated with a minimum of one inch of insulation.
Use insulation with a vapor barrier on the outside of the
insulation. Flexible joints should be used to connect the
duct work to the equipment in order to keep the noise
transmission to a minimum.
All models covered by this installation instructions
require a 1/4 inch clearance to combustible material
for the first three feet of duct attached to the outlet air
frame is required. See Wall Mounting Instructions and
Figures 2 and 3 on pages 8 and 9 for further details.
Ducts through the walls must be insulated and all joints
taped or sealed to prevent air or moisture entering the
wall cavity.
Some installations may not require any return air duct.
A metallic return air grille is required with installations
not requiring a return air duct. The spacing between
louvers on the grille shall not be larger than 5/8 inch.
Any grille that meets with 5/8 inch louver criteria may
be used. It is recommended that Bard Return Air
Grille Kit RG5 or RFG5 be installed when no return
duct is used. Contact distributor or factory for ordering
information. If using a return air filter grille, filters
must be of sufficient size to allow a maximum velocity
of 400 fpm.
NOTE: If no return air duct is used, applicable
installation codes may limit this cabinet to installation
only in a single story structure.
FILTERS
A 2-inch pleated filter is standard with each unit. The
filter slides into position making it easy to service. This
filter can be serviced from the outside by removing the
filter access panel.
CONDENSATE DRAIN
A plastic drain hose extends from the drain pan at
the top of the unit down to the unit base. There are
openings in the unit base for the drain hose to pass
through. In the event the drain hose is connected to
a drain system of some type, it must be an open or
vented type system to assure proper drainage.

Manual 2100-628
Page 6 of 24
Clearances Required for Service Access and
Adequate Condenser Airflow
MODELS LEFT
SIDE
RIGHT
SIDE
DISCHARGE
SIDE
K36A, K42A, K48A, K60A 20" 20" 10'
K36L, K42L, K48L, K60L 20" 20" 10'
Minimum Clearances Required to
Combustible Materials
MODELS SUPPLY AIR DUCT
FIRST THREE FEET CABINET
K36A, L/K42A, L
K48A, L/K60A, L 1/4" 0"
NOTE: For side by side installation of two (2) K**A models there
must be 20" between units. This can be reduced to 15" by using
a K**L model (left side compressor and controls) for the left unit
and K**A (right side compressor and controls) for right unit.
See specification S3498.
INSTALLATION
WARNING
Failure to provide the 1/4 inch clearance
between the supply duct and a combustible
surface for the rst 3 feet of duct can result in
re causing damage, injury or death.
WALL MOUNTING INFORMATION
1. Two holes for the supply and return air openings
must be cut through the wall as shown in Figure 2
on page 8.
2. On wood frame walls, the wall construction must be
strong and rigid enough to carry the weight of the
unit without transmitting any unit vibration.
3. Concrete block walls must be thoroughly inspected
to insure that they are capable of carrying the
weight of the installed unit.
MOUNTING THE UNIT
1. These units are secured by wall mounting brackets
which secure the unit to the outside wall surface at
both sides. A bottom mounting bracket, attached
to skid for shipping, is provided for ease of
installation, but is not required.
2. The unit itself is suitable for 0 inch clearance,
but the supply air duct flange and the first 3 feet
of supply air duct require a minimum of 1/4 inch
clearance to combustible material. However, it is
generally recommended that a 1 inch clearance is
used for ease of installation and maintaining the
required clearance to combustible material. See
Figure 2 on page 8 for details on opening sizes.
3. Locate and mark lag bolt locations and bottom
mounting bracket location. See Figure 2.
4. Mount bottom mounting bracket.
5. Hook top rain flashing, attached to front-right of
supply flange for shipping, under back bend of top.
6. Position unit in opening and secure with 5/16 lag
bolts; use 7/8 inch diameter flat washers on the lag
bolts.
7. Secure rain flashing to wall and caulk across entire
length of top. See Figure 2.
8. For additional mounting rigidity, 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). Be sure to
observe required clearance if combustible wall.
9. On side-by-side installations, maintain a minimum
of 20 inches clearance on right side to allow access
to control panel and heat strips, and to allow proper
airflow to the outdoor coil. Additional clearance
may be required to meet local or national codes.

Manual 2100628
Page 7 of 24
FIGURE 1
All dimensions are in inches. Dimensional drawings are not to scale.
Dimensions of Basic Unit for Architectural and Installation Requirements (Nominal)
Model Width
(W)
Depth
(D)
Height
(H)
Supply Return
A B C B E F G I J K L M N O P Q R S T
K36A/L
K42A/L 42.075 22.432 84.875 9.88 29.88 15.88 29.88 43.88 13.56 31.66 30.00 32.68 26.94 34.69 32.43 3.37 43.00 23.88 10.00 1.44 16.00 1.88
K48A/L
K60A/L 42.075 22.432 93.000 9.88 29.88 15.88
29.88 43.88 13.56 37.00 30.00 40.81 35.06 42.81 40.56 3.37 43.00 31.00 10.00 1.44 16.00 10.00
Back ViewSide ViewFront View
SUPPLY AIR OPENING
MIS-3666 A
Air Outlet
Condenser Cond.
Air
Inlet
Filter
Access Panel
G
W
ELECTRICAL
LOW VOLTAGE
(LOCKABLE)
PANEL
ACCESS
HEATER
ELECTRICAL
ENTRANCE
HIGH VOLTAGE
ENTRANCE
ELECTRIC HEAT
ACCESS PANEL
DISCONNECT
C. BREAKER/
BUILT IN
RAIN HOOD
4° PITCH
J
K
H
C
I
A
2.13D
3/4" I.D.
DRAIN HOSE
Mounting
Brackets
Location
Shipping
Flashing
Entrances
Electrical
Optional
Top Rain
(Built In)
Side Wall
BOTTOM
INSTALLATION
BRACKET
RETURN AIR
OPENING
E
T
S
S
S
S
S
O
L
Q
N
P
M
R
.44
SIDE VIEW
OPENING
FRONT VIEW
RETURN AIR
BACK VIEW
Condenser
Air Outlet
FILTER
ACCESS PANEL
G
W
MIS-3665 A
Electrical
Optional
Entrances
Shipping
Flashing
Top Rain
Mounting
Brackets
(Built In)
Location
Side Wall
BOTTOM
INSTALLATION
BRACKET
SUPPLY AIR OPENING
M
L
E
O
.44 R
S
S
S
S
S
N
Q
T
P
BUILT IN
LOW VOLTAGE
Cond.
4° PITCH
RAIN HOOD
Air
Inlet
ENTRANCE
ELECTRICAL
ELECTRIC HEAT
(LOCKABLE)
ACCESS PANEL
DISCONNECT
PANEL
HEATER
ACCESS
C. BREAKER/
HIGH VOLTAGE
ELECTRICAL
ENTRANCE
D
J
K
C
I
A
2.13
H
3/4" I.D.
DRAIN HOSE
K**A
RIGHT
HAND
UNIT
K**L
LEFT
HAND
UNIT

Manual 2100-628
Page 8 of 24
FIGURE 2
K36A2, K36L2, K42A2, K42L2, K48A2, K48L2, K60A2, K60L2
MOUNTING INSTRUCTIONS
D
16" 16" 16" 16" 16"
17
8"
61
2" 6 1
2"
21
8"
7 8"
1"
3"
4"
Typ.
4"
Typ.
61
2"30"
E
16"
A CC
31
8"
B
Wall Opening and Hole Location View
RETURN AIR
1
REQUIRED DIMENSIONS TO MAINTAIN
1/4" MIN. CLEARANCE FROM
COMBUSTIBLE MATERIALS
REQUIRED DIMENSIONS TO MAINTAIN 29
DUCT
COMBUSTIBLE MATERIALS
A B C DE
30 1/2 10 1/2 6 1/4 1 1/4 29 3/4
32 12 5 1/2 2
NOTES:
WALL STRUCTURE
1
SUPPLY AIR
IT IS RECOMMENDED THAT A BEADOF
OPENING
Right Side View
RAIN FLASHING
SILICONE CAULKING BE PLACED BEHIND
RECOMMENDED 1" CLEARANCE FROM
THE SIDE MOUNTING FLANGES AND UNDER
TOP FLASHING AT TIME OFINSTALLATION.
TOP.
PANEL
HEATER ACCESS
FOUR SIDES OFSUPPLY
AIRDUCTIS REQUIRED
FROM COMBUSTABLE
WALL
1/4" CLEARANCE ONALL MATERIALS
Supply Opening
FOAMAIRSEAL
SUPPLIED
SEAL WITH BEAD
OF CAULKING ALONG
ENTIRE LENGTH OF
TOP
1
Return Opening
MIS-416 E
Dimension is 21" on 95" tall units.
2
Dimension is 10" on T48H1 & T60H1.
2
Dimension is 6" on T48H1 & T60H1.
3
3

Manual 2100628
Page 9 of 24
FIGURE 3
ELECTRIC HEAT CLEARANCE
K36A2, K36L2, K42A2, K42L2, K48A2, K48L2, K60A2, K60L2
WARNING
A minimum of 1/4 inch clearance must be maintained between
the supply air duct and combustible materials. This is required for
the rst 3 feet of ducting.
It is important to insure that the 1/4 inch minimum spacing is
maintained at all points.
Failure to do this could result in overheating the combustible
material and may result in a re causing damage, injury or death.
NOTE 1: SIDE SECTION VIEW OF SUPPLY AIR DUCT
FOR WALL MOUNTED UNIT SHOWING 1/4 INCH
CLEARANCE TO COMBUSTIBLE SURFACES.

Manual 2100-628
Page 10 of 24
FIGURE 4
WALL MOUNTING INSTRUCTIONS
FIGURE 5
WALL MOUNTING INSTRUCTIONS
DUCT
OPENING
RETURN AIR
SUPPLY AIR
WOOD FRAME WALL INSTALLATION
OPENING
WALL BEFORE
MOUNT ON UNIT
OPENING
BEFORE INSTALLATION
BOTTOM MOUNTING
CONCRETE BLOCK WALL INSTALLATION
BRACKET. MOUNT ON
OPENING
WOOD OR STEELSIDING
OPENING
INSTALLING UNIT.
RETURN AIR
WALL STRUCTURE
RETURN AIR
SUPPLY AIR
FACTORY SUPPLIED
RAIN FLASHING.
SUPPLY AIR
MIS-548 A
SIDE VIEW
I
A
C
K
E + 1.000
B
1.000
SUPPLY DUCT
OVER FRAME
INTERIOR FINISHED WALL
ALL AROUND DUCT
FRAMING MATERIAL
EXTERIOR FINISH WALL
OPENING
FOR ACTUAL DIMENSIONS.
2 x 4'S, 2 x 6'S &/OR
STRUCTURAL STEEL
ATTACH TO TOP
1.000" CLEARANCE
1.000" CLEARANCE
PLATE OF WALL
C
SEE UNIT DIMENSIONS, FIGURE 2,
OPENING
RETURN DUCT
2 x 6
ATTACH TO BOTTOM
OVER FRAME
PLATE OF WALL
L
THIS STRUCTURAL MEMBER
LOCATED TO MATCH STUD
SPACING FOR REST OF WALL.
A SECOND MEMBER MAY BE
REQUIRED FOR SOME WALLS.
MIS-549 B
ALL AROUND DUCT