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SERVICE INSTRUCTIONS
AIR CONDITIONER
Part of the Bard Free Cooling System
NOTE: LV1000 Controller is required for operation when
multiple HR**AP* units are used.
FUSION-TEC
WALL-MOUNT
Models:
HR36APA HR36APB
HR58APA HR58APB
Bard Manufacturing Company, Inc.
Bryan, Ohio 43506
www.bardhvac.com
®
Manual:
2100-670I
Supersedes:
2100-670H
Date:
9-26-18
Page
1 of 47
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Table of Contents
Troubleshooting
Related Manuals for Bard FUSION-TEC HR Series
Summary of Contents for Bard FUSION-TEC HR Series
- Page 1 FUSION-TEC ® WALL-MOUNT AIR CONDITIONER Models: HR36APA HR36APB HR58APA HR58APB Part of the Bard Free Cooling System NOTE: LV1000 Controller is required for operation when multiple HR**AP* units are used. Bard Manufacturing Company, Inc. Manual: 2100-670I Bryan, Ohio 43506 Supersedes: 2100-670H www.bardhvac.com...
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Page 2: Table Of Contents
CONTENTS Using the TEC-EYE ............6 Dirty Filter Switch ........20 Dirty Filter Alarm ........20 TEC-EYE Hand-Held Diagnostic Tool ......6 Filter Indicator Light ........20 TEC-EYE Menu Structure ........7 Freezestat ..........20 TEC-EYE Acronyms ..........7 Indoor Airflow Operation ........20 Main Status Screen ..........7 Blower Speed Control .........20 Quick Menu ............8 Additional Indoor Airflow Alarms ......22 Setpoints ............8... - Page 3 Fan Blade Setting ........22 Thermal Overload ........34 Figure 36 Adjusting Discharge/Liquid Transducer Electric Heat Operation ........34 Pressure Values .........23 Bard Guard Anti-Theft System Option ......35 Figure 37 Voltage to Pressure: Discharge/Liquid Pressure Transducer ........23 Smoke Detector Unit Disable Option ......35 Inverter Option ............35...
- Page 4 Free Cooling Unit System Fire Protection Association for the Installation of Air Conditioning and Ventilating Systems of Other Than This Bard Free Cooling Unit 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 Menu Structure
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 (Stand Alone Temperature Control) Information TABLE 2 Alarm Log Unit Status Messages Main Menu System Config: A1-A10 User (2000) Adv Sys Config: B1-B5 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 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 http://www.bardhvac.com/software-download/ Last 24 Hour Operation Alarm Log... -
Page 10: Addressing Wall-Mount Units
Addressing Wall-Mount Units 6. Press UP or DOWN key to change value to ON. The run test will begin and the screen will change to Each unit must have a unique address for the system Run Test Summary. to operate correctly with the LV controller (Ex: 1, 2, 3, 4 depending on the number of units). -
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
7960-816 for information on exporting 7 day I/O logs. FIGURE 16 Clearing All Alarms Stand Alone (Orphan) Mode FUSION-TEC HR Series wall-mount units have the capability to run without the LV1000 controller attached—this feature is called stand alone or orphan mode. This keeps the shelter between 45°F and 79°F (factory default settings) by the use of the... -
Page 13: 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 14: 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 15: Heating
The valve can also be opened or closed using the EEV indoor humidity sensors and a command service tool (Bard Part # 2151-021). This magnetic from the LV to enter dehumidification mode. EEV service tool (shown in Figure 24 on page 16) is See the latest revision of LV1000 Service used to manually open the EEV. -
Page 16: System Pressures
FIGURE 24 Electronic Expansion Valve (EEV) and Service Tool are 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 17: 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 18: Eev Operation
FIGURE 28 5. Press ENTER key to scroll to Blower OV Speed (see Adjusting Freeze Setpoint and Alarm Delay Figure 29). 6. Press UP or DOWN keys to adjust the speed to the desired output (see Table 3A or 3B). 7. -
Page 19: Blower Status Switch
Blower Status Switch TABLE 3B HR58AP* Blower Speeds The unit is equipped with a differential pressure airflow switch to monitor the blower (see Figure 30). If the Speed Controller blower is turned on and the switch doesn't open to Mode Percentage Output Volts indicate there is differential pressure between the inlet... -
Page 20: Blower Status Alarm
Blower Status Alarm on the dial. When the pressure difference returns below the setting on the dial, the switch will close. If the blower is commanded on and the fan status switch (differential pressure) has not indicated the fan Adjustment of dirty filter switch may be necessary to is running within 45 seconds, the system will generate ensure proper operation. -
Page 21: Filter Switch Pressure Settings
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 22: Additional Indoor Airflow Alarms
Additional Indoor Airflow Alarms 5. The fan should now run at the selected speed. The output can be verified by again referencing the Fan Supply Air Temperature Alarm Speed parameter. When the supply air temperature sensor value is out of The override will last for 5 minutes or until the Override range (-41.0 to 303.0°F), the controller will generate parameter is set to Disabled again. -
Page 23: Troubleshooting The Discharge/Liquid Pressure Transducer
The liquid temperature sensor can be verified and 8. Once adjusted, the ESCAPE key several times to return to Main Menu screen. adjusted by: 1. Press MENU key to go to the Main Menu screen. FIGURE 36 2. Press UP or DOWN keys and ENTER key to enter Adjusting Discharge/Liquid Transducer Pressure Values TECHNICIAN password 1313. -
Page 24: High Pressure Control
FIGURE 39 Condenser Fan Speed Control conditions become unfavorable for optimized cooling, Low Ambient Control the system will change to mechanical cooling only. At low ambient outdoor air temperatures, the fan motor When this occurs, the fan speed will remain at normal will cycle as a means of controlling the system's head speed for 2 minutes, allowing for the damper blade to pressure to protect the system from evaporator coil... -
Page 25: Compressor
dirty the coil gets before an alarm is generated and how pressure rises when the compressor is energized. many consecutive cycles before the alarm is triggered. Reverse rotation also results in an elevated sound level over that with correct rotation, as well as substantially To change these settings: reduced current draw compared to tabulated values. -
Page 26: Test Mode
FIGURE 41 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 the compressor. -
Page 27: High Pressure Safety Switch
power is removed from the Y terminal. This condition If a fault condition occurs, reverse two of the supply does not prevent operation, it only indicates that a leads to the unit. Do not reverse any of the unit factory brownout condition was present at some point during wires as damage may occur. -
Page 28: Additional Compressor Alarms
Economizer compressors at the same time when there is a quick change in the load. When connected to the LV, this is Economizer Components taken care of by LV logic. Actuator Additional Compressor Alarms The actuator rotates up to 90° based on a 0-10v signal Refrigerant Low Pressure Alarm sent to it by the controller. -
Page 29: Dust Sensor Failure Alarm
To ensure proper performance, cleaning may be controller has adjustable software setpoints (default to required. Vacuuming or blowing the dust off the sensor 80%) to indicate dust levels are too high and to disable with forced air is recommended. Avoid inserting any the economizer operation for 5 minutes (unit default). -
Page 30: Damper Failed To Open Alarm
FIGURE 48 To verify the status of the switch: Adjusting Damper 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 31: Outdoor Temperature Sensor Failure Alarm
5. Reference the Value to see the input of the sensor Outdoor Temperature Sensor Failure Alarm (see Figure 49). When the sensor reads a value that is outside of the 6. To apply an offset, press ENTER key to scroll to acceptable -41 to 303.0°... -
Page 32: Supply Temperature Sensor Failure Alarm
Supply Temperature Sensor Failure Alarm 3. Press UP or DOWN keys to scroll to System Config; press ENTER key. When the sensor reads a value that is outside of the acceptable -41.0 to 303.0° range, an alarm will be 4. Press UP or DOWN keys to scroll to Alarm Setup generated indicating the sensor has failed. -
Page 33: Figure 54 Economizer Setup - Enthalpy Control
FIGURE 54 6. Press UP or DOWN keys to change the Type desired value to None, Dry Bulb, TempHum or Economizer Setup – Enthalpy Control Enthalpy. 7. Press ENTER key to save the value and scroll to the next parameter. NOTE: The following parameters are for the temperature consideration for economizer use. -
Page 34: Emergency Cooling Mode
TABLE 8 Economizer Default Settings Mode Consideration Economizer Available for Cooling Economizer Not Available for Cooling When the outdoor air temperature When the outdoor air temperature Temperature is below 70°F is above 75°F LV Online: When the outdoor humidity LV Online: When the outdoor humidity is below 80% is above 80% Humidity... -
Page 35: Bard Guard Anti-Theft System 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 36: Figure 56 Wall-Mount Unit Control Board
FIGURE 56 FUSION-TEC HR Series Wall-Mount Unit Control Board 8301-068-002* + Communication Wire – Communication Wire Micro USB FieldBus2 24VAC Hot 24VAC Common Smoke Detector Jumper Dirty Filter Switch 24VAC + Compressor Alarm Relay Control To CCM Y Stand-by Compressor Staging... -
Page 37: Wall-Mount Unit Control Board Terminals
TABLE 9 FUSION-TEC HR Series Wall-Mount Unit Control Board Terminals Terminal Function Type Form Rx+/Tx+ Communication Rx-/Tx- Communication Smoke Detector Digital Dirty Filter Switch Digital Compressor Alarm Relay Digital Not Used Not Used Damper Blade Switch Digital Airflow Digital Digital Ground... -
Page 38: Figure 57 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 2100-670I... -
Page 39: 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... -
Page 40: 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 41: 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 42: Troubleshooting
TROUBLESHOOTING 8301-067 Outdoor Temperature/Humidity Sensor FIGURE 58 8301-067 Sensor DIP Switches and Terminal Block Manual 2100-670I Page 42 of 47... -
Page 43: Table 11
TABLE 11 8301-067 Sensor: Temperature/Resistance Temperature Resistance Temperature Resistance Temperature Resistance Temperature Resistance Ω Ω Ω Ω -31.7 148,452.94 -10.6 48,892.46 10.6 18,337.51 31.7 7679.76 -31.1 143,910.37 -10.0 47,571.97 11.1 17,898.38 32.2 7515.86 -30.6 139,521.46 -9.4 46,291.29 11.7 17,471.09 32.8 7355.94 -30.0 135,280.55 -8.9... -
Page 44: Table 12 8301-067 Sensor: Humidity/Ma
TABLE 12 8301-067 Sensor: Humidity/mA mA Output mA Output mA Output 4.000 mA 9.440 mA 14.880 mA 4.160 mA 9.600 mA 15.040 mA 4.320 mA 9.760 mA 15.200 mA 4.480 mA 9.920 mA 15.360 mA 4.640 mA 10.080 mA 15.520 mA 4.800 mA 10.240 mA 15.680 mA... -
Page 45: 8408-044 Return Air Sensor/Suction Sensor
8408-044 Return Air Sensor/Suction Sensor TABLE 13 8408-044 Sensor: Temperature/Resistance Curve J Temperature Resistance Temperature Resistance Temperature Resistance Temperature Resistance ºF Ω ºF Ω ºF Ω ºF Ω -25.0 196871 13.0 56985 53.0 19374 89.0 7507 -24.0 190099 14.0 55284 52.0 18867 90.0... -
Page 46: 8301-066 Supply Air Sensor
8301-066 Supply Air Sensor TABLE 14 8301-066 Sensor: Temperature/Resistance Temperature Resistance Temperature Resistance Temperature Resistance °C Ω °C Ω °C Ω 29,490 6501 1868 28,157 6260 1810 26,891 6028 1754 25,689 5806 1700 24,547 5594 1648 23,462 5390 1598 22,431 5195 1550 21,450... -
Page 47: 8301-057 Blower Status Switch/Dirty Filter Switch
8301-057 Blower Status Switch/Dirty Filter Switch FIGURE 59 8301-057 Air Differential Switch Terminals Terminals 1 − Normally Open 2 − Normally Closed 3 − Common Manual 2100-670I Page 47 of 47...
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