BSDE AW series User manual

OWNER'S MANUAL
Industrial Grade Through-the-Wall and Split Air Conditioners
"AW" and "AS" Series
For further assistance, please contact your local sales representative
or
Brooklyn Severe-Duty Equipment Corporation
Brooklyn Navy Yard, Unit 236
Brooklyn, New York 11205 U.S.A.
Telephone: [phone]
Fax: [phone]
[email protected]

2
TABLE OF CONTENTS
Section I: Special Benefits of BSDE Air Conditioners Page 3
Section II: Installation and Operation of Air Conditioners Page 6
A. Design and Manufacturing Standards Page 6
B. Unpacking and Inspecting the Equipment Page 6
C. Installation Page 7
1. General Safety Precautions Page 7
2. Installation Procedure Page 8-11
3. Special Considerations for Hazardous-Location Equipment Pages 7-10, 12-15
4. Special Instructions for Installing Split Units Page 10
D. Operation of Air Conditioners Page 13
E. Maintenance of Air Conditioners Page 14
Section III: Parts List Page 16
Section IV: Warranty Page 18
Section V: Registration of Your Unit Page 19
3301-12 AW Operating Manual 041018.doc 10/26/2004 1:13:00 PM

3
Section I:
Special Benefits of BSDE Air Conditioners
Brooklyn Severe-Duty Equipment makes all its air conditioners for your tough industrial,
marine, and military applications.
As a result, you will find that we have constructed your air-conditioner of materials and
components much more robust than those used in normal residential and commercial-grade
through-the-wall and window air conditioners.
1. Among the differences is that the BSDE units are made of thicker-gauge materials to make
them stronger and heavier weight.
BSDE makes the standard cabinet from 18-gauge 316L stainless steel instead of the lighter
weight 20 and 22 gauge painted steel commonly used by other manufacturers. They have
reinforced 16-gauge 316L stainless-steel base pans to give them added strength.
2. The evaporator and condenser coils have a maximum of only 10 fins per inch instead of the
more common 16 or more per inch.
The wider spacing allows dirt and dust particles, which would have clogged the fins on other
air conditioners, to pass through the BSDE coils.
Less obstruction reduces the need for frequent cleaning and other maintenance, lowers head
pressure thereby reducing strain on the compressor and other components, and increases their
life spans.
It also increases the efficiency of the units, especially as the units age, because they run
cleaner, thereby reducing electrical consumption and costs.
The downside is that the wider spacing requires that the condenser and evaporator be
physically larger than those with denser spacing are, and as a result, the cabinets are also
larger. However, in most industrial applications this difference in size causes few problems
and the longer life and reduced maintenance more than compensate for the any problem with
the slightly larger size.
3. Standard BSDE units also have several types of corrosion protection which most
manufacturers offer only as expensive options.
a. The most important is an anti-corrosion coating which is applied to all BSDE
condensers,evaporators and copper tubing. This newly-developed low-porosity epoxy
material is applied in extremely thin layers by dipping the entire coil into a bath of the
coating where it is electrostatically charged to assure complete and uniform coverage.
Then the coating is baked on to cure it. This dipping and baking procedure is repeated as
necessary to assure complete protection of the coils.

4
However, despite effectiveness of the coating, the film is so thin that it has almost no effect
on the heat-transferring characteristics of the coils. By utilizing the latest generation of this
coating, BSDE assures that its coils and tubing have one of the most effective coatings
available to protect against corrosive gases and the salt and humidity in marine
environments.
b. To improve the fan motor's resistance to corrosion, the shaft is made of stainless steel
and the motor itself is totally enclosed to keep out dusts and liquids.
c. The standard cabinet is made of 316L stainless steel, one of the strongest and most
corrosion-resistant construction metals available. As an option, cabinets can also be made
of such materials as aluminum and 304 stainless steel.
d. BSDE also reduces corrosion by designing the units to run with dry condensers. Most
window and through-the-wall air conditioners use a slinger rig on the condenser fan to pull
condensate water up from the pan and throw it onto the condenser. While this procedure
helps to cool the condenser,it has the disadvantage in dirty atmospheres of wetting the
condenser so that the dirt in the air sticks to the evaporator. This dirt gradually fills the
spaces between the fins on the condenser reducing the flow of air. The water can also mix
with gases and other contaminants in the air to form acids and other corrosive liquids which
can damage your air conditioner.
4. To further protect the units, standard BSDE air conditioners are made with only mechanical
controls.
Unlike electronic controls which can be extremely sensitive to voltage fluctuations, analog
controls have the advantage of being more tolerant of voltage fluctuations, as well as being
easier and less expensive to service. In addition, they are readily available worldwide so they
help eliminate the need to keep expensive chips and other components in stock.
5. BSDE air conditioners use only dependable and proven reciprocating compressors—never
rotary compressors.
6. All standard air conditioners come with high and low-pressure safety switches which will
automatically shut down the entire unit before other components can be damaged by
maintenance or other problems in the system.
7. HAZARDOUS-DUTY UNITS: BSDE also offers units designed specifically to be safe
for use in areas classified as "hazardous" such as those which have explosive or flammable
gases, dusts, or flyings present.
a. Unlike most manufacturers of hazardous-duty air conditioning who buy and modify
existing units made for household or commercial use by other manufacturers, Brooklyn
Severe-Duty Equipment designs its units from scratch specifically for hazardous locations.
Therefore, the units we build work better and look better than units which had to be taken
apart, modified and then reassembled with components the cabinet was not originally
designed to enclose.

5
b. Also unlike most manufacturers, when BSDE makes air conditioners for hazardous duty,
all appropriate components utilized by BSDE, including the compressors, are specifically
recognized by Underwriters Laboratories (UL) as suitable for use in the indicated
environments.
c. All BSDE "explosion-proofed" models are well-enough protected against the corrosion
that they resist the corrosive effects of such hazardous gases as H2S far better than
competitor's models.
d. In addition, BSDE offers units modified for use in Class II and Class III areas which
include locations with explosive, flammable, and otherwise hazardous dusts, flyings and
other air-borne particles. Common locations with hazardous dusts include coal mines,
grain elevators, and textile plants.
8. BSDE designs its air conditioners so that they will provide their full rated capacities at
131ºF (55ºC) in order that they will provide full cooling even in hot industrial locations or at
high altitudes.
Most manufacturers rate their air conditioners' capacities at standard ARI conditions which
call for testing the capacity at only 95ºF (35ºC). When the units are run at higher
temperatures, their capacity falls off quickly as the temperatures rise. In addition, most
standard air conditioners will not run well at temperatures above 120ºF (49ºC), and if they are
forced to do so, they run under such strain that they do not last long.
By designing its units for high ambient temperatures and altitudes, BSDE assures that its units
will run at full capacity for many years.
9. To assure that its units will run at high temperatures, BSDE has also had to make
adaptations to allow them to run properly at lower ambient temperatures. As a result, we
make all our units with receivers, accumulators, and head-pressure controls, features which
are rarely found in other standardized air conditioners.
These features offer you the additional advantages of an air conditioner which will provide its
full cooling capacity without modification at ambient temperatures as low as 32ºF (0ºC).
With modification, they will maintain their full cooling down to -40ºF/C.
10. Furthermore, our designing the units for high ambient temperatures and other difficult
conditions make the units more energy efficient than competitive units.
Also important for you the user is that this efficiency does not only exist under the ideal test
conditions present in laboratories when new, clean units are rated. BSDE air conditioners'
resilience and adaptation for high temperatures and harsh conditions assure you that the
contrast in efficiency compared to residential and commercial-grade units will grow as the
units age and competitive units start to corrode or lose part of their efficiency by being
clogged by dust and other airborne particles.
11. All BSDE units are run tested under load in the factory before shipping to assure you that
they will perform as promised.

6
Section II:
Installation and Operation of Air-Conditioners
A. Design and Manufacturing Standards
1. Brooklyn Severe-Duty Equipment Corporation designs and builds all its air conditioners for
industrial, not residential or even commercial applications.
Therefore, we use industrial-grade materials and design into the units adaptations for the harsh
conditions caused by the corrosion and dirt which are often found in industrial, marine,
military, and mining environments.
B. Unpacking and Inspecting the Equipment
1. Since our units undergo extensive inspection and testing in the factory,we know that your
unit worked properly when it left our plant. Before we ship the units, we pack them securely,
on a pallet in a wooden crate or in a heavy corrugated box with a wooden base, to assure that
they reach you in perfect condition.
2. Damage in Transit: Sometimes, despite out best efforts, rough handling in transit causes
obvious or hidden damage. Therefore, you must inspect the units thoroughly as soon as you
receive them to assure that they were not harmed. Although problems are rare, our experience
is that the vast majority of the problems which users have with our equipment stem from
damages in transit which were not detected during the initial inspection.
3. Inspect Immediately Upon Receipt: As soon as you receive the units, open them and
inspect them for damage. If you detect any problem, even small dents, they may be
indications of more serious internal damage. You must inform the transport company
immediately so that you retain your option to filea claim in the future if problems occur.
BSDE is not responsible for any damages occurring in transit, no matter how soon or late they
are detected.
4. NOTE: IF THE UNIT ARRIVES ON ITS SIDE, END OR UPSIDE DOWN, YOU MUST
INFORM THE TRANSPORT COMPANY AND FILE A CLAIM WITH THEM
IMMEDIATELY. BSDE air conditioners are built to be stored, transported and used only in a
upright position.
5. Pallet: Since BSDE ships virtually all of its equipment on a pallet, if this unit arrives not
mounted on a pallet,it was probably removed in transit. Therefore, since one purpose of the
pallet is to protect the air conditioner, unless the packing list gives you reason to believe that it
was purposely not shipped from the factory on a pallet, you should immediately inform the
carrier and prepare to file a claim with them.
6. Filing Claims with Shipping and Insurance Companies: Normally you have up to 30 days
to file a claim with the carrier and often longer with the insurance company. However,

7
generally,the sooner you file your claim,the easier it is to obtain compensation for damage
from the carrier. Informing them of problems at the time of delivery helps establish your
claim. Photographs of the packaging and damages can help substantiate a claim.
7. BSDE's liability: Ownership of the unit transfers from BSDE to the customer upon
acceptance of the unit by the carrier. As a result, BSDE has no liability for damages in transit.
C. Installation
1. General Safety Precautions
a. The unit should be installed, started up, and maintained only by qualified and competent
technicians.
b. BSDE air conditioning units draw enough power that they should only be installed on a
circuit dedicated to the air conditioner.
c. Always comply with local electrical codes and ordinances. It is a good idea to comply
with the National Electrical Code (NEC), even if the unit is being installed in a country
other than the United States.
d. Verify that the wall, roof or other platform and the supports on which you will mount the
air conditioner is strong enough to safely support its weight.
e. Always disconnect the power from the unit before working on it.
f. Since the units are heavy, be sure to have an adequate crew and equipment to safely
handle the weight without risk of injury or damage.
g. Never modify or alter the unit; doing so may damage the unit and will usually void the
warranty. Utilize only replacement parts obtained from BSDE.
h. Units supplied with a plug-in cord should not be connected to an extension cord.
i. When installing hazardous-duty units in classified areas:
1'. Be sure that the rating of the air conditioner is suitable for the classification of the
environment. Division 1 equipment can be used in Division 2 areas, but Division 2
equipment can NOT be used safely in Division 1 areas, even for short periods!!!!
2'. All repairs requiring open flame or high temperature should not be made in the
classified area unless the location has been declassified by purging or other suitable
method. Given that these units are movable, it would generally be safer to transport
them to an unclassified location before doing such repairs.
3'. All hazardous-duty units must be hard wired; they can not have plug-in cords.
4'. Most BSDE hazardous-duty units are factory sealed (see the label on the unit to be
sure). However, the wiring connections made at the site MUST BE PROPERLY

8
SECURED AND SEALED as specified by the National Electrical Code (NEC) and any
other applicable code to make them safe.
2. Cabinet Installation Procedure
a. Choose a location which will allow a minimum of one foot, and preferably two feet, of
unobstructed air space around the outside of each of the sides and of the back of the unit to
allow good air circulation. These distances should be maintained around the outside ends
and louvers of through-the-wall units and around the ends of condensing sections and the
louvers of evaporating sections of split units.
These minimum dimensions assume good ventilation. The temperature of the air entering
the condenser should not be allowed to rise in temperature by being trapped in an area with
insufficient ventilation. The higher the temperature of the air which enters its condenser,
the less capacity any air conditioner has and the lower its efficiency.
b. Cut and prepare a rough opening in the wall by making it square and plumb with
dimensions of approximately 28-1/2" wide by 18-1/2" high for units up to "18" models and
20-1/2" high for models above "18".
The louvers on the tops and sides of the cabinets must have unrestricted air flow.
Therefore, assure that the distance from the front of grill covering the evaporator back to
the front of the louvers on the sides of the cabinet (which must be exposed completely to
the free air) is a minimum of 13"(33 cm) on models up to "18" and a minimum of 17-1/2"
(44 cm) for larger models.
c. Fully frame the opening to support the unit and permit attachment of the sleeve to the
supports.
d. Remove the front cover and then pull the chassis assembly (insert) from the sleeve of the
cabinet. If the sleeve is still protected by plastic film, peel it off before inserting the sleeve
into the wall.
e. Insert the sleeve into the opening in the wall and support it with the optional pair of
support brackets manufactured by BSDE or with a suitably strong and securely mounted
alternative support system.
f. Carefully reinsert the chassis (insert) into the sleeve.
g. Position the front cover on the unit and secure it.
h. Wiring: Be sure that the on-off switch is in the "off" position before connecting power.
See plate inside cold-air discharge duct for electrical specifications for the unit. Verify that
the circuit provides the correct voltage, proper amperage supply and limit, and the correct
number of phases to the unit. Also, verify that the wiring is of sufficient gauge to handle
the start-up amperage of the compressor during the 20-30 seconds it may take to start the
compressor. Connect units only to circuits dedicated to the air conditioner and protected by
a time-delay fuse or breaker.

9
Note: a leading cause of failure of air conditioners, which is not covered by the
warranty, is connecting themto wires which would be adequate were the air conditioner
installed close to the circuit-breaker but which are toosmall to carry sufficient amperage
over a longer distance to handle the high start-up amperage of the air conditioner. This
start-up demand can be a multiple of the FLA of the unit for the first 20-30 seconds.
The time-delay fuse or circuit breaker will handle the additional load during the start-up,
but under-sized wires will not and the most common result is greatly shortened life for
the compressor.
Connect the wires either by plugging the cord into a dedicated outlet or by wiring it as
necessary to meet all applicable electrical codes.
BSDE supplies a cord with a plug for 115-volt units and a cord without a plug for 200-240
volt units. We build all hazardous-duty units with a conduit seal and sufficient wire to
enable the installer to properly connect to a power source.
Be sure to connect the phases correctly in three-phase units; incorrect installation will not
only make the unit run poorly, if it runs at all, but also it will also void the warranty.
Note for Installers of Hazardous-Duty Models: If your unit is designed for and being
installed into a hazardous location, the unit does not have a power cord. The NEC, UL
and other electrical codes require that it be hard wired directly into the power circuit.
The air conditioner must be connected and then secured in a way which will eliminate the
possibility that the connected wires can pull apart, particularly in a location exposed to the
hazardous environment. It is essential to prevent the separation of the wires while power is
applied because if they do separate they will cause a spark which could ignite or cause an
explosion of hazardous materials present in the vicinity.

10
SPECIAL INSTRUCTIONS FOR INSTALLING SPLIT UNITS
1. Supply power is connected to only one section of the split unit, usually the condensing section.
Therefore, supply power for the other sections, as well as the control wires,must be installed by
the user. BSDE sizes its wiring for installations of with up to fifty feet (15 meters) of distance
between the condensing and evaporating sections.
2. All wires to be connected between the condensing unit and evaporating unitsare color coded
and labeled. The gauge of wire must be maintained to assure that the units will run correctly and
safely.
There is no need to open the NEMA 7/9 boxes installed in the units. In addition, all connections
should be made in properly sealed junction boxes approved for the area as classified under all
applicable electrical and other codes.
3. Maximum separation of condensing and evaporating sections: for tubing 100 feet (30 meters);
for wiring 50 feet (15 meters). The distancescan generally be increased, but only by increasing
the gauge of the wires and tubing and making other adaptations. Contact factory for further
information.
4. Since BSDE can not know how you will connect the systems, BSDE provides 6 feet of each
wire in each section to connect to your additional wiring in a junction box.
In most hazardous-duty units, the wires leaving the NEMA 4X/7/9 boxes are completely sealed,
and as long as the integrity of the conduit seals is not violated, the units will need no additional
sealing except on the wiring and junction boxes you install.
BSDE does not make an exit hole in either cabinet for wiring between sections. We leave you
the opportunity to choose the best location for your installation. Once you choose the location,
make a ¾" diameter or larger hole with a knock-out punch or other tool, and line it with a
protective grommet to ensure that the wiring is not damaged on the sharp edges. Better would be
to install wiring in a protective conduit.
5. BSDE installs shut off valves with access (Schrader) valves to enable the installer to easily
evacuate and then fill the lines with either liquid (the 3/8" line) or gaseous refrigerant.
Warning: DO NOT OPEN BALL VALVES OR RECEIVER UNTIL TUBING IS
COMPLETELY ASSEMBLED AND LINES ARE CHARGED.
BSDE supplies no extra gas in its system for charging the user-installed lines between the two
sections because we do not know the length of the lines you will be installing.
6. Low pressure lines should be insulated to minimize condensation and cooling loss.
7. NOTE: IF IT BECOMES NECESSARY FOR ADDITIONAL REFRIGERANT TO BE ADDED TO THE
SYSTEM FOR ANY REASON: If you can not determine the exact weight of the gas lost, you must