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SERVICE INSTRUCTIONS
FUSION-TEC
AIR CONDITIONER
NOTE: LC6000 controller is required for operation when
WR**BP* units are used.
®
Bard Manufacturing Company, Inc.
Bryan, Ohio 43506
www.bardhvac.com
WALL-MOUNT
Models:
WR36BPA WR58BPA
WR36BPB WR58BPB
Manual:
2100-695
Supersedes:
NEW
Date:
5-10-19
Page
1 of 54
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Table of Contents
Troubleshooting
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Summary of Contents for Bard FUSION-TEC WR36BPA
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Page 1: Air Conditioner
SERVICE INSTRUCTIONS FUSION-TEC WALL-MOUNT ® AIR CONDITIONER Models: WR36BPA WR58BPA WR36BPB WR58BPB NOTE: LC6000 controller is required for operation when WR**BP* units are used. Bard Manufacturing Company, Inc. Manual: 2100-695 Bryan, Ohio 43506 Supersedes: www.bardhvac.com Date: 5-10-19 Page 1 of 54... -
Page 2: Table Of Contents
CONTENTS Using the TEC-EYE ............6 Indoor Airflow Components ........19 Blower .............19 TEC-EYE Hand-Held Diagnostic Tool ........6 Blower Status Switch .........20 TEC-EYE Screen Structure and Password Level ....7 Blower Status Alarm ........21 TEC-EYE Acronyms ............7 Filters ..............22 Main Status Screen ............7 Dirty Filter Switch ..........22 Quick Menu ..............8 Dirty Filter Alarm ........22... - Page 3 Figure 35 Dirty Filter Switch and Filter Indicator Light ..22 Electric Heat Operation ..........36 Figure 36 Enabling High Sensible Mode ......23 Bard Guard Anti-Theft System Option .......36 Figure 37 Verifying Condenser Fan Output ......23 Smoke Detector Unit Disable Option .........36 Figure 38 Fan Blade Setting .........24...
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Page 4: General Information
Air Conditioning System Conditioning and Ventilating Systems of Other Than Residence Type, NFPA No. 90A, and Residence Type This Bard air conditioning system is composed of Warm Air Heating and Air Conditioning Systems, NFPA FUSION-TEC WR Series wall-mounted air conditioners No. - Page 5 ANSI Z535.5 Definitions: WARNING DANGER: Indicate[s] a hazardous situation which, if not avoided, will result in death or serious injury. The signal word “DANGER” is to be limited to the most Electrical shock hazard. extreme situations. DANGER [signs] should not be used for property damage hazards unless personal injury risk Have a properly trained individual perform appropriate to these levels is also involved.
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Page 6: Using The Tec-Eye Tm
USING THE TEC-EYE FIGURE 1 TEC-EYE (Bard P/N 8301-059) Display and Interface (Status Screen Shown) UP KEY ALARM KEY MENU KEY ENTER KEY ESCAPE KEY DOWN KEY ALARM KEY UP KEY Allows viewing of active alarms Steps to next screen in the display menu Silences audible alarms Changes (increases) the value of a modifiable field... -
Page 7: Tec-Eye Screen Structure And Password Level
TEC-EYE Screen Structure and Password Level speed, condenser fan speed, damper position and unit status are also displayed. See Table 2 for wall-mount Quick Menu unit status messages. Setpoints (Orphan Mode Temperature Control) Information TABLE 2 Alarm Log Unit Status Messages Main Menu System Config: A1-A10 User (2000) Adv Sys Config: B1-B8 Technician (1313) -
Page 8: Quick Menu
The Quick Menu is accessible from the Main Status 4. Press UP or DOWN key on desired value until value Screen. Setpoints, Information and Alarm Log are displays correctly. available through the Quick Menu. Pressing the UP 5. Press ENTER key to save and scroll to next or DOWN keys while on the Main Status Screen will parameter. -
Page 9: A/C Circuit Measurements
Current software versions, change log and installation instructions are available on the Bard website at http://www.bardhvac.com/software-download/ Alarm Log The alarm log screens show a log of each alarm. There... -
Page 10: Addressing Wall-Mount Units
FIGURE 11 Addressing Wall-Mount Units Executing Run Test Each unit must have a unique address for the system to operate correctly with th LC controller (Ex: 1, 2, 3, ...14 depending on the number of units). The wall- mount unit address is displayed in the upper right corner on the Status screen on the TEC-EYE display (see Figure 1 on page 6). -
Page 11: Run Test Parameter Descriptions
FIGURE 13 7. Press UP or DOWN key to change value to YES; Run Test: Motors & Sensors press ENTER key. 8. System will restart with default values. FIGURE 15 Restoring Factory Default Settings The A/C Circuit screen (Figure 14) displays all unit inputs, outputs and calculations associated with the A/C circuit operation. -
Page 12: Operation
OPERATION NOTE: Screenshots shown in this manual reflect the screen at the end of the alarm list (shown in Figure 16) and press and hold the ALARM key for 3 seconds. default settings (when applicable). Unit On/Off FIGURE 16 Clearing All Alarms The wall-mount unit can be turned on and off from the TEC-EYE. -
Page 13: Exporting 7 Day Logs
Once the first of the Bard that it is exposed to the entering airstream. An alarm... -
Page 14: Return Air Temperature Alarm
8. The update will not take effect until the cursor is 2. Press ENTER key to scroll to Cool Setpoint or Heat moved out of the Offset parameter. Setpoint (see Figure 4 on page 8). 9. Once adjusted, press the ESCAPE key several 3. -
Page 15: Cooling Sequence: Economizer Not Available
when the return air temperature reaches the setpoint To enable this delay: plus the stage off differential. 1. Press MENU key to go to the Main Menu screen. Staging 2. Press UP or DOWN keys and ENTER key to enter The unit will stage the cooling components based on TECHNICIAN password 1313. -
Page 16: Adjusting Heating Staging
7. Press ENTER key to save value and move cursor to 10. Repeat steps 6 through 9 for Stage 2 and Stage 3 Stage 1 Off Differential. differentials. 8. Press UP or DOWN keys to adjust number of 11. Press ESCAPE key several times to return to Main degrees below setpoint to turn cooling operation Menu screen. -
Page 17: System Pressures
The valve can also be opened or closed using the EEV The unit has a pressure transducer installed on the service tool (Bard Part # 2151-021). This magnetic EEV suction line between the evaporator coil and compressor. service tool (shown in Figure 26) is used to manually The transducer is used for system monitoring of suction open the EEV. -
Page 18: Troubleshooting The Suction Pressure Transducer
The suction temperature sensor measurement can be 8. The update will not take effect until the cursor is moved out of the Offset parameter. verified and adjusted by: 1. Press MENU key to go to the Main Menu screen. 9. Once adjusted, press the ESCAPE key several times to return to Main Menu screen. -
Page 19: Eev Operation
reset hold time (5 minutes factory default), normal There are two forms of low superheat protection on operation will continue. the FUSION-TEC WR Series units. One form will be active once the superheat value is at or below 5°F. At To adjust the freeze setpoint and/or alarm delay time: this point, the control will aggressively close the valve 1. -
Page 20: Blower Status Switch
TABLE 5 6. Press UP or DOWN key to change OFF to ON. Rated Airflow 7. Press ENTER key to scroll to OV Speed. 8. Press UP or DOWN keys to adjust the speed to the Nominal Rated CFM Nominal Rated ESP desired output. -
Page 21: Blower Status Alarm
All units tested equipped with MERV 8 filters. Appropriate supply (SG) and return (RG) grilles installed during testing. Pressure switch adjustment may be necessary due to variations in filter type, installation and room pressure. Bard recommends filter switch be set at 50% filter blockage or less. Higher settings may significantly hinder unit performance. Manual... -
Page 22: Filters
6. Press UP or DOWN keys to change to the desired Adjustment of dirty filter switch may be necessary to value. ensure proper operation. See Table 8 and Figure 35 to aid in setting the filter switch to operate at different 7. -
Page 23: Indoor Airflow Operation
Additional Indoor Airflow Alarms filter needs to be replaced. Once the filter(s) has been changed, the indicator light will turn off. Supply Air Temperature Alarm Indoor Airflow Operation When the supply air temperature sensor value is out of range (-41.0 to 303.0°F), the controller will generate High Sensible Mode a sensor failure alarm to indicate the sensor is not High sensible mode allows for higher airflow through... -
Page 24: Liquid Line Pressure Transducer
4. Press UP or DOWN keys to change the value to the 7. Press UP or DOWN keys to adjust the offset. The update will not take effect until the cursor is desired override speed. moved out of the offset parameter. 5. -
Page 25: Condenser Fan Operation
The temperature is measured with a 10k ohm NTC 9. Press ESCAPE key several times to return to Main thermistor. Menu screen. The liquid temperature sensor can be verified and Condenser Fan Operation adjusted by: Condenser Fan Speed Control 1. Press MENU key to go to the Main Menu screen. The unit is equipped with a variable speed ECM 2. -
Page 26: Second Stage Drop Out
Second Stage Drop Out The direction of rotation of the compressor may be changed by reversing any two line connections to the If the liquid pressure reaches 620 PSI, the second wall-mount unit. stage of cooling will be disabled for the remainder Compressor Control Module (CCM) of the current cooling call. -
Page 27: Brownout Protection W/Adjustment
FIGURE 43 8201-164 Compressor Control Module High Pressure Switch Compressor Contactor Output 18-30 VAC Input Alarm Output Y Input from Thermostat Common and High Pressure Switch Troubleshooting Light Delay-on-Break Time Adjustment Potentiometer Jumper Brownout Ignore Time DIP Switches* * Turn on only one switch for that specific ignore time setting Brownout Protection with Adjustment the voltage recovers during the brownout time period, the compressor will start. -
Page 28: High Pressure Safety Switch
almost instantaneous transfer switches, the millisecond These delays can be changed by: long power glitch can be enough that the compressor will 1. Press MENU key to go to the Main Menu screen. start to run backwards. In this scenario, the CCM will 2. -
Page 29: Additional Compressor Alarms
5. Press ENTER key to scroll to Comp. Limit (see 9. Press ENTER key to save. Figure 45). 10. Press the ESCAPE key several times to return to 6. Press UP or DOWN keys to change ON or OFF Main Menu screen. value. -
Page 30: Dust Sensor
8. Press ENTER key to save the value and move NOTE: The sensor can be disabled if required for cursor to Damper Override. troubleshooting. 9. Press UP or DOWN keys to change the value from 9. Press ENTER key to scroll to Enable parameter. OFF to ON. -
Page 31: Damper Blade
NOTE: When the temperature outside is measured Damper Switch at or below 0°F, the dust sensor alarm will be The economizer utilizes a magnetic switch to determine disabled to allow economizer operation. This if the damper is operating correctly. This switch will be is done because the compressor is disabled closed when the damper is closed and open when the below 0°F and the system would not have the... -
Page 32: Damper Failed To Close Alarm
6. Press UP or DOWN keys to change to the desired The outdoor temperature can be verified by: value. 1. Press MENU key to go to the Main Menu screen. 7. Press ENTER key to save the value. 2. Press UP or DOWN keys and ENTER key to enter TECHNICIAN password 1313. -
Page 33: Outdoor Temperature Sensor Failure Alarm
6. To apply an offset, press ENTER key to scroll to Supply Temperature Sensor Failure Alarm Offset. When the sensor reads a value that is outside of the 7. Press UP or DOWN keys to change to the desired acceptable -41.0 to 303.0° range, an alarm will be value. -
Page 34: Economizer Operation
4. Press UP or DOWN keys to scroll to Alarm Setup NOTE: Some of the following parameters may not be present until the control type that it is used with is selected. 5. Press ENTER key to scroll to Lo and Diff value (see 8. -
Page 35: Emergency Cooling Mode
10. Press ESCAPE key several times to return to Main in the air filters. After the time has expired and on a call Menu screen. for cooling, the economizer will open again to sample the air. The wall-mount unit will either return to normal NOTE: The economizer delay parameter adjusts the operation or remain locked out for another 5 minutes. -
Page 36: Electric Heat Option
The unit has the option to be shipped from the factory with a low pressure switch, panel sensors and a speaker. These devices are used with the Bard Guard BG1000 anti- theft controller to provide an anti-theft measure. These sensors and switch form a loop that when connected to... -
Page 37: Figure 59 Fusion-Tec Wr Series Nomenclature
5 – Internal and External Cabinet Component Coating, Coated Evaporator Coil, Coated Condenser Coil ACCESSORIES AND CONTROLS OPTIONS X – Standard accessories including airflow sensor, dirty filter sensor, pressure transducers, crankcase heater S – All standard accessories plus additional Bard Guard security features and security frame Manual... -
Page 38: Figure 60 Fusion-Tec Wr Series Unit Control Board
FIGURE 60 FUSION-TEC WR Series Wall-Mount Unit Control Board 8301-068-004* + Communication Wire – Communication Wire Micro USB FieldBus2 24VAC Hot 24VAC Common Unit Disable Relay/Switch Jumper Dirty Filter Switch 24VAC + Compressor Alarm Relay Power Loss Relay (if equipped) Control To CCM Y Stand-by... - Page 39 TABLE 10 FUSION-TEC WR Series Wall-Mount Unit Control Board Terminals Terminal Function Type Form Rx+/Tx+ Communication Rx-/Tx- Communication Unit Disable Relay/Switch Digital Dirty Filter Switch Digital Compressor Alarm Relay Digital Power Loss Relay (if used) Digital Not Used Damper Blade Switch Digital Airflow Digital...
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Page 40: Refrigerant Information
Topping Off System Charge the quantity of refrigerant listed on the serial plate. AHRI capacity and efficiency ratings were determined If a leak has occurred in the system, Bard by testing with this refrigerant charge quantity. Manufacturing recommends reclaiming, evacuating (see criteria above) and charging to the nameplate Table 10 shows nominal pressures for the units. -
Page 41: Pressure Service Ports
Pressure Service Ports WARNING! Do NOT use a Schrader valve core removal tool with these valves. Use of such a tool could result High and low pressure service ports are installed on all in eye injuries or refrigerant burns! wall-mount units so that the system operating pressures To change a Coremax valve without first removing the can be observed. -
Page 42: Maintenance
LED will illuminate. As long as for the evaporator or condenser coil. the blue LED is illuminated, the Bard Guard system • Condenser coil: Remove the upper side panels is disarmed and will remain disarmed depending from the condenser section. -
Page 43: Troubleshooting
TROUBLESHOOTING 8301-067 Outdoor Temperature/Humidity Sensor 8301-067 Sensor Connections This unit utilizes a two wire 4-10mA signal from Tables 12 and 13 on pages 44 and 45 are correlation the 8301-067 sensor to communicate outdoor charts for troubleshooting the sensor with a test meter: humidity and a 10KΩ... - Page 44 TABLE 12 8301-067 Sensor: Temperature to Thermocouple Resistance Temperature Resistance Temperature Resistance Temperature Resistance Temperature Resistance -31.7 148,453 -10.6 48,892 10.6 18,338 31.7 7680 -31.1 143,910 -10.0 47,572 11.1 17,898 32.2 7516 -30.6 139,521 -9.4 46,291 11.7 17,471 32.8 7356 -30.0 135,281 -8.9...
- Page 45 TABLE 13 8301-067 Sensor: Relative Humidity to Humidity Sensor Current Output Humidity Signal Humidity Signal Humidity Signal % RH % RH % RH 4.000 9.440 14.880 4.160 9.600 15.040 4.320 9.760 15.200 4.480 9.920 15.360 4.640 10.080 15.520 4.800 10.240 15.680 4.960 10.400...
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Page 46: 8301-067 Humidity Sensor Test Value Outputs
8301-067 Humidity Sensor Test Value Outputs 8301-067 Humidity Sensor Calibration This sensor has the ability to output fixed test signals The 8301-067 sensor has the ability to be calibrated when testing/troubleshooting sensor operation. via the sensor control board through the use of the These settings are to be used for sensor testing/ DIP switches and/or the use of ZERO P1 or SPAN P2. -
Page 47: 8301-057 Blower Status Switch/Dirty Filter Switch
8301-057 Blower Status Switch/Dirty Filter Switch FIGURE 64 8301-057 Air Differential Switch Terminals Terminals 1 − Normally Closed 2 − Normally Open 3 − Common NOTE: Contact position is in resting state. P1: Hose Connected P2: Stub Connected Manual 2100-695 Page 47 of 54... -
Page 48: 8612-061 Dust (Particulate) Sensor Control Board
8612-061 Dust (Particulate) Sensor Control Board 8612-061 Control Board Output Signal Not Responsive 3. With a voltmeter, measure voltage between the to Dust following terminals: 1. With a voltmeter, verify 24Vac present across A. Component U1 pin 2 and terminal block pin 4 24VAC pin terminals. -
Page 49: Figure 66 Dust Sensor Alarm Board Power Supply Check
FIGURE 66 Dust Sensor Alarm Board Power Supply Check Manual 2100-695 Page 49 of 54... -
Page 50: 8301-073 Dust (Particulate) Sensor
8301-073 Dust (Particulate) Sensor TABLE 14 8301-073 Sensor: Dust/Volts Dust Signal Dust Signal Dust Signal 0.00 1.70 3.40 0.05 1.75 3.45 0.10 1.80 3.50 0.15 1.84 3.54 0.19 1.89 3.59 0.24 1.94 3.64 0.29 1.99 3.69 0.34 2.04 3.74 0.39 2.09 3.79 0.44... -
Page 51: 8408-044 Return Air Sensor/Suction Sensor
8408-044 Return Air Sensor/Suction Sensor TABLE 15 8408-044 Sensor: Temperature/Resistance Curve J Temperature Resistance Temperature Resistance Temperature Resistance Temperature Resistance ºF ºC ºF ºC ºF ºC ºF ºC -31.7 196,871 -10.6 56,985 10.6 19,374 31.7 7507 -31.1 190,099 -10.0 55,284 11.1 18,867 32.2... -
Page 52: 8301-066 Supply Air Sensor
8301-066 Supply Air Sensor TABLE 16 8301-066 Sensor: Temperature/Resistance Temperature Resistance Temperature Resistance Temperature Resistance °F °C °F °C °F °C 29,490 96.8 6501 161.6 1868 33.8 28,157 98.6 6260 163.4 1810 35.6 26,891 100.4 6028 165.2 1754 37.4 25,689 102.2 5806 1700... -
Page 53: 8406-157 Liquid Line Pressure Transducer
8406-157 Liquid Line Pressure Transducer TABLE 17 8406-157 0-650psi Pressure Transducer: Pressure/DC Voltage Pressure Signal Pressure Signal Pressure Signal Pressure Signal 0.500 11.2 1.515 22.5 2.531 33.7 3.546 0.531 11.6 1.546 22.8 2.562 34.0 3.577 0.562 11.9 1.577 23.1 2.592 34.4 3.608 0.592... -
Page 54: 8406-158 Suction Pressure Transducer
8406-158 Suction Pressure Transducer TABLE 18 8406-158 0-250psi Pressure Transducer: Pressure/DC Voltage Pressure Signal Pressure Signal Pressure Signal Pressure Signal 0.500 1.524 2.548 13.1 3.572 0.532 1.556 2.580 13.2 3.604 0.564 1.588 2.612 13.3 3.636 0.596 1.620 2.644 13.5 3.668 0.628 1.652 2.676...