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SERVICE INSTRUCTIONS
FUSION-TEC
AIR CONDITIONER
NOTE: LV1000 controller is required for operation when
HR**BP* units are used.
®
HR35BPA HR36BPA HR58BPA
HR35BPB HR36BPB HR58BPB
Bard Manufacturing Company, Inc.
Bryan, Ohio 43506
www.bardhvac.com
WALL-MOUNT
Models:
Manual:
Supersedes:
Date:
2100-694B
2100-694A
2-14-20
Page
1 of 62
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Table of Contents
Troubleshooting
Related Manuals for Bard FUSION-TEC HR35BPA
Summary of Contents for Bard FUSION-TEC HR35BPA
- Page 1 SERVICE INSTRUCTIONS FUSION-TEC WALL-MOUNT ® AIR CONDITIONER Models: HR35BPA HR36BPA HR58BPA HR35BPB HR36BPB HR58BPB NOTE: LV1000 controller is required for operation when HR**BP* units are used. Bard Manufacturing Company, Inc. Manual: 2100-694B Bryan, Ohio 43506 Supersedes: 2100-694A www.bardhvac.com Date: 2-14-20 Page...
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Page 2: Table Of Contents
Electric Heating Element ........36 Filters ..............21 Thermal Overload ..........36 Electric Heat Operation ..........36 Dirty Filter Switch ..........21 Dirty Filter Alarm ........21 Bard Guard Anti-Theft System Option .......36 Filter Indicator Light .........21 Inverter Option ...............36 Freezestat ............23 Manual 2100-694B Page 2 of 62... - Page 3 Maintenance ..............42 Standard Maintenance Procedures ........42 Figure 40 Adjusting Compressor Delays ......28 Bard Guard Anti-Theft System Option .......42 Figure 41 Adjusting Low Temperature Compressor Disable .. 28 Troubleshooting .............. 43 Figure 42 Adjusting Low Pressure Alarm Settings ....29 8301-067 Outdoor Temperature/Humidity Sensor ....43...
- Page 4 Air Conditioning System Fire Protection Association for the Installation of Air Conditioning and Ventilating Systems of Other Than This Bard air conditioning system is composed of Residence Type, NFPA No. 90A, and Residence Type FUSION-TEC HR Series wall-mounted air conditioners Warm Air Heating and Air Conditioning Systems, NFPA matched with an LV1000 lead/lag controller.
- 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... -
Page 7: Tec-Eye Acronyms
TABLE 2 The wall-mount unit address is displayed in the upper right corner on the main status screen (see Figure TEC-EYE Screen Structure and Password Level 1). The main status screen also shows the current Password Level date, time, return air temperature (RAT), mixed air Menu/Screen Structure Required temperature (MAT), supply air temperature (SAT) -
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 or 5. Press ENTER key to save and scroll to next DOWN keys while on the main Status screen will change parameter. -
Page 9: A/C Circuit Measurements
It is important to check the software version during installation to ensure that the latest version has been installed. Current software versions, change log and installation instructions are available on the Bard website at Software Version http://www.bardhvac.com/software-download/ The Software Version screen displays the model number of the unit as well as all software version information for the PLC (see Figure 9). -
Page 10: Alarm Log
Alarm Log 4. Press UP or DOWN keys to scroll to Self Test A10 screen. The alarm log screens show a log of each alarm. There will be a log for when alarm occurred and if the alarm 5. Press ENTER key to scroll to Enable parameter auto clears, it will show when the alarm cleared. -
Page 11: Reset To Factory Defaults
Skip Cool Test: Compressor tests skipped due to condition preventing safe compressor operation. Skip Heat Test: Heating tests skipped due to heat package not being installed or condition preventing safe heat operation. Complete: Self Test functions have completed. Reset to Factory Defaults To reset to factory default settings: 1. -
Page 12: Operation
OPERATION NOTE: Screenshots shown in this manual reflect Clearing Alarm Logs and Counters default settings (when applicable). To clear the alarm log and alarm counters: Unit On/Off 1. Press MENU key to go to the Main Menu screen. The wall-mount unit can be turned on and off from 2. -
Page 13: Unit Disable
locked out due to this alarm, the user will need to 4. Press UP or DOWN keys to scroll to Adv. Alarm clear the alarm before unit operation resumes. Config B5 screen. Unit Disable 5. Press ENTER key to go to Advanced Alarm Configuration menu. -
Page 14: Temperature/Humidity Control
Once the first of the Bard FUSION-TEC HR Series wall-mount units is installed and powered on, it will operate in orphan mode—... -
Page 15: Figure 19 Cooling W/Economizer
FIGURE 19 Cooling w/Economizer Freecooling Compressor Stage 1 Compressor Stage 2 100% 110% 120% -10% Deadband Deadband (sometimes called a neutral zone or dead zone) is an interval of a signal domain or band where no action occurs FIGURE 20 Cooling w/No Economizer Compressor Stage 1 Compressor Stage 2 -10%... -
Page 16: Staging
See the latest revision of LV1000 Service The valve can also be opened or closed using the EEV Instructions 2100-673 for adjustment of the service tool (Bard Part # 2151-021). This magnetic dehumidification setpoint and differentials. EEV service tool (shown in Figure 24) is used to manually open the EEV. -
Page 17: System Pressures
FIGURE 24 Electronic Expansion Valve (EEV) and Service Tool provided on the tool). Opening the valve to the full This sensor can be verified and adjusted by: open position will aid in the refrigerant reclamation and 1. Press MENU key to go to the Main Menu screen. evacuation processes. -
Page 18: Troubleshooting The Suction Pressure Transducer
FIGURE 27 Troubleshooting the Suction Pressure Transducer Adjusting Suction Temperature Sensor Values 0-250 psig -5v Nominal .5 – 4.5v Actual 4v/250 psig = .016 volts per 1 psig Example: 125 psig x .016 + .5 volts = 2.5 volts Formula for Tech: Measured Pressure x .016 + Sensor Offset = Expected Transducer Signal Voltage (see Figure 26). -
Page 19: Eev Operation
FIGURE 28 The blower output can be put into an override mode for Adjusting Freeze Setpoint and Alarm Delay verification or troubleshooting. To put the blower into override: 1. Press MENU key to go to the Main Menu screen. 2. Press UP or DOWN keys and ENTER key to enter TECHNICIAN password 1313. -
Page 20: Blower Status Switch
TABLE 8 TABLE 6B Indoor Blower Performance HR36BP* Blower Speeds Speed High Speed Controller Mode Percentage Output Volts (Inch H Coil Coil Coil Coil High Sensible 94.0 9.4 v 1500 HR35BP* 0.00 1150 1100 Full Load Cooling HR36BP* 0.00 1260 1200 High Sensible 54.0... -
Page 21: Blower Status Alarm
Differential airflow status can be viewed by: FIGURE 32 Adjusting Air Flow Alarm Delay 1. Press MENU key to go to the Main Menu screen. 2. Press UP or DOWN keys and ENTER key to enter TECHNICIAN password 1313. 3. Press UP or DOWN keys to scroll to I/O Config; press ENTER key. -
Page 22: Figure 33 Dirty Filter Switch And Filter Indicator Light
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. -
Page 23: Freezestat
FIGURE 34 Freezestat Verifying Condenser Fan Output Earlier units were equipped with a switch that monitored the temperature of the refrigerant line leaving the evaporator coil. To prevent the coil from freezing and potentially allowing liquid refrigerant from the evaporator to enter the compressor, the freezestat switch was designed to open when the temperature at this sensor is between 26.5°F and 37.5°F and close again when the temperature is between 49.5°F and... -
Page 24: Liquid Line Pressure Transducer
Liquid Line Pressure Transducer FIGURE 37 Voltage to Pressure: The unit has a pressure transducer installed on the Discharge/Liquid Pressure Transducer liquid line between the condenser and electronic expansion valve (EEV). The transducer is used for system monitoring of the liquid side system pressures. This information is used to indicate when outdoor coil cleaning is necessary based on outdoor conditions and system pressures. -
Page 25: Condenser Fan Operation
the condenser fan may stay off for prolonged durations 6. If an offset needs to be applied, press ENTER key to scroll to Offset. due to low liquid pressures. 7. Press UP or DOWN keys to change the offset to Compressor desired value. -
Page 26: Short Cycle Protection/Delay-On-Break
the same Y call, the compressor will be de-energized. structure so that all of the units do not start at the same time which could happen after a power loss or The ALR terminal will be energized, signaling the unit building shutdown. -
Page 27: High Pressure Safety Switch
circumstances, allowing the brownout to be ignored for wall-mount unit until manually cleared with TEC-EYE a time period should not be needed. The 8201-169 is hand-held diagnostic tool. shipped with all the DIP switches in the 'off' or 'do not In addition to the CCM, the discharge pressure ignore' position (see Figure 39). -
Page 28: Low Temperature Compressor Disable
FIGURE 40 9. Press ENTER key to save. Adjusting Compressor Delays 10. Press ESCAPE key several times to return to Main Menu screen. FIGURE 41 Adjusting Low Temperature Compressor Disable The address-based delay only applies to the wall-mount unit when in orphan mode. The controller will delay the unit compressor based on the value entered on screen B2 multiplied by the unit address. -
Page 29: Economizer
FIGURE 42 10. The Damper Position will update with the new Adjusting Low Pressure Alarm Settings override value and the damper will travel to that position. NOTE: This override will last for 5 minutes or until the Override is changed back to Disabled. Dust Sensor The unit has a dust sensor installed in the outdoor air inlet next to the outdoor air sensor. -
Page 30: Dust Sensor Failure Alarm
Dust Sensor Failure Alarm 11. Press ENTER key to save the value. NOTE: When the temperature outside is measured When the sensor reads a value that is outside of the acceptable 0 to 100% range, an alarm will be at or below 0°F, the dust sensor alarm will be generated indicating the sensor has failed. -
Page 31: Damper Failed To Close Alarm
Disabling the damper switch in I/O Config disables this NOTE: The damper failed to open/close alarms will still alarm. generate and alarm regardless of model number configuration. NOTE: The damper failed to open/close alarms will still generate and alarm regardless of model number To adjust the damper failed to close delay: configuration. -
Page 32: Outdoor Temperature Sensor Failure Alarm
The outdoor humidity can be verified by: 3. Press UP or DOWN keys to scroll to I/O Config; press ENTER key. 1. Press MENU key to go to the Main Menu screen. 4. Press UP or DOWN keys to scroll to Supply Air 2. -
Page 33: Low Supply Air Temperature Alarm
FIGURE 51 cooling call. The third mode is "TempHum" where the Adjusting Supply Air Temperature Differential outdoor temperature and humidity are considered for economizer use on a free cooling call. The fourth mode is "Enthalpy" where the outdoor temperature, humidity and calculated dew point are considered for economizer operation on a free cooling call. -
Page 34: Figure 53 Economizer Setup A3
15. Press UP or DOWN keys to change the parameter 27. Press ENTER key to move cursor to the Mixed Air to the desired value. Temp parameter. 16. Press ENTER key to save the value and move to 28. Press UP or DOWN keys to change the parameter the next parameter. -
Page 35: Economizer Operation - Minimum Position
Economizer Operation – Minimum Position Emergency Off This unit has the ability to use the damper to bring If the supervisory controller Emergency Off input in fresh air whenever the blower is operating. The becomes active, an alarm will be generated at the minimum position feature will open the economizer supervisory controller and communicated to all blade slightly, whenever the blower is running. -
Page 36: Electric Heat Option
NOTE: When re-entering the model number, only valid with a low pressure switch, panel sensors and a speaker. model number entries will be accepted by the These devices are used with the Bard Guard BG1000 anti- PLC. theft controller to provide an anti-theft measure. These... -
Page 37: Figure 54 Wall-Mount Unit Model 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 2100-694B... -
Page 38: Figure 55 Wall-Mount Unit Control Board
FIGURE 55 FUSION-TEC HR Series Wall-Mount Unit Control Board 8301-068-002* + Communication Wire – Communication Wire 5VDC Micro USB FieldBus2 24VAC Hot 24VAC Common Unit Disable Dirty Filter Switch Jumper Compressor Alarm Relay 24VAC + Power Loss Relay (if equipped) Control To CCM Y Stand-by... - Page 39 TABLE 12 FUSION-TEC HR Series Wall-Mount Unit Control Board Terminals Terminal Function Type Form Rx+/Tx+ Communication Rx-/Tx- Communication Unit Disable Digital Input Dirty Filter Switch Digital Input Compressor Alarm Relay Digital Input Power Loss Relay (if equipped) Digital Input Not Used Damper Blade Switch Digital Input Airflow...
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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 13 shows nominal pressures for the units. - Page 41 This unit employs high-flow Coremax valves instead of To change a Coremax valve without first removing the the typical Schrader type valves. refrigerant, a special tool is required which can be obtained at www.fastestinc.com/en/SCCA07H. See the WARNING! Do NOT use a Schrader valve core removal replacement parts manual for replacement core part tool with these valves.
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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 4-20mA signal from to the main unit wiring harness. See Figures 56 and 57 the 8301-067 sensor to communicate outdoor for sensor wiring and terminal location. humidity and a 10KΩ... -
Page 44: 8301-067 Outdoor Temperature Sensor Troubleshooting
8301-067 Outdoor Temperature Sensor Troubleshooting To verify sensor operation: 4. Using an ohmmeter or resistance mode on a multimeter, measure resistance across white leads 1. Remove lid from outdoor temperature/humidity leading to the temperature sensor (see Figure 59). sensor. 5. Cross reference readings with Table 14. 2. - Page 45 TABLE 14 8301-067 Sensor: Temperature to Thermocouple Resistance Temperature Resistance Temperature Resistance Temperature Resistance Temperature Resistance Ω Ω Ω Ω -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...
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Page 46: 8301-067 Humidity Sensor Test Value Outputs
8301-067 Humidity Sensor Test Value Outputs FIGURE 59 8301-067 DIP Switch/Output Configuration This sensor has the ability to output fixed test signals when testing/troubleshooting sensor operation. These settings are to be used for sensor testing/ troubleshooting only and need to be removed before unit can resume normal operation. - Page 47 TABLE 15 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 48: 8301-057 Blower Status Switch/Dirty Filter Switch
0.70 0.90 HR58BP* Standard Airflow Evaporator Airflow % 100% 99.8% 98.5% 96.8% 89.9% 82.2% * Bard recommends filter switch be set at 50% filter blockage or less. Higher settings may significantly hinder unit performance. Manual 2100-694B Page 48 of 62... -
Page 49: 8612-061 Dust (Particulate) Sensor Control Board
8612-061 Dust (Particulate) Sensor Control Board 8612-061 Control Board Output Signal Not Responsive B. Component U1 pin 3 and terminal block pin 4 to Dust (see Figure 62). 1. With a voltmeter, verify 24VAC present across Should read 24VAC 24VAC pin terminals. C. -
Page 50: 8301-073 Dust (Particulate) Sensor
8301-073 Dust (Particulate) Sensor The following measurements are taken across V+ and GND on Dust Sensor Alarm B TABLE 17 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... -
Page 51: 8612-064 Dust (Particulate) Sensor Control Board
8612-064 Dust (Particulate) Sensor Control Board 8612-064 Control Board Output Signal Not Responsive 1. With a voltmeter, verify 24VAC present across 24VAC pin terminals. A. If 24VAC is not present, trace back wires to source. 2. Inspect and re-seat the dust sensor communication cable. -
Page 52: 8301-091 Dust (Particulate) Sensor
8301-091 Dust (Particulate) Sensor The following measurements are taken across V+ and GND on Dust Sensor Alarm TABLE 18 8301-073 Sensor: Dust/Volts Dust Signal Dust Signal Dust Signal µg/m3 µg/m3 µg/m3 0.10 1.77 3.43 0.15 1.82 3.48 0.20 1.86 3.53 0.25 1.91 3.58... -
Page 53: 8408-044 Return Air Sensor/Suction Sensor
8408-044 Return Air Sensor/Suction Sensor TABLE 19 8408-044 Sensor: Temperature/Resistance Curve J Temperature Resistance Temperature Resistance Temperature Resistance Temperature Resistance ºF ºC Ω ºF ºC Ω ºF ºC Ω ºF ºC Ω -31.7 196,871 -10.6 56,985 10.6 19,374 31.7 7507 -31.1 190,099 -10.0... -
Page 54: 8301-066 Supply Air Sensor
8301-066 Supply Air Sensor TABLE 20 8301-066 Sensor: Temperature/Resistance Temperature Resistance Temperature Resistance Temperature Resistance °F °C Ω °F °C Ω °F °C Ω 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... -
Page 55: 8406-157 Liquid Line Pressure Transducer
8406-157 Liquid Line Pressure Transducer TABLE 21 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 56: 8406-158 Suction Pressure Transducer
8406-158 Suction Pressure Transducer TABLE 22 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... -
Page 57: 5154-007 Dec Star Blower Motor (Hr58 Models Only)
5154-007 DEC Star Blower Motor (HR58 Models Only) ® Troubleshooting 5154-007 DEC Star Motor 1. Remove panels to access the control panel. 2. Connect TEC-EYE to the PLC. 3. Verify there are no alarms. NOTE: Under certain alarms, the blower function will be disabled. -
Page 58: Figure 66 Testing Voltage On Blower Motor 6-Pin Plug
FIGURE 66 Testing Voltage on Blower Motor 6-Pin Plug Terminal #10 See Table 23 Speed Signal TABLE 23 FIGURE 67 DEC Star Terminal 10 Output DEC Star Blower Control Module Bolt Removal VDC at Terminal Blower % Y1 VDC 10 at Plug 11.2 12.6 18. -
Page 59: Figure 68 Dec Star Motor Plug Testing
FIGURE 68 DEC Star Motor Plug Testing A. Measurement steps (from Figure 68). Phase A to Phase C Phase A to Phase B Phase B to Phase C Phase A to Ground Phase B to Ground Phase C to Ground 22. -
Page 60: 5154-002 Fasco (Heb) Blower Motor
5154-002 FASCO (HEB) Blower Motor (HR35-36 Models Only) Troubleshooting 5154-002 FASCO (HEB) Motor 1. Remove panels to access the control panel. 2. Connect TEC-EYE to the PLC. 3. Verify there are no alarms. NOTE: Under certain alarms, the blower function will be disabled. -
Page 61: Figure 70 Testing Voltage On Blower Motor 6-Pin Plug
FIGURE 70 Testing Voltage on Blower Motor 6-Pin Plug Terminal #10 See Table 23 Speed Signal TABLE 24 FIGURE 71 FASCO Terminal 10 Output FASCO Blower Control Module Bolt Removal VDC at Terminal Blower % Y1 VDC 10 at Plug 11.2 12.6 18. -
Page 62: Figure 72 Fasco Motor Plug Testing
FIGURE 72 FASCO Motor Plug Testing 21. Resistance should be equal and none should be grounded. A. If this fails, replace the blower assembly. B. If it passes, replace the control module. Manual 2100-694B Page 62 of 62...