Bard FUSION-TEC HR58APA Installation Support Materials
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INSTALLATION
SUPPORT
MATERIALS
FUSION-TEC™
WALL-MOUNT PACKAGE
AIR CONDITIONER
Models:
HR58APA
HR58APB
Part of the Bard Free Cooling Unit System
NOTE: LV1000 Controller is required for operation when multiple HR58AP*
units are used.
Bard Manufacturing Company, Inc.
Bryan, Ohio 43506
Date:
4-18-17
www.bardhvac.com
Page
1 of 53
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Table of Contents
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Summary of Contents for Bard FUSION-TEC HR58APA
- Page 1 MATERIALS FUSION-TEC™ WALL-MOUNT PACKAGE AIR CONDITIONER Models: HR58APA HR58APB Part of the Bard Free Cooling Unit System NOTE: LV1000 Controller is required for operation when multiple HR58AP* units are used. Bard Manufacturing Company, Inc. Bryan, Ohio 43506 Date: 4-18-17 www.bardhvac.com...
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Page 2: Table Of Contents
CONTENTS SECTION 1: Installation Instructions ......................7 List of Necessary Materials/Tools ........................8 Site Preparation ............................. 9 Model Indentification ..........................9 New Shelter Installation vs. Retrofit Installation ..................9 Minimum Clearance ..........................9 Clearance to Combustibles ........................9 Wall-Mount Unit Mounting ..........................11 Wall-Mount Unit Wiring .......................... - Page 3 Indoor Airflow ............................33 Indoor Airflow Components ........................ 33 Blower ............................33 Filters ............................34 Differential Airflow Switch ......................34 Freezestat ..........................34 Dirty Filter Switch ........................35 Filter Indicator Light ........................35 Indoor Airflow Operation ........................35 Blower Speed Control ......................... 35 Indoor Airflow Alarms........................
- Page 4 Electric Heat Components ......................... 46 Electric Heating Element ......................46 Thermal Overload ........................46 Electric Heat Operation ........................47 Bard Guard Anti-Theft System Option ....................... 47 Smoke Detector Option ........................... 47 Refrigerant Information ..........................48 General ..............................48 Topping Off System Charge ........................48 Safety Practices .............................
- Page 5 Free Cooling Unit System Conditioning and Ventilating Systems of Other Than Residence Type, NFPA No. 90A, and Residence Type This Bard Free Cooling Unit System is composed of Warm Air Heating and Air Conditioning Systems, NFPA FUSION-TEC wall-mounted air conditioners matched No.
- Page 6 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 7: Section 1: Installation Instructions
SECTION 1: INSTALLATION INSTRUCTIONS Page 7 of 53... -
Page 8: List Of Necessary Materials/Tools
LIST OF NECESSARY MATERIALS/TOOLS Additional hardware and miscellaneous supplies are needed for installation. These items are field supplied and must be sourced before installation. This list also includes tools needed for installation. List of Materials/Tools • Personal protective equipment/safety devices •... -
Page 9: Site Preparation
10" . modifications. Although Bard Manufacturing follows a long-established tradition of manufacturing equipment Clearance to Combustibles... -
Page 10: Figure 1.2 Dimensions
Page 10 of 53... -
Page 11: Wall-Mount Unit Mounting
In retrofit (unit replacement) installations, the openings NOTE: At the time of installation, Bard highly cut for the original equipment may not line up exactly recommends prefilling of the traps on both of with needs of this installation. -
Page 12: Hoses
FIGURE 1.3 Prefilling Traps on Indoor Drain Pan Hoses Evaporator Drain Pan Left Side Drain Hose Evaporator Drain Pan Right Right Drain Hose Pour water into evaporator drain pan directly above left and right drain fittings until coiled drain tubes are visibly full. FIGURE 1.4 Hanging Front Access Panel to Allow Access to Control Panel... -
Page 13: Figure 1.4 Mounting Instructions
Page 13 of 53... -
Page 14: Figure 1.5 Electric Heat Clearance
FIGURE 1.5 Electric Heat Clearance Typical Building Outside Sheeting Wall Frame Inside Sheeting 1/4" Min. Supply Air Duct Flange of Wall 1/4" Min. SUPPLY GRILLE MIS-3897 FIGURE 1.6 Wall Mounting Instructions WALL STRUCTURE See FIGURE 2 – Mounting Instructions FACTORY SUPPLIED RAIN FLASHING. -
Page 15: Figure 1.7 Wall Mounting Instructions
FIGURE 1.7 Wall Mounting Instructions SEE UNIT DIMENSIONS, FIGURE 1.2, SEE UNIT DIMENSIONS, FIGURE 2, FOR ACTUAL DIMENSIONS. FOR ACTUAL DIMENSIONS. E + 1.000 ATTACH TO TOP PLATE OF WALL 1.000 1.000" CLEARANCE ALL AROUND DUCT IF REQUIRED RETURN DUCT INTERIOR FINISHED WALL OPENING OVER FRAME... -
Page 16: Wall-Mount Unit Wiring
WALL-MOUNT UNIT WIRING The unit rating plate and Table 1.3 list fuse and wire WARNING sizes (75°C copper) for all models including the most commonly used heater sizes. Also shown are the number of field power circuits required for the various models with heaters. -
Page 17: Figure 1.9 Wire Routing
230VAC NEW IMAGE NEEDED Shelter supply breaker in ON position Bard system breaker in OFF position 3. If incoming AC voltage is below 220VAC..shut off AC breaker to unit 230V/208V Single Phase Voltage Range: and move factory "240V" wire to "208V" terminal 197VAC –... -
Page 18: Communication Wiring
208V taps are: 240V Tap (253 – 216) and 208 Tap (220 – 197). NOTE: The voltage should be measured at the field power connection point in the unit and while the unit is operating at full load (maximum amperage operating condition. Communication Wiring For low voltage wiring, 2-wire 18 gauge shielded with drain is recommended. -
Page 19: Figure 1.13 Wiring: Hr58Aap* Wiring Diagram
FIGURE 1.13 HR58AAP* Wiring Diagram Blk/Wht BOTTOM Page 19 of 53... -
Page 20: Preliminary Start Up
Be sure to reconnect the plug before operating the wall-mount unit as part of the Bard Free Cooling Unit System. Additionally, should any or all of the FUSION-TEC wall-mount units lose communication with the LV1000 controller (such as during maintenance), they will continue to serve the shelter’s needs until a repair can... -
Page 21: Completing Wall-Mount Set Up
COMPLETING WALL-MOUNT SET UP Setting Up Wall-Mount Unit for 1. Press MENU key to access the Main Menu screen. Operation 2. Press UP or DOWN keys and ENTER key to enter USER password 2000. The TEC-EYE hand-held diagnostic tool, shipped with the LV1000 controller, is needed to complete the 3. -
Page 22: Addressing Wall-Mount Units
FIGURE 1.16 Changing Unit Setup Values Supply Air Grill Installation Bard model SGR-5W grille is custom designed for utilization with Bard wall-mount unit HR58AP for optimizing the air flow pattern and distribution to minimize recirculation issues, and optimizing airflow In addition to the address setup, the user may also patterns within the shelter. -
Page 23: Completing The Installation
At this stage, the installation process of the wall-mount the return air opening. The curved diverter blades unit is finished. To complete the Bard Free Cooling are shipped in the flat position and need to be System installation, refer to the LV1000 controller folded out to between 75-90°... - Page 24 Page 24 of 53...
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Page 25: Section 2: Service Instructions
SECTION 2: SERVICE INSTRUCTIONS Page 25 of 53... -
Page 26: Using The Tec-Eye Tm
USING THE TEC-EYE FIGURE 2.1 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... -
Page 27: Tec-Eye Tm Menu Structure
TEC-EYE Menu Structure Quick Menu Setpoints Quick Menu Setpoints From this screen, the unit heating and cooling Information setpoints can be changed (see Setpoints on page Alarm Log 21). This screen also displays the current cooling and Main Menu heating setpoints which when connected to the LV1000 System Configuration controller will show the heating and cooling setpoints Advanced System Configuration... -
Page 28: Operation
OPERATION Unit On/Off Stand Alone Mode The wall unit can be turned on and off from the See PRELIMINARY START UP on page 20. TEC-EYE . Turning the unit off with the following Temperature/Humidity Control instructions will disable heating and cooling operation but may not disable the blower. -
Page 29: Temperature/Humidity Control Operation
Temperature/Humidity Control Operation Cooling The unit is equipped with 1 stage of freecooling and The unit utilizes a PID control loop for space control. 2 stages of mechanical cooling (compressor and This control will compare the space temperature to unloader) for a total of 3 cooling stages (see Figure the space setpoint. -
Page 30: Dehumidification
FIGURE 2.8 Cooling w/No Economizer Compressor Stage 1 Compressor Stage 2 -10% 100% 110% 120% Deadband Deadband (sometimes called a neutral zone or dead zone) is an interval of a signal domain or band where no action occurs FIGURE 2.9 Heating Electric Heat -10% 110%... -
Page 31: Electronic Expansion Valve (Eev)
Electronic Expansion Valve (EEV) The temperature is measured with a 10k ohm NTC thermistor. EEV Components The suction temperature sensor measurement can be Electronic Expansion Valve verified and adjusted by: The electronic expansion valve is a stepper motor that 1. Press MENU key to go to the Main Menu screen. is controlled with a step output from the controller. -
Page 32: System Pressures
To manually override the valve: The valve can also be opened or closed using the EEV service tool (Bard Part # 2151-021). This magnetic NOTE: The unit must be off to perform this override. EEV service tool (shown in Figure 2.14) is used to 1. -
Page 33: Eev Alarms
EEV Alarms Suction Pressure Alarm When the suction pressure sensor value is out of range Refrigerant Low Pressure Alarm (0-250 PSIG), the controller will generate a sensor When the low pressure transducer indicates a pressure failure alarm to indicate the sensor is not working value less than the low pressure alarm setpoint of properly. -
Page 34: Filters
FIGURE 2.16 3. Press UP or DOWN keys to scroll to I/O Config; Putting Blower Output into Override Mode press ENTER key. 4. Press UP or DOWN keys to scroll to Digital In Config (C2); press ENTER key. 5. Reference 7 NoAir row and Val column (see Figure 2.17). -
Page 35: Dirty Filter Switch
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 the filter switch be set at 50% filter blockage or less. Higher settings may significantly hinder unit performance. -
Page 36: Freezestat Alarm
Freezestat Alarm Supply Air Temperature Alarm When the freezestat digital input indicates a low When the supply air temperature sensor value is out of temperature event has occurred for longer than 120 range (-41.0 to 303.0°F), the controller will generate seconds, the controller will generate a freezestat alarm. -
Page 37: High Pressure Transducer
5. The fan should now run at the selected speed. The 6. If the measurement needs to be adjusted, apply an output can be verified by again referencing the Fan offset value by pressing the ENTER key to scroll to Speed parameter. -
Page 38: Condenser Fan Operation
FIGURE 2.24 High Pressure Control Adjusting Discharge Temperatue Input Condenser Fan Speed When the discharge pressure reaches 590 PSI, the condenser fan will begin to speed up to attempt to bring the pressure back down. The speed will continue to ramp up until the discharge pressure reaches 630 PSI. -
Page 39: Condenser Fan Alarms
Condenser Fan Alarms Compressor Dirty Condenser Coil Alarm Compressor Components The unit will continuously monitor system conditions Compressor to determine if the condenser coil is dirty or blocked. Three Phase Scroll Compressor Start Up Information If the system monitors three consecutive cooling cycles that indicate a dirty condenser coil, an alarm Scroll compressors, like several other types of will be generated. -
Page 40: High Pressure Safety Switch
will allow one automatic retry (after soft lockout delay) These delays can be changed by: before disabling the compressor in a hard lockout 1. Press MENU key to go to the Main Menu screen. (requires manual reset). If hard lockout does occur, 2. -
Page 41: Economizer
Economizer Dust Sensor The unit has a dust sensor installed near the outdoor Economizer Components air inlet. The dust sensor checks for excessive Actuator particulates in the outdoor air, and will close the economizer if the dust is excessive. The sensor uses a The actuator rotates up to 90°... -
Page 42: Outdoor Temperature And Humidity Combination Sensor
To verify the status of the switch: FIGURE 2.31 Outdoor Air Sensor 1. Press MENU key to go to the Main Menu screen. 2. Press UP or DOWN keys and ENTER key to enter USER password 2000. 3. Press UP or DOWN keys to scroll to I/O Config; press ENTER key. -
Page 43: Economizer Operation
3. Press UP or DOWN keys to scroll to I/O Config; FIGURE 2.34 press ENTER key. Economizer Setup 4. Press UP or DOWN keys to scroll to Supply Air Sensor (C6); press ENTER key. 5. Reference the Value to see the input of the sensor (see Figure 2.33). -
Page 44: Economizer Alarms
FIGURE 2.36 23. Press UP or DOWN keys to adjust the dew point setpoint for economizer operation to the desired Economizer Setup – TempHum Control value. 24. Press ENTER key to save the value and scroll to Off Diff. 25. Press UP or DOWN keys to adjust the differential where dew point no longer allows economizer operation. -
Page 45: Damper Failed To Open Alarm
4. Press UP or DOWN keys to scroll to Alarm Setup condition will disable the economizer when the mode is (A4); press ENTER key. set to temperature and humidity or enthalpy. 5. Press ENTER key to scroll to Close Delay (see This alarm is fixed and cannot be adjusted. -
Page 46: High Supply Air Temperature Alarm
disabled to allow economizer operation. This 4. Press UP or DOWN keys to scroll to Alarm Setup is done because the compressor is disabled (A5); press ENTER key. below 0°F and the system would not have the 5. Press ENTER key to scroll to Lo and Diff value (see capability to cool. -
Page 47: Electric Heat Operation
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... -
Page 48: Refrigerant Information
Topping Off System Charge R410-A Refrigerant Charge If a leak has occurred in the system, Bard This unit was charged at the factory with the quantity Manufacturing recommends reclaiming, evacuating of refrigerant listed on the serial plate. AHRI capacity... -
Page 49: Pressure Service Ports
TABLE 2.5 Cooling Pressures Full Load Cooling Air Temperature Entering Outdoor Coil °F Return Air Temp Model Pressure 100 105 110 115 120 125 (DB/WB) Low Side 75/62 High Side Low Side HR58 80/67 High Side Low Side 85/72 High Side Part Load Cooling Air Temperature Entering Outdoor Coil °F Return Air Temp... -
Page 50: Maintenance And Troubleshooting
MAINTENANCE AND TROUBLESHOOTING Standard Maintenance Procedures 4. Manually spin fan and blower motors to ensure they turn freely. All motors are permanently lubricated, so no oil is necessary. WARNING 5. Inspect free cooling damper actuator and linkage. 6. Install new air filter; check for additional filter grilles internal to the structure. -
Page 51: Figure 2.14 Electronic Expansion Valve (Eev) And Table 2.7 Indoor Blower Performance
TABLE 2.6 Rated Airflow Nominal Rated CFM Nominal Rated ESP High 1800 1400 TABLE 2.7 Indoor Blower Performance Speed High Dry Coil Wet Coil Dry Coil Wet Coil (Inch H20) 1885 1800 1470 1400 TABLE 2.8 Maximum ESP of Operation Electric Heat Only Model Static Pressure*... -
Page 52: Troubleshooting Fusion-Tec Wall-Mount Unit Alarms
In the event that a problem is encountered with a wall-mount unit, the TEC-EYE hand-held tool may be used to diagnose the cause. If the problem can’t be resolved using these guidelines, contact the BARD Technical Service Department at 419.636.0439 for assistance. - Page 53 Device Signal Description Possible Cause Component to Check Recommended Action Actions Check the mixed air The alarm is activated The alarm is activated temperature sensor Mixed Air if the sensor is faulty, a if the sensor is faulty, a Replace the supply wiring.