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INSTALLATION AND
SERVICE INSTRUCTIONS
D25A2PA
D35A2PA
D35A2PB
D28A2PA
D36A2PA
D28A2PB
D36A2PB
Part of the Bard DC Free Cooling Unit System
NOTE: LC Series Controllers must be used with
DUAL-TEC™
WALL-MOUNT PACKAGE
AIR CONDITIONER
Models:
D42A2PA
D42A2PB
D48A2PA
D48A2PB
D60A2PA
D60A2PB
D-Series Wall-Mount Units
Bard Manufacturing Company, Inc.
Bryan, Ohio 43506
www.bardhvac.com
D25L2PA
D35L2PA
D25L2PB
D35L2PB
D28L2PA
D36L2PA
D28L2PB
D36L2PB
Manual:
Supersedes:
Date:
D42L2PA
D42L2PB
D48L2PA
D48L2PB
D60L2PA
D60L2PB
2100-643C
2100-643B
7-28-16
Page
1 of 59
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Summary of Contents for Bard D25A2PA
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Page 1: Air Conditioner
D36A2PB D48A2PB D28L2PB D36L2PB D48L2PB D60A2PA D60L2PA D60A2PB D60L2PB Part of the Bard DC Free Cooling Unit System NOTE: LC Series Controllers must be used with D-Series Wall-Mount Units Bard Manufacturing Company, Inc. Manual: 2100-643C Bryan, Ohio 43506 Supersedes: 2100-643B... -
Page 2: Table Of Contents
Circuit Routing Label ......15 Figure 1.9 WIRING: VAC and VDC Supply Wiring Landing Points ........17 Figure 1.10 Adjusting the 230/208VAC Transformer ..17 Figure 1.11 Bard Polarity-Voltage Monitor ....18 Figure 2.1 Refrigerant Sight Glass ......23 Figure 2.2 Wall-Mount Unit Control Board ....25 Figure 2.3... -
Page 3: General Information
While these instructions are intended as a general recommended guide, they do not supersede any national The Bard DC Free Cooling Unit system is composed and/or local codes in any way. Authorities having of two (2) D-Series DUAL-TEC™ wall-mount air... - Page 4 American Society of Heating, Refrigeration and Air WARNING Conditioning Engineers, Inc. (ASHRAE) 1791 Tullie Circle, N.E. Atlanta, GA 30329-2305 Telephone: (404) 636-8400 Fax: (404) 321-5478 Electrical shock hazard. National Fire Protection Association (NFPA) Have a properly trained individual perform Batterymarch Park these tasks.
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Page 5: Section 1: Installation Instructions
SECTION 1: INSTALLATION INSTRUCTIONS Manual 2100-643C Page 5 of 59... -
Page 6: 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 7: Site Preparation
These installation instructions cover both new shelter installations and retrofit installations. Each installation is unique and may require special accomodations and modifications. Although Bard Manufacturing follows a Fire hazard. long-established tradition of manufacturing equipment using industry standard dimensions for building Maintain minimum 1/4"... -
Page 8: Figure 1.2 Dimensions
FIGURE 1.2 Dimensions of Basic Unit for Architectural and Installation Requirements (Nominal) Supply Return Width Depth Height Model D25A/L 38.200 17.125 74.563 7.88 27.88 13.88 27.88 40.00 10.88 29.75 17.93 30.75 32.75 33.25 31.00 2.75 39.13 26.75 9.14 4.19 12.00 9.00 D35A/L D28A/L D36A/L... -
Page 9: Wall-Mount Unit Installation
WALL-MOUNT UNIT INSTALLATION MOUNTING THE UNITS 5. If desired, hook top rain flashing (attached to front- right of supply flange for shipping) under back bend of top. WARNING 6. Position unit in opening and secure with fasteners sufficient for the application such as 5/16" lag/ anchor/carriage bolts;... -
Page 10: Mounting Instructions
Manual 2100-643C Page 10 of 59... -
Page 11: Mounting Instructions
Manual 2100-643C Page 11 of 59... -
Page 12: Mounting Instructions
Manual 2100-643C Page 12 of 59... -
Page 13: Figure 1.4 Electric Heat Clearance
FIGURE 1.4 Electric Heat Clearance FIGURE 1.5 Wall Mounting Instructions WALL STRUCTURE See FIGURE 2 – Mounting Instructions FACTORY SUPPLIED RAIN FLASHING. MOUNT ON UNIT BEFORE INSTALLATION SUPPLY AIR SUPPLY AIR SUPPLY AIR DUCT OPENING OPENING RETURN AIR RETURN AIR RETURN AIR OPENING OPENING... -
Page 14: Figure 1.6 Wall Mounting Instructions
FIGURE 1.6 Wall Mounting Instructions SEE UNIT DIMENSIONS, FIGURE 2, SEE UNIT DIMENSIONS, FIGURE 1-2, FOR ACTUAL DIMENSIONS. FOR ACTUAL DIMENSIONS E + 1.000 ATTACH TO TOP PLATE OF WALL 1.000 1.000" CLEARANCE ALL AROUND DUCT SUPPLY DUCT OPENING INTERIOR FINISHED WALL OVER FRAME 1.000"... -
Page 15: Wall-Mount Unit Supply Wiring
240 and 208V taps are: 240V Tap (253 – 216) The electrical data lists fuse and wire sizes (75°C SCALE DRAWN BY Bard Mfg. Co. and 208 Tap (220 – 197). copper) for all models including the most commonly Bryan, Ohio... -
Page 16: Electrical Specifications
TABLE 1.1 Electrical Specifications AC POWER CIRCUIT DC POSITIVE GROUND POWER CIRCUIT Rated Volts, Model Minimum Maximum Field Power/ Minimum Maximum Field Power/ Hertz & Phase Circuit External Fuse or Ground Wire Circuit External Fuse Ground Wire Ampacity Ckt. Breaker Size Ampacity or Ckt. -
Page 17: Figure 1.9 Wiring: Vac And Vdc Supply Wiring Landing Points
2. If incoming AC voltage is 220VAC or above..do not adjust transformer 230VAC 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"... -
Page 18: Figure 1.11 Bard Polarity-Voltage Monitor
VDC terminal block, the VDC controls and motors will not activate and the wall-mounted unit will not function. The Bard Polarity-Voltage Monitor continually monitors for correct polarity and voltage. If field wiring is connected improperly, or the voltage is outside of the system parameters, the Polarity-Voltage Monitor will not allow any VDC voltage to enter the system, protecting the internal controls and equipment. -
Page 19: Preliminary Start-Up
During installation, this allows deactivation of one of the two existing, older wall-mount units, while keeping the shelter cool with the other unit still operating. Once the first of the two Bard wall-mount units is installed, Orphan Mode can be enabled early in the installation—keeping the climate inside the shelter stable and the installers comfortable while the remainder of the older equipment is removed and the second Bard wall-mount unit and controller are installed. - Page 20 Manual 2100-643C Page 20 of 59...
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Page 21: Section 2: Service Instructions
SECTION 2: SERVICE INSTRUCTIONS Manual 2100-643C Page 21 of 59... -
Page 22: General Refrigerant Information
TOPPING OFF SYSTEM CHARGE The pressure table found on the following page shows nominal pressures for the units. Since many If a leak has occurred in the system, Bard installation specific situations can affect the pressure Manufacturing recommends reclaiming, evacuating... -
Page 23: Figure 2.1 Refrigerant Sight Glass
This unit employs high-flow Coremax valves instead of To change a Coremax valve without first removing the the typical Shrader 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. -
Page 24: Sequence Of Operation
SEQUENCE OF OPERATION D-SERIES WALL-MOUNT UNIT 1. The outdoor temperature is below 70°F SEQUENCE OF OPERATION 2. The dewpoint of the outdoor air is below 60°F Overview 3. The outdoor humidity is below 80% RH This product is designed to function like a typical 4. -
Page 25: Figure 2.2 Wall-Mount Unit Control Board
• If conditions outside are not conducive to free Loss of Utility Power cooling, the control board will send: When AC power is lost to the unit (no shore power, 1. 24VAC signal from N02 to CCM (Compressor) no generator), the AC power loss relay will send a digital input to terminal DI 1, alerting the board. - Page 26 Special Considerations • High Temperature 2 Alarm – Should the shelter controller see 90°F, both free-cooling dampers will • Compressor Run Time – Once activated, the open (regardless of outdoor temperature) to cool compressor will run for a minimum of 5 minutes, the building.
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Page 27: Using The Tec-Eye Tm
USING THE TEC-EYE FIGURE 2.3 TEC-EYE Display 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 Resets active alarms ENTER KEY MENU KEY... -
Page 28: Figure 2.5 Tec-Eye Tm Status Display
TEC-EYE Menu Structure Status Screen On/Off Unit The STATUS screen is the default start-up screen and Setpoints also the return screen after 5 minutes of no activity. Clock/Scheduler The screen can be accessed any time by pressing the Input/Output ESCAPE button repeatedly. Analog Inputs The STATUS screen displays the current date, time, Digital Inputs... - Page 29 DOWN key to change Auto to Hand. CAUTION The Bard DC Free Cooling Unit System has been pre-programmed with what is widely considered to be the best settings for efficiency and operation. Any changes to internal programming through the LC Series Controller or the TEC-EYE...
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Page 30: Componentry Specifications
Under nominal conditions, a green LED light will show on the face of the monitor. If there White, decorative plastic casing, Bard logo, field- is improper phasing, voltage imbalance or frequency installed in shelter: 10k ohm resistance, see Table 2.3. - Page 31 TABLE 2.3 Temperature (F) vs. Resistance (R) of Temperature Sensor -25.0 196871 13.0 56985 53.0 19374 89.0 7507 -24.0 190099 14.0 55284 52.0 18867 90.0 7334 -23.0 183585 15.0 53640 53.0 18375 91.0 7165 -22.0 177318 16.0 52051 54.0 17989 92.0 7000 -21.0...
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Page 32: Figure 1.3B D28A, D28L, D36A, D36L, D42A, D42L, Table 2.4 Indoor Blower Performance
OUTDOOR FAN MOTOR FIGURE 2.6 Fan Blade Setting Due to design considerations of the condenser section of the wall-mount unit, placement/clearance of the motor/fan blade is critical to heat dispersal. Should a change of motor or fan blade be necessary, please view Figure 2.6 for proper clearance adjustment. -
Page 33: Figure 2.8 Power Loss Relay Circuit
FIGURE 2.8 Power Loss Relay Circuit FIGURE 2.9 High Pressure Relay Circuit FIGURE 2.10 Blower Motor Start Relay Circuit Blower Motor Start Relay Manual 2100-643C Page 33 of 59... -
Page 34: Figure 2.11 D25A/L, D35A/L Unit Control Panel
FIGURE 2.11 D25A/L, D35A/L Unit Control Panel DC POLARITY VOLTAGE MONITOR CABLE DUCT CONTROL PANEL DC CONVERTOR 2 POLE CONTACTOR 20 AMP DC CIRCUIT BREAKER FILTER SWITCH CIRCUIT BREAKER BASE ASSEMBLY TERMINAL BLOCK LABELS CIRCUIT BREAKER CIRCUIT BREAKER SPDT RELAY MOUNTING FOOT 24 VDC COIL DIN RAIL... -
Page 35: Figure 2.12 D28A/L, D36A/L, D42A/L, D48A/L, D60A/L Unit Control Panel
FIGURE 2.12 D28A/L, D36A/L, D42A/L, D48A/L, D60A/L Unit Control Panel 2 POLE EVAP. TEMP. CABLE CONTACTOR SENSOR DUCT TRANSFORMER 20 AMP DC POLARITY VOLTAGE MONITOR DC CONVERTER "L1" CIRCUIT FILTER BREAKER SWITCH ASSEMBLY CIRCUIT BREAKER BASE DC CIRCUIT BREAKER COMPRESSOR GROUND RELAY TERMINAL... -
Page 36: Figure 2.13 Wiring: D25A/L, D35A/L Unit Wiring Diagram
FIGURE 2.13 D25A/L, D35A/L Unit Wiring Diagram MOTOR POWER PLUG WHITE WHITE Red/Black BLOWER BLACK BLACK MOTOR MOTOR SECONDARY CONTROLLER LIMIT YELLOW YELLOW BLUE BLUE Brown ORANGE ORANGE BROWN BROWN Brown MOTOR POWER BLACK PLUG Pink MOTOR PLUG COMP. RELAY PRIMARY 5 KW HEAT STRIP LIMIT... -
Page 37: D48A/L, D60A/L Unit Wiring Diagram
FIGURE 2.14 D28A/L, D36A/L, D42A/L, D48A/L, D60A/L Unit Wiring Diagram Red/Black Black/Red MOTOR POWER PLUG WHITE WHITE BLOWER BLACK BLACK MOTOR MOTOR SECONDARY CONTROLLER LIMIT YELLOW YELLOW BLUE BLUE Brown ORANGE ORANGE BROWN BROWN Black/Red Brown MOTOR POWER BLACK PLUG ANALOG ISOLATION Pink MOTOR... -
Page 38: Maintenance And Troubleshooting
MAINTENANCE AND TROUBLESHOOTING STANDARD MAINTENANCE 4. Manually spin fan and blower motors to ensure they turn freely. All motors are permanently PROCEDURES lubricated, so no oil is necessary. 5. Inspect free cooling damper actuator and linkage. WARNING 6. Install new air filter; check for additional filter grilles internal to the structure. -
Page 39: Figure 2.15 Troubleshooting Motor Power Supply
SPECIFIC TROUBLESHOOTING – disconnect the 9-pin Molex plug connecting the motor control to the wall-mount unit control wiring harness 48VDC Blower Motor (this Molex is located in the chassis wall of the control To troubleshoot the 48VDC blower motor, check for panel) and test for the items in Table 2.5 (see Figure proper voltage and commands to the motor controller 2.15 below and Figures 2.16 and 2.17 on page 40). -
Page 40: Figure 1.3C D48A, D48L, D60A, D60L Table 2.6 Blower Speed Voltage Chart
FIGURE 2.16 Troubleshooting Motor Start Command Motor Start Command: With the meter set to Continuity Beeper, place the black (–) lead on Pin 5 and the red (+) lead on Pin 4 of the female portion of the Molex-style plug connecting the motor controller to the back of the wall-mount control cabinet. -
Page 41: Figure 2.18 Vdc Polarity Check
0 VDC Step 1 Multimeter set to VDC: Display reveals "0" voltage potential Shelter VDC Power Supply -48VDC, Positive Ground Bard System Supply Breakers: VDC breaker in OFF position 0 VDC Step 2 Multimeter set to VDC: Positive-to-ground reveals "0" voltage potential... -
Page 42: Figure 2.19 Verifying Incoming Voltage: Vdc
52VDC 48VDC Shelter System Voltage Range: 40VDC – 56VDC Typical Running Range: 48VDC – 53VDC Shelter supply breaker in ON position Displayed voltage must be within this range Bard system breaker in OFF position Manual 2100-643C Page 42 of 59... - Page 43 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 44 Should any assistance be required during the installation or servicing of this product, contact the Bard Technical Service Department at 419.636.0439. Manual 2100-643C Page...
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Page 45: Section 3: Appendix
SECTION 3: APPENDIX Manual 2100-643C Page 45 of 59... -
Page 46: Wall-Mount Unit Architecture
WALL-MOUNT UNIT ARCHITECTURE CAUTION: The Bard DC Free Cooling Unit System has been pre-programmed with what is widely considered to be the best settings for efficiency and operation. Any changes to internal programming through the LC Series controller or the TEC-EYE not covered within this manual may cause the systems to operate improperly, cause internal damage to the HVAC units, cause the shelter to overheat or other very serious consequences. - Page 47 Screen Menu Item Range Default Value Description Temperature sensed by Freezestat which Reset Temperature 0°F – 99.9°F 55°F cancels compressor shutdown Time alloted which will also cancel Reset Time 0-999 300 seconds compressor shutdown Blower Settings Continuous None/Both/Lead None Blower Speeds Control voltage supplied from wall-mount Heat 0.0 –...
- Page 48 WALL-MOUNT UNIT ARCHITECTURE (CONT.) Screen Menu Item Range Default Value Description Maximum -1000 – 1000 1000 Period 500 – 9999mS 500mS End of SETPOINTS CLOCK/SCHEDULER Clock Time Date (Current date) Hour 1:00 – 24:00 (Current time) (Current day of Mon. – Fri. week) System clock will follow DST Protocol, Daylight Savings Time...
- Page 49 ALARM HISTORY 020: Damper Close Fail Supply Air Outdoor Air Return Air Outdoor Humidity Blower Speed Damper Position End of ALARM HISTORY TECHNICIAN Information -3276.8 – Bard Code Unit Controller 3276.7 Version 0-99 1.20 Bios 0-99 6.33 Boot 0-99 4.05...
- Page 50 WALL-MOUNT UNIT ARCHITECTURE (CONT.) Screen Menu Item Range Default Value Description Working Hours -3276.8 – Run Hours 3276.7 Compressor -3276.8 – Run Hours Hours of operation 3276.7 -3276.8 – Num Starts Number of starts 3276.7 Compressor Full Load -3276.8 – Run Hours Hours of operation 3276.7...
- Page 51 Screen Menu Item Range Default Value Description Language Language English Probe Adjustment Analog Inputs SAT Input B001 Offset -9.9 – 9.9 -3276.8 – Value 3276.7 OAT Input B002 Offset -9.9 – 9.9 -3276.8 – Value 3276.7 RAT Input B003 Offset -9.9 –...
- Page 52 WALL-MOUNT UNIT ARCHITECTURE (CONT.) Screen Menu Item Range Default Value Description Return Air Temp On to manually change temperature seen Manual Control B003 Off/On by controller Degrees of change in sensor for manual Manual Position -1000 – 1000 control Current temperature plus the value in Value (Temp + Value) manual position...
- Page 53 Screen Menu Item Range Default Value Description Current status of low pressure input D4 Status (open means no input) Blower Status "On" to allow artificial manipulation of Manual DI 5 Off/On blower status input Change to "Closed" to artifically create Manual Position Closed/Open Closed...
- Page 54 WALL-MOUNT UNIT ARCHITECTURE (CONT.) Screen Menu Item Range Default Value Description Current status of blower relay (off means Relay 7 Status Off/On no relay action) Analog Outputs Analog Output 1 Blower Motor Mode Hand/Auto Auto Manual Value 0.0 – 10.0vdc 0vdc Output 0.0 –...
- Page 55 Screen Menu Item Range Default Value Description Time 0m – 500m Local Setpoint Reset 0m – 180m PW/Return Delay 0s – 9999s 300s I/O Configuration Analog Inputs Supply Air Temp Enable B001 On/Off Resolution Normal/High Res. Ohm x5, Ohm x1, NTC, PT1000, 0-1VDC, 0-10VDC,...
- Page 56 WALL-MOUNT UNIT ARCHITECTURE (CONT.) Screen Menu Item Range Default Value Description -3276.8 – Maximum 100.0 3276.7 -3276.8 – Offset 3276.7 -3276.8 – Value 3276.7 Outdoor Air Temp Input B002 Out of Range Alarm Power Delay 0s – 999s 5 Seconds Run Delay 0s –...
- Page 57 Screen Menu Item Range Default Value Description Ohm x5, Ohm x1, NTC, PT1000, 0-1VDC, 0-10VDC, 4-20mA, On/Off, Type Normal 4-20mA 0-4VDC, NTC HT, 50T90, 10T170, nu10, SPKP00B7T0, nu12, nu13 -3276.8 – Minimum 3276.7 -3276.8 – Maximum 100.0 3276.7 -3276.8 – Offset 3276.7 -3276.8 –...
- Page 58 WALL-MOUNT UNIT ARCHITECTURE (CONT.) Screen Menu Item Range Default Value Description Power Delay 0s – 999s 5 Seconds Run Delay 0s – 535s 5 Seconds Pressure/ Units Temperature/ Pressure Other Digital Inputs Power Loss Switch Enable Channel 1 On/Off Action Closed/Open Closed Delay...
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Page 59: Manual 2100-643C
Screen Menu Item Range Default Value Description Cooling Stage 2 Enable No/Yes Channel Direction N.O./N.C. N.O. Status Heating Enable No/Yes Channel Direction N.O./N.C. N.O. Status Blower Enable No/Yes Channel Direction N.O./N.C. N.O. Status Analog Outputs Blower Motor Enable Yes/No Channel Action Direct/Reverse Direct...
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