Bard FUSION-TEC HR36APA, FUSION-TEC HR36APB, FUSION-TEC HR58APA, FUSION-TEC HR58APB Service Instructions Manual

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Page 1

SERVICE INSTRUCTIONS

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. Bryan, Ohio 43506 www.bardhvac.com

Manual: 2100-670I Supersedes: 2100-670H Date: 9-26-18

Page 1 of 47

Page 2

CONTENTS

Using the TEC-EYETM .................................................... 6

TEC-EYE Hand-Held Diagnostic Tool ............................6

TEC-EYE Menu Structure .....................................7

TEC-EYE

Main Status Screen .............................................7

Quick Menu .......................................................8

Setpoints ....................................................8

Information .................................................8

Staging Information ..............................8

Stand Alone Demand and Staging ..........8

Master Staging .....................................8

A/C Circuit Measurements ......................9

Last 24 Hour Operation .........................9

Software Version ...................................9

Alarm Log ...................................................9

Addressing Wall-Mount Units .............................10

Executing a Run Test ........................................10

Run Test Parameter Descriptions .................11

Reset to Factory Defaults ...................................11

Acronyms .............................................7

Operation .....................................................................12

Unit On/Off .............................................................12

Alarm Adjustment ..................................................12

Acknowledging Alarms.......................................12

Clearing Alarms ................................................12

Clearing Alarm Logs and Counters ......................12

Exporting Alarm Logs ........................................12

Exporting 7 Day Logs ........................................12

Stand Alone (Orphan) Mode ......................................12

Temperature/Humidity Control ...................................13

Temperature/Humidity Control Components .........13

Return Air Temperature Sensor ....................13

Return Air Temperature Alarm ..............13

Temperature/Humidity Control Operation .............13

Cooling .....................................................13

Cooling w/No Economizer ...........................13

Heating .....................................................15

Staging .....................................................15

Dehumidiﬁcation .......................................15

Electronic Expansion Valve (EEV) ..............................15

EEV Components ..............................................15

Electronic Expansion Valve .........................15

EEV Instructions for Vacuum,

Reclaim, Charge Unit ..........................15

System Pressures ................................16

Suction Pressure Transducer .......................16

Troubleshooting the Suction

Pressure Transducer ............................17

Suction Pressure Alarm .......................17

Suction Temperature Sensor .......................17

Suction Temperature Alarm ..................17

EEV Operation ..................................................18

EEV Superheat Control ...............................18

Additional EEV Alarms ......................................18

Low Superheat Alarm .................................18

Indoor Airﬂow ..........................................................18

Indoor Airﬂow Components ................................18

Blower ......................................................18

Blower Status Switch ..........................19

Blower Status Alarm ............................20

Filters .......................................................20

Evaporator Freeze Condition Alarm ..........

Dirty Filter Switch ......................................20

Dirty Filter Alarm ................................20

Filter Indicator Light ..................................20

Freezestat .................................................20

Indoor Airﬂow Operation ....................................20

Blower Speed Control .................................20

Additional Indoor Airﬂow Alarms ........................22

Supply Air Temperature Alarm .....................22

Condenser Fan ........................................................22

Condenser Fan Components ...............................22

Condenser Fan ..........................................22

Liquid Line Pressure Transducer ..................22

Troubleshooting the Discharge/

Liquid Pressure Transducer ..................23

Discharge/Liquid Pressure

Transducer Alarm ................................23

Liquid Temperature Sensor .........................23

Condenser Fan Operation ...................................23

Condenser Fan Speed Control .....................23

Mechanical Cooling Only .....................23

Optimized Cooling (Concurrent Economizer and Mechanical

Cooling) .............................................23

High Pressure Control .................................24

Condenser Fan Speed ..........................24

Second Stage Drop Out .......................24

Low Ambient Control ..................................24

Additional Condenser Fan Alarms .......................24

Dirty Condenser Coil Alarm .........................24

Compressor .............................................................25

Compressor Components ...................................25

Compressor ...............................................25

Compressor Control Module (CCM) ..............25

Delay-on-Make Timer ...........................25

Short Cycle Protection/

Delay-on-Break ...................................25

High Pressure Detection ......................25

Test Mode ..........................................26

High Pressure Safety Switch .......................27

Refrigerant High Pressure Alarm ...........27

Phase Monitor ...........................................27

Compressor Operation .......................................27

Additional Compressor Alarms ............................28

Refrigerant Low Pressure Alarm ...................28

Economizer .............................................................28

Economizer Components ...................................28

Actuator ....................................................28

Dust Sensor ..............................................28

Dust Sensor Failure Alarm ...................29

High Dust Limit Alarm .........................29

Damper Blade ...........................................29

Damper Switch ..........................................29

Damper Failed to Open Alarm ..............30

Damper Failed to Close Alarm ..............30

Outdoor Temperature and Humidity

Combination Sensor ...................................30

Outdoor Temperature Sensor

Failure Alarm ......................................31

Outdoor Humidity Sensor

Failure Alarm ......................................31

Brownout Protection w/Adjustment ..........

Manual 2100-670I Page 2 of 47

Page 3

Supply Temperature Sensor ........................31

Supply Temperature Sensor

Failure Alarm ......................................32

High Supply Air Temperature Alarm ......32

Low Supply Air Temperature Alarm .......32

Economizer Operation .......................................32

Emergency Cooling Mode..........................................34

Emergency Ventilation Mode .....................................34

Model/Serial Number Conﬁguration ...........................34

Electric Heat Option ................................................34

Electric Heat Components .................................34

Electric Heating Element ............................34

Thermal Overload .......................................34

Electric Heat Operation .....................................34

Bard Guard Anti-Theft System Option ........................35

Smoke Detector Unit Disable Option ..........................35

Inverter Option ........................................................35

Refrigerant Information ...........................................39

General ...................................................................39

Topping Off System Charge .......................................39

Safety Practices .......................................................39

Important Installer Note ...........................................39

R410-A Refrigerant Charge .......................................39

Pressure Service Ports ..............................................40

Maintenance ................................................................ 41

Standard Maintenance Procedures ............................41

Bard Guard Anti-Theft System Option ........................41

Troubleshooting .........................................................42

8301-067 Outdoor Temperature/Humidity Sensor .......42

8408-044 Return Air Sensor/Suction Sensor ..............45

8301-066 Supply Air Sensor ....................................46

301-057 Blower Status Switch/Dirty Filter Switch ........

FIGURES AND TABLES

Figure 1 TEC-EYE Display and Interface ......................6

Figure 2 TEC-EYE Connection to Unit Control ..............6

Figure 3 Quick Menu Icons ........................................8

Figure 4 Cool and Heat Setpoints ...............................8

Figure 5 Stand Alone Demand and Staging .................8

Figure 6 Master Staging ............................................8

Figure 7 A/C Circuit Measurements .............................9

Figure 8 Last 24 Operation ........................................9

Figure 9 Software Version ..........................................9

Figure 10 Changing Unit Address ...............................10

Figure 11 Executing Run Test ....................................10

Figure 12 Run Test Summary .....................................10

Figure 13 Run Test: Motors & Sensors ........................11

Figure 14 Run Test: A/C Circuit ..................................11

Figure 15 Restoring Factory Default Settings ...............11

Figure 16 Clearing All Alarms ....................................12

Figure 17 Clearing Alarm Logs and Counters ...............12

Figure 18 Adjusting Return Air Sensor ........................13

Figure 19 Cooling w/Economizer ................................14

Figure 20 Cooling w/No Economizer ...........................14

Figure 21 Heating .....................................................14

Figure 22 Viewing Unit Stages ...................................15

Figure 23 Overriding EEV Output ...............................15

Figure 24 Electronic Expansion Valve (EEV) and

Service Tool ...............................................16

Figure 25 Adjusting Suction Sensor/Transducer

Pressure Values .........................................16

Figure 26 Voltage to Pressure: Suction Pressure

Transducer ................................................17

Figure 27 Adjusting Suction Temperature Sensor

Values.......................................................17

Figure 28 Adjusting Freeze Setpoint and Alarm Delay ..18 Figure 29 Figure 30

Figure 31 Verifying Differential Airﬂow Status ..............19

Figure 32 Adjusting Air Flow Alarm Delay ...................20

Figure 33 Dirty Filter Switch and Filter Indicator Light .21

Figure 34 Verifying Condenser Fan Output ..................22

Figure 35 Fan Blade Setting ......................................22

Figure 36 Adjusting Discharge/Liquid Transducer

Pressure Values .........................................23

Figure 37 Voltage to Pressure: Discharge/Liquid

Pressure Transducer ...................................23

Figure 38 Adjusting Discharge/Liquid Temperature

Input ........................................................23

Figure 39 Condenser Fan Speed Control .....................24

Figure 40 Adjusting Dirty Condenser Coil Alarm

Settings ....................................................25

Figure 41

Figure 42 Adjusting Compressor Delays ......................27

Figure 43

Figure 44 Damper Override ........................................28

Figure 45 Dust Sensor ..............................................29

Figure 46

Figure 47 Damper Switch ..........................................30

Figure 48 Adjusting Damper Alarm Delay ....................30

Figure 49 Outdoor Air Sensor .....................................31

Figure 50 Outdoor Humidity Sensor ............................31

Figure 51 Supply Air Sensor ......................................31

Figure 52 Adjusting Supply Air Temperature

Differential ................................................32

Figure 53 Economizer Setup ......................................32

Figure 54 Figure 55

Figure 56 Wall-Mount Unit Control Board ....................36

Figure 57 Wall-Mount Unit Model Nomenclature .........38

Figure 58 8301-067 Sensor Dip Switches and

Terminal Block ..........................................42

Figure 59

Table 1 Table 2

Table 3A HR36AP* Blower Speeds ...........................18

Table 3B HR58AP* Blower Speeds ...........................19

Table 4 Rated Airﬂow .............................................19

Table 5 Indoor Blower Performance .........................19

Table 6 Maximum ESP of Operation:

Electric Heat Only ......................................19

Table 7 Filter Switch Pressure Settings ....................21

Table 8 Economizer Default Settings .......................34

Table 9

Table 10 Cooling Pressures ......................................40

Table 11 8301-067 Sensor: Temp/Resistance ............43

Table 12 8301-067 Sensor: Humidity/mA .................44

Table 13 8408-044 Sensor:

Temperature/Resistance Curve J ..................42

Table 14

Putting Blower Output into Override Mode ......

Dirty Filter Switch/Blower Status Switch ........

8201-164 Compressor Control Module

Adjusting Low Pressure Alarm Settings ...........

Adjusting Dust Sensor Alarm Setpoint

Economizer Setup – Enthalpy Control ...........

Economizer Setup – TempHum Control ...........

8301-057 Air Differential Switch Terminals...

LV1000/TEC-EYE Passwords (Defaults)

Unit Status Messages ......................................

Wall-Mount Unit Control Board Terminals ......

8301-066 Sensor: Temperature/Resistance ...

...........26

............29

18 19

33 33

.............6

Manual 2100-670I Page 3 of 47

Page 4

GENERAL INFORMATION

Free Cooling Unit System

This Bard Free Cooling Unit System is composed of FUSION-TEC HR Series wall-mounted air conditioners matched with an LV1000 lead/lag controller. The wall mounts are speciﬁcally engineered for telecom/motor control center rooms.

NOTE: The LV1000 lead/lag controller and FUSION-

TEC HR Series wall-mount units are designed speciﬁcally to work together. The controller cannot run other Bard models or other brands of systems, nor can other controllers run the FUSION-TEC HR Series wall-mount units. They are a complete system, and must be used together.

Wall-Mount Air Conditioner Units

The FUSION-TEC power.

The units will supply 100% of rated cooling airﬂow in free cooling mode with ability to exhaust the same amount through the unit itself without any additional relief openings in the shelter.

Each of these units are fully charged with refrigerant and have optional auxiliary heat.

HR Series

units operate on VAC

General

The equipment covered in this manual is to be installed by trained, experienced service and installation technicians.

The refrigerant system is completely assembled and charged. All internal wiring is complete.

The unit is designed for use without duct work. Flanges are provided for transition from unit to wall grilles.

These instructions explain the recommended method to install the air cooled self-contained unit and the electrical wiring connections to the unit.

These instructions and any instructions packaged with any separate equipment required to make up the entire air conditioning system should be carefully read before beginning the installation. Note particularly any tags and/or labels attached to the equipment.

While these instructions are intended as a general recommended guide, they do not supersede any national and/or local codes in any way. Authorities having jurisdiction should be consulted before the installation is made. See Additional Publications for information on codes and standards.

Sizing of systems for proposed installation should be based on heat loss and heat gain calculations made according to methods of Air Conditioning Contractors of America (ACCA). The supply ﬂange should be installed in accordance with the Standards of the National

Fire Protection Association for the Installation of Air Conditioning and Ventilating Systems of Other Than Residence Type, NFPA No. 90A, and Residence Type Warm Air Heating and Air Conditioning Systems, NFPA No. 90B. Where local regulations are at a variance with

instructions, installer should adhere to local codes.

Shipping Damage

Upon receipt of equipment, the cartons should be checked for external signs of shipping damage. If damage is found, the receiving party must contact the last carrier immediately, preferably in writing, requesting inspection by the carrier’s agent.

These units must remain in upright position at all times.

Additional Publications

These publications can help when installing the air conditioner. They can usually be found at the local library or purchased directly from the publisher. Be sure to consult the current edition of each standard.

National Electrical Code ...................... ANSI/NFPA 70

Standard for the Installation of Air Conditioning

and Ventilating Systems ...................ANSI/NFPA 90A

Standard for Warm Air Heating

and Air Conditioning Systems ............ANSI/NFPA 90B

Load Calculation for Residential Winter

and Summer Air Conditioning ............. ACCA Manual J

For more information, contact these publishers:

Air Conditioning Contractors of America (ACCA) 1712 New Hampshire Ave. N.W. Washington, DC 20009 Telephone: (202) 483-9370 Fax: (202) 234-4721

American National Standards Institute (ANSI) 11 West Street, 13th Floor New York, NY 10036 Telephone: (212) 642-4900 Fax: (212) 302-1286

American Society of Heating, Refrigeration and Air Conditioning Engineers, Inc. (ASHRAE)

1791 Tullie Circle, N.E. Atlanta, GA 30329-2305 Telephone: (404) 636-8400 Fax: (404) 321-5478

National Fire Protection Association (NFPA) Batterymarch Park P. O. Box 9101 Quincy, MA 02269-9901 Telephone: (800) 344-3555 Fax: (617) 984-7057

Manual 2100-670I Page 4 of 47

Page 5

ANSI Z535.5 Deﬁnitions:

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 extreme situations. DANGER [signs] should not be used for property damage hazards unless personal injury risk appropriate to these levels is also involved.

WARNING: Indicate[s] a hazardous situation which, if not avoided, could result in death or serious injury. WARNING [signs] should not be used for property damage hazards unless personal injury risk appropriate to this level is also involved.

CAUTION: Indicate[s] a hazardous situation which, if not avoided, could result in minor or moderate injury. CAUTION [signs] without a safety alert symbol may be used to alert against unsafe practices that can result in property damage only.

NOTICE: [this header is] preferred to address practices not related to personal injury. The safety alert symbol shall not be used with this signal word. As an alternative to “NOTICE” the word “CAUTION” without the safety alert symbol may be used to indicate a message not related to personal injury.

WARNING

Electrical shock hazard.

Have a properly trained individual perform these tasks.

Failure to do so could result in electric shock or death.

WARNING

Fire hazard.

Maintain minimum 1/4" clearance between the

supply ange and combustible materials.

Failure to do so could result in re causing damage, injury or death.

WARNING

Heavy item hazard.

Use more than one person to handle unit.

Failure to do so could result in unit damage or serious injury.

CAUTION

Cut hazard.

Wear gloves to avoid contact with sharp edges.

Failure to do so could result in personal injury.

Manual 2100-670I Page 5 of 47

Page 6

USING THE TEC-EYE

TEC-EYE (Bard P/N 8301-059) Display and Interface (Status Screen Shown)

FIGURE 1

ALARM KEY

MENU KEY

ESCAPE KEY

ALARM KEY

Allows viewing of active alarms Silences audible alarms Resets active alarms

MENU KEY

Allows entry to Main Menu

ESCAPE KEY

Returns to previous menu level Cancels a changed entry

TEC-EYE Hand-Held Service Tool

The TEC-EYE service tool is used to communicate with the FUSION-TEC unit logic board. By connecting directly to the logic board inside the unit control panel, it is possible to perform diagnostics on the unit, adjust certain settings and verify unit and economizer operation through a run test procedure. The TEC-EYE service tool is required for unit setup and operation. The TEC-EYE is supplied with the LV1000 controller but can also be ordered separately (Bard P/N 8301-059).

The menu driven interface provides users the ability to scroll through two menu levels: Quick Menu and Main Menu. The menus permit the user to easily view, control and conﬁgure the unit.

The controller is completely programmed at the factory; the default setpoints and their ranges are easily viewed and adjusted from the TEC-EYE display. The program and operating parameters are permanently stored on FLASH-MEMORY in case of power failure.

The TEC-EYE connects to the wall-mount unit control board via an RJ11 modular phone connector as shown in Figure 2.

When not being used, the TEC-EYE hand-held diagnostic tool should be stored inside or near the LV1000 controller. Do not let the TEC-EYE leave the shelter site.

UP KEY

ENTER KEY

DOWN KEY

UP KEY

Steps to next screen in the display menu Changes (increases) the value of a modiﬁable ﬁeld

ENTER KEY

Accepts current value of a modiﬁable ﬁeld Advances cursor

DOWN KEY

Steps back to previous screen in the display menu Changes (decreases) the value of a modiﬁable ﬁeld

FIGURE 2

TEC-EYE Connection to Unit Control

Modular Phone Connector for TEC-EYE Hand-Held Diagnostic Tool

TABLE 1

LV1000/TEC-EYE Passwords (Defaults)

User 2000

Technician 1313

Engineer 9254

Use UP or DOWN keys and ENTER key to enter password

Manual 2100-670I Page 6 of 47

Page 7

TEC-EYE Screen Structure and Password Level

Quick Menu Setpoints (Stand Alone Temperature Control) Information Alarm Log Main Menu System Conﬁg: A1-A10 User (2000) Adv Sys Conﬁg: B1-B5 Technician (1313) I-O Conﬁg: C1-C16 Technician (1313) On/Off: User (2000) Alarm Logs: User (2000) Settings Date/Time: Technician (1313) Language: User (2000) Import/Export Parameter Conﬁg: Engineer (9254) Alarm Export: User (2000) Trend Log Export: User (2000) Initialization Clear Logs: User (2000) System Default: Engineer (9254) Serial Ports: Technician (1313) Change Passwords Logout

In addition to the menu structure above, there are also Status and Alarm screens.

TEC-EYE Acronyms

MAT – Mixed air temperature (calculated value) RAT – Return air temperature SAT – Supply air temperature OAT – Outdoor air temperature OAH – Outdoor air humidity ODP – Outdoor dew point (calculated value) Blower – Indoor blower speed Fan – Outdoor fan speed Damper – Free cooling damper position FC – Free cooling status CL1 – Compressor stage 1 status CL2 – Compressor stage 2 status H1 – Heater stage 1 status H2 – Heater stage 2 status ST – Number of start requests in last hour

NOTE: Digital refers to On/Off whereas analog is a

variable input.

Main Status Screen

The main Status screen is the default start-up screen and also the return screen after 5 minutes of no activity. The screen can be accessed at any time by pressing the ESCAPE key repeatedly.

The wall-mount unit address is displayed in the upper right corner on the main Status screen (see Figure

1). The main Status screen also shows the current date, time, return air temperature (RAT), mixed air temperature (MAT), supply air temperature (SAT) outdoor air temperature (OAT), outdoor air humidity (OAH) and outdoor dew point (ODP) conditions. Blower

speed, condenser fan speed, damper position and unit status are also displayed. See Table 2 for wall-mount unit status messages.

TABLE 2

Unit Status Messages

Message Description

Waiting...

Stand Alone

LV Online

Cont. Blower

Power Loss

Freecooling Unit is actively economizing.

Optimized Cool

Cooling Unit is actively mechanical cooling.

Heating Unit is actively heating.

Passive Dehum

Active Dehum

Self Test Unit is performing a self test.

Off by Alarm

Off by DI

Off by LV

Off by Keyboard

Override Active

Emergency Vent

Emergency Cool

Emergency Off

PLC is on and has not started running the application yet.

Unit is on and in orphan mode with no calls for heating or cooling.

Unit is on and communicating with the LV1000 with no heating or cooling calls.

Unit is operating with continuous blower when no heating or cooling calls are present.

Unit has experienced a loss of main utility power. Alarm only available with inverter units.

Unit is mechanical cooling while actively economizing.

Unit is taking measures to decrease humidity without using extra energy.

Unit is taking active measures to decrease humidity.

Unit has major fault preventing operation.

Unit is disabled by the local unit disable/smoke input.

Unit has been turned off by the supervisory controller.

Unit has been turned off by the local user.

There is an active override on the system.

Unit is in Emergency Ventilation. LV1000 has an active hydrogen alarm.

Unit is in Emergency Cooling. Indoor temperatures have exceded high temp alarms.

Unit is in Emergency Off. LV1000 has an active smoke alarm.

Manual 2100-670I Page 7 of 47

Page 8

The Quick Menu is accessible from the main Status screen. Setpoints, Information and Alarm Log are available through the Quick Menu. Pressing the UP or DOWN keys while on the main Status screen will change the Quick Menu icon displayed (see Figure 3). Press the ENTER key when the desired icon is displayed.

FIGURE 3

Quick Menu Icons

Alarm Log Information

NOTE: Screenshots shown in this manual reﬂect

default settings (when applicable).

Quick Menu

Setpoints

From this screen, the local unit heating and cooling setpoints, used for stand alone operation only, can be changed.

Once the supervisory controller is connected, cooling and heating setpoints will be communicated and local cooling and heating setpoints will be replaced with the communicated cooling and heating setpoints.

If at any time the wall-mount unit(s) loses communication with the LV1000 controller, the wall-mount unit(s) will go into stand alone mode and operate using the last communicated setpoints.

To verify or change the wall-mount unit cooling and heating setpoints in stand alone mode:

1. Connect the TEC-EYE diagnostic tool to the control

board located in the unit.

2. From the Status screen, press UP or DOWN key

until Quick Menu displays Setpoints icon. Press ENTER key.

3. Press ENTER key to scroll to the selected choice

(see Figure 4).

Setpoints

FIGURE 4

Cool and Heat Setpoints

4. Press UP or DOWN key on desired value until value displays correctly.

5. Press ENTER key to save and scroll to next parameter.

6. Press ESCAPE key until Main Menu screen is displayed.

Information

The information screens are used as a quick reference to show unit operational information such as staging, A/C circuit measurements, last 24 hour run times, component lifetime hours and software versioning.

Staging Information

Staging information is used to show any unit operation that should be taking place. The look of the staging display depends on if the unit is communicating with a supervisory controller.

Stand Alone Demand and Staging

If the unit is operating in a stand alone mode, the title will display as Unit Demand (see Figure 5). This signiﬁes that the local unit has control of the unit heating and cooling stages.

FIGURE 5

Stand Alone Demand and Staging

Master Staging

If the unit is communicating with a supervisory controller, the title will display as Master Staging (see Figure 6). This signiﬁes that the supervisory controller has control of the unit heating and cooling stages.

FIGURE 6

Master Staging

Manual 2100-670I Page 8 of 47

Page 9

A/C Circuit Measurements

A/C Circuit Information can be found in two screens within the information menu (see Figure 7). The information and measurements provided are liquid line temperature, liquid line pressure, condensing saturated temperature, suction line temperature, suction line pressures, suction saturated temperature, super heat, sub-cooling and electronic expansion valve position.

Software Version

The Software Version screen displays the model number of the unit as well as all software version information for the PLC (see Figure 9). This information can be used to determine whether a software update may be required based on information found in the software change log. This change log can be found at http://www.bardhvac.com/software-download/.

FIGURE 7

A/C Circuit Measurements

FIGURE 9

Software Version

NOTICE

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

Last 24 Hour Operation information tracks the runtimes (Time) and start calls (Start) of different components or operations in the last 24 hour period (see Figure 8).

FIGURE 8

Last 24 Hour Operation

Alarm Log

The alarm log screens show a log of each alarm. There will be a log for when alarm occurred and if the alarm auto clears, it will show when the alarm cleared.

Manual 2100-670I Page 9 of 47

Page 10

Addressing Wall-Mount Units

Each unit must have a unique address for the system to operate correctly with the LV controller (Ex: 1, 2, 3, 4 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).

To change the unit address:

1. Press MENU key to access 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 Sys Conﬁg; press ENTER key.

4. Press UP or DOWN keys to scroll to Unit Setup (A1) screen.

5. Press ENTER key to scroll to Controller Address (see Figure 10).

6. Press UP or DOWN keys to change the address to a value between 1 and 4.

7. Press ENTER key to save

FIGURE 10

Changing Unit Address

6. Press UP or DOWN key to change value to ON. The run test will begin and the screen will change to

Run Test Summary.

FIGURE 11

Executing Run Test

7. Press UP or DOWN key to scroll between Run Test Summary, Motors & Sensors and A/C Circuit

screens.

NOTE:

If the Run Test screens have been exited out of, they can be returned to by navigating to Run Test (A10) as provided in the instructions above, pressing ENTER key to scroll to Return to Screens, pressing UP or DOWN key to change value to YES and pressing ENTER key.

Executing a Run Test

This unit has the ability to perform a run test that will operate all available unit functions in order to quickly determine unit operation. Some unit parameters are adjustable.

To execute a run test:

1. Press MENU key to access 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 Sys Conﬁg; press ENTER key.

4. Press UP or DOWN keys to scroll to Run Test (A10) screen.

5. Press ENTER key to scroll to Run Test Enable parameter (see Figure 11).

The Run Test Summary screen (Figure 12) contains a readout of the test that is currently taking place, and the Task the technician should be completing to verify operation.

FIGURE 12

Run Test Summary

The Motors & Sensors screen (Figure 13) displays output and estimated positional values for unit motors and actuators, and also temperature and humidity sensor values.

Manual 2100-670I Page 10 of 47

Page 11

FIGURE 13

Run Test: Motors & Sensors

The A/C Circuit screen (Figure 14) displays all unit inputs, outputs and calculations associated with the A/C circuit operation.

FIGURE 14

Run Test: A/C Circuit

7. Press UP or DOWN key to change value to YES; press ENTER key.

8. System will restart with default values.

FIGURE 15

Restoring Factory Default Settings

Run Test Parameter Descriptions

Econ Stage Time: Amount of time (in seconds) allowed for damper blade movement in each direction.

Cool Stage Time: Amount of time (in seconds) allowed for each stage of cooling.

Heat Stage Time: Amount of time (in seconds) allowed for heating stage.

Reset to Factory Defaults

To reset to factory default settings:

1. Press MENU key to go to the Main Menu screen.

2. Use UP or DOWN keys and ENTER key to enter ENGINEER password 9254.

3. Press UP or DOWN keys to scroll to Settings; press ENTER key.

4. Press UP or DOWN keys to scroll to Initialization; press ENTER key.

5. Press UP or DOWN keys to scroll to the Default Installation screen; press ENTER key.

6. Press ENTER key to scroll to Reset to Factory Defaults (see Figure 15).

Manual 2100-670I Page 11 of 47

Page 12

OPERATION

NOTE: Screenshots shown in this manual reﬂect

default settings (when applicable).

Unit On/Off

The wall-mount unit can be turned on and off from the TEC-EYE. Turning the unit off with the following instructions will disable all unit operation.

To turn the unit on or off:

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 On/Off; press ENTER key.

4. Press UP or DOWN keys to change value from On to Off or from Off to On.

5. Press ESCAPE key several times to return to Main Menu screen.

The wall-mount unit may also be turned off by certain alarms such as the smoke alarm input on the wallmount unit board or the return air temperature sensor failure when not connected to the LV1000.

Alarm Adjustment

Acknowledging Alarms

Alarm conditions activate a red LED indicator that backlights the ALARM function key. As an option, an alarm condition may also be enunciated by an audible alarm signal. An alarm is acknowledged by pressing the ALARM key. This calls up alarm display screen(s) that provide a text message detailing the alarm condition(s).

Clearing Alarms

Alarms can only be cleared after the alarm condition has been corrected. To clear a single alarm, press and hold the ALARM key for 3 seconds while viewing a specific alarm screen. To clear all alarms, navigate to the screen at the end of the alarm list (shown in Figure

16) and press and hold the ALARM key for 3 seconds.

FIGURE 16

Clearing All Alarms

Clearing Alarm Logs and Counters

To clear the alarm log and alarm counters:

1. Press MENU key to go to the Main Menu screen.

2. Use UP or DOWN keys and ENTER key to enter USER password 2000.

3. Press UP or DOWN keys to scroll to Settings; press ENTER key.

4. Press UP or DOWN keys to scroll to Initialization; press ENTER key. (Alarm Management screen will be displayed.)

5. Press ENTER key to scroll to Clear Alarm Logs? (see Figure 17).

6. Press UP or DOWN key to change value to YES; press ENTER key.

7. Press ENTER key to scroll to Clear Counters.

8. Press UP or DOWN key to value to YES; press ENTER key.

FIGURE 17

Clearing Alarm Logs and Counters

Exporting Alarm Logs

See latest version of Supplemental Instructions manual 7960-815 for information on exporting alarm logs.

Exporting 7 Day Logs

See latest version of Supplemental Instructions manual 7960-816 for information on exporting 7 day I/O logs.

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 factory-installed return air sensor in each wall-mount unit. In stand alone mode, no auxiliary temperature measurement devices are required for operation. The wall-mount unit automatically uses a continuous blower setting to circulate room air into the return air inlet and

Manual 2100-670I Page 12 of 47

Page 13

uses the return air temperature sensor to control room temperature.

To change default setpoints, refer to Setpoints on page 8.

During installation, the ability to run in stand alone mode allows deactivation of one of the existing, older wall-mount units, while keeping the shelter cool with the other unit still operating. Once the ﬁrst of the Bard FUSION-TEC HR Series wall-mount units is installed and powered on, it will operate in orphan mode— keeping the climate inside the shelter stable and the installers comfortable while the remainder of the older equipment is removed and the remaining Bard FUSION-TEC HR Series wall-mount units and LV1000 controller are installed.

Additionally, should any or all of the FUSION-TEC HR Series 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 be made.

Temperature/Humidity Control

Temperature/Humidity Control Components

Return Air Temperature Sensor

The unit is equipped with a return air temperature sensor to monitor the space temperature when the unit is in stand alone mode. The return air sensor is located in the upper part of the return opening in such a way that it is exposed to the entering airstream. An alarm signal will be sent to the LV controller if the return air temperature sensor is disconnected. The temperature is measured with a 10k ohm NTC thermistor.

This sensor can be veriﬁed and adjusted by:

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.

4. Press UP or DOWN keys to scroll to Return Air Sensor (C5); press ENTER key.

5. Verify the measurement displayed on screen is accurate (see Figure 18).

6. If the measurement needs to be adjusted, apply an offset value by pressing ENTER to scroll to Offset.

7. Press UP or DOWN keys to adjust the offset.

8. The update will not take effect until the cursor is moved out of the Offset parameter.

9. Once adjusted, press the ESCAPE key several times to return to Main Menu screen.

FIGURE 18

Adjusting Return Air Sensor

Return Air Temperature Alarm

When the return air temperature sensor value is out of range (-41.0 to 303.0°F), the controller will generate a sensor failure alarm to indicate the sensor is not working properly.

This alarm is ﬁxed and cannot be adjusted.

Temperature/Humidity Control Operation

The unit utilizes a PID control loop for space control. This control will compare the space temperature to the space setpoint. Based on how far away from the setpoint the temperature is, the loop will output a cooling or heating capacity number between 0 and 100%. The unit will then take all of the available cooling methods and distribute them evenly across the 0-100% range. The stages are then brought on as the heating or cooling capacity reaches the percentage that brings the stages on or off. There are separate setpoints for cooling and heating.

To change or view the unit setpoint:

1. From the Status screen, press UP or DOWN key until Quick Menu displays Setpoints icon ( ). Press ENTER key.

2. Press ENTER key to scroll to Cool Setpoint or Heat Setpoint (see Figure 4 on page 8).

3. Press UP or DOWN keys to change the value to desired heating and/or cooling setpoint.

Cooling

The unit is equipped with 1 stage of freecooling and 2 stages of mechanical cooling (compressor and solenoid) for a total of 3 cooling stages (see Figure 19 on page

14).

Cooling w/No Economizer

The unit is equipped with 1 stage of freecooling and 2 stages of mechanical cooling (compressor and solenoid). However, the outdoor conditions are not favorable for economizer operation so there are a total of 2 cooling stages (see Figure 20 on page 14).

Manual 2100-670I Page 13 of 47

Page 14

Freecooling

Compressor Stage 1

Compressor Stage 2

FIGURE 19

Cooling w/Economizer

-10% 0%

10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

Off

Deadband On

110% 120%

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% 0%

10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

Off

Deadband On

Deadband(sometimes called a neutral zone or dead zone) is an interval of a signal domain or band where no action occurs

110% 120%

Electric Heat

-10% 10% 30% 50% 70% 90% 110%

Deadband(sometimes called a neutral zone or dead zone) is an interval of a signal domain or band where no action occurs

Manual 2100-670I Page 14 of 47

Off

FIGURE 21

Heating

Deadband On

Page 15

Heating

The unit is equipped with 1 stage of electric heat (see Figure 21).

Staging

The unit will stage the cooling components based on the cooling demand referenced in the temperature control. The unit will stage the economizer on ﬁrst if the indoor and outdoor conditions are favorable. The compressor stage 1 will be enabled next as the demand increases. Finally, the compressor stage 2 will be enabled as the demand continues to increase.

The unit is only equipped with one stage of heat and will turn on based on the heating demand.

To view unit stages:

1. From the Status screen, press UP or DOWN key until Quick Menu displays Unit Information icon

( ). Press ENTER key.

2. The cooling and heating demand are visible on this screen. The unit stages will display here when active as FC, CL1, CL2 or H1 (see Figure 22).

FIGURE 22

Viewing Unit Stages

Electronic Expansion Valve (EEV)

EEV Components

Electronic Expansion Valve

The electronic expansion valve is a stepper motor that is controlled with a step output from the controller. The valve is capable of 480 steps represented by a 0-100% signal on the controller. The motor drives a needle valve that regulates the ﬂow of refrigerant.

EEV Instructions for Vacuum, Reclaim, Charge Unit

The electronic expansion valve moves to the 20% open position when the unit is not actively cooling. The valve may need to be manually positioned for service or troubleshooting. The valve can be positioned by using a menu override.

To manually override the valve:

NOTE: The unit must be off to perform this 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.

3. Press UP or DOWN keys to scroll to I/O Conﬁg; press ENTER key.

4. Press UP or DOWN keys to scroll to TEEV Service (C16); press ENTER key.

Press ENTER key to scroll to Enable (see Figure 23).

Press UP or DOWN key to change Disable to Enable.

7. Press ENTER key to scroll to Position.

8. Press UP or DOWN keys to adjust to the desired value.

9. Press ENTER key to save.

Dehumidiﬁcation

The unit uses a dehumidiﬁcation sequence that does

not require the electric heat to run at the same time as the compressor. Instead, the unit will turn on the compressor to cool down to the heating setpoint. Once the lower setpoint has been reached, the unit will heat the space back up to the upper setpoint. This cycle continues until the humidity level in the shelter reaches an acceptable level. At this point, the unit will revert back to normal operation. The economizer will also be disabled while the unit is in the dehumidiﬁcation mode.

NOTE: This feature is dependent upon the LV1000

indoor humidity sensors and a command from the LV to enter dehumidiﬁcation mode. See the latest revision of LV1000 Service Instructions 2100-673 for adjustment of the dehumidiﬁcation setpoint and differentials.

FIGURE 23

Overriding EEV Output

The valve can also be opened or closed using the EEV service tool (Bard Part # 2151-021). This magnetic EEV service tool (shown in Figure 24 on page 16) is used to manually open the EEV. To do this, remove the EEV stator coil (red color with retaining nut on top), slide the magnetic tool over the shaft where the stator was removed and turn in a clockwise direction to open the valve to the full open position (directional arrows

Manual 2100-670I Page 15 of 47

Page 16

FIGURE 24

Electronic Expansion Valve (EEV) and Service Tool

are provided on the tool). Opening the valve to the full open position will aid in the refrigerant reclamation and evacuation processes.

With the stator removed, the resistance should be 40 ohms +/- 10%. There are two sets of three wires that will have this resistance.

Reapply the EEV stator coil and retaining nut. Upon powering the unit back up, the control board will automatically drive the EEV back to the fully shut position, and then back to the 20% open position prior to starting the compressor back up. Once the compressor starts, the control board will again modulate the EEV position to control the system superheat.

System Pressures

To view system pressure and temperatures during this process:

1. From the Status screen, press UP or DOWN key until Quick Menu displays Information icon

( ). Press ENTER key.

2. Press UP or DOWN keys to scroll to EEV 1 Circuit and EVD 1 Compressor screens.

3. Reference the Pressures and Temperatures on EVD 1 Compressor and the Superheat and Subcooling on EEV 1 Circuit.

Suction Pressure Transducer

The unit has a pressure transducer installed on the suction line between the evaporator coil and compressor. The transducer is used for system monitoring of suction system pressures. The sensor is used with the suction temperature sensor to provide a real time superheat calculation that determines the EEV position.

This sensor can be veriﬁed and adjusted by:

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.

4. Press UP or DOWN keys to scroll to Suction Pr Sensor (C11); press ENTER key.

5. Verify the measurement displayed on screen is accurate (see Figure 25).

6. If the measurement needs to be adjusted, apply an offset value by pressing ENTER to scroll to Offset.

7. Press UP or DOWN keys to adjust the offset.

8. The update will not take effect until the cursor is moved out of the Offset parameter.

9. Once adjusted, press the ESCAPE key several times to return to Main Menu screen.

FIGURE 25

Adjusting Suction Sensor/Transducer

Pressure Values

Manual 2100-670I Page 16 of 47

Page 17

Troubleshooting the Suction Pressure Transducer

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).

FIGURE 26

Voltage to Pressure: Suction Pressure Transducer

Suction Pressure Alarm

When the suction pressure transducer value is out of range (0-250 PSIG), the controller will generate a sensor failure alarm to indicate the sensor is not working properly.

This alarm cannot be adjusted.

Suction Temperature Sensor

The suction temperature sensor is used to calculate superheat. The EEV uses this value to control the EEV. The temperature is measured with a 10k ohm NTC thermistor.

The suction temperature sensor measurement can be veriﬁed and adjusted by:

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.

4. Press UP or DOWN keys to scroll to Suct Temp Sensor (C9); press ENTER key.

5. Verify the measurement displayed on screen is accurate (see Figure 27).

6. If the measurement needs to be adjusted, apply an offset value by pressing ENTER to scroll to Offset.

7. Press UP or DOWN keys to adjust the offset.

8. The update will not take effect until the cursor is moved out of the Offset parameter.

FIGURE 27

Adjusting Suction Temperature Sensor Values

Suction Temperature Alarm

When the suction temperature sensor value is out of range (-41.0 to 303.0°F), the controller will generate a sensor failure alarm to indicate the sensor is not working properly.

This alarm cannot be adjusted.

Evaporator Freeze Condition Alarm

The FUSION-TEC Freeze alarm (Evaporator Coil Freeze Protection) uses the suction temperature sensor to alarm and manage operation when conditions are favorable for an evaporator coil freeze condition. Whenever the compressor is running, the system will constantly monitor the suction line temperature. If the suction line temperature falls below the freeze setpoint (33°F factory default) for a period of time exceeding freeze alarm delay time (180 seconds factory default), the system will alarm a freeze condition. Once a freeze condition is triggered, the system will stop the compressor operation and increase the blower speed to 80% in order to rapidly warm and thaw the evaporator coil. After a period of 5 minutes has elapsed, normal operation will continue.

To adjust the freeze setpoint and/or alarm delay time:

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 System Conﬁg; press ENTER key.

4. Press UP or DOWN keys to scroll to Alarm Setup (A7); press ENTER key.

5. Press ENTER key to scroll to Setpoint (see Figure 28 on page 18).

6. Press UP or DOWN keys to change to the desired value.

7. Press ENTER key to save the value/scroll to Delay.

8. Press UP or DOWN keys to change to the desired Delay value.

9. Press ENTER key to save the value.

Manual 2100-670I Page 17 of 47

Page 18

FIGURE 28

Adjusting Freeze Setpoint and Alarm Delay

EEV Operation

EEV Superheat Control

The electronic expansion valve (EEV) will open or close to maintain 10° of superheat while the compressor is running. When the compressor is not running, the valve will close.

Low superheat protection will be active once the superheat value is at or below 5°F. At this point, the control will aggressively close the valve so that superheat is maintained.

Additional EEV Alarms

Low Superheat Alarm

This alarm will become active when the calculated superheat goes below 5°F. This alarm will clear itself when the condition is no longer present.

This alarm cannot be adjusted.

Indoor Airflow

Indoor Airﬂow Components

Blower

The unit is equipped with a blower that is driven by an electronically commutated motor (ECM). This blower is controlled by a 0-10v signal provided from the controller. This 0-10v signal is converted to a PWM signal with an adapter. The blowers on both the HR36AP* and HR58AP* models use a 10" diameter wheel. The HR36AP* operates between 250-850 rpm while the HR58AP* operates between 250-1400 rpm.

The blower output can be put into an override mode for 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.

3. Press UP or DOWN keys to scroll to I/O Conﬁg; press ENTER key.

4. Press UP or DOWN keys to scroll to Blower Fan (C13); press ENTER key.

5. Press ENTER key to scroll to Blower OV Speed (see Figure 29).

6. Press UP or DOWN keys to adjust the speed to the desired output (see Table 3A or 3B).

7. Press ENTER key to scroll to Override.

8. Press UP or DOWN key to change Disabled to Enabled.

9. Press ENTER key to save.

FIGURE 29

Putting Blower Output into Override Mode

TABLE 3A

HR36AP* Blower Speeds

Mode

Freezestat Active 94.0 9.4 v 1500

High Sensible

Full Load Cooling

High Sensible

Part Load Cooling

Standard Full

Load Cooling

Standard Part

Load Cooling

Economizer Standard Economizer High S/T

Heating 63.0 6.3 v 1200

Dehumidiﬁcation

Mode

Speed

Percentage

94.0 9.4 v 1500

54.0 5.4 v 1100

63.0 6.3 v 1200

43.0 4.3 v 950

90.0

63.0

19.0 1.9 v 470

Controller

Output Volts

9.0 v

6.3 v

CFM

1450 1200

Manual 2100-670I Page 18 of 47

Page 19

TABLE 3B

HR58AP* Blower Speeds

Mode

Freezestat Active 80.0 8.0 v 2260

High Sensible Full

Load Cooling

High Sensible Part

Load Cooling

Standard Full Load

Cooling

Standard Part Load

Cooling

Economizer Standard Economizer High S/T

Heating 35.0 3.5 v 1335

Speed

Percentage

75.0 7.5 v 2180

50.0 5.0 v 1705

55.0 5.5 v 1830

35.0 3.5 v 1335

45.0

75.0

Controller

Output Volts

4.5 v

7.5 v

CFM

1600 1950

Blower Status Switch

The unit is equipped with a differential pressure airﬂow switch to monitor the blower (see Figure 30). If the blower is turned on and the switch doesn't open to indicate there is differential pressure between the inlet and outlet of the blower, an alarm will be generated. For switch settings, see Figure 30.

FIGURE 30

Dirty Filter Switch and Blower Status Switch

Dehumidiﬁcation

Mode

35.0 3.5 v 1335

TABLE 4

Rated Airﬂow

Nominal Rated CFM

High Low

HR36AP* 1200 950 0.00

HR58AP* 1800 1400 0.10

Nominal Rated ESP

TABLE 5

Indoor Blower Performance

Speed High Low

ESP

(Inch H

HR36AP* 0.00

HR58AP* 0.10

Dry

Coil

1260 1200 995 950

1885 1800 1470 1400

Wet Coil

Dry

Coil

TABLE 6

Maximum ESP of Operation

Electric Heat Only

Wet

Coil

Differential airﬂow status can be viewed by:

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.

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

31).

FIGURE 31

Verifying Differential Airﬂow Status

Model Static Pressure*

-A0Z

-A05

-B0Z

-B06

* Unit is rated for free blow non-ducted

operation with SGR-5W Supply Grille and RGR-5W Return Grille.

.00" .00"

Manual 2100-670I Page 19 of 47

Page 20

Blower Status Alarm

If the blower is commanded on and the fan status switch (differential pressure) has not indicated the fan is running within 45 seconds, the system will generate an alarm.

Disabling the blower status switch in I/O Conﬁg disables this alarm.

This alarm is just a notiﬁcation and will clear itself when the conditions are no longer present.

To adjust the 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 USER password 2000.

3. Press UP or DOWN keys to scroll to System Conﬁg; press ENTER key.

4. Press UP or DOWN keys to scroll to Alarm Setup (A8); press ENTER key.

5. Press ENTER key to scroll to Air Flow Alarm Del (see Figure 32).

6. Press UP or DOWN keys to change to the desired value.

7. Press ENTER key to save the value.

FIGURE 32

Adjusting Air Flow Alarm Delay

Filters

The unit is equipped with two (2) 20" x 30" x 2" MERV 8 ﬁlters. The ﬁlters slide into position making them easy to service. The ﬁlters can be serviced from the outside by removing either the right or left ﬁlter access panel.

Dirty Filter Switch

These units are equipped with a differential pressure switch to indicate when the ﬁlter(s) needs to be replaced (see Figure 30). The dirty ﬁlter switch measures the pressure difference across the ﬁlter through silicone tubing routed to the blower and vent areas of the unit.

The switch circuit consists of a normally open ﬁlter pressure switch. The switch will open when the pressure differential goes above the setting indicated

on the dial. When the pressure difference returns below the setting on the dial, the switch will close.

Adjustment of dirty ﬁlter switch may be necessary to ensure proper operation. See Table 7 and Figure 33 to aid in setting the ﬁlter switch to operate at different percentages of ﬁlter blockage.

Dirty Filter Alarm

The wall-mount unit is equipped with a differential pressure switch input to the controller (see Figure 30). When the switch indicates a dirty ﬁlter, the controller will generate an alarm. Once the condition is no longer present, the alarm will automatically clear. Additionally, an indicator light will be turned on with the alarm and turned off when the alarm clears.

Disabling the dirty ﬁlter switch in I/O Conﬁg disables this alarm.

The threshold of this alarm is adjusted by changing the settings on the switch (see Table 7).

Filter Indicator Light

These units are equipped with a 24v indicator light mounted on side of unit that displays the current status of the ﬁlter (as shown in Figure 33). When the light is on, the ﬁlter needs to be replaced. Once the ﬁlter(s) has been changed, the indicator light will turn off.

Freezestat

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

64.5°F. This switch was used in units running software version 1.0.4 and earlier and has been removed. The evaporator coil freeze protection alarm is now calculated using system temperatures (see Evaporator Freeze Condition Alarm on page 17).

Indoor Airﬂow Operation

Blower Speed Control

The blower is capable of changing speeds to best match the requirements of the system depending on which mode the system is in (see Table 3A or 3B on page 19).

The unit will automatically switch to the required speed for each mode. High sensible mode and dehumidiﬁcation mode are both communicated separately from the LV. For more information on the high sensible command from LV, please see LV1000 Service Instructions 2100-673.

Manual 2100-670I Page 20 of 47

Page 21

TABLE 7

AIRSTREAM BEFORE FILTER

TUBE LOCATED IN

COVER

REMOVE COVER

SCREW TO

TUBE LOCATED IN

AIRSTREAM AFTER FILTER

ADJUSTMENT

INDICATOR ARROW

ADJUSTMENT

KNOB

FILTER

LIGHT

Filter Switch Pressure Settings

Unit Filter Blockage % 0% 10% 20% 30% 40% 50% 60% 70%

HR36AP*

(Default) High S/T

HR36AP*

Standard Airﬂow

HR58AP*

(Default) High S/T

HR58AP*

Standard Airﬂow

Switch Static Setting 0.12 0.12 0.12 0.20 0.20 0.35 0.35 0.40

Evaporator Airﬂow % 100% 99.3% 99.4% 98.7% 96.5% 92.1% 91.3% 87.9%

Switch Static Setting 0.12 0.12 0.12 0.12 0.20 0.20 0.20 0.30

Evaporator Airﬂow % 100% 99.3% 99.4% 98.8% 97.3% 91.5% 89.8% 88.3%

Switch Static Setting 0.40 0.50 0.60 0.70 0.75 0.80 0.90 1.00

Evaporator Airﬂow % 100% 98.7% 98.1% 97.5% 91.7% 81.3% 79.1% 78.6%

Switch Static Setting 0.30 0.35 0.40 0.45 0.50 0.65 0.70 0.90

Evaporator Airﬂow % 100% 99.8% 99% 98.5% 96.8% 89.9% 84% 82.2%

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.

FIGURE 33

Dirty Filter Switch and Filter Indicator Light

MIS-3901

Manual 2100-670I Page 21 of 47

Page 22

Additional Indoor Airﬂow Alarms

Supply Air Temperature Alarm

When the supply air temperature sensor value is out of range (-41.0 to 303.0°F), the controller will generate a sensor failure alarm to indicate the sensor is not working properly.

This alarm is ﬁxed and cannot be adjusted.

Condenser Fan

Condenser Fan Components

Condenser Fan

The unit is equipped with a condenser fan that is driven by an electronically commutated motor (ECM). This fan is controlled by a 0-10vdc signal provided from the controller. The fan operates between 100-1200 rpm.

To view the output of the condenser fan:

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.

4. Press UP or DOWN keys to scroll to Condenser Fan (C15); press ENTER key.

5. Reference Fan Speed parameter for the current output to the condenser fan (see Figure 34).

FIGURE 34

Verifying Condenser Fan Output

If required, the condenser fan output can be manually set for 5 minutes for troubleshooting purposes.

While looking at Condenser Fan (C15) screen:

1. Press ENTER key to scroll to Fan OV Speed (see Figure 36).

2. Press UP or DOWN keys to change the value to the desired override speed.

3. Press ENTER key to save the value and move cursor to the Override parameter.

4. Press UP or DOWN keys to change the value from Disabled to Enabled.

5. The fan should now run at the selected speed. The output can be veriﬁed by again referencing the Fan Speed parameter.

The override will last for 5 minutes or until the Override parameter is set to Disabled again.

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, see Figure 35 for proper clearance adjustment.

FIGURE 35

Fan Blade Setting

.75"

(from the closest point on the fan blade)

Liquid Line Pressure Transducer

The unit has a pressure transducer installed on the 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. The sensor is also used to adapt the condenser fan speed for high and low ambient conditions.

The liquid pressure sensor input can be veriﬁed and adjusted by:

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.

4. Press UP or DOWN keys to scroll to Liquid Pr Sensor (C10); press ENTER key.

5. Verify the measurement displayed on screen is accurate (see Figure 36).

6. If the measurement needs to be adjusted, apply an offset value by pressing the ENTER key to scroll to Offset.

7. Press UP or DOWN keys to adjust the offset. The update will not take effect until the cursor is moved out of the offset parameter.

Manual 2100-670I Page 22 of 47

Page 23

8. Once adjusted, the ESCAPE key several times to return to Main Menu screen.

FIGURE 36

Adjusting Discharge/Liquid Transducer

Pressure Values

Troubleshooting the Discharge/Liquid Pressure Transducer

0-650 psig 0-5vdc 4v/650 psig = .00615 volts per 1 psig

Example: 325 psig x .00615 + .5 v = 2.5 volts

Formula for Tech: Measured Pressure x .00615 + Sensor Offset = Expected Transducer Signal Voltage (see Figure 37).

The liquid temperature sensor can be veriﬁed and adjusted by:

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.

4. Press UP or DOWN keys to scroll to Liquid Temp Sensor (C3); press ENTER key.

5. Reference the Value to verify the temperature (see Figure 38).

6. If an offset needs to be applied, press ENTER key to scroll to Offset.

7. Press UP or DOWN keys to change the offset to desired value.

8. Press ENTER key to save.

9. Press ESCAPE key several times to return to Main Menu screen.

FIGURE 38

Adjusting Discharge/Liquid Temperature Input

FIGURE 37

Voltage to Pressure:

Discharge/Liquid Pressure Transducer

Discharge/Liquid Pressure Transducer Alarm

When the discharge pressure transducer value is out of range (0-650 PSIG), the controller will generate a sensor failure alarm to indicate the transducer is not working properly.

This alarm is ﬁxed and cannot be adjusted.

Liquid Temperature Sensor

The unit is equipped with a liquid line temperature sensor to monitor the temperature of the liquid refrigerant leaving the condenser and entering the EEV. The temperature is measured with a 10k ohm NTC thermistor.

Condenser Fan Operation

Condenser Fan Speed Control

Mechanical Cooling Only

The condenser fan motor speed is selected based on outdoor air temperature. Above 80°F, the fan speed will be set to a nominal output speed. Below 80°F, the condenser fan speed will operate at reduced speeds based on outdoor air temperatures until the slowest fan speed is reached. This operation allows for more stable head pressures at lower ambient conditions, which also allows for increased unit efﬁciency. See Figure 39 on page 24 for more detail.

NOTE: If the outdoor temperature sensor fails, the

condenser fan speed will be set to the nominal operating speed.

Optimized Cooling (Concurrent Economizer and Mechanical Cooling)

During optimized cooling mode, the condenser fan motor speed will be set to the normal operating speed and will not change based on outdoor air conditions. If

Manual 2100-670I Page 23 of 47

Page 24

FIGURE 39

Condenser Fan Speed Control

conditions become unfavorable for optimized cooling, the system will change to mechanical cooling only. When this occurs, the fan speed will remain at normal speed for 2 minutes, allowing for the damper blade to fully close. After the 2-minute period, the condenser fan speed may be reduced to optimize head pressures. During optimized cooling, all fan speed control will be handled by the low ambient controls and high pressure controls if system pressures were to get out of range.

High Pressure Control

Condenser Fan Speed

When the liquid pressure reaches 550 PSI, the condenser fan will speed up, moving as much air as possible in an attempt to reduce system pressures. The condenser fan will operate at increased speed until the liquid pressure reaches 450 PSI. At this point, the fan will return to normal operating speed.

Second Stage Drop Out

If the liquid pressure reaches 620 PSI, the second stage of cooling will be disabled for 2 minutes to reduce the required condenser airﬂow. After 2 minutes, if the pressure is less than the pressure cutout, it will resume stage 2 operation.

Low Ambient Control

At low ambient outdoor air temperatures, the fan motor will cycle as a means of controlling the system's head pressure to protect the system from evaporator coil freeze conditions. The process for this system is as follows: If the liquid pressure falls below 250 PSI, the condenser fan will turn off. The fan will remain off while the compressor remains running, allowing the head pressure to build up. Once the liquid pressure reaches 350 PSI, the fan will then turn back on at the appropriate speed. At lower ambient outdoor temperatures, this may cycle regularly as normal operation. In some cases, in higher wind prone areas, the condenser fan may stay off for prolonged durations due to low liquid pressures.

Additional Condenser Fan Alarms

Dirty Condenser Coil Alarm

The unit will continuously monitor system conditions to determine if the condenser coil is dirty or blocked. If the system monitors three consecutive cooling cycles that indicate a dirty condenser coil, an alarm will be generated. This alarm is a notiﬁcation and will automatically reset when conditions are no longer present. The end user has the ability to adjust how

Manual 2100-670I Page 24 of 47

Page 25

dirty the coil gets before an alarm is generated and how many consecutive cycles before the alarm is triggered.

To change these settings:

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 Adv System Conﬁg; press ENTER key.

4. Press UP or DOWN keys to scroll to Dirty Cond Alarm (B3); press ENTER key.

5. Press ENTER key to scroll to Alarm Threshold (see Figure 40).

6. Press UP or DOWN keys to adjust the % restriction to desired level.

7. Press ENTER key to save value and move the cursor to Trips before alarm.

8. Press UP or DOWN keys to change the Trips before alarm to the desired value.

9. Press ENTER key to save.

10. Press ESCAPE key several times to return to Main Menu screen.

FIGURE 40

Adjusting Dirty Condenser Coil Alarm Settings

Compressor

Compressor Components

Compressor

Three Phase Scroll Compressor Start Up Information

Scroll compressors, like several other types of compressors, will only compress in one rotational direction. Direction of rotation is not an issue with single phase compressors since they will always start and run in the proper direction.

However, three phase compressors will rotate in either direction depending upon phasing of the power. Since there is a 50-50 chance of connecting power in such a way as to cause rotation in the reverse direction, veriﬁcation of proper rotation must be made. Veriﬁcation of proper rotation direction is made by observing that suction pressure drops and discharge

pressure rises when the compressor is energized. Reverse rotation also results in an elevated sound level over that with correct rotation, as well as substantially reduced current draw compared to tabulated values.

Veriﬁcation of proper rotation must be made at the time the equipment is put into service. If improper rotation is corrected at this time, there will be no negative impact on the durability of the compressor. However, reverse operation for over 1 hour may have a negative impact on the bearing due to oil pump out.

NOTE: If compressor is allowed to run in reverse

rotation for an extended period of time, the compressor’s internal protector will trip.

All three phase compressors are wired identically internally. As a result, once the correct phasing is determined for a speciﬁc system or installation, connecting properly phased power leads to the same Fusite terminal should maintain proper rotation direction.

The direction of rotation of the compressor may be changed by reversing any two line connections to the wall-mount unit.

Compressor Control Module (CCM)

Delay-on-Make Timer Short Cycle Protection/Delay-on-Break Test Mode High Pressure Detection Brownout Protection with Adjustment

The LPC terminals are jumpered in this application. Instead, the low pressure transducer is used for low pressure monitoring.

Delay-on-Make Timer

In the event of power loss, a delay-on-make timer is included to be able to delay startup of the compressor. This is desired when more than one unit is on a structure so that all of the units do not start at the same time which could happen after a power loss or building shutdown. The delay-on-make time period is 2 minutes plus 10% of the delay-on-break time period. To ensure that all of the units do not start at the same time, adjust the delay-on-break timer on each unit to a slightly different delay time.

Short Cycle Protection/Delay-on-Break

An anti-short cycle timer is included to prevent short cycling the compressor. This is adjustable from 30 seconds to 5 minutes via the adjustment knob (see Figure 41 on page 26). Once a compressor call is lost, the time period must expire before a new call will be initiated.

10% of this time is also considered on the delay-onmake timer (see above).

High Pressure Detection

High pressure switch monitoring allows for a lockout condition in a situation where the switch is open. If the high pressure switch opens, the CCM will de-energize

Manual 2100-670I Page 25 of 47

Page 26

FIGURE 41

8201-164 Compressor Control Module

High Pressure Switch Compressor Contactor Output

18-30 VAC Input

Y Input from Thermostat

and High Pressure Switch

Troubleshooting Light

Jumper

the compressor. If the switch closes, it will then restart the compressor after the delay-on-break setting has expired on the device. If the switch trips again during the same Y call, the compressor will be de-energized. The ALR terminal will be energized, signaling the unit control board that a high pressure event has occurred (see Refrigerant High Pressure Alarm on page 27).

Test Mode

By rapidly rotating the potentiometer (POT) clockwise (see Figure 41), all timing functions will be removed for testing.

The conditions needed for the unit to enter test mode are as follows: POT must start at a time less than or equal to the 40 second mark. The POT must then be rapidly rotated to a position greater than or equal to the 280 second mark in less than ¼ second. Normal operation will resume after power is reset or after the unit has been in test mode for at least 5 minutes.

Brownout Protection with Adjustment

Brownout protection may be necessary if the utility power or generator power has inadequate power to prevent the voltage from dropping when the compressor

Alarm Output

Common

Delay-on-Break Time Adjustment Potentiometer

Brownout Ignore Time DIP Switches*

* Turn on only one switch for that speciﬁc ignore time setting

starts. This is rare but can happen if the generator is undersized at the site or if the site is in a remote location far from the main power grid. Under normal circumstances, allowing the brownout to be ignored for a time period should not be needed. The 8201-164 is shipped with all the DIP switches in the 'off' or 'do not ignore' position (see Figure 41).

If ignoring the brownout is needed because of the above conditions, three preset timers can be set by DIP switches in order to delay signaling a power brownout for a speciﬁc length of time after compressor contactor is energized. This allows the compressor a time period to start even if the voltage has dropped and allows the voltage to recover. This delay only happens when the CC terminal energizes. The delay can be set to 500 milliseconds (A DIP switch), 1000 milliseconds (B DIP switch) or 1500 milliseconds (C DIP switch); time is not cumulative—only the longest setting will apply. If the voltage recovers during the brownout time period, the compressor will start.

If a brownout condition is detected by the 8201-164, the troubleshooting light will ﬂash blue. The light will continue to ﬂash until the cooling call is satisﬁed or

Manual 2100-670I Page 26 of 47

Page 27

power is removed from the Y terminal. This condition does not prevent operation, it only indicates that a brownout condition was present at some point during the cooling call. If a brownout condition is detected, CC will be de-energized and will retry after the delayon-make timer is satisﬁed; this process will continue until call is satisﬁed.

If user chooses the 'do not ignore' position when the site has inadequate utility or generator power, this could lead to the compressor never starting. The control will

A common scenario and one that has been seen in the ﬁeld is when a unit or units switches from utility power to generator power. With slower transfer switches, the time delay between the utility power and generator power didn’t cause a problem. The units lost power, shut off and came back on line normally. With the introduction of almost instantaneous transfer switches, the millisecond long power glitch can be enough that the compressor will start to run backwards. In this scenario, the CCM will catch this and restart the units normally.

High Pressure Safety Switch

All units have a high pressure switch as a safety device. This device will open when pressure in the system reaches 650 PSIG. The sensor is directly connected to the dedicated compressor control module (see High

Pressure Detection on page 25).

Refrigerant High Pressure Alarm

When the wall-mount unit receives a signal from the compressor control module (CCM) indicating a high pressure event, the wall-mount unit will generate an alarm. Upon receiving the alarm, the wall-mount unit will remove the “Y” call from the CCM, resetting the status of the CCM. The alarm will stay present on the wall-mount unit until manually cleared with TEC-EYE hand-held diagnostic tool.

In addition to the CCM, the discharge pressure transducer is used to prevent a high pressure event. When the discharge pressure is above the discharge pressure alarm setpoint (set 30 PSI below high pressure switch, which is 650 PSI), the system will disable stage 2 of mechanical cooling.

Phase Monitor

Used only on three phase equipment, the phase monitor is a compressor protection device that will prohibit operation of the compressor if the device senses a possible reverse-rotation situation due to incorrect phasing. On a call for compressor (and only compressor), the device will check incoming phase, check for severe voltage imbalance and check for proper frequency. Under nominal conditions, a green LED light will show on the face of the monitor. If there is improper phasing, voltage imbalance or frequency deviation, the device will show a red LED light and prohibit compressor operation.

see the brownout immediately and not start.

If a fault condition occurs, reverse two of the supply leads to the unit. Do not reverse any of the unit factory

wires as damage may occur.

Compressor Operation

The compressor will be enabled when the unit (in stand alone mode) or LV provide a cooling stage 1 call. The compressor call from the controller has several delays that may affect the start or stop time of the compressor in regards to the cooling demand. The compressor has a minimum on time of 120 seconds to prevent short cycling the compressor. The compressor also has a minimum off time of 120 seconds to prevent start ups before the pressure in the refrigeration system equalizes. When the second stage is engaged, it also has a minimum run time of 120 seconds to allow the system to stabilize before returning to single stage or shutting down.

These delays can be changed by:

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 Adv System Conﬁg; press ENTER key.

4. Press UP or DOWN keys to scroll to Unit Conﬁg (B2); press ENTER key.

5. Press ENTER key to scroll to Min On, Min Off, Min On Same, Unloader Del or Address Delay (see Figure 42).

6. Press UP or DOWN keys to change the value.

7. Press ENTER key to save value and move the cursor to next parameter or top of screen.

8. Press ESCAPE key several times to return to Main Menu screen.

FIGURE 42

Adjusting Compressor Delays

The address-based delay only applies to the wall-mount unit when in stand alone mode. The controller will delay the unit compressor based on the value entered on screen B2 multiplied by the unit address. This is intended to keep multiple units from starting their

Manual 2100-670I Page 27 of 47

Page 28

compressors at the same time when there is a quick change in the load. When connected to the LV, this is taken care of by LV logic.

Additional Compressor Alarms

Refrigerant Low Pressure Alarm

When the suction pressure transducer indicates a pressure value less than the low pressure alarm setpoint of 40 PSIG and there is an active call for cooling, the controller will disable the compressor (after a 180-second delay). NOTE: The second call will be

delayed based on the delay off value mentioned in the compressor section. The controller will try to run the

refrigeration system two (2) times within 900 seconds before the alarm will lock the compressor out. This alarm needs to be manually cleared before compressor operation will resume.

To adjust the low pressure alarm settings:

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 System Conﬁg; press ENTER key.

4. Press UP or DOWN keys to scroll to Alarm Setup (A6); press ENTER key.

5. Press ENTER key to scroll to Delay to adjust how long the compressor waits before turning the compressor off (see Figure 43).

6. Press UP or DOWN keys to adjust the time delay.

7. Press ENTER key to scroll to Two Count Del.

8. Press UP or DOWN keys to adjust the delay value.

9. Press ENTER key to save.

10. Press the ESCAPE key several times to return to Main Menu screen.

Economizer

Economizer Components

Actuator

The actuator rotates up to 90° based on a 0-10v signal sent to it by the controller. The actuator is rated at 44 lb-in and is spring return when power is lost. This component is what opens and closes the damper blade.

To verify the output from the controller to the actuator:

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.

4. Press UP or DOWN keys to scroll to Damper Override (C14); press ENTER key.

5. Reference the Damper Position for the current output to the damper (see Figure 44).

6. To override the current position, press ENTER key to scroll to Damper OV Pos.

7. Press UP or DOWN keys to change the value to the desired output.

8. Press ENTER key to save the value and move cursor to Override.

9. Press UP or DOWN keys to change the value from Disabled to Enabled.

10. The Damper Position will update with the new 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.

FIGURE 44

Damper Override

FIGURE 43

Adjusting Low Pressure Alarm Settings

Manual 2100-670I Page 28 of 47

Dust Sensor

The unit has a dust sensor installed near the outdoor air inlet. The dust sensor checks for excessive particulates in the outdoor air, and will close the economizer if the dust is excessive. The sensor uses a PWM signal converted to 0-5v output to the controller.

Page 29

To ensure proper performance, cleaning may be required. Vacuuming or blowing the dust off the sensor with forced air is recommended. Avoid inserting any objects into the sensor.

The dust sensor can be veriﬁed by:

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.

4. Press UP or DOWN keys to scroll to Dust Sensor (C8); press ENTER key.

5. Reference the Value for the current sensor reading (see Figure 45).

6. To apply an offset to the current reading, press ENTER key to scroll to Offset.

7. Press UP or DOWN keys to adjust the value to the desired value.

8. Press ENTER key to save the value and move cursor to next parameter.

NOTE: The sensor can be disabled if required for

troubleshooting.

9. With the cursor on the Enable parameter, press UP or DOWN keys to change the value from ON to OFF.

10. Press ENTER key to save.

controller has adjustable software setpoints (default to 80%) to indicate dust levels are too high and to disable the economizer operation for 5 minutes (unit default). This alarm is not communicated to the NOC. Once the conditions are no longer present, the alarm will automatically clear.

Disabling the dust sensor in I/O Conﬁg disables this alarm.

To adjust the dust sensor alarm setpoint:

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 System Conﬁg; press ENTER key.

4. Press UP or DOWN keys to scroll to Alarm Setup (A9); press ENTER key.

5. Press ENTER key to scroll to Setpoint (see Figure

46).

6. Press UP or DOWN keys to change to the desired value.

7. Press ENTER key to save the value.

NOTE: When the temperature outside is measured

at or below 0°F, the dust sensor alarm will be disabled to allow economizer operation. This is done because the compressor is disabled below 0°F and the system would not have the capability to cool.

FIGURE 45

Dust Sensor

Dust Sensor Failure Alarm

When the sensor reads a value that is outside of the acceptable 0 to 100% range, an alarm will be generated indicating the sensor has failed. This alarm is just a notiﬁcation and will not disable any other features on the controller.

This alarm is ﬁxed and cannot be adjusted.

High Dust Limit Alarm

When dust content in the air is high and is a risk to prematurely reducing airﬂow through the ﬁlters, the unit will restrict the use of the economizer. The

FIGURE 46

Adjusting Dust Sensor Alarm Setpoint

Damper Blade

The system utilizes three damper blades used to bring in outdoor air and exhaust space air for economizer operation. The damper blades are made of sheet metal and are integrated into the equipment.

Damper Switch

The economizer utilizes a magnetic switch to determine if the damper is operating correctly. This switch will be closed when the damper is closed and open when the damper is open.

Manual 2100-670I Page 29 of 47

Page 30

To verify the status of the switch:

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.

4. Press UP or DOWN keys to scroll to Digital In Conﬁg (C2); press ENTER key.

5. Reference the value located at 6 Damp row and Val column (see Figure 47).

6. The input will display ON when the damper is closed (reﬂecting closed circuit on damper switch) and will display OFF when the damper is open (reﬂecting open circuit on damper switch).

FIGURE 47

Damper Switch

Damper Failed to Open Alarm

When the controller commands the economizer damper actuator to a position other than 0% and the damper switch indicates the damper is not open, after a delay of 20 seconds the controller will generate a damper failed to open alarm. This alarm is just a notiﬁcation and will not disable any features on the controller.

Disabling the damper switch in I/O Conﬁg disables this alarm.

To adjust the damper failed to open delay:

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 System Conﬁg; press ENTER key.

4. Press UP or DOWN keys to scroll to Alarm Setup (A4); press ENTER key.

5. Press ENTER key to scroll to Open Delay (see Figure 48).

6. Press UP or DOWN keys to change to the desired value.

7. Press ENTER key to save the value.

FIGURE 48

Adjusting Damper Alarm Delay

Damper Failed to Close Alarm

When the controller commands the economizer damper actuator to the 0% position and the damper switch indicates the damper is not closed, after a delay of 300 seconds the controller will generate a damper failed to close alarm. This alarm is just a notiﬁcation and will not disable any features on the controller.

Disabling the damper switch in I/O Conﬁg disables this alarm.

To adjust the damper failed to close delay:

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 System Conﬁg; press ENTER key.

4. Press UP or DOWN keys to scroll to Alarm Setup (A4); press ENTER key.

5. Press ENTER key to scroll to Close Delay (see Figure 48).

6. Press UP or DOWN keys to change to the desired value.

7. Press ENTER key to save the value.

Outdoor Temperature and Humidity Combination Sensor

The unit is equipped with a combination outdoor temperature and humidity sensor to monitor outdoor conditions for the economizer operation. The temperature is measured with a 10k ohm NTC thermistor. The humidity is measured with a humidity sensor that outputs a 4-20mA signal to the controller.

The outdoor temperature can be veriﬁed by:

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.

4. Press UP or DOWN keys to scroll to Outdoor Air Sensor (C4); press ENTER key.

Manual 2100-670I Page 30 of 47

Page 31

5. Reference the Value to see the input of the sensor (see Figure 49).

6. To apply an offset, press ENTER key to scroll to Offset.

7. Press UP or DOWN keys to change to the desired value.

8. Press ENTER key to save the value.

FIGURE 49

Outdoor Air Sensor

The outdoor humidity can be veriﬁed by:

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.

4. Press UP or DOWN keys to scroll to Outdoor Hum Sensor (C7); press ENTER key.

5. Reference the Value to see the input of the sensor (see Figure 50).

6. To apply an offset, press ENTER key to scroll to Offset.

7. Press UP or DOWN keys to change to the desired value.

8. Press ENTER key to save the value.

FIGURE 50

Outdoor Humidity Sensor

Outdoor Temperature Sensor Failure Alarm

When the sensor reads a value that is outside of the acceptable -41 to 303.0° range, an alarm will be generated indicating the sensor has failed. This alarm condition will disable the economizer.

This alarm is ﬁxed and cannot be adjusted.

Outdoor Humidity Sensor Failure Alarm

When the sensor reads a value that is outside of the acceptable 0 to 100% RH range, an alarm will be generated indicating the sensor has failed. This alarm condition will disable the economizer when the mode is set to temperature and humidity or enthalpy.

This alarm is ﬁxed and cannot be adjusted.

Supply Temperature Sensor

The unit is equipped with a supply air temperature sensor to monitor the leaving air temperature of the unit. The temperature is measured with a 10k ohm NTC thermistor.

The supply air temperature can be veriﬁed by:

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.

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 51).

6. To apply an offset, press ENTER key to scroll to Offset.

7. Press UP or DOWN keys to change to the desired value.

8. Press ENTER key to save the value.

FIGURE 51

Supply Air Sensor

Manual 2100-670I Page 31 of 47

Page 32

Supply Temperature Sensor Failure Alarm

When the sensor reads a value that is outside of the acceptable -41.0 to 303.0° range, an alarm will be generated indicating the sensor has failed.

This alarm is ﬁxed and cannot be adjusted.

High Supply Air Temperature Alarm

When the supply air temperature measurement for the economizer to be enabled is above the outdoor air temperature setpoint (70°F) for 120 seconds, an alarm will be generated and the economizer will be disabled until the cooling call has been removed. This alarm will automatically reset once the economizer is no longer disabled.

To change the high supply air temperature alarm:

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 System Conﬁg; press ENTER key.

4. Press UP or DOWN keys to scroll to Alarm Setup (A5); press ENTER key.

5. Press ENTER key to scroll to Hi and Diff value (see Figure 52).

6. Press UP or DOWN keys to change the differential to the desired value.

7. Press ENTER key to save and scroll to the next parameter.

FIGURE 52

Adjusting Supply Air Temperature Differential

3. Press UP or DOWN keys to scroll to System Conﬁg; press ENTER key.

4. Press UP or DOWN keys to scroll to Alarm Setup (A5); press ENTER key.

5. Press ENTER key to scroll to Lo and Diff value (see Figure 52).

6. Press UP or DOWN keys to change the differential to the desired value.

7. Press ENTER key to save value and scroll to Delay.

8. Press UP or DOWN keys to adjust the delay value.

NOTE: This delay is also applied to the high supply air

temperature alarm.

9. Press ENTER key to save.

Economizer Operation

The economizer has four types of operation. The ﬁrst mode is "None" where the economizer is never utilized, except for emergency purposes. The second mode is "Dry Bulb" where the outdoor temperature is the only consideration for economizer use on a freecooling call. The third mode is "TempHum" where the outdoor temperature and humidity are considered for economizer use on a freecooling call. The fourth mode is "Enthalpy" where the outdoor temperature, humidity and calculated dew point are considered for economizer operation on a freecooling call.

To change the economizer type:

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 System Conﬁg; press ENTER key.

4. Press UP or DOWN keys to scroll to Economizer Setup (A2); press ENTER key.

5. Press ENTER key to scroll to Type (see Figure 53).

Low Supply Air Temperature Alarm

When the supply air temperature is below 45°F for 120 seconds, an alarm will be generated and the economizer will be disabled until the cooling call has been removed. This alarm will automatically reset when the economizer is no longer disabled.

To change the low supply air temperature alarm:

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.

Manual 2100-670I Page 32 of 47

FIGURE 53

Economizer Setup

Page 33

6. Press UP or DOWN keys to change the Type

desired value to None, Dry Bulb, TempHum or 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. Applies to Dry Bulb, TempHum and Enthalpy type.

8. The cursor should now be on the Outdoor Set

parameter.

9. Press UP or DOWN keys to change the parameter

to the desired value.

10. Press ENTER key to save the value and scroll to

the next parameter.

11. The cursor should now be on Off Diff parameter.

12. Press UP or DOWN keys to change the parameter

to the desired value.

13. Press ENTER key to save the value and move to

the next parameter.

14. The cursor is now on the Mixed FC Set parameter.

15. Press UP or DOWN keys to change the parameter

to the desired value.

16. Press ENTER key to save the value.

17. Press the DOWN key to navigate to the A3 screen.

NOTE:

This screen will not display if economizer mode is set to Dry Bulb or None. Also, the contents of the screen will change when type is set to Enthalpy (see Figure 54) as compared to when type is set to TempHum (see Figure 58 on page 34). The following menu shows the Enthalpy content which also contains parameters that would be shown on TempHum.

18. Press ENTER key to scroll to OA Humid Set (see

Figure 55).

19. Press UP or DOWN keys to change the humidity

setpoint to desired value.

20. If set to TempHum, continue on to Step 22. If set

to Enthalpy, press ENTER key to save the value and scroll to OA Dew Pt Set.

21. Press UP or DOWN keys to adjust the outdoor dew

point setpoint for economizer operation to the desired value.

22. Press ENTER key to save the value and scroll to On

Diff.

23. Press UP or DOWN keys to adjust the outdoor

humidity differential for which the economizer is re-enabled.

24. Press ENTER key to save the value and scroll to

parameter Delay.

FIGURE 54

Economizer Setup – Enthalpy Control

FIGURE 55

Economizer Setup – TempHum Control

25. Press UP or DOWN keys to adjust the time the actual measurements can be outside of the disabling parameters before the economizer operation is disabled.

26. Press ENTER key to save the value.

27. Press ESCAPE key several times to return to Main Menu screen.

See Table 8 on page 34 for default settings for economizer operation.

When the economizer is activated during a freecooling call only, using any of the previously mentioned modes, a 0-10v analog signal will be sent to the economizer actuator. Regardless of economizer only, or optimized cooling mode, the actuator will then open and close the damper blades to maintain a supply air temperature of 55°F. During optimized cooling mode, the damper blades will be limited to a max output of 60%. When the supply/ mixed air temperature increases, the damper will open and when the mixed air temperature decreases, the damper will close.

The economizer may be disabled by the LV if the system determines it needs to enter dehumidiﬁcation mode. More information about the dehumidiﬁcation sequence can be found on page 15 and in the latest revision of LV1000 Service Instructions 2100-673. In addition to dehum mode, the economizer may be disabled for 5 minutes (adjustable) if the dust sensor indicates the outdoor air may cause particulate buildup in the

Manual 2100-670I Page 33 of 47

Page 34

TABLE 8

Economizer Default Settings

Mode Consideration Economizer Available for Cooling Economizer Not Available for Cooling

Only

Temp

Temp & Humidity

* In Enthalpy mode, outdoor temperature, humidity and calculated dew point are all considered for economizer operation.

Temperature

Humidity

Enthalpy*

Dew Point

air ﬁlters. After the time has expired and on a call for cooling, the economizer will open again to sample the air. The wall-mount unit will either return to normal operation or remain locked out for another 5 minutes.

When the outdoor air temperature

is below 70°F

LV Online: When the outdoor humidity

is below 80%

LV Ofﬂine: When the outdoor humidity

is below 60%

When the outdoor dew point

is below 55°F

To update model/serial numbers:

1. Press MENU key to go to the Main Menu screen.

2. Press UP or DOWN keys and ENTER key to enter

When the outdoor air temperature

is above 75°F

LV Online: When the outdoor humidity

is above 80%

LV Ofﬂine: When the outdoor humidity

is above 60%

When the outdoor dew point

is above 60°F

ENGINEER password 9254.

Emergency Cooling Mode

If the shelter temperature is above the high temperature alarm setpoint on the LV, the unit will be commanded into emergency cooling mode. In this mode, the unit will operate the economizer regardless of the economizer setup, as long as the outdoor temperature is below the indoor temperature. The cooling demand will be automatically set to 100% in this mode, meaning mechanical cooling should be operating at full capacity while this mode is active. This will stay active until the LV returns the unit to normal operation. This mode is only available when connected to the LV.

Emergency Ventilation Mode

If a hydrogen detector is connected to the LV/FUSIONTEC system and there is a hydrogen alarm event, the system will go into emergency ventilation mode. In emergency ventilation mode, the economizers on the wall units will be commanded to 100%. After 2 minutes, the blowers will turn on in order to exhaust any hydrogen gas buildup within the shelter. Once the hydrogen alarm clears, the system will resume normal operation. This mode is only available when connected to the LV.

3. Press UP or DOWN keys to scroll to Adv Sys Conﬁg; press ENTER key.

4. Press UP or DOWN keys to scroll to Factory Settings (B1).

5. Press ENTER key to advance the cursor to the digit that needs changed in the model/serial number.

6. Press UP or DOWN keys to change value of the digit.

7. Continue Steps 5 and 6 until the model/serial number(s) are correct and reﬂect the number on the product label.

For more information on the options and settings available for speciﬁc model numbers, please see the model number breakdown in Figure 57 on page 38.

Electric Heat Option

Electric Heat Components

Electric Heating Element

The unit is optionally equipped with a 1.5kw or 5kw heat strip. The heat strip is located next to the blower assembly and uses resistive heat.

Model/Serial Number Configuration

FUSION-TEC wall-mount units conﬁgure some settings based on the model number that is input into the unit. The model and serial numbers are entered at the factory and should be retained during a software update. However, after a software update, it is best practice to verify that the model and serial numbers are still present and accurate. If the model and/or serial number is missing or incorrect, they will need to be re-entered.

NOTE:

When re-entering the model number, only valid model number entries will be accepted by the

Thermal Overload

The heater assembly has a thermal overload wired in series with the heating element. This device has a cycling limit which opens at 130°F and resets at 80°F. The limit is also equipped with a redundant thermal fuse that will open at 150°F.

Electric Heat Operation

The heat strip will be activated on a call for heat. This call can be generated by the LV or the wall-mount unit operating in stand alone mode.

PLC.

Manual 2100-670I Page 34 of 47

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 antitheft controller to provide an anti-theft measure. These sensors and switch form a loop that when connected to the BG1000 controller will cause the system to go into alarm if any of the front panels or coil assemblies are removed without being disarmed. The speaker provides an audible alert that the system is being tampered with. The Bard Guard anti-theft control sensor connection is wired to terminals 7 and 8 on the wall-mount unit. The speaker connection is wired to terminals 5 and 6 on the wallmount unit. See the latest revision of BG1000 Installation Instructions 2100-672 for directions on connecting the wall-mount units to the BG1000 controller.

Smoke Detector Unit Disable Option

The unit is equipped with an input that can be used with a smoke detector or unit disable switch with a dry contact. When this input indicates a smoke event, the system will be shut down. The alarm will automatically clear when the alarm condition is no longer present.

Inverter Option

The inverter is only used in applications where a generator is not present and the wall-mount units must run during a power loss event. The inverter will always keep power available to the wall-mount units during a power outage. In the event of a power outage, a power loss relay in the FUSION-TEC unit will be energized and will only allow the blower and economizer to run while powering the controller. The inverter converts either 24 VDC or 48 VDC, depending on the model, to 230 VAC. A relay output from the inverter will also communicate an alarm to the supervisory controller in the event of an inverter failure. This variable can be communicated through the Ethernet port for integration into a building management system. The units will continue to run in economizer-only operation until power has been restored or the battery power has been depleted.

When the FUSION-TEC operating under inverter power, shelter economizer cooling will only occur if outside temperatures fall below indoor temperatures and blower speeds are slightly reduced to conserve battery power.

HR Series

wall-mount

wall-mount unit is

Manual 2100-670I Page 35 of 47

Page 36

FUSION-TEC HR Series Wall-Mount Unit Control Board 8301-068-002*

Micro USB

Smoke Detector

Dirty Filter Switch

Compressor Alarm Relay

Damper Blade Switch

Airﬂow Switch

Digital Ground

Liquid Line Temp Sensor Outdoor Air Temp Sensor

Return Air Temp Sensor

Supply Air Temp Sensor

Outdoor Humidity Sensor

Dust Sensor Board

Suction Temp Sensor

Analog Ground

24VDC to Outdoor Humidity Sensor

Liquid Pressure Transducer

Suction Pressure Transducer

Ground

Blower Motor Signal

Condenser Fan Motor

DI1 DI2 DI3 DI4 DI5 DI6 DI7 GND

B1 B2 B3 B4 B5 B6 B7 GND

+Vdc

B8 B9

GND Y1 Y2 Y3

FIGURE 56

24VAC Hot 24VAC Common

Control Stand-by

BMS Card

EEV1

Rx+/Tx+

Rx-/Tx-

GND

FieldBus2

Jumper

NO8

NO9

+ Communication Wire

– Communication Wire

NO1

NO2

NO3

NO4

NO5

NO6

NO7

NC7

24VAC + To CCM Y Compressor Staging Solenoid

24VAC + Stage 1 Heat

24VAC + Dirty Filter Light

Expansion Valve:

Purple, Yellow – 40 ohms

Red/White – 40 ohms Red/Green – 40 ohms

White/Green – 80 ohms

Blue/Yellow – 83 ohms

* Asterisk represents letter at end of part number that designates software version (Example: 8301-068-002A).

Manual 2100-670I Page 36 of 47

Page 37

TABLE 9

FUSION-TEC HR Series Wall-Mount Unit Control Board Terminals

Terminal Function Type Form

Rx+/Tx+ Communication

Rx-/Tx- Communication

DI1 Smoke Detector Digital N/C

DI2 Dirty Filter Switch Digital N/C

DI3 Compressor Alarm Relay Digital N/C

DI4 Not Used

DI5 Not Used

DI6 Damper Blade Switch Digital N/C

DI7 Airﬂow Digital N/C

GND Digital Ground

B1 Liquid Line Temperature Sensor Analog Output 10K Ohm Curve J

B2 Outdoor Air Temperature Sensor Analog Output 10K Ohm Type III (AN)

B3 Return Air Temperature Sensor Analog Output 10K Ohm Curve J

B4 Supply Air Temperature Sensor Analog Output 10K NTC Thermistor

B5 Outdoor Humidity Sensor Analog Output

B6 Dust Sensor Board Analog Output 0-5VDC

B7 Suction Temperature Sensor Analog Output 10K Ohm Curve J

GND Analog Ground

+VDC 24VDC to Outdoor Humidity Sensor

B8 Liquid Pressure Transducer Analog Output .5VDC to 4.5VDC

B9 Suction Pressure Transducer Analog Output .5VDC to 4.5VDC

Y1 Blower Motor Signal

Y2 Not Used

Y3 Condenser Motor Signal

GND Ground

C1 24VAC+ Power

NO1 to CCM "Y" Relay Output

NO2 Compressor Staging Solenoid Relay Output

NO3 Not Used

C2 24VAC+ Power

NO4 Stage 1 Heating Relay Output

NO5 Not Used NO6 Not Used

NO7 Not Used

C7 Not Used

NC7 Not Used

C8 24VAC+ Power

NO8 Dirty Filter Light Relay Output

GO 24VAC Common

G 24VAC Hot

Manual 2100-670I Page 37 of 47

Page 38

FUSION-TEC HR Series Wall-Mount Unit Model Nomenclature

UNIT SERIES

MAXIMUM SENSIBLE CAPACITY

36 – 3 Ton 2 Stage Step Capacity 58 – 5 Ton 2 Stage Step Capacity

CONTROL LOGIC AND CLIMATE OPTIONS

0Z – O kW with Circuit Breaker

01 – 1.5 kW with Circuit Breaker

05 – 5 kW with Circuit Breaker

5 – Internal and External Cabinet Component Coating, Coated Evaporator Coil, Coated Condenser Coil

X – Standard accessories including airﬂow sensor, dirty ﬁlter sensor, pressure transducers, crankcase heater

FIGURE 57

HR 58 A P A 0Z E P X X X X

REVISION

A – Revision Level

P – Programmable Logic Board

VOLTS & PHASE

A – 230/208/60/1

B – 230/208/60/3

MZ – O kW with Circuit Breaker and Inverter

M1 – 1.5 kW with Circuit Breaker and Inverter

M5 – 5 kW with Circuit Breaker and Inverter

E – Factory-Installed Economizer (All Units)

X – Copper/Aluminum Evaporator Coil, Copper/Aluminum Condenser Coil

4 – Condenser Section Component Coating, Coated Evaporator Coil, Coated Condenser Coil

S – All standard accessories plus additional Bard Guard

ELECTRIC HEAT

VENT PACKAGE

FILTER

P – MERV8 Disposable Pleated Filter

COLOR AND CABINET FINISH

X – Beige Baked Enamel Finish

1 – White Baked Enamel Finish

4 – Buckeye Gray Baked Enamel Finish

5 – Desert Brown Baked Enamel Finish

8 – Dark Bronze Baked Enamel Finish

COIL AND UNIT COATING OPTIONS

3 – Coated Evaporator Coil, Coated Condenser Coil

ACCESSORIES AND CONTROLS OPTIONS

PLACEHOLDER

X – Future Use

1 – Coated Evaporator Coil 2 – Coated Condenser Coil

security features and security frame

Manual 2100-670I Page 38 of 47

Page 39

These units require R-410A refrigerant and polyol ester oil.

General

1. Use separate service equipment to avoid cross contamination of oil and refrigerants.

2. Use recovery equipment rated for R-410A refrigerant.

3. Use manifold gauges rated for R-410A (800 PSI/250 PSI low).

4. R-410A is a binary blend of HFC-32 and HFC-

125.

5. R-410A is nearly azeotropic—similar to R-22 and R-12. Although nearly azeotropic, charge with liquid refrigerant.

6. R-410A operates at 40-70% higher pressure than R-22, and systems designed for R-22 cannot withstand this higher pressure.

7. R-410A has an ozone depletion potential of zero, but must be reclaimed due to its global warming potential.

8. R-410A compressors use polyol ester oil.

9. Polyol ester oil is hygroscopic; it will rapidly absorb moisture and strongly hold this moisture in the oil.

10. A liquid line dryer must be used—even a deep vacuum will not separate moisture from the oil.

11. Limit atmospheric exposure to 15 minutes.

12. If compressor removal is necessary, always plug compressor immediately after removal. Purge with small amount of nitrogen when inserting plugs.

Topping Off System Charge

If a leak has occurred in the system, Bard Manufacturing recommends reclaiming, evacuating (see criteria above) and charging to the nameplate charge. If done correctly, topping off the system charge can be done without problems.

With R-410A, there are no signiﬁcant changes in the refrigerant composition during multiple leaks and recharges. R-410A refrigerant is close to being an azeotropic blend (it behaves like a pure compound or single component refrigerant). The remaining refrigerant charge in the system may be used after leaks have occurred. “Top-off” the charge by utilizing the pressure charts on the inner control panel cover as a guideline.

REFRIGERANT INFORMATION

REMEMBER: When adding R-410A refrigerant, it must come out of the charging cylinder/tank as a liquid to avoid any fractionation and to insure optimal system performance. Refer to instructions for the cylinder that is being utilized for proper method of liquid extraction.

Safety Practices

1. Never mix R-410A with other refrigerants.

2. Use gloves and safety glasses. Polyol ester oils can be irritating to the skin, and liquid refrigerant will freeze the skin.

3. Never use air and R-410A to leak check; the mixture may become ﬂammable.

4. Do not inhale R-410A—the vapor attacks the nervous system, creating dizziness, loss of coordination and slurred speech. Cardiac irregularities, unconsciousness and ultimately death can result from breathing this concentration.

5. Do not burn R-410A. This decomposition produces hazardous vapors. Evacuate the area if exposed.

6. Use only cylinders rated DOT4BA/4BW 400.

7. Never ﬁll cylinders over 80% of total capacity.

8. Store cylinders in a cool area, out of direct sunlight.

9. Never heat cylinders above 125°F.

10. Never trap liquid R-410A in manifold sets, gauge lines or cylinders. R-410A expands signiﬁcantly at warmer temperatures. Once a cylinder or line is full of liquid, any further rise in temperature will cause it to burst.

Important Installer Note

For improved start-up performance, wash the indoor coil with a dishwashing detergent.

R410-A Refrigerant Charge

This wall-mount unit was charged at the factory with the quantity of refrigerant listed on the serial plate. AHRI capacity and efﬁciency ratings were determined by testing with this refrigerant charge quantity.

Table 10 on page 40 shows nominal pressures for the units. Since many installation speciﬁc situations can affect the pressure readings, this information should only be used by certiﬁed technicians as a guide for evaluating proper system performance. They shall not be used to adjust charge. If charge is in doubt, reclaim, evacuate and recharge the wall-mount unit to the serial plate charge.

Manual 2100-670I Page 39 of 47

Page 40

Pressure Service Ports

High and low pressure service ports are installed on all wall-mount units so that the system operating pressures can be observed. Pressures are shown in Table 10.

This unit employs high-ﬂow Coremax valves instead of the typical Schrader type valves.

TABLE 10

Cooling Pressures

Full Load Cooling Air Temperature Entering Outdoor Coil °F

WARNING! Do NOT use a Schrader valve core removal tool with these valves. Use of such a tool could result in eye injuries or refrigerant burns!

To change a Coremax valve without ﬁrst removing the refrigerant, a special tool is required which can be obtained at www.fastestinc.com/en/SCCA07H. See the replacement parts manual for replacement core part numbers.

Model

HR36

HR58

Model

HR36

HR58

Return Air Temp

(DB/WB)

75/62

80/67

85/72

75/62

80/67

85/72

Part Load Cooling Air Temperature Entering Outdoor Coil °F

Return Air Temp

(DB/WB)

75/62

80/67

85/72

75/62

80/67

85/72

Pressure 75 80 85 90 95 100 105 110 115 120 125

Low Side

High Side

Low Side

High Side

Low Side

High Side

Low Side

High Side

Low Side

High Side

Low Side

High Side

Pressure 75 80 85 90 95 100 105 110 115 120 125

Low Side

High Side

Low Side

High Side

Low Side

High Side

Low Side

High Side

Low Side

High Side

Low Side

High Side

130 290

139 297

144 307

129 318

138 326

143 337

119 268

127 275

131 285

135 283

144 290

149 300

131 312

140 320

145 331

130 340

139 349

144 361

125 288

134 295

139 305

136 304

145 312

150 323

132 334

141 343

146 355

131 365

140 374

145 387

131 308

140 316

145 327

136 327

145 335

150 347

134 359

143 368

148 381

132 389

141 399

146 413

136 331

145 339

150 351

137 350

146 359

151 372

135 384

144 394

149 408

133 414

142 425

147 440

140 354

150 363

155 376

137 375

147 385

152 398

136 411

145 422

150 437

134 440

143 451

148 467

143 378

153 388

158 402

138 402

148 412

153 426

137 439

147 450

152 466

136 467

145 479

150 496

146 405

156 415

161 430

138 428

148 439

154 454

138 468

148 480

153 497

137 495

146 508

151 526

148 432

158 443

164 459

140 456

150 468

155 484

139 498

149 511

154 529

137 527

147 537

152 556

149 460

159 472

165 489

141 486

151 498

156 515

140 530

150 544

155 563

139 553

149 567

154 587

150 490

160 503

166 521

142 416

152 529

157 548

142 564

152 578

157 598

140 584

150 599

155 620

149 522

159 535

165 554

143 547

153 561

158 581

Low side pressure ± 4 PSIG High side pressure ± 10 PSIG

Tables are based upon rated CFM (airﬂow) across the evaporator coil. If there is any doubt as to correct operating charge being in the system, the charge should be removed and system evacuated and recharged to serial plate charge weight.

NOTE: Pressure table based on high speed condenser fan operation. If condensing pressures appear elevated check

condenser fan wiring. See “Condenser Fan Operation” on page 24.

Manual 2100-670I Page 40 of 47

Page 41

MAINTENANCE

Standard Maintenance Procedures

WARNING

Electrical shock hazard.

Disconnect all power supplies before

servicing.

Failure to do so could result in electric shock or death.

CAUTION

Cut hazard.

Wear gloves to avoid contact with sharp edges.

Failure to do so could result in personal

injury.

1. Disable system from LV1000 controller (see latest revision of LV1000 Service Instructions 2100-

673).

2. Turn off AC breakers at wall-mount units.

3. Check inlet sides of condenser and evaporator coils for obstructions/debris—clean if necessary using a quality manufactured coil cleaning product speciﬁc for the evaporator or condenser coil.

•

• Evaporator coil: Open ﬁlter access panels

Condenser coil: Remove the upper side panels from the condenser section. This will give clear access to the inlet side of the coil for cleaning. Follow the coil cleaner manufacturer’s directions for necessary safety gear and precautions, as well as for application and use. More than one application may be necessary. Rinse thoroughly.

and remove ﬁlters. Apply speciﬁc evaporator cleaner directly to the inlet side of coil, being very careful not to overspray into insulation or surrounding panels and wiring. Residual cleaner and dissolved debris should drip into the drain pan and leave the unit through the condensate hose. More than one application may be necessary. Rinse thoroughly.

4. Manually spin fan and blower motors to ensure they turn freely. All motors are permanently lubricated, so no oil is necessary.

5. Inspect free cooling damper actuator and linkage.

6. Install new air ﬁlter; check for additional ﬁlter grilles internal to the structure.

7. Inspect the control panel of the system.

• Look for insect or rodent activity and remove

any nesting materials.

• Manually push contactor closed, observe for

movement—contactor points should have minimal discoloration, no spalling or other signs of arcing. Replace if doubtful.

• Check ﬁeld and factory wiring for tightness and

look for signs of overheating (discoloration of terminals or wire insulation).

8. Ensure that supply and return registers are not obstructed, and more importantly, are not recycling the air to one another. Adjust supply louvers if necessary to direct discharge air away from any direct route to the return grille.

Re-assemble wall-mount unit, turn breakers back on.

10. Enable system to LV1000 controller (see latest revision of LV1000 Service Instructions 2100-

673).

11. Repeat steps for additional wall-mount units.

Bard Guard Anti-Theft System Option

While the system is powered, push DISARM/RESET button to disarm the system. Once the button is pushed, the blue LED will illuminate. As long as the blue LED is illuminated, the Bard Guard system is disarmed and will remain disarmed depending on the preset time for up to 250 minutes (default approximatey 15 minutes). After the preset time expires, the system will rearm automatically.

For situations that require an individual unit to be disconnected from the Bard Guard security system for an extended period of service time (longer than the maximum 250 minutes disarm time), place a jumper across the appropriate terminals on the BG1000 terminal block to temporarily remove the unit from the security system. Be sure to remove the jumper from the

terminals after service has been completed.

See the latest revision of BG1000 Installation Instructions 2100-672 for information on operating the BG1000 controller.

Manual 2100-670I Page 41 of 47

Page 42

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

8301-067 Sensor: Temperature/Resistance

Temperature Resistance

F C Ω

-25 -31.7 148,452.94

-24 -31.1 143,910.37

-23 -30.6 139,521.46

-22 -30.0 135,280.55

-21 -29.4 131,182.22

-20 -28.9 127,221.25

-19 -28.3 123,392.63

-18 -27.8 119,691.54

-17 -27.2 116,113.37

-16 -26.7 112,653.66

-15 -26.1 109,308.15

-14 -25.6 106,072.72

-13 -25.0 102,943.44

-12 -24.4 99,916.50

-11 -23.9 96,988.26

-10 -23.3 94,155.21

-9 -22.8 91,413.97

-8 -22.2 88,761.30

-7 -21.7 86,194.07

-6 -21.1 83,709.29

-5 -20.6 81,304.06

-4 -20.0 78,975.60

-3 -19.4 76,721.24

-2 -18.9 74,538.41

-1 -18.3 72,424.61

0 -17.8 70,377.48

1 -17.2 68,394.70

2 -16.7 66,474.07

3 -16.1 64,613.46

4 -15.6 62,810.82

5 -15.0 61,064.17

6 -14.4 59,371.62

7 -13.9 57,731.32

8 -13.3 56,141.52

9 -12.8 54,600.50

10 -12.2 53,106.64

11 -11.7 51,658.35

12 -11.1 50,254.11

Temperature Resistance

F C Ω

13 -10.6 48,892.46

14 -10.0 47,571.97

15 -9.4 46,291.29

16 -8.9 45,049.09

17 -8.3 43,844.12

18 -7.8 42,675.14

19 -7.2 41,540.99

20 -6.7 40,440.51

21 -6.1 39,372.62

22 -5.6 38,336.26

23 -5.0 37,330.40

24 -4.4 36,354.06

25 -3.9 35,406.29

26 -3.3 34,486.17

27 -2.8 33,592.81

28 -2.2 32,725.36

29 -1.7 31,883.00

30 -1.1 31,064.92

31 -0.6 30,270.36

32 0.0 29,498.58

33 0.6 28,748.85

34 1.1 28,020.48

35 1.7 27,312.81

36 2.2 26,625.18

37 2.8 25,956.98

38 3.3 25,307.60

39 3.9 24,676.45

40 4.4 24,062.97

41 5.0 23,466.62

42 5.6 22,886.87

43 6.1 22,323.22

44 6.7 21,775.16

45 7.2 21,242.23

46 7.8 20,723.96

47 8.3 20,219.91

48 8.9 19,729.65

49 9.4 19,252.76

50 10.0 18,788.84

Temperature Resistance

F C Ω

51 10.6 18,337.51

52 11.1 17,898.38

53 11.7 17,471.09

54 12.2 17,055.30

55 12.8 16,650.65

56 13.3 16,256.82

57 13.9 15,873.48

58 14.4 15,500.34

59 15.0 15,137.09

60 15.6 14,783.44

61 16.1 14,439.11

62 16.7 14,103.83

63 17.2 13,777.34

64 17.8 13,459.38

65 18.3 13,149.70

66 18.9 12,848.07

67 19.4 12,554.26

68 20.0 12,268.04

69 20.6 11,989.19

70 21.1 11,717.51

71 21.7 11,452.79

72 22.2 11,194.83

73 22.8 10,943.45

74 23.3 10698.45

75 23.9 10,459.65

76 24.4 10,226.90

77 25.0 10,000.00

78 25.6 9778.81

79 26.1 9563.15

80 26.7 9352.89

81 27.2 9147.86

82 27.8 8947.93

83 28.3 8752.95

84 28.9 8562.79

85 29.4 8377.31

86 30.0 8196.39

87 30.6 8019.91

88 31.1 7847.74

Temperature Resistance

F C Ω

89 31.7 7679.76

90 32.2 7515.86

91 32.8 7355.94

92 33.3 7199.88

93 33.9 7047.59

94 34.4 6898.95

95 35.0 6753.88

96 35.6 6612.28

97 36.1 6474.05

98 36.7 6339.11

99 37.2 6207.37

100 37.8 6078.74

101 38.3 5953.15

102 38.9 5830.51

103 39.4 5710.75

104 40.0 5593.78

105 40.6 5479.55

106 41.1 5367.98

107 41.7 5258.99

108 42.2 5152.53

109 42.8 5048.52

110 43.3 4946.91

111 43.9 4847.63

112 44.4 4750.62

113 45.0 4655.83

114 45.6 4563.20

115 46.1 4472.67

116 46.7 4384.19

117 47.2 4297.71

118 47.8 4213.18

119 48.3 4130.55

120 48.9 4049.77

121 49.4 3970.79

122 50.0 3893.58

123 50.6 3818.08

124 51.1 3744.26

125 51.7 3672.07

Manual 2100-670I Page 43 of 47

Page 44

TABLE 12

8301-067 Sensor: Humidity/mA

RH% mA Output

0 4.000 mA

1 4.160 mA

2 4.320 mA

3 4.480 mA

4 4.640 mA

5 4.800 mA

6 4.960 mA

7 5.120 mA

8 5.280 mA

9 5.440 mA

10 5.600 mA

11 5.760 mA

12 5.920 mA

13 6.080 mA

14 6.240 mA

15 6.400 mA

16 6.560 mA

17 6.720 mA

18 6.880 mA

19 7.040 mA

20 7.200 mA

21 7.360 mA

22 7.520 mA

23 7.680 mA

24 7.840 mA

25 8.000 mA

26 8.160 mA

27 8.320 mA

28 8.480 mA

29 8.640 mA

30 8.800 mA

31 8.960 mA

32 9.120 mA

33 9.280 mA

RH% mA Output

34 9.440 mA

35 9.600 mA

36 9.760 mA

37 9.920 mA

38 10.080 mA

39 10.240 mA

40 10.400 mA

41 10.560 mA

42 10.720 mA

43 10.880 mA

44 11.040 mA

45 11.200 mA

46 11.360 mA

47 11.520 mA

48 11.680 mA

49 11.840 mA

50 12.000 mA

51 12.160 mA

52 12.320 mA

53 12.480 mA

54 12.640 mA

55 12.800 mA

56 12.960 mA

57 13.120 mA

58 13.280 mA

59 13.440 mA

60 13.600 mA

61 13.760 mA

62 13.920 mA

63 14.080 mA

64 14.240 mA

65 14.400 mA

66 14.560 mA

67 14.720 mA

RH% mA Output

68 14.880 mA

69 15.040 mA

70 15.200 mA

71 15.360 mA

72 15.520 mA

73 15.680 mA

74 15.840 mA

75 16.000 mA

76 16.160 mA

77 16.320 mA

78 16.480 mA

79 16.640 mA

80 16.800 mA

81 16.960 mA

82 17.120 mA

83 17.280 mA

84 17.440 mA

85 17.600 mA

86 17.760 mA

87 17.920 mA

88 18.080 mA

89 18.240 mA

90 18.400 mA

91 18.560 mA

92 18.720 mA

93 18.880 mA

94 19.040 mA

95 19.200 mA

96 19.360 mA

97 19.520 mA

98 19.680 mA

99 19.840 mA

100 20.000 mA

Manual 2100-670I Page 44 of 47

Page 45

8408-044 Return Air Sensor/Suction Sensor

TABLE 13

8408-044 Sensor: Temperature/Resistance Curve J

TemperatureºFResistanceΩTemperatureºFResistanceΩTemperatureºFResistanceΩTemperatureºFResistance

-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 171289 17.0 50514 55.0 17434 93.0 6840

-20.0 165487 18.0 49028 56.0 16984 94.0 6683

-19.0 159904 19.0 47590 57.0 16547 95.0 6531

-18.0 154529 20.0 46200 58.0 16122 96.0 6383

-17.0 149355 21.0 44855 59.0 15710 97.0 6239

-16.0 144374 22.0 43554 60.0 15310 98.0 6098

-15.0 139576 23.0 42295 61.0 14921 99.0 5961

-14.0 134956 24.0 41077 62.0 14544 100.0 5827

-13.0 130506 25.0 39898 63.0 14177 101.0 5697

-12.0 126219 26.0 38757 64.0 13820 102.0 5570

-11.0 122089 27.0 37652 65.0 13474 103.0 5446

-10.0 118108 28.0 36583 66.0 13137 104.0 5326

-9.0 114272 29.0 35548 67.0 12810 105.0 5208

-8.0 110575 30.0 34545 68.0 12492 106.0 5094

-7.0 107010 31.0 33574 69.0 12183 107.0 4982

-6.0 103574 32.0 32634 70.0 11883 108.0 4873

-5.0 100260 33.0 31723 71.0 11591 109.0 4767

-4.0 97064 34.0 30840 72.0 11307 110.0 4663

-3.0 93981 35.0 29986 73.0 11031 111.0 4562

-2.0 91008 36.0 29157 74.0 10762 112.0 4464

-1.0 88139 37.0 28355 75.0 10501 113.0 4367

0.0 85371 38.0 27577 76.0 10247 114.0 4274

1.0 82699 39.0 26823 77.0 10000 115.0 4182

2.0 80121 40.0 26092 78.0 9760 116.0 4093

3.0 77632 41.0 25383 79.0 9526 117.0 4006

4.0 75230 42.0 24696 80.0 9299 118.0 3921

5.0 72910 43.0 24030 81.0 9077 119.0 3838

6.0 70670 44.0 23384 82.0 8862 120.0 3757

7.0 68507 45.0 22758 83.0 8653 121.0 3678

8.0 66418 46.0 22150 84.0 8449 122.0 3601

9.0 64399 47.0 21561 85.0 8250 123.0 3526

10.0 62449 48.0 20989 86.0 8057 124.0 3452

11.0 60565 49.0 20435 87.0 7869

12.0 58745 50.0 19896 88.0 7686

Manual 2100-670I Page 45 of 47

Page 46

8301-066 Supply Air Sensor

TABLE 14

8301-066 Sensor: Temperature/Resistance

Temperature Resistance

°C Ω

0 29,490

1 28,157

2 26,891

3 25,689

4 24,547

5 23,462

6 22,431

7 21,450

8 20,518

9 19,631

10 18,787

11 17,983

12 17,219

13 16,490

14 15,797

15 15,136

16 14,506

17 13,906

18 13,334

19 12,788

20 12,268

21 11,771

22 11,297

23 10,845

24 10,413

25 10,000

26 9606

27 9229

28 8869

29 8525

30 8196

31 7882

32 7581

33 7293

34 7018

35 6754

Temperature Resistance

°C Ω

36 6501

37 6260

38 6028

39 5806

40 5594

41 5390

42 5195

43 5007

44 4828

45 4656

46 4490

47 4332

48 4180

49 4034

50 3893

51 3759

52 3629

53 3505

54 3386

55 3271

56 3160

57 3054

58 2952

59 2854

60 2760

61 2669

62 2582

63 2498

64 2417

65 2339

66 2264

67 2191

68 2122

69 2055

70 1990

71 1928

Temperature Resistance

°C Ω

72 1868

73 1810

74 1754

75 1700

76 1648

77 1598

78 1550

79 1503

80 1458

81 1414

82 1372

83 1332

84 1293

85 1255

86 1218

87 1183

88 1149

89 1116

90 1084

91 1053

92 1023

93 994

94 967

95 940

96 913

97 888

98 864

99 840

100 817

101 795

102 774

103 753

104 733

105 713

106 694

107 676

Manual 2100-670I Page 46 of 47

Page 47

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