Page 1
INSTALLATION
SUPPORT
MATERIALS
FUSION-TEC™
WALL-MOUNT PACKAGE
AIR CONDITIONER
Models:
HR58APA
HR58APB
Part of the Bard Free Cooling Unit System
NOTE: LV1000 Controller is required for operation when multiple HR58AP*
units are used.
Bard Manufacturing Company, Inc.
Bryan, Ohio 43506
www.bardhvac.com
Date: 4-18-17
Page 1 of 53
Page 2
CONTENTS
SECTION 1: Installation Instructions ......................................................................................................... 7
List of Necessary Materials/Tools ...................................................................................................................... 8
Site Preparation ............................................................................................................................................. 9
Model Indentification ................................................................................................................................ 9
New Shelter Installation vs. Retrofit Installation .......................................................................................... 9
Minimum Clearance .................................................................................................................................. 9
Clearance to Combustibles ........................................................................................................................ 9
Wall-Mount Unit Mounting ............................................................................................................................. 11
Wall-Mount Unit Wiring ................................................................................................................................. 16
Main Power Wiring .................................................................................................................................. 16
Unit Voltage Wiring ................................................................................................................................. 16
Communication Wiring ............................................................................................................................ 18
Preliminary Start Up ..................................................................................................................................... 20
Running in Stand Alone (Orphan) Mode .................................................................................................... 20
Completing Wall-Mount Set Up ...................................................................................................................... 21
Setting Up Wall-Mount Unit for Operation ................................................................................................. 21
Setpoints ......................................................................................................................................... 21
Executing a Run Test ........................................................................................................................ 21
Addressing Wall-Mount Units............................................................................................................. 22
Supply Air Grill Installation ..................................................................................................................... 22
Completing the Installation...................................................................................................................... 23
SECTION 2: Service Instructions ............................................................................................................... 26
Using the TEC-EYETM .................................................................................................................................... 26
TEC-EYETM Hand-Held Diagnostic Tool ...................................................................................................... 26
TEC-EYETM Menu Structure ............................................................................................................... 27
TEC-EYE
Status Screen .................................................................................................................................. 27
Quick Menu ..................................................................................................................................... 27
Operation ..................................................................................................................................................... 28
Unit On/Off ............................................................................................................................................ 28
Alarm Adjustment ................................................................................................................................... 28
Acknowledging/Clearing Alarms ......................................................................................................... 28
Stand Alone Mode .................................................................................................................................. 28
Temperature/Humidity Control ................................................................................................................. 28
Temperature/Humidity Control Components ........................................................................................ 28
Return Air Temperature Sensor .................................................................................................... 28
Temperature/Humidity Control Operation ............................................................................................ 29
Cooling ..................................................................................................................................... 29
Heating ..................................................................................................................................... 29
Staging ..................................................................................................................................... 29
Dehumidification ....................................................................................................................... 30
Temperature/Humidity Control Alarms ................................................................................................ 30
Return Air Temperature Alarm ..................................................................................................... 30
Electronic Expansion Valve (EEV) ............................................................................................................. 31
EEV Components .............................................................................................................................. 31
Electronic Expansion Valve .......................................................................................................... 31
Low Pressure Transducer............................................................................................................. 31
EEV Operation ................................................................................................................................. 31
EEV Superheat Control ............................................................................................................... 31
EEV Instructions for Vacuum, Reclaim, Charge Unit ...................................................................... 31
System Pressures ....................................................................................................................... 32
EEV Alarms ..................................................................................................................................... 33
Refrigerant Low Pressure Alarm ................................................................................................... 33
Suction Temperature Alarm ......................................................................................................... 33
Suction Pressure Alarm .............................................................................................................. 33
Low Superheat Alarm ................................................................................................................. 33
TM
Acronyms ........................................................................................................................ 27
Page 2 of 53
Page 3
Indoor Airflow ......................................................................................................................................... 33
Indoor Airflow Components ................................................................................................................ 33
Blower ...................................................................................................................................... 33
Filters ....................................................................................................................................... 34
Differential Airflow Switch ........................................................................................................... 34
Freezestat ................................................................................................................................. 34
Dirty Filter Switch ...................................................................................................................... 35
Filter Indicator Light .................................................................................................................. 35
Indoor Airflow Operation ................................................................................................................... 35
Blower Speed Control ................................................................................................................. 35
Indoor Airflow Alarms........................................................................................................................ 35
Blower Status Alarm ................................................................................................................... 35
Freezestat Alarm ........................................................................................................................ 36
Dirty Filter Alarm ....................................................................................................................... 36
Supply Air Temperature Alarm ..................................................................................................... 36
Condenser Fan ....................................................................................................................................... 36
Condenser Fan Components .............................................................................................................. 36
Condenser Fan ........................................................................................................................... 36
High Pressure Transducer ........................................................................................................... 37
Discharge Temperature Sensor .................................................................................................... 37
Condenser Fan Operation .................................................................................................................. 38
Condenser Fan Speed Control ...................................................................................................... 38
High Pressure Control ................................................................................................................. 38
Low Pressure Control .................................................................................................................. 38
Condenser Fan Alarms ...................................................................................................................... 39
Dirty Condenser Coil Alarm ......................................................................................................... 39
Compressor ............................................................................................................................................ 39
Compressor Components ................................................................................................................... 39
Compressor ............................................................................................................................... 39
Compressor Control Module (CCM) ............................................................................................... 39
High Pressure Safety Switch ....................................................................................................... 40
Phase Monitor ........................................................................................................................... 40
Compressor Operation ....................................................................................................................... 40
Compressor Alarms ........................................................................................................................... 40
Refrigerant High Pressure Alarm .................................................................................................. 40
Economizer ............................................................................................................................................ 41
Economizer Components ................................................................................................................... 41
Actuator .................................................................................................................................... 41
Damper Blade ............................................................................................................................ 41
Dust Sensor ............................................................................................................................... 41
Damper Switch .......................................................................................................................... 41
Outdoor Temperature and Humidity Combination Sensor ................................................................ 42
Supply Temperature Sensor ......................................................................................................... 42
Economizer Operation ....................................................................................................................... 43
Economizer Alarms ........................................................................................................................... 44
Damper Failed to Close Alarm ..................................................................................................... 44
Damper Failed to Open Alarm ..................................................................................................... 45
Outdoor Temperature Sensor Failure Alarm ................................................................................... 45
Outdoor Humidity Sensor Failure Alarm ........................................................................................ 45
Supply Temperature Sensor Failure Alarm .................................................................................... 45
Dust Sensor Failure Alarm .......................................................................................................... 45
Dust Limit Alarm ....................................................................................................................... 45
High Supply Air Temperature Alarm ............................................................................................. 46
Low Supply Air Temperature Alarm .............................................................................................. 46
Emergency Ventilation Mode .................................................................................................................... 46
Page 3 of 53
Page 4
Model/Serial Number Configuration .......................................................................................................... 46
Electric Heat Option ............................................................................................................................... 46
Electric Heat Components ................................................................................................................. 46
Electric Heating Element ............................................................................................................ 46
Thermal Overload ....................................................................................................................... 46
Electric Heat Operation ..................................................................................................................... 47
Bard Guard Anti-Theft System Option ....................................................................................................... 47
Smoke Detector Option ........................................................................................................................... 47
Refrigerant Information ................................................................................................................................. 48
General ................................................................................................................................................. 48
Topping Off System Charge ...................................................................................................................... 48
Safety Practices ..................................................................................................................................... 48
Important Installer Note .......................................................................................................................... 48
R410-A Refrigerant Charge ..................................................................................................................... 48
Pressure Service Ports ............................................................................................................................ 49
Maintenance and Troubleshooting .................................................................................................................. 50
Standard Maintenance Procedures ........................................................................................................... 50
Troubleshooting FUSION-TEC Wall-Mount Unit Alarms ............................................................................... 52
FIGURES AND TABLES
Figure 1.1 FUSION-TEC Model Nomenclature ...........8
Figure 1.2 Dimensions ..........................................10
Figure 1.3 Prefilling Traps on Indoor Drain Pan
Hoses
Figure 1.4 Mounting Instructions ...........................13
Figure 1.5 Electric Heat Clearance .........................14
Figure 1.6 Wall Mounting Instructions ....................14
Figure 1.7 Wall Mounting Instructions ....................15
Figure 1.8 Common Wall Mounting Installations ......15
Figure 1.9 Wire Routing ........................................17
Figure 1.10 WIRING: VAC Supply Wiring
Landing Points .....................................17
Figure 1.11 Adjusting the 230/208 VAC
Transformer ..........................................17
Figure 1.12` WIRING: Connecting Communication
Wires to Unit ........................................18
Figure 1.13 WIRING: HR58AAP* Wiring Diagram ......19
Figure 1.14 Cooling and Heating Setpoints ...............21
Figure 1.15 Executing Run Test ...............................21
Figure 1.16 Addressing Wall-Mount Units .................22
Figure 1.17 Changing Economizer Control Type .........22
Figure 1.18 Fold-Out Diverter ..................................23
Figure 1.19 Downward Curved Diverter Blades ..........23
Figure 1.20 View of Installed Grille ..........................23
Figure 2.1 TEC-EYETM Display and Interface ............26
Figure 2.2 TEC-EYETM Connection to Unit Control ....26
Figure 2.3 Quick Menu Icons .................................27
Figure 2.4 Clearing All Alarms ...............................28
Figure 2.5 Adjusting Return Air Sensor ...................28
Figure 2.6 Setpoints .............................................29
Figure 2.7 Cooling w/Economizer ...........................29
Figure 2.8 Cooling w/No Economizer ......................30
Figure 2.9 Heating ...............................................30
Figure 2.10 Viewing Unit Stages ..............................30
Figure 2.11 Adjusting Low Pressure Sensor Values ....31
Figure 2.12 Adjusting Suction Temperature Sensor
Values .................................................31
Figure 2.13 Overriding EEV Output ..........................32
Figure 2.14 Electronic Expansion Valve (EEV) and
Service Tool .........................................32
Figure 2.15 Adjusting Low Pressure Alarm Settings ...33
....................................................
12
Figure 2.16 Putting Blower Output into Override
Mode ...................................................32
Figure 2.17 Verifying Differential Airflow Status ........34
Figure 2.18 Verifying Freeze Switch Status ...............35
Figure 2.19 Adjusting Air Flow Alarm Delay ..............35
Figure 2.20 Adjusting Freezestat Alarm Delay ...........36
Figure 2.21 Verifying Condenser Fan Output .............36
Figure 2.22 Fan Blade Setting .................................37
Figure 2.23 Adjusting High Pressure Input ...............37
Figure 2.24 Adjusting Discharge Temperatue Input ....38
Figure 2.25 Pressure Control ...................................38
Figure 2.26 Adjusting Dirty Condenser Alarm
Setting ................................................39
Figure 2.27 Adjusting Compressor Delays .................40
Figure 2.28 Damper Override ..................................41
Figure 2.29 Dust Sensor .........................................41
Figure 2.30 Damper Switch .....................................42
Figure 2.31 Outdoor Air Sensor ...............................42
Figure 2.32 Outdoor Humidity Sensor ......................42
Figure 2.33 Supply Air Sensor .................................43
Figure 2.34 Economizer Setup ................................43
Figure 2.35 Economizer Setup – Enthalpy Control .....44
Figure 2.36 Economizer Setup – TempHum Control ...44
Figure 2.37 Adjusting Damper Failed to Close Delay ..45
Figure 2.38 Adjusting Dust Sensor Alarm Setpoint ....45
Figure 2.39 Adjusting High Supply Air Temperature
Differential ..........................................46
Table 1.1 Clearance Required for Service Access
and Adequate Condenser Airflow ..............9
Table 1.2 Minimum Clearances Required to
Combustible Materials ............................9
Table 1.3 Electrical Specification .........................16
Table 2.1 Blower Speeds .....................................34
Table 2.2 Filter Switch Pressure Settings ..............35
Table 2.3 Condenser Fan Speeds ..........................38
Table 2.4 Economizer Default Setting ...................44
Table 2.5 Cooling Pressures .................................49
Table 2.6 Rated Airflow .......................................51
Table 2.7 Indoor Blower Performance ....................51
Table 2.8 Maximum ESP of Operation:
Electric Heat Only ................................51
Page 4 of 53
Page 5
GENERAL INFORMATION
Free Cooling Unit System
This Bard Free Cooling Unit System is composed of
FUSION-TEC 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 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
wall-mount units. They are a complete system,
and must be used together.
Wall-Mount Air Conditioner Units
The FUSION-TEC units operate on VAC power.
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.
The
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
furnace. 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
Page 5 of 53
Page 6
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.
Page 6 of 53
Page 7
SECTION 1:
INSTALLATION
INSTRUCTIONS
Page 7 of 53
Page 8
LIST OF NECESSARY MATERIALS/TOOLS
Additional hardware and miscellaneous supplies are needed for installation. These items are field supplied and must
be sourced before installation. This list also includes tools needed for installation.
List of Materials/Tools
• Personal protective equipment/safety devices
• SGR-5W Supply Grille and RGR-5W Return Grille
• Field-fabricated sleeves (if necessary)
• Bottom mounting bracket #113-140 (optional)
• Fasteners sufficient for mounting the units such as
5/16" diameter anchor/lag bolts
• 7/8" diameter washers
• Commercial grade outdoor silicone sealant
• Miscellaneous hand and power tools and jobsite or
shop materials
• Lifting equipment with the necessary capacity and
rigging to safely move/install the systems
FIGURE 1.1
FUSION-TEC Wall-Mount Unit Model Nomenclature
HR 58 A P A 0Z E P X X X X
UNIT SERIES
MAXIMUM SENSIBLE CAPACITY
58 – 5 Ton 2 Stage Step Capacity
REVISION
A – Revision Level
CONTROL LOGIC AND CLIMATE OPTIONS
P – Programmable Logic Board
VOLTS & PHASE
A – 230/208/60/1
B – 230/208/60/3
ELECTRIC HEAT
0Z – O kW with Circuit Breaker
05 – 5 kW with Circuit Breaker
MZ – O kW with Circuit Breaker and Inverter
M5 – 5 kW with Circuit Breaker and Inverter
E – Factory-Installed Economizer (All Units)
P – MERV8 Disposable Pleated Filter
4 – Buckeye Gray Baked Enamel Finish
5 – Desert Brown Baked Enamel Finish
8 – Dark Bronze Baked Enamel Finish
X – Copper/Aluminum Evaporator Coil, Copper/Aluminum Condenser Coil
1 – Copper/Aluminum Evaporator Coil, AeroMarine Coated Condenser Coil
3 – AeroMarine Coated Evaporator Coil, AeroMarine Coated Condenser Coil
4 – Condenser Section Component Coating, AeroMarine Coated Evaporator Coil and Condenser Coil
5 – Internal and External Cabinet Component Coating, AeroMarine Coated Evaporator Coil and Condenser Coil
X – Standard accessories including airflow sensor, dirty filter sensor, pressure transducers, crankcase heater
S – All standard accessories plus additional security features and security cage
• Water to prime drain traps
• Electrical supplies
- Various size circuit breakers for the shelter AC
breaker box (see Table 1.3 on page 16)
- High-voltage wire of various gauges
(see Table 1.3)
- Communication wire: 2-wire, 18 gauge,
shielded with drain
- Miscellaneous electrical supplies including
rigid/flexible conduit and fittings, junction
boxes, wire connectors and supports
VENT PACKAGE
FILTER
COLOR AND CABINET FINISH
X – Beige Baked Enamel Finish
1 – White Baked Enamel Finish
PLACEHOLDER
X – Future Use
COIL AND UNIT COATING OPTIONS
ACCESSORIES AND CONTROLS OPTIONS
Page 8 of 53
Page 9
SITE PREPARATION
Model Identification
Identify the specific model using the model
nomenclature information found in Figure 1.1 and
the model/serial tag found on the unit. See Figure 1.2
on page 10 for dimensions and critical installation
requirements.
New Shelter Installation vs. Retrofit
Installation
These installation instructions cover both new shelter
installations and retrofit installations. Each installation
is unique and may require special accommodations and
modifications. Although Bard Manufacturing follows a
long-established tradition of manufacturing equipment
using industry standard dimensions for building
penetration, it is occasionally necessary to move or
enlarge supply and return openings when replacing
non-standardized equipment in a retrofit application.
IMPORTANT: All retrofit installations require any
existing supply and return grilles be removed and
discarded. This is a counterflow unit and requires
specified grilles to ensure proper system performance.
Minimum Clearance
Counter flow wall-mount air conditioner models have
a removable lower front service panel that allows
access to the control panel, blower, compressor, circuit
breakers and heat strip. There is a hinged access panel
on both sides for filter change and evaporator coil
service.
The upper side panel is removable to allow access
to condenser fan, condenser coil and filter drier. The
design allows for installations to place units within
close proximity without complicating maintenance and
repair.
To maintain full serviceability, side-by-side installations
require 15" of clearance between units.
The condenser discharge air exits through the top
of the unit. Although this reduces the potential for
recirculation, it is still critical to system performance
that any obstruction, shrubbery or structure adhere to
minimum clearances listed (see Table 1.1).
For overhangs not exceeding 12" from exterior wall,
minimum allowable clearance from top of unit
to bottom of overhang should be no less than 5".
For overhangs greater than 12" from exterior wall,
minimum allowable clearance from top of unit to
bottom of overhang should be no less than 10" .
Clearance to Combustibles
!
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.
The unit itself is suitable for 0" clearance, but the
supply air flange requires a minimum of 1/4" clearance
to combustible material. However, it is generally
recommended that a 1" clearance is used for ease of
installation and maintaining the required clearance to
combustible material. See Figure 1.4 on page 13 for
details on opening sizes.
TABLE 1.1
Clearance Required for Service Access and Adequate Condenser Airflow
Model Side(s)
HR58 15" 5" 10"
Discharge (Top)
Overhang 12" or less
Discharge (Top)
Overhang
Exceeding 12"
TABLE 1.2
Minimum Clearances Required to Combustible Materials
Model Supply Air Flange Cabinet
HR58 1/4" 0"
Intake (Base) Front of Unit
15" from
Snowline
36" 24"
Shelter
Equipment from
Supply Grille
Page 9 of 53
Page 10
Side ViewFront View
Electric
Heat
Back View
G
F
W
2° Pitch
Rain Hood
Access Panel
Access Panel
Condenser
Disconnect
C. Breaker
Built In
Service Port
Cover
L
7.125
D
M
C
I
1.500
K
J
N
A
H
Mounting
Brackets
Side Wall
(Built In)
Top Rain
Flashing
Shipping
Location
Q
E
B
B
Q
Q
P
.500
R
Q
O
MIS-3894
HR58
UNIT
FIGURE 1.2
Return Supply
A B C B E F G I J K L M N O P Q R
Page 10 of 53
Dimensions of Basic Unit for Architectural and Installation Requirements (Nominal)
(H)
Height
(D)
Depth
(W)
Width
Model
HR58 42.00 30.00 76.00 9.88 29.88 14.25 15.63 44.00 39.00 35.00 30.00 29.13 13.00 31.13 34.13 3.50 43.00 6.69 16.00 3.88
All dimensions are in inches. Dimensional drawings are not to scale.
Page 11
WALL-MOUNT UNIT MOUNTING
Mounting the Units
!
WARNING
Heavy item hazard.
Use more than one person to handle unit.
Failure to do so could result in unit damage or
serious injury.
NOTE: It may be best to spot some electrical knockouts
(such as those located on the sides of the
wall-mount unit) before units are mounted and
access is unavailable or limited (see Figure 1.2
to locate pre-punched knockouts).
Two holes for the supply and return air openings must
be cut through the wall as shown in Figure 1.4 on page
13. On wood frame walls, the wall construction must
be strong and rigid enough to carry the weight of the
unit without transmitting any unit vibration. All walls
must be thoroughly inspected to ensure that they are
capable of carrying the weight of the installed unit.
In retrofit (unit replacement) installations, the openings
cut for the original equipment may not line up exactly
with needs of this installation. Modifications may need
to be made, such as increasing or decreasing the size
of the wall cutouts. The existing bolt placement may
not line up in which case the original bolts would need
to be removed or cut away.
These units are secured by wall mounting flanges which
secure the unit to the outside wall surface at both
sides. An optional bottom mounting bracket (purchased
separately) is available, but not required.
The unit itself is suitable for 0" clearance, but the
supply air flange requires a minimum of 1/4" clearance
to combustible material. However, it is generally
recommended that a 1" clearance is used for ease of
installation and maintaining the required clearance
to combustible material. See Figure 1.4 for details on
opening sizes.
IMPORTANT: When removing the shipping pallet from
beneath the wall unit, do not loosen or remove any of
the screws from either side of the unit.
1. Locate and mark lag bolt locations on both sides
and location for optional bottom mounting bracket,
if desired (see Figure 1.4).
NOTE: Top rain flashing is attached to back of unit
for shipping purposes. Be sure to remove this
flashing before installing unit.
2. If desired, hook top rain flashing under back bend
of top.
3. Position unit in opening and secure with fasteners
sufficient for the application such as 5/16" lag/
anchor bolts; use 7/8" diameter flat washers on
the lag bolts. It is recommended that a bead of
commercial grade outdoor silicone sealant caulk be
placed behind the side mounting flanges.
NOTE: Opening and removing the filter access door
from each side may make fastening unit to wall
easier.
4. Secure optional rain flashing to wall and caulk
around entire unit (see Figure 1.4).
5. For additional mounting rigidity, the return air
and supply air frames or collars can be drilled
and screwed or welded to the structural wall itself
(depending upon wall construction). Be sure to
observe required clearance if combustible wall.
6. Four plastic drain hoses extend from the condenser
and evaporator drain pans. The drain hoses are
secured to fittings mounted to the unit base.
NOTE: At the time of installation, Bard highly
recommends prefilling of the traps on both of
the indoor drain pan hoses to ensure proper unit
drainage at start. The water traps can easily
be seen with the front service panel removed.
To fill traps, pour water into both sides of
evaporator drain pan until the drain hoses are
visibly full (see Figure 1.3 on page 12.)
A unique feature of the FUSION-TEC is ability to hang
the font service panel on the unit in a position that
allows full access to the control panel (see Figure 1.4
on page 12). To do this, remove the panel and hook top
lip of panel into bottom channel of control panel. For
added front panel stability, use several of the screws
that were removed to temporarily connect the panel to
the unit.
Page 11 of 53
Page 12
FIGURE 1.3
Prefilling Traps on Indoor Drain Pan Hoses
Evaporator Drain Pan Left Side Drain Hose Evaporator Drain Pan Right Right Drain Hose
Pour water into evaporator drain pan directly above left and right
drain fittings until coiled drain tubes are visibly full.
FIGURE 1.4
Hanging Front Access Panel to Allow
Access to Control Panel
Page 12 of 53
Page 13
MIS-3898
Wall Structure
THE SIDE MOUNTING FLANGES AND UNDER
NOTES:
TOP FLASHING AT TIME OF INSTALLATION
IT IS RECOMMENDED THAT A BEAD OF
SILICONE CAULKING BE PLACED BEHIND
Foam Air Seal
Supplied
FIGURE 1.4
Mounting Instructions
Of Calking Along
Seal With Bead Rain Flashing
Entire Length Of Top
Top Of Unit
Air
Return
Supply Air
Opening
Right Side View
B
E
16"
WALL
A
30"
Return Air Opening
Supply Air Opening
D
Wall Opening and Hole Location View
17"
17"
17"
17"
Page 13 of 53
Page 14
Electric Heat Clearance
Typical Building
Outside Sheeting
FIGURE 1.5
Wall Frame
Inside Sheeting
Wall Mounting Instructions
See FIGURE 2 – Mounting Instructions
Supply Air Duct
Flange of Wall
1/4" Min.
FIGURE 1.6
1/4" Min.
SUPPLY GRILLE
FACTORY SUPPLIED
RAIN FLASHING.
MOUNT ON UNIT
BEFORE INSTALLATION
MIS-3897
WALL STRUCTURE
RETURN AIR
OPENING
SUPPLY AIR
OPENING
RETURN AIR
OPENING
SUPPLY AIR
OPENING
WOOD OR STEEL SIDING
CONCRETE BLOCK WALL INSTALLATION WOOD FRAME WALL INSTALLATION
Page 14 of 53
SIDE VIEW
RETURN AIR
OPENING
SUPPLY AIR
OPENING
MIS-3896
Page 15
FIGURE 1.7
Wall Mounting Instructions
ATTACH TO TOP
PLATE OF WALL
SEE UNIT DIMENSIONS, FIGURE 1.2,
SEE UNIT DIMENSIONS, FIGURE 2,
FOR ACTUAL DIMENSIONS.
FOR ACTUAL DIMENSIONS.
E + 1.000
B
MIS-3895
FRAMING MATERIAL
2 x 4'S, 2 x 6'S &/OR
STRUCTURAL STEEL
1.000" CLEARANCE
ALL AROUND DUCT
IF REQUIRED
INTERIOR FINISHED WALL
OVER FRAME
1.000" CLEARANCE
ALL AROUND DUCT
IF REQUIRED
EXTERIOR FINISH WALL
OVER FRAME
ATTACH TO BOTTOM
PLATE OF WALL
FIGURE 1.8
Common Wall Mounting Installation
RETURN DUCT
OPENING
SUPPLY DUCT
OPENING
2 x 6
1.000
A
I
C
K
C
L
THIS STRUCTURAL MEMBER
LOCATED TO MATCH STUD
SPACING FOR REST OF WALL.
A SECOND MEMBER MAY BE
REQUIRED FOR SOME WALLS.
RAIN
FLASHING
OUTSIDE
WALL
RAFTERS
SUPPLY AIR
OPENING W/ GRILLE
FREE AIR FLOW
NO DUCT
FINISHED CEILING SURFACE
RETURN AIR DUCT
W/ GRILLE
MIS-3899
Page 15 of 53
Page 16
WALL-MOUNT UNIT WIRING
!
WARNING
Electrical shock hazard.
Have a properly trained individual perform
these tasks.
Failure to do so could result in electric shock
or death.
Main Power Wiring
Refer to the unit rating plate or Table 1.3 for wire
sizing information and maximum fuse or circuit breaker
size. Each outdoor unit is marked with a “Minimum
Circuit Ampacity”. The field wiring used must be sized
to carry
installed KW of electric heat, there may be two field
power circuits required. If this is the case, the unit
rating plate will so indicate. All models are suitable
only for connection with copper wire. Each unit and/or
wiring diagram will be marked “Use Copper Conductors
Only”. These instructions must be adhered to. Refer
to the National Electrical Code (NEC) for complete
current carrying capacity data on the various insulation
grades of wiring material. All wiring must conform to
NEC and all local codes.
that amount of current. Depending on the
The unit rating plate and Table 1.3 list fuse and wire
sizes (75°C copper) for all models including the most
commonly used heater sizes. Also shown are the
number of field power circuits required for the various
models with heaters.
The unit rating plate lists a maximum circuit breaker or
fuse that is to be used with the equipment. The correct
size must be used for proper circuit protection and also
to assure that there will be no nuisance tripping due to
the momentary high starting current of the compressor
motor.
The main unit circuit breaker disconnect access is
located on the front panel of the unit. Located at the
upper right corner of this panel is the rubber circuit
breaker boot. This allows unit power to be disconnected
without panel removal.
Route all field wires in channel under the control panel
as shown in Figure 1.9.
See Figure 1.10 to reference VAC landing points.
Unit Voltage Wiring
230/208V 1 phase and 3 phase equipment use dual
primary voltage transformers. All equipment leaves the
factory wired on 240V tap. It is very important that
the correct voltage tap is used. For 208V operation,
reconnect from 240V to 208V tap (see Figure 1.11).
The acceptable operating voltage range for the 240 and
TABLE 1.3
Electrical Specifications – HR58AP Series
Single Circuit
Model
HR58 A0Z
HR58 B0Z
Maximum size of the time delay fuse or circuit breaker for protection of field wiring conductors.
Based on 75°C copper wire. All wiring must conform to the National Electrical Code and all local codes.
These “Minimum Circuit Ampacity” values are to be used for sizing the field power conductors. Refer to the National
Electrical code (latest version), Article 310 for power conductor sizing.
CAUTION: When more than one field power circuit is run through one conduit, the conductors must be derated. Pay
IMPORTANT: While this electrical data is presented as a guide, it is important to electrically connect properly sized fuses
Rated Volts
& Phase
230/208-1
A05
230/208-3
B06
special attention to Note 8 of Table 310 regarding Ampacity Adjustment Factors when more than three current
carrying conductors are in a raceway.
and conductor wires in accordance with the National Electrical Code and all local codes.
No. Field
Power
Circuits
1
1
1
1
Minimum Circuit
Ampacity
43
43
30
30
Maximum
External Fuse or
Circuit Breaker
60
60
45
45
Field Power
Wire Size
8
8
8
8
Ground Wire
10
10
10
10
Page 16 of 53
Page 17
FIGURE 1.9
Wire Routing
VAC Supply Wiring Landing Points
FIGURE 1.10
FIGURE 1.11
Adjusting the 230/208 VAC Transformer
230/208V 1 phase and 3 phase equipment use dual primary voltage transformers. All equipment leaves the factory wired on
240V tap. It is very important that the correct voltage tap is used. For 208V operation, reconnect from 240V to 208V tap.
The acceptable operating voltage range for the 240 and 208V taps are: 240V Tap (253 – 216) and 208 Tap (220 – 197).
1. Verify incoming AC voltage: Multimeter set to VAC
.
NEW IMAGE
NEEDED
Shelter supply breaker in ON position
Bard system breaker in OFF position
230V/208V Single Phase Voltage Range:
197VAC – 253VAC
230V/208V Three Phase Voltage Range:
197VAC – 253VAC
(not shown)
2. If incoming AC voltage is 220VAC or above...
...do not adjust transformer
230VAC
+
3. If incoming AC voltage is below 220VAC...
...shut off AC breaker to unit
and move factory "240V" wire to "208V" terminal
Page 17 of 53
Page 18
208V taps are: 240V Tap (253 – 216) and 208 Tap
(220 – 197).
NOTE: The voltage should be measured at the field
power connection point in the unit and while
the unit is operating at full load (maximum
amperage operating condition.
Communication Wiring
For low voltage wiring, 2-wire 18 gauge shielded with
drain is recommended.
From the controller, extend the shielded cable through
a separate conduit and route to the terminal block
mounted on the wall-mount unit next to the control
board (see Figure 1.12).
Note that the terminal block label is clearly marked “+”
and “-”. These connections are polarity-sensitive. Twowire communication from control board is prewired to
terminal block. Make sure to match "+" and "-" symbols
on controller terminal block.
Make small service loop in cable and attach EMI filter
(included) as shown if unit is last in communication
chain. See LV1000 controller manual 2100-673 for
complete information on connecting the wall units to
the LV controller.
FIGURE 1.11
Connecting Communication Wires to Unit
1 2 4 5 7 9 108 12 14 16 173 6
Unit Terminal Block
13 15
11
– +
From LV1000
Controller
Page 18 of 53
Page 19
FIGURE 1.13
Damper Motor
Black
HR58AAP* Wiring Diagram
4097-701 B
GND
7
L2
CB
AC
L1
8
Coil
Comp
Alaram
Contactor
21
Black/White
Yellow/Red
19
CC
12
HPC
Red
23
HPC
1
3
2
2-10
VDC
GND
24VAC
3
21
+5V
Black
30
Gray/Black
Gray/White
Red/Yellow
80
80
73
Red/White
Black/White
15
66
65
1 1
Black
Red
Black/White
Black/White
17 17
13
Relay Coil
Black/White
17
Pink
24
Blue
C
LPCLPC
ALR
R
Red
23
FIELD BUS 2
DI1
Yellow/White
Red/Yellow
2
2
43
Orange
22
Blue
Y
42
22
20
22
Yellow
67
Blue Blue
40
C1
NO2
NO1
GO
G
DI2
DI3
DI4
25
93
73
4
5
3
453
Power loss(OPT)
NO3
Red/White
18
DI5
68
SPEAKER
6
6
DFS
18
Red/White
SOLINOID
UNLOADER
Heat
Contactor
Blue
Brown/White
56
C2
NO4
DI6
DI7
GND
Orange/Black
LOOP
SECURITY
88
7
7
EHT
T
F
Remove jumpers
Red
38 36
8
8
Coil
NO5
LT
9
9
Black
58
smoke sensor
when connecting
Red
94
CNC
L1
AUX
72
Black
CAP
41 35
Yellow Yellow
Red/White
NO6
B1
B2B3B4
LT
10101112
34
Black
32
L2
T1
CONTACTOR
COMPRESSOR
T2
41
41
10
Red
29
CCH
NO7
Black
64
Blue/White
Orange/Black
11
12
43
Orange
Black
COMPRESSOR
C7
B5B6B7
13
13
72
Black
NC7
48
14
Gray/Green
62
61
18
Red/White
GND
49
44
Com
NC
Black/Green
151416171818
15
Blue/Wht
Red
Black
ELECTRONIC EXPANSION VALVE
LIQUID TEMPERATURE
AIR FLOW SWITCH
DIRTY FILTER SWITCH
OUTDOOR TEM P. AND HUMID. SENSOR
SUCTION PRESSURE SENSOR
DISCHARGE PRESSURE SENSOR
SUPPLY AIR TEMPERATURE
RETURN AIR TEMPERATURE
SUCTION TEMPERATURE
BLADE SWITCH
FREEZE STAT
DIRTY FILTER LIGHT
Block
Terminal
9
Black
46
46
Red
Red/White
Black/White
+VDC
Pink
63
Blade Switch
69
44
AFS
48
Red
Black
Red
FAN
MOTOR
BLOWER
C8
18
17
18
Blue
B8
B9
48
SAT
Alarm Relay
RAT
NO C
Gray/Black
Black/Green
Black/Green
Black/Green
Black
Black/Green
26
16
17
19 19
Black
Gray/Red
Black
48
Gray/White
ST
OATH
49
Red
45
EEVLTAFS
DFS
OATH
Red
31
33
11
TRANSFORMER
Black
Black
MOTOR
NO9
NO8
Green
Red/White
47
Y1
Y2
Y3
GND
18
27
45
51
Blue
Black/Green
Black/Green
28
28
2020
2121
2323
22 22
Black
45
FS
SP
57
Black
103
Red
103
SATDPSP
Black/White
17
Yellow
EEV
Yellow
62
50
AC
ACG
103
Red/White
53
Orange
25
24
24
25
DP
DUST
SENSOR
52
Blk/Wht
TOP
2626
BOTTOM
27 27
Black
57
Field OptionalFactory
D-10VDC
Low Voltage
High Voltage
HIGH PRESSURE CONTROL
TERMINAL BLOCK
CRANKCASE HEATER
CCH
HPCTBDFLFSBSSTRAT
Red
Red/White
71
47
DFL
White
79
V+
Dust
GND
Sensor
BOARD
Black/White
70
47
Page 19 of 53
Page 20
PRELIMINARY START UP
Running in Stand Alone (Orphan) Mode
With the AC breakers turned on, each FUSION-TEC
wall-mount unit has the capability to run without the
LV1000 controller attached—this feature is called
stand alone or orphan mode. This keeps the shelter
between 60°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, the wall
unit uses a continuous blower setting to circulate room
air into the return air inlet and uses the return air
temperature sensor to control room temperature.
The wall-mount unit can be turned on and off with
the TEC-EYE
chosen, the system will heat or cool.
NOTE: The blower will continue to run when OFF is
The unit will not go into stand alone mode until after
an initial call for cooling. (?)
To change default setpoints, refer to Setpoints on page
21.
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 wall-mount units is installed,
orphan mode can be enabled early in the installation—
keeping the climate inside the shelter stable and
the installers comfortable while the remainder of the
older equipment is removed and the remaining Bard
FUSION-TEC wall-mount units and LV1000 controller
are installed.
To ensure units will go into stand alone mode,
disconnect the plug marked R-T-/R+T+/GND on the
control board located in the wall-mount unit. Be sure
to reconnect the plug before operating the wall-mount
unit as part of the Bard Free Cooling Unit System.
Additionally, should any or all of the FUSION-TEC
wall-mount units lose communication with the LV1000
controller (such as during maintenance), they will
continue to serve the shelter’s needs until a repair can
be made.
See the LV1000 controller manual for complete
information on connecting the communication wiring
from the controller to the wall-mount units and
operating the Bard Free Cooling Unit System.
TM
hand-held diagnostic tool. When ON is
chosen. Refer to page 28 to change ON/OFF
Control.
Page 20 of 53
Page 21
COMPLETING WALL-MOUNT SET UP
Setting Up Wall-Mount Unit for
Operation
The TEC-EYETM hand-held diagnostic tool, shipped
with the LV1000 controller, is needed to complete the
installation of the wall-mount unit. Refer to page 26
for information on connecting and using the TEC-EYE
before proceeding with unit set up.
Setpoints
If at any time the unit(s) loses communication with the
LV1000 controller, the unit(s) will go into stand alone
mode. Local cooling and heating setpoints only apply to
stand alone mode.
The LV1000 setpoints will determine the cooling and
heating setpoints when communicating with the wall
units. The unit cooling and heating setpoints will
determine the cooling and heating setpoints when in
stand alone mode.
To verify or change the wall-mount unit cooling and
heating setpoints (local):
TM
1. Connect the TEC-EYE
control board located in the unit (as shown in
Figure 2.2 on page 26).
2. From the Status screen, press UP or DOWN key
until Quick Menu displays Setpoints icon (see
Figure 2.3 on page 27 ). Press ENTER key.
3. Press ENTER key to scroll to the selected choice
(see Figure 1.14).
4. Press UP or DOWN key on desired value until value
displays correctly.
5. Press ENTER key to submit value and move to next
parameter.
6. Press ESCAPE key until Main Menu screen is
displayed.
diagnostic tool to the
FIGURE 1.14
Cool and Heat Setpoints
Executing a Run Test
Execute a run test on each unit to verify the equipment
is functioning correctly. The run test parameters are not
adjustable.
TM
1. Press MENU key to access 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 Sys Config;
press ENTER key.
4. Press UP key to scroll to Run Test (A10) screen.
5. Press ENTER key to scroll to Run Test Enable
parameter (see Figure 1.15).
6. Press UP or DOWN key to change value to ON. The
run test will begin.
FIGURE 1.15
Executing Run Test
Parameter Description
Damper Test Volts: This is the control voltage applied to
the actuator during opening sequence for damper.
Damper Time: This is the time (in seconds) allowed for
both the opening sequence and closing sequence.
Heat/Cool Time: This is the time (in seconds) allowed
for cooling sequence and heating sequence.
Run Test Approximate Timings (in Minutes)
0:00 • Blower starts.
• Damper begins to open to damper test volts
parameter. To verify damper operation, open
unit side door. Inspect upper and lower
blades.
2:30 • Damper begins to close to 0 volts.
5:00 • Compressor turns on. Condenser fan
may also turn on depending on ambient
conditions.
6:00 • Compressor turns off. Condenser fan turns
off (if applicable).
• Heat turns on.
7:00 • Heat turns off.
8:00 • Blower turns off.
Page 21 of 53
Page 22
Addressing the Wall-Mount Units
Each unit must have a unique address for the system
to operate correctly with th LV controller (Ex: 1,
2, 3, 4 depending on the number of units). The
unit only needs the address to be changed for the
communication to work properly.
The wall-mount unit address is displayed in the upper
TM
right corner on the Status screen on the TEC-EYE
display (see Figure 2.1 on page 26).
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
USER password 2000.
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 1.16).
6. Press UP or DOWN keys to change the address to a
value between 1 and 4.
NOTE: Each unit must have a unique address for the
communication to work properly. Bard also
recommends labeling each unit for ease in
identification.
6. If desired, press UP or DOWN keys to change the
value from USA to SI, NC, LON, CAN or UK. Units
are preconfigured for each selection.
7. Press ENTER key to scroll to Continuous Blower.
8. If desired, press UP or DOWN keys to change the
value from None to Lead or All. Refer to Continous
Blower settings in Service Section for more
information on settings.
9. Press ENTER key to save and move the cursor back
to the top left position.
10. Press DOWN key to navigate to Economizer Setup
(A2) screen.
11. Press ENTER key to scroll to Type (see Figure
1.17).
12. Press UP or DOWN keys to change economizer
type to None, Drybulb, Temperature and Humidity
or Enthalpy.
13. Press ENTER key to save.
Basic wall unit parameter settings are now set and the
unit is ready to communicate with the LV.
FIGURE 1.17
Changing Economizer Control Type
FIGURE 1.16
Changing Unit Setup Values
In addition to the address setup, the user may also
want to set the unit of measure, continuous blower
setting and economizer control type.
To change these settings:
1. Press MENU key to access 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 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 UOM (see Figure
1.16).
Supply Air Grill Installation
Bard model SGR-5W grille is custom designed for
utilization with Bard wall-mount unit HR58AP for
optimizing the air flow pattern and distribution to
minimize recirculation issues, and optimizing airflow
patterns within the shelter. It is engineered to ensure
that the distributed air is forced in a downward and
outward direction to eliminate obstructions and such
from causing the distributed air from stratifying close
to the unit and getting drawn back into the return air
opening. With the optimized air pattern, the shelter
should experience distributed air at the opposite end of
the room.
To accomplish this, the grille has two special features:
1. The grille has a specialty fold-out diverter on
the backside of the grille that directs the supply
airflow in an outward pattern, thereby eliminating
the potential for the obstruction of supply air if
Page 22 of 53
Page 23
equipment would be directly mounted in front of
the unit. The rear deflectors must be folded out and
secured by the installer with the supplied screws
(see Figure 1.21).
FIGURE 1.21
Fold-Out Diverter
Rear deflectors as shipped
FIGURE 1.22
Downward Curved Diverter Blades
Rear deflectors raised and secured together
2. The grille is also equipped with downward curved
diverter blades to ensure a smooth and efficient
means of directing the air pattern in a downward
pattern, and away from being drawn back into
the return air opening. The curved diverter blades
are shipped in the flat position and need to be
folded out to between 75-90° (best tuned to each
individual structure). See Figures 1.22 and 1.23.
Diverter blades as shipped (left), and after raising (right)
FIGURE 1.23
View of Installed Grille (as seen from above)
Completing the Installation
At this stage, the installation process of the wall-mount
unit is finished. To complete the Bard Free Cooling
System installation, refer to the LV1000 controller
manual 2100-673.
Page 23 of 53
Page 24
Page 24 of 53
Page 25
SECTION 2:
SERVICE
INSTRUCTIONS
Page 25 of 53
Page 26
USING THE TEC-EYE
TEC-EYETM (Bard P/N 8301-059) Display and Interface (Status Screen Shown)
TM
FIGURE 2.1
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-EYETM Hand-Held Diagnostic Tool
The microprocessor control used in the FUSION-TEC
wall-mount air conditioners allows for complete control
and monitoring through the use of the provided TECEYETM hand-held monitor. This comprehensive service
tool utilizes the latest in state-of-the-art technology
including a large, easy-to-read backlit LCD graphic
display.
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
and operating parameters are permanently stored
on FLASH-MEMORY in case of power failure. The
controller is designed to manage temperature levels to
a user-defined setpoint via control output signals to the
wall mount air conditioning system.
TM
The TEC-EYE
board via an RJ11 modular phone connector as shown
in Figure 2.2.
connects to the wall-mount unit control
TM
display. The program
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 2.2
TEC-EYETM Connection to Unit Control
Modular Phone Connector for
TEC-EYETM Hand-Held Diagnostic Tool
When not being used, the TEC-EYETM hand-held
diagnostic tool should be stored inside or near the
LV1000 controller. Do not let the TEC-EYETM leave the
shelter.
Page 26 of 53
Page 27
TEC-EYETM Menu Structure
Quick Menu
Setpoints
Information
Alarm Log
Main Menu
System Configuration
Advanced System Configuration
I/O Configuration
On/Off
Alarm Logs
Settings
Logout
In addition to the menu structure above, there are also
Status and Alarm screens.
TM
TEC-EYE
Acronyms
MAT – Mixed air temperature
RAT – Return air temperature
OAT – Outdoor air temperature
OAH – Outdoor air humidity
Blower – Indoor blower status
Damper – Free cooling damper position status
CL1 – Compressor stage 1 status
CL2 – Compressor stage 2 status
H1 – Heater stage 1 status
H2 – Heater stage 2 status
ODP – Calculated outdoor dew point
FC – Free cooling status
RN – Component run time in minutes in last hour
ST – Number of start requests in last hour
NOTE: Digital refers to On/Off whereas analog is a
variable input.
Status Screen
The Status screen is the default start-up screen and
also the return screen after 5 minutes of no activity.
The screen can be accessed any time by pressing the
ESCAPE key repeatedly.
The wall-mount unit address is displayed in the upper
right corner on the Status screen (see Figure 2.1). The
Status screen also shows the current date, time, return
air temperature, mixed air temperature, outdoor air
temperature, outdoor humidity and outdoor dew point
conditions. Blower, damper and unit status are also
displayed.
The Quick Menu is accessible from the Status screen.
Setpoints, Information and Alarm Log are available
through the Quick Menu. Pressing the UP or DOWN
keys while on the Status screen will change the Quick
Menu icon displayed (see Figure 2.3). Press the
ENTER key when the desired icon is displayed.
Quick Menu
Setpoints
From this screen, the unit heating and cooling
setpoints can be changed (see Setpoints on page
21). This screen also displays the current cooling and
heating setpoints which when connected to the LV1000
controller will show the heating and cooling setpoints
that are being communicated.
Information
These screens show electronic expansion valve (EEV)
information, run hours, averages and program version
information.
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.
FIGURE 2.3
Quick Menu Icons
Data Log Unit Information
Setpoints
Page 27 of 53
Page 28
OPERATION
Unit On/Off
The wall unit can be turned on and off from the
TEC-EYE
instructions will disable heating and cooling operation
but may not disable the blower. The blower may
continue to run if the unit or the LV1000 have the
continuous blower option enabled.
NOTE: Blower will run if the unit is in stand alone
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
3. Press UP or DOWN keys to scroll to On/Off; press
4. Press UP or DOWN keys to change value from On
5. Press ESCAPE key several times to return to Main
The wall unit may also be turned off by certain alarms
such as the smoke alarm input on the wall unit board
or the return air temperature sensor failure when not
connected to the LV1000.
TM
. Turning the unit off with the following
mode.
USER password 2000.
ENTER key.
to Off or from Off to On.
Menu screen.
Alarm Adjustment
Acknowledging/Clearing 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).
After an alarm condition is corrected, the alarm can be
cleared by pressing the ALARM key for 3 seconds.
To clear all alarms, navigate to the end of the alarm list
to the screen shown in Figure 2.4.
Stand Alone Mode
See PRELIMINARY START UP on page 20.
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
USER password 2000.
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 2.5).
6. If the measurement needs to be adjusted, apply
an offset value by pressing ENTER to 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 2.5
Adjusting Return Air Sensor
Page 28 of 53
FIGURE 2.4
Clearing All Alarms
Page 29
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 Local Cool or Local
Heat (see Figure 2.6).
3. Press UP or DOWN keys to change the value to
desired heating and/or cooling setpoint.
FIGURE 2.6
Setpoints
Cooling
The unit is equipped with 1 stage of freecooling and
2 stages of mechanical cooling (compressor and
unloader) for a total of 3 cooling stages (see Figure
2.7).
The unit is equipped with 1 stage of freecooling and
2 stages of mechanical cooling (compressor and
unloader). However, the outdoor conditions are not
favorable for economizer operation so there are a total
of 2 cooling stages (see Figure 2.8 on page 30).
Heating
The unit is equipped with 1 stage of electric heat (see
Figure 2.9 on page 30).
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 2.10 on
page 30).
Freecooling
Compressor Stage 1
Compressor Stage 2
Deadband(sometimes called a neutral zone or dead zone) is an interval of a signal domain or
band where no action occurs
-10% 0%
FIGURE 2.7
Cooling w/Economizer
10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Off
Deadband On
Page 29 of 53
110% 120%
Page 30
Compressor Stage 1
Compressor Stage 2
FIGURE 2.8
Cooling w/No Economizer
-10% 0%
Deadband(sometimes called a neutral zone or dead zone) is an interval of a signal domain or
band where no action occurs
10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Off
Deadband On
FIGURE 2.9
Heating
Electric Heat
-10% 10% 30% 50% 70% 90% 110%
Off
Deadband(sometimes called a neutral zone or dead zone) is an interval of a signal domain or
band where no action occurs
FIGURE 2.10
Viewing Unit Stages
Deadband On
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 may 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 LV manual for adjustment of the
dehumidification setpoint and differentials.
110% 120%
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.
Page 30 of 53
Temperature/Humidity Control Alarms
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.
Page 31
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.
Low Pressure Transducer
The unit has a low side pressure transducer installed
on the suction line between the evaporator coil
and compressor. The transducer is used for system
monitoring of low side 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
USER password 2000.
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 2.11).
6. If the measurement needs to be adjusted, apply
an offset value by pressing ENTER to 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 2.11
Adjusting Low Pressure Sensor Values
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
USER password 2000.
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 2.12).
6. If the measurement needs to be adjusted, apply
an offset value by pressing ENTER to 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 2.12
Adjusting Suction Temperature Sensor Values
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.
EEV Instructions for Vacuum, Reclaim, Charge Unit
The electronic expansion moves to the 0 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.
Page 31 of 53
Page 32
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
USER password 2000.
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.
5. Press ENTER key to scroll to Enable (see Figure
2.13).
6. 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.
10. Press the ESCAPE key several times to return to
Main Menu screen.
FIGURE 2.13
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 2.14) 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 are
provided on the tool). Opening the valve to the full
open position will aid in the refrigerant reclamation and
evacuation processes.
Following the above procedure, 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 Unit 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.
Page 32 of 53
FIGURE 2.14
Electronic Expansion Valve (EEV) and Service Tool
Page 33
EEV Alarms
Refrigerant Low Pressure Alarm
When the low 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 2.15).
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.
FIGURE 2.15
Adjusting Low Pressure Alarm Settings
Suction Pressure Alarm
When the suction pressure sensor 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.
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. This blower uses a 10" diameter
wheel operating 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
USER password 2000.
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 2.16 on page 32).
6. Press UP or DOWN keys to adjust the speed to the
desired output (see Table 2.1 on page 34).
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.
10. Press the ESCAPE key several times to return to
Main Menu screen.
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.
Page 33 of 53
Page 34
FIGURE 2.16
Putting Blower Output into Override Mode
TABLE 2.1
Blower Speeds
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
2.17).
FIGURE 2.17
Verifying Differential Airflow Status
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 Speed 45.0 4.5 v 1600
Heating 35.0 3.5 v 1335
Dehumidification
Mode
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
35.0 3.5 v 1335
Controller
Output Volts
CFM
Filters
The unit is equipped with two (2) 20" x 30" x 2" MERV
8 filters. The filers 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.
Differential Airflow Switch
The unit is equipped with a differential pressure airflow
switch to monitor the blower. If the blower is turned
on and the switch doesn't close to indicate there is
differential pressure between the inlet and outlet of the
blower, an alarm will be generated. (need to include
blower switch settings?)
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
USER password 2000.
Freezestat
These units are equipped with a switch that monitors
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 switch will 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 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
USER password 2000.
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 (C1); press ENTER key.
5. Reference 5 Freeze row and Val column (see Figure
2.18).
6. This value will display ON when the freezestat
has tripped and OFF when the freezestat is in its
normal position.
NOTE: This input is automatically configured by
the model number and cannot be enabled or
disabled on this screen.
Page 34 of 53
Page 35
FIGURE 2.18
Verifying Freeze Switch Status
Dirty Filter Switch
These units are equipped with a differential pressure
switch to indicate when the filter(s) needs to be
replaced. 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 2.2 to aid in setting
the filter switch to operate at different percentages of
filter blockage.
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. When the light is on, the filter needs to
be replaced. Once the filter(s) has been changed, the
indicator light will turn off.
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 the LV
manual.
Indoor Airflow Alarms
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.
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 2.19).
6. Press UP or DOWN keys to change to the desired
value.
7. Press ENTER key to save the value.
FIGURE 2.19
Adjusting Air Flow Alarm Delay
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 2.1).
TABLE 2.2
Filter Switch Pressure Settings
Unit Filter Blockage % 0% 10% 20% 30% 40% 50% 60% 70%
HR58APA
(Default) High S/T
HR58APA
Standard Airflow
All units tested equipped with MERV 8 filters. Appropriate supply (SG) and return (RG) grilles installed during testing. Pressure
switch adjustment may be necessary due to variations in filter type, installation and room pressure.
Bard recommends the filter switch be set at 50% filter blockage or less. Higher settings may significantly hinder unit
performance.
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%
Page 35 of 53
Page 36
Freezestat Alarm
When the freezestat digital input indicates a low
temperature event has occurred for longer than 120
seconds, the controller will generate a freezestat alarm.
This will then change the blower to high speed and
turn off the compressor for a minimum of 300 seconds.
The blower speed will return to normal once the alarm
condition has been removed. The compressor will start
again when the freezestat indicates no alarm and 300
seconds has passed. Once the condition is no longer
present, the alarm will automatically clear.
To adjust the freezestat 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
(A7); press ENTER key.
5. Press ENTER key to scroll to FreezeStat Alarm
Delay (see Figure 2.20).
6. Press UP or DOWN keys to change to the desired
value.
7. Press ENTER key to save the value.
FIGURE 2.20
Adjusting Freezestat Alarm Delay
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 0-10v signal provided from
the controller. The fan operates between 200-1800
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
USER password 2000.
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 2.21).
FIGURE 2.21
Verifying Condenser Fan Output
Dirty Filter Alarm
The wall unit is equipped with a differential pressure
switch input to the controller. When the switch
indicates a dirty filter alarm, 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.
The threshold of this alarm is adjusted by changing the
settings on the switch (see Table 2.2 on page 35).
Page 36 of 53
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 2.21).
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.
Page 37
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 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 2.22 for
proper clearance adjustment.
FIGURE 2.22
Fan Blade Setting
Model Dimension A
HR58 1.75"
High Pressure Transducer
The unit has a high side pressure transducer installed
on the liquid line between the condenser and electronic
expansion valve (EEV). The transducer is used for
system monitoring of high 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 high pressure 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
USER password 2000.
3. Press UP or DOWN keys to scroll to I/O Config;
press ENTER key.
4. Press UP or DOWN keys to scroll to Disch Pr
Sensor (C10); press ENTER key.
5. Verify the measurement displayed on screen is
accurate (see Figure 2.23).
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 to adjust the offset.
The update will not take effect until the cursor is
moved out of the offset parameter.
8. Once adjusted, the ESCAPE key several times to
return to Main Menu screen.
FIGURE 2.23
Adjusting High Pressure Input
Discharge 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.
The discharge 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
USER password 2000.
3. Press UP or DOWN keys to scroll to I/O Config;
press ENTER key.
4. Press UP or DOWN keys to scroll to Disch Temp
Sensor (C3); press ENTER key.
5. Reference the Value to verify the temperature (see
Figure 2.24 on page 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.
Page 37 of 53
Page 38
FIGURE 2.24
Adjusting Discharge Temperatue Input
Condenser Fan Operation
Condenser Fan Speed Control
The condenser fan motor maintains its high efficiency
across a wide operating range. The result is a
significant reduction in energy use when the motor is
run at reduced speeds. See Table 2.3.
TABLE 2.3
Condenser Fan Speeds
Mode Speed %
High Ambient 71 – 100 7.1 v – 10.0 v
Low Ambient 25 – 71 2.5 v – 7.1 v
Controller
Output Volts
CFM
2726 –
3703
1130 –
2726
High Pressure Control
Condenser Fan Speed
When the discharge pressure reaches 590 PSI, the
condenser fan will begin to speed up to attempt to
bring the pressure back down. The speed will continue
to ramp up until the discharge pressure reaches 630
PSI. At this point, the fan will be operating at full
speed, moving as much air as possible.
Second Stage Drop Out
The second stage of cooling wll be disabled when the
discharge pressure reaches 620 PSI to reduce the
required condenser airflow.
High Pressure Cut Out
See chart in Figure 2.25.
Low Pressure Control
When the discharge pressure reaches 375 PSI, the
condenser fan will begin to slow down to attempt to
bring the pressure back up. The speed will continue
to ramp down until the discharge pressure reaches
340 PSI. At this point, the fan will be operating at
minimum speed, moving as little air as possible.
If the discharge pressure continues to go down to
250 PSI, the condenser fan will turn off. The fan
will remain off with the compressor running until the
pressure reaches 340 PSI. The fan will then turn back
on at the minimum speed. The fan will continue to run
at the minimum speed until the pressure drops again or
starts to rise above the 340 PSI setpoint and begins to
speed up again.
Normal 71 7.1 v 2726
Pressure Control
FIGURE 2.29
Page 38 of 53
Page 39
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
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
USER password 2000.
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 (B4); press ENTER key.
5. Press ENTER key to scroll to Alarm Threshold (see
Figure 2.26).
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 2.26
Adjusting Dirty Condensor Alarm Settings
High Pressure Transducer Alarm
When the high pressure transducer sensor value is out
of range (0-650 PSIG), the controller will generate
a sensor failure alarm to indicate the sensor is not
working properly.
This alarm is fixed and cannot be adjusted.
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
unit.
Compressor Control Module (CCM)
The compressor control module is a low voltage
monitoring device necessary to monitor power and
indicate a low incoming voltage situation caused by
inadequate shore power or generator operation. The
monitoring device protects the unit against compressor
contactor “chatter” and reverse compressor rotation
during these situations.
Compressor protection device has an adjustable
30-second to 5-minute timer (red-dial). This module
features a delay-on-make for initial start up (or anytime
power is interrupted) for a minimum 2 minutes plus
10% of the red-dial setting. There is no delay during
routine operation of the unit. The compressor control
module also monitors the high pressure switch, and
Page 39 of 53
Page 40
will allow one automatic retry (after soft lockout delay)
before disabling the compressor in a hard lockout
(requires manual reset). If hard lockout does occur,
the ALR terminal on the CCM will become active with
24v, which will power the high pressure relay within
the wall unit. The relay contacts are monitored by the
unit controller. If the CCM indicates an alarm to the
wall unit controller, an alarm will be generated and the
compressor will be locked out by the controller.
NOTE: The controller will remove cooling call on the Y
terminal of the CCM, reseting it almost instantly.
The compressor remains locked out by the
controller until manually cleared.
Switch is jumpered in this application. Instead, the low
pressure transducer is used for low pressure monitoring.
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. This module
will disable any call for cooling if the pressure is above
this limit. If tripped, the high pressure switch can be
reset by turning the output off and then back on again.
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.
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.
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
USER password 2000.
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 2.27).
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.
The address-based delay only applies to the wall 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 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.
FIGURE 2.27
Adjusting Compressor Delays
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.
Page 40 of 53
Compressor Alarms
Refrigerant High Pressure Alarm
When the wall unit receives a signal from the
compressor control module (CCM) indicating a high
pressure event, the wall unit will generate an alarm.
Upon receiving the alarm, the wall unit will remove
the “Y” call from the CCM, resetting the status of the
CCM. The alarm will stay present on the wall unit until
manually cleared.
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 pounds below high
pressure switch, which is 650), the system will disable
stage 2 of mechanical cooling.
Page 41
Economizer
Economizer Components
Actuator
The actuator rotates up to 90° based on a 2-10v 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
USER password 2000.
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 2.28).
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 2.28
Damper Override
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.
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
USER password 2000.
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 2.29).
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.
FIGURE 2.29
Dust Sensor
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.
Page 41 of 53
Page 42
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
USER password 2000.
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 2.30).
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 2.30
Damper Switch
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
USER password 2000.
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.
5. Reference the Value to see the input of the sensor
(see Figure 2.31).
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 2.31
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
USER password 2000.
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 2.32).
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 2.32
Outdoor Air Sensor
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
USER password 2000.
Page 42 of 53
Page 43
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 2.33).
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 2.34
Economizer Setup
FIGURE 2.33
Supply Air Sensor
Economizer Operation
The economizer has four types of operation. The first
mode is "None" where the economizer is never utilized.
The second mode is "Dry Bulb Only" where the outdoor
temperature is the only consideration for economizer
use on a cooling call. The third mode is "Temperature
and Humidity" where the outdoor temperature and
humidity are considered for economizer use on a
cooling call. The fourth mode is "Enthalpy" where the
outdoor temperature, humidity and calculated dew
point are considered for economizer operation on a
cooling 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
2.34).
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 (Figure 2.35 on page 44)
as compared to when type is set to TempHum
(Figure 2.36 on page 44). 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 2.35).
19. Press UP or DOWN keys to change the humidity
setpoint to desired value.
20. Press ENTER key to save the value and scroll to
W/O LV Set.
21. Press UP or DOWN keys to change the humidity
setpoint for stand alone mode to desired value.
22. Press ENTER key to save the value and scroll to OA
Dew Pt Set.
Page 43 of 53
Page 44
23. Press UP or DOWN keys to adjust the dew point
setpoint for economizer operation to the desired
value.
24. Press ENTER key to save the value and scroll to
Off Diff.
25. Press UP or DOWN keys to adjust the differential
where dew point no longer allows economizer
operation.
26. Press ENTER key to save the value and scroll to
parameter Delay.
27. Press UP or DOWN keys to adjust the delay
before the dew point consideration will allow the
economizer to operate.
28. Press ENTER key to save the value.
29. Press ESCAPE key several times to return to Main
Menu screen.
FIGURE 2.35
Economizer Setup – Enthalpy Control
FIGURE 2.36
Economizer Setup – TempHum Control
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 30 and in the LV
manual. In addition to dehum mode, the economizer
may be disabled for 30 minutes (adjustable) if the dust
sensor indicates the outdoor air is not acceptable for
cooling. After the time has expired and on a call for
cooling, the economizer will open again to sample the
air. The unit will either return to normal operation or
remain locked out for another 30 minutes.
Economizer Alarms
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
See Table 2.4 for default settings for economizer
operation.
If the economizer is activated during a cooling call using
any of the previously mentioned modes, a 0-10v signal
will be sent to the actuator. The actuator will then open
and close the damper blades to maintain a mixed air
temperature of 55°F. When the mixed air temperature
increases the damper will open and when the mixed air
temperature decreases the damper will close.
TABLE 2.4
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
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
close alarm. This alarm is just a notification and will
not disable any features on the controller.
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.
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
Page 44 of 53
Page 45
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 2.37).
6. Press UP or DOWN keys to change to the desired
value.
7. Press ENTER key to save the value.
FIGURE 2.37
Adjusting Damper Failed to Close Delay
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.
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 2.37).
6. Press UP or DOWN keys to change to the desired
value.
7. Press ENTER key to save the value.
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 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.
Dust 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
is just a notification and will not disable any other
features on the controller.
This alarm is fixed and cannot be adjusted.
Dust Limit Alarm
The controller has adjustable software setpoints
(default to 80%) to indicate dust levels are too high
and disable the economizer operation for 30 minutes.
This alarm is not communicated to the NOC. Once
the conditions are no longer present, the alarm will
automatically clear.
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
2.38).
6. Press UP or DOWN keys to change to the desired
value.
7. Press ENTER key to save the value.
FIGURE 2.38
Adjusting Dust Sensor Alarm Setpoing
NOTE: When the temperature outside is measured
at or below 0°F, the dust sensor alarm will be
Page 45 of 53
Page 46
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.
High Supply Air Temperature Alarm
When the supply air temperature measurement is above
the outdoor air temperature setpoint (70°F) for the
economizer to be enabled 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 2.39).
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 2.39
Adjusting High Supply Air Temperature Differential
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 2.39).
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.
7. Press ENTER key to save.
Emergency Ventilation Mode
If the shelter temperature is above the high
temperature alarm 2 on the LV, the unit will be
commanded into emergency ventilation mode. In this
mode, the unit will open the economizer to 100%. The
compressor may run during this mode. This will stay
active until the LV returns the unit to normal operation.
This mode is only available when connected to the LV.
Model/Serial Number Configuration
The system will automatically configure some settings
based on the model number input into the unit. The
model and serial number are entered at the factory.
During a program update, the model and serial number
may be lost and need to be re-entered.
The unit will look at model number character number
10 to determine if the economizer should be disabled.
If the character is a E or e, the economizer operation
will be disabled.
The unit will look at model number characters 8 and 9
to determine how many heat stages are available. If the
characters are 0Z, 0z, MZ, Mz, mZ or mz, the unit will
be set to 0 stages of heat. If the characters are 05, m5
or M5, the unit will be set to 1 stage of heat.
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.
3. Press UP or DOWN keys to scroll to System Config;
press ENTER key.
Page 46 of 53
Electric Heat Option
Electric Heat Components
Electric Heating Element
The unit is optionally equipped with a 5kw heat strip.
The heat strip is located next to the blower assembly
and uses resistive heat.
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.
Page 47
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 unit
operating in stand alone mode.
Bard Guard Anti-Theft System Option
The unit has the option to be shipped from the factory
with a low pressure switch, panel sensors and a
speaker. These devices are used with the Bard Guard
BG1000 anti-theft controller to provide an anti-theft
measure. These sensors and switch form a loop that
when connected to 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 unit. The speaker connection is wired to
terminals 5 and 6 on the wall unit. See the BG1000
controller manual for directions on connecting the wall
units to the BG1000 controller.
Smoke Detector Option
The unit is equipped with an input that requires a dry
contact. This will disable unit operation and is intended
to be used with a smoke detector (not supplied). 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.
Page 47 of 53
Page 48
GENERAL REFRIGERANT INFORMATION
occurred. “Top-off” the charge by utilizing the pressure
charts on the inner control panel cover as a guideline.
REMEMBER: When adding R-410A refrigerant, it must
come out of the charging cylinder/tank as a liquid to
These units require R-410A refrigerant and
polyol ester oil.
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.
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.
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.
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
Page 48 of 53
R410-A Refrigerant Charge
This 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 2.5 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 unit to the serial plate charge.
Page 49
TABLE 2.5
Cooling Pressures
Full Load Cooling Air Temperature Entering Outdoor Coil °F
Model
HR58
Model
HR58
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
Return Air Temp
(DB/WB)
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
check condenser fan wiring. See “Condenser Fan Operation”.
Pressure 75 80 85 90 95 100 105 110 115 120 125
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
129
318
138
326
143
337
135
283
144
290
149
300
130
340
139
349
144
361
136
304
145
312
150
323
131
365
140
374
145
387
136
327
145
335
150
347
132
389
141
399
146
413
137
350
146
359
151
372
133
414
142
425
147
440
137
375
147
385
152
398
134
440
143
451
148
467
138
402
148
412
153
426
136
467
145
479
150
496
138
428
148
439
154
454
137
495
146
508
151
526
140
456
150
468
155
484
137
527
147
537
152
556
141
486
151
498
156
515
139
553
149
567
154
587
142
416
152
529
157
548
140
584
150
599
155
620
143
547
153
561
158
581
Pressure Service Ports
High and low pressure service ports are installed on
all units so that the system operating pressures can
be observed. Pressures are shown in Table 2.5. It is
imperative to match the correct pressure table to the
unit by model number.
This unit employs high-flow Coremax valves instead of
the typical Shrader type valves.
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.
Page 49 of 53
Page 50
MAINTENANCE AND TROUBLESHOOTING
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
controller manual).
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.
9.
10. Enable system to LV1000 controller (see controller
manual).
11. Repeat steps for additional wall-mount units.
Page 50 of 53
Page 51
TABLE 2.6
Rated Airflow
Nominal Rated CFM
High Low
1800 1400 .10
Nominal Rated ESP
TABLE 2.7
Indoor Blower Performance
Speed High Low
ESP
(Inch H20)
0.1
Dry Coil Wet Coil Dry Coil Wet Coil
1885 1800 1470 1400
TABLE 2.8
Maximum ESP of Operation
Electric Heat Only
Model Static Pressure*
-A0Z
-A05
-B0Z
-B06
.00"
.00"
.00"
.00"
* Unit is rated for free blow non-ducted
operation with SGR-5W Supply Grille
and RGR-5W Return Grille.
Page 51 of 53
Page 52
Troubleshooting FUSION-TEC Wall-Mount Unit Alarms
In the event that a problem is encountered with a wall-mount unit, the TEC-EYETM hand-held tool may be used to
diagnose the cause.
Department at 419.636.0439 for assistance.
If the problem can’t be resolved using these guidelines, contact the BARD Technical Service
Signal Description Possible Cause Component to Check Recommended Action
Low Pressure
Alarm
High Pressure
Alarm
Dirty Air Filter
Alarm
Alarm is activated
when a low pressure
event is present in the
refrigeration system
and the compressor is
running.
Alarm is activated
when a high pressure
event is present in the
refrigeration system.
The alarm is a warning
to check the filter.
Alarm can only be
reset manually.
Lack of refrigerant
The switch is defective.
Connection to the
corresponding
input terminal is
disconnected or the
controller board is
defective.
Abnormal site
condition
Condenser fan has
failed. The condenser
fan speed controller
has failed.
The switch is defective.
Connection to the
corresponding
input terminal is
disconnected or the
controller board is
defective.
Filter is clogged.
Connection to the
corresponding
input terminal is
disconnected or the
controller board is
defective.
The value set for the
differential air pressure
switch is too low.
Run the unit and
check if the low
pressure value is in
the normal range.
Check if the pressure
switch is OK.
Check if the
connection is OK.
Check if the controller
board is OK.
Check open door or
for abnormal site
condition. Check if
the high pressure
value is in the normal
range.
Check the condenser
fan status while the
high pressure is
outside the normal
setting.
Check if the high
pressure switch is
OK.
Check if the
connection is OK.
Check if the controller
board is OK.
Check if the filter is
dirty.
Check if the
connection is OK.
Check if the controller
board is OK.
Check the differential
air pressure switch
value.
Charge appropriate
amount of
refrigeration.
If defective, replace.
Repair connection. If
the controller board is
defective, replace.
Clean the condenser.
Replace the
condenser fan.
Replace the
condenser low
ambient (fan speed)
controller.
If defective, replace.
Repair connection. If
the controller board is
defective, replace.
Clean or replace the
filter.
Repair connection. If
the controller board is
defective, replace.
Correct the value of
the switch to standard
value.
Device
Actions
Compressor/
Condenser Fan:
Off
Compressor/
Condenser Fan:
Off
Freeze Alarm
Page 52 of 53
Low temperature
detected at evaporator
coil.
Low airflow Blower
Low load
Space temperature
input
Ensure blower is
operating correctly.
Ensure sensor is
operating correctly.
Compressor: Off
Blower: On
Page 53
Signal Description Possible Cause Component to Check Recommended Action
Device
Actions
Mixed Air
Temperature
Sensor Failed
Alarm
Outdoor
Temperature
Sensor Failed
Alarm
Outdoor
Humidity Sensor
Failed Alarm
Return Air
Temperature
Sensor Failed
Alarm
High Mixed Air
Temperature
Alarm
The alarm is activated
if the sensor is faulty, a
sensor wire is loose or
an out-of-range value
is read.
The alarm is activated
if the sensor is faulty, a
sensor wire is loose or
an out-of-range value
is read.
The alarm is activated
if the sensor is faulty, a
sensor wire is loose or
an out-of-range value
is read.
The alarm is activated
if the sensor is faulty, a
sensor wire is loose or
an out-of-range value
is read.
During economizer
operation, MAT was
above alarm setpoint.
The alarm is activated
if the sensor is faulty, a
sensor wire is loose or
an out-of-range value
is read.
The alarm is activated
if the sensor is faulty, a
sensor wire is loose or
an out-of-range value
is read.
The alarm is activated
if the sensor is faulty, a
sensor wire is loose or
an out-of-range value
is read.
The alarm is activated
if the sensor is faulty, a
sensor wire is loose or
an out-of-range value
is read.
Bringing in warm air
from outside.
Check the mixed air
temperature sensor
wiring.
Check temperature
vs. resistance of
temperature sensor.
Check the outdoor
temperature sensor
wiring.
Check temperature
vs. resistance of
temperature sensor.
Check the humidity
sensor wiring.
Check the return air
temperature sensor
wiring.
Check temperature
vs. resistance of
temperature sensor.
Damper
OAT sensor
Replace the supply
air temperature
sensor.
Replace the outdoor
temperature sensor.
Replace the humidity
sensor.
Replace the return air
temperature sensor.
Verify damper
operation.
Verify sensor
operation.
Low Mixed Air
Temperature
Alarm
Damper Open
Fail Alarm
Damper Close
Fail Alarm
Smoke Alarm
During economizer
operation, MAT was
below alarm setpoint.
Alarm is reset
automatically.
Alarm is reset
automatically.
Smoke detector input
signals smoke event.
Damper
Bringing in cool air
from outside.
OAT sensor
Free cooling damper
fails to open.
Free cooling damper
fails to close.
Smoke sensor fail. Smoke detector
Check the damper
linkage. Check to see
if anything is in the
way of the damper.
Check the damper
linkage. Check to see
if anything is in the
way of the damper.
Verify damper
operation.
Verify sensor
operation.
Replace smoke
detector
Indoor Blower:
On
Damper: Off
Indoor Blower:
On
Damper: Off
Unit disabled
Page 53 of 53
Loading...