Bard FUSION-TEC WR36BPA, FUSION-TEC WR58BPA, FUSION-TEC WR36BPB, FUSION-TEC WR58BPB Service Instructions Manual

SERVICE INSTRUCTIONS

FUSION-TEC® WALL-MOUNT

AIR CONDITIONER

Models:

WR36BPA WR58BPA

WR36BPB WR58BPB

NOTE: LC6000 controller is required for operation when

WR**BP* units are used.

Bard Manufacturing Company, Inc.
Bryan, Ohio 43506
www.bardhvac.com

Manual: 2100-695
Supersedes: NEW
Date: 5-10-19

Page 1 of 54

CONTENTS

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

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

TEC-EYE Screen Structure and Password Level ..............

TEC-EYE

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

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

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

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

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

Orphan Mode Staging ...................................8

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

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

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

Component Lifetime Hours ...........................9

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Exporting 7 Day Logs ...............................................13

Orphan Model ................................................................13

Zone ..............................................................................13

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

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

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

Return Air Temperature Alarm .....................14

Temperature/Humidity Control Operation ....................14

Heating Sequence.............................................15

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

Adjusting Cooling Staging ...........................15

Adjusting Heating Staging ..........................16

Dehumidification ..............................................16

Electronic Expansion Valve (EEV) .....................................16

EEV Components .....................................................16

Electronic Expansion Valve ................................16

EEV Instructions for Vacuum, Reclaim,

Charge Unit ...............................................16

System Pressures .......................................17

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

Troubleshooting the Suction Pressure

Transducer ................................................18

Suction Pressure Alarm ..............................18

Suction Temperature Sensor ..............................18

Suction Temperature Alarm .........................18

EEV Operation .........................................................19

EEV Superheat Control ......................................19

Additional EEV Alarms .............................................19

Low Superheat Alarm ........................................19

Indoor Airflow .................................................................19

Cooling Sequence: Economizer Available ...............

Economizer Operation in Orphan Mode .........

Cooling Sequence: Economizer Not Available .........

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

14
14
15

18

Indoor Airflow Components .......................................19

Blower .............................................................19

Blower Status Switch .................................20

7

Blower Status Alarm ...................................21

Filters ..............................................................22

Dirty Filter Switch .............................................22

Dirty Filter Alarm .......................................22

Filter Indicator Light .........................................22

Indoor Airflow Operation ...........................................23

High Sensible Mode ..........................................23

Blower Speed Control ........................................23

Additional Indoor Airflow Alarms ...............................23

Supply Air Temperature Alarm ............................23

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

Condenser Fan Components ......................................23

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

Liquid Line Pressure Transducer .........................24

Troubleshooting the Liquid Pressure

Transducer ................................................24

Liquid Pressure Transducer Alarm ...............24

Liquid Temperature Sensor ................................24

Condenser Fan Operation..........................................25

Condenser Fan Speed Control

High Pressure Control........................................25

Condenser Fan Speed .................................25

Second Stage Drop Out ..............................26

Low Ambient Control .........................................26

Additional Condenser Fan Alarms ..............................26

Dirty Condenser Coil Alarm ................................26

Compressor ....................................................................26

Compressor Components ..........................................26

Compressor ......................................................26

Compressor Control Module (CCM) .....................26

Delay-on-Make Timer ..................................26

Short Cycle Protection/Delay-on-Break .........26

High Pressure Detection .............................26

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

High Pressure Safety Switch ..............................28

Refrigerant High Pressure Alarm ..................28

Phase Monitor ..................................................28

Compressor Operation ..............................................28

Compressor Low Temperature Limit ....................28

Additional Compressor Alarms ...................................29

Refrigerant Low Pressure Alarm ..........................29

Economizer ....................................................................29

Economizer Components ..........................................29

Actuator ...........................................................29

Dust Sensor .....................................................30

Dust Sensor Failure Alarm ..........................30

High Dust Limit Alarm ................................30

Damper Blade ..................................................31

Minimum Damper Position .........................31

Damper Switch .................................................31

Damper Failed to Open Alarm .....................31

Damper Failed to Close Alarm .....................32

Outdoor Temperature and Humidity Combination

Sensor .............................................................32

Outdoor Temperature Sensor Failure Alarm ...33

Supply Temperature Sensor ...............................33

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

Outdoor Humidity Sensor Failure Alarm ..........

............................25

27

33

Manual 2100-695
Page 2 of 54

Supply Temperature Sensor Failure Alarm ....33

High Supply Air Temperature Alarm .............33

Low Supply Air Temperature Alarm ..............33

Economizer Operation ..............................................34

Emergency Cooling Mode ................................................35

Emergency Ventilation Mode ............................................35

Model/Serial Number Configuration ..................................35

Electric Heat Option .......................................................36

Electric Heat Components ........................................36

Electric Heating Element ...................................36

Thermal Overload ..............................................36

Electric Heat Operation ............................................36

Bard Guard Anti-Theft System Option ...............................36

Smoke Detector Unit Disable Option .................................36

Inverter Option ...............................................................36

Refrigerant Information ...........................................40

General ..........................................................................40

Topping Off System Charge ..............................................40

Safety Practices..............................................................40

Important Installer Note ..................................................40

R410-A Refrigerant Charge ..............................................40

Pressure Service Ports .....................................................41

Maintenance ................................................................ 42

Standard Maintenance Procedures ...................................42

Bard Guard Anti-Theft System Option ...............................42

Troubleshooting ......................................................... 43

8301-067 Outdoor Temperature/Humidity Sensor ..............43

8301-067 Sensor Connections .................................43

8301-067 Humidity Sensor Test Value Outputs ..........46

8301-067 Humidity Sensor Calibration .....................46

8

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

8612-061 Dust (Particulate) Sensor Control Board ............48

8612-061 Control Board Output Signal Not

Responsive to Dust ..................................................48

8301-073 Dust (Particulate) Sensor .................................50

8408-044 Return Air Sensor/Suction Sensor .....................51

8301-066 Supply Air Sensor ...........................................52

8406-157 Liquid Line Pressure Transducer ......................53

8406-158 Suction Pressure Transducer ............................54

47

FIGURES AND TABLES

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

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

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

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

Figure 5 Orphan Mode Staging ......................................8

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

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

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

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

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

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

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

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

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

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

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

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

Figure 18 Changing Zone ..............................................13

Figure 19 Adjusting Return Air Sensor ...........................13

Figure 20 Staging ........................................................14

Figure 21 Enabling Free Cooling Delay ...........................15

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

Figure 23 Adjusting Cooling Stage Differentials ...............16

Figure 24 Adjusting Heating Stage Differentials ..............16

Figure 25 Overriding EEV Output ...................................17

Figure 26 Electronic Expansion Valve and Service Tool ....17

Figure 27 Adjusting Suction Pressure Transducer Values ..18
Figure 28
Figure 29 Adjusting Suction Temperature Sensor Values ..18
Figure 30

Figure 31 Putting Blower Output into Override Mode .......19

Figure 32 Dirty Filter Switch/Blower Status Switch ..........21

Figure 33 Verifying Differential Airflow Status .................21

Figure 34 Adjusting Air Flow Alarm Delay .......................21

Figure 35

Figure 36 Enabling High Sensible Mode .........................23

Figure 37 Verifying Condenser Fan Output ......................23

Figure 38 Fan Blade Setting .........................................24

Figure 39 Adjusting Liquid Pressure Transducer Values ....24

Figure 40 Voltage/Pressure: Liquid Pressure Transducer ...24

Figure 41 Adjusting Liquid Temperature Values ...............25

Figure 42 Liquid Pressure Control Setpoint .....................25

Figure 43

Figure 44 Adjusting Compressor Delays ..........................28

Figure 45 Adjusting Compressor Low Temp Limit ............29

Figure 46

Figure 47 Damper Output and Override ..........................29

Figure 48 Dust Sensor ..................................................30

Figure 49

Figure 50 Adjusting Minimum Damper Position ..............31

Figure 51 Damper Switch .............................................31

Figure 52 Adjusting Damper Alarm Delay .......................32

Figure 53 Outdoor Air Sensor ........................................32

Figure 54 Outdoor Humidity Sensor ...............................32

Figure 55 Supply Air Sensor ..........................................33

Figure 56 Adjusting Supply Air Temperature Differential ..33

Figure 57 Economizer Setup A2 ....................................34

Figure 58

Figure 59 FUSION-TEC WR Series Nomenclature ............37

Figure 60

Figure 61 8301-067 Sensor Electrical Connections ........43

Figure 62 8301-067 Sensor Terminal Connections ..........43

Figure 63 8301-067 DIP Switch/Output Configuration ....46

Figure 64 8301-057 Air Differential Switch Terminals .....47

Figure 65 8612-061 Dust Sensor Alarm Board ...............48

Figure 66

Table 1

Table 2 Unit Status Messages ......................................7

Table 3 Unit Specific Superheat Settings ....................19

Table 4A WR36BP* Blower Speeds ..............................20

Table 4B WR58BP* Blower Speeds ..............................20

Table 5 Rated Airflow ................................................20

Table 6 Indoor Blower Performance ............................20

Table 7 Maximum ESP of Operation:

Electric Heat Only .........................................20

Table 8 Filter Switch Pressure Settings .......................21

Table 9 Economizer Default Settings ...........................35

Table 10 FUSION-TEC WR Series Board Terminals .........39

Table 11 Cooling Pressures ..........................................41

Table 12 8301-067 Sensor: Temperature to

Thermocouple Resistance ..............................44

Table 13 8301-067 Sensor: Relative Humidity to

Humidity Sensor Current Output .....................45

Table 14 8301-073 Sensor: Dust/Volts .........................50

Table 15 8408-044 Sensor: Temperature/Resistance ....51

Table 16 8301-066 Sensor: Temperature/Resistance .....52

Table 17 8406-157 0-65psi Pressure Transducer ..........53

Table 18 8406-1580-250psi Pressure Transducer .........54

Voltage/Pressure: Suction Pressure Transducer ..

Adjusting Freeze Setpoint and Alarm Delay .......

Dirty Filter Switch and Filter Indicator Light .......

8201-164 Compressor Control Module

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

Adjusting Dust Sensor Alarm Setpoint

Economizer Setup A3 .....................................

FUSION-TEC WR Series Unit Control Board .......

Dust Sensor Alarm Board Power Supply Check ..

LC6000/TEC-EYE Passwords (Defaults) ................

..............27

................30

18

18

22

29

35

38

49

6

Manual 2100-695
Page 3 of 54

GENERAL INFORMATION

Air Conditioning System

This Bard air conditioning system is composed of
FUSION-TEC WR Series wall-mounted air conditioners
matched with an LC6000 lead/lag controller. The wall
mounts are specifically engineered for telecom/motor
control center rooms.

NOTE: The LC6000 lead/lag controller and FUSION-

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

Wall-Mount Air Conditioner Units

The wall-mount units operate on VAC power.
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 units

General

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

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

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

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

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

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

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

Fire Protection Association for the Installation of Air

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

instructions, installer should adhere to local codes.

Shipping Damage

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

These units must remain in upright position at all
times.

Additional Publications

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

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

Standard for the Installation of Air Conditioning

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

Standard for Warm Air Heating

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

Load Calculation for Residential Winter

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

For more information, contact these publishers:

Air Conditioning Contractors of America (ACCA)
1712 New Hampshire Ave. N.W.
Washington, DC 20009
Telephone: [phone] Fax: [phone]

American National Standards Institute (ANSI)
11 West Street, 13th Floor
New York, NY 10036
Telephone: [phone] Fax: [phone]

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

1791 Tullie Circle, N.E.
Atlanta, GA 30329-2305
Telephone: [phone] Fax: [phone]

National Fire Protection Association (NFPA)
Batterymarch Park
P. O. Box 9101
Quincy, MA 02269-9901
Telephone: [phone] Fax: [phone]

Manual 2100-695
Page 4 of 54

ANSI Z535.5 Definitions:

DANGER: Indicate[s] a hazardous situation which, if

not avoided, will result in death or serious injury. The
signal word “DANGER” is to be limited to the most
extreme situations. DANGER [signs] should not be used
for property damage hazards unless personal injury risk
appropriate to these levels is also involved.

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

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

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

!

WARNING

Electrical shock hazard.
Have a properly trained individual perform

these tasks.
Failure to do so could result in electric shock

or death.

!

WARNING

Fire hazard.
Maintain minimum 1/4" clearance between the

supply ange and combustible materials.

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

!

WARNING

Heavy item hazard.
Use more than one person to handle unit.

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

!

CAUTION

Cut hazard.

Wear gloves to avoid contact with sharp
edges.

Failure to do so could result in personal injury.

Manual 2100-695
Page 5 of 54

USING THE TEC-EYE

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

TM

FIGURE 1

ALARM KEY

MENU KEY

ESCAPE KEY

ALARM KEY

Allows viewing of active alarms
Silences audible alarms
Resets active alarms

MENU KEY

Allows entry to Main Menu

ESCAPE KEY

Returns to previous menu level
Cancels a changed entry

TEC-EYE Hand-Held Diagnostic Tool

The TEC-EYE service tool is used to communicate
with the FUSION-TEC unit logic board. By connecting
directly to the logic board inside the unit control
panel, it is possible to perform diagnostics on the unit,
adjust certain settings and verify unit and economizer
operation through a run test procedure. The TEC-EYE
service tool is required for unit setup and operation. The
TEC-EYE is supplied with the LC6000 controller but
can also be ordered separately (Bard P/N 8301-059).

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

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

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

When not being used, the TEC-EYE hand-held
diagnostic tool should be stored inside or near the
LC6000 controller. Do not let the TEC-EYE leave the
shelter site.

UP KEY

ENTER KEY

DOWN KEY

UP KEY

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

ENTER KEY

Accepts current value of a modifiable field
Advances cursor

DOWN KEY

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

FIGURE 2

TEC-EYE Connection to Unit Control

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

TABLE 1

LC6000/TEC-EYE Passwords (Defaults)

User 2000

Technician 1313

Engineer 9254

Use UP or DOWN keys and ENTER key to enter password

Manual 2100-695
Page 6 of 54

TEC-EYE Screen Structure and Password Level

Quick Menu
Setpoints (Orphan Mode Temperature Control)
Information
Alarm Log
Main Menu
System Config: A1-A10 User (2000)
Adv Sys Config: B1-B8 Technician (1313)
I-O Config: C1-C15 Technician (1313)
On/Off: User (2000)
Alarm Logs: User (2000)
Settings
Date/Time: Technician (1313)
Language: User (2000)
Import/Export
Unit Parameters: Engineer (9254)
Alarm Log Export: User (2000)
7 Day Log Export: User (2000)
Initialization
Alarm Management: User (2000)
System Default: Engineer (9254)
Change Passwords
Logout

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

TEC-EYE Acronyms

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

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

variable input.

Main Status Screen

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

The wall-mount unit address is displayed in the upper
right corner on the main Main Status Screen (see
Figure 1). The Main Status Screen also shows the
current date, time, return air temperature (RAT), mixed
air temperature (MAT), supply air temperature (SAT),
outdoor air temperature (OAT), outdoor air humidity
(OAH) and outdoor dew point (ODP) conditions. Blower

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

TABLE 2

Unit Status Messages

Message Description

Waiting...

Orphan Mode

LC Online

Cont. Blower

Power Loss

Free Cooling Unit is actively economizing.

Optimized Cool

Cooling Unit is actively mechanical cooling.

Heating Unit is actively heating.

Passive Dehum

Active Dehum

Self Test Unit is performing a self test.

Off by Alarm

Off by DI

Off by LC

Off by Keyboard

Override Active

Emergency Vent

Emergency Cool

Emergency Off

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

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

Unit is on and communicating with
the LC6000 with no heating or
cooling calls.

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

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

Unit is mechanical cooling while
actively economizing.

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

Unit is taking active measures to
decrease humidity.

Unit has major fault preventing
operation.

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

Unit has been turned off by the
supervisory controller.

Unit has been turned off by the local
user.

There is an active override on the
system.

Unit is in Emergency Ventilation.
LC6000 has an active hydrogen
alarm.

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

Unit is in Emergency Off. LC6000
has an active smoke alarm.

Manual 2100-695
Page 7 of 54

The Quick Menu is accessible from the
Screen

. Setpoints, Information and Alarm Log are
available through the Quick Menu. Pressing the UP
or DOWN keys while on the
change the Quick Menu icon displayed (see Figure

3). Press the ENTER key when the desired icon is
displayed.

Main Status Screen

Main Status

will

FIGURE 3

Quick Menu Icons

Alarm Log Information

NOTE: Screenshots shown in this manual reflect

default settings (when applicable).

Quick Menu

Setpoints

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

Once the supervisory controller (LC6000) is connected,
cooling and heating setpoints will be communicated
and local cooling and heating setpoints will be replaced
with the communicated cooling and heating setpoints.

If at any time the wall-mount unit(s) loses
communication with the LC6000 controller, the wall­mount unit(s) will go into orphan mode and operate
using the last communicated setpoints.

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

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

board located in the unit.

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

until Quick Menu displays Setpoints icon. Press
ENTER key.

3. Press ENTER key to scroll to the selected choice

(see Figure 4).

Setpoints

FIGURE 4

Cool and Heat Setpoints

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

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

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

Information

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

Staging Information

Staging information is used to show if free cooling
is available or if any unit operation should be taking
place. The look of the staging display depends on if the
unit is communicating with a supervisory controller or
operating in orphan mode.

Orphan Mode Staging

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

FIGURE 5

Orphan Mode Staging

Master Staging

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

FIGURE 6

Master Staging

Manual 2100-695
Page 8 of 54

A/C Circuit Measurements

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

FIGURE 7

A/C Circuit Measurements

Software Version

The Software Version screen displays the model
number of the unit as well as all software version
information for the PLC (see Figure 9).

FIGURE 9

Software Version

NOTICE

It is important to check the software version

during installation to ensure that the latest

version has been installed. Current software

versions, change log and installation

instructions are available on the Bard website at

http://www.bardhvac.com/software-download/

Last 24 Hour Operation

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

FIGURE 8

Last 24 Hour Operation

Alarm Log

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

Manual 2100-695
Page 9 of 54

Addressing Wall-Mount Units

Each unit must have a unique address for the system
to operate correctly with th LC controller (Ex: 1, 2, 3,
...14 depending on the number of units). The wall­mount unit address is displayed in the upper right
corner on the Status screen on the TEC-EYE display
(see Figure 1 on page 6).

To change the unit address:

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

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

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

4. Press ENTER key to scroll to Unit Address (see
Figure 10).

5. Press UP or DOWN keys to change the address to a
value between 1 and 14.

7. Press ENTER key to save.

See page 13 for information on changing unit zone.

FIGURE 10

Changing Unit Address

FIGURE 11

Executing Run Test

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

screens.

NOTE:

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

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

Executing a Run Test

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

To execute a run test:

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

2. Press UP or DOWN keys and ENTER key to enter
TECHNICIAN password 1313.

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

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

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

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

Run Test Summary.

FIGURE 12

Run Test Summary

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

Manual 2100-695
Page 10 of 54

FIGURE 13

Run Test: Motors & Sensors

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

FIGURE 14

Run Test: A/C Circuit

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

8. System will restart with default values.

FIGURE 15

Restoring Factory Default Settings

Run Test Parameter Descriptions

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

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

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

Reset to Factory Defaults

To reset to factory default settings:

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

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

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

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

5. Press UP or DOWN keys to scroll to the Default
Installation screen.

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

Manual 2100-695
Page 11 of 54

OPERATION

NOTE: Screenshots shown in this manual reflect

default settings (when applicable).

Unit On/Off

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

To turn the unit on or off:

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

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

3. Press UP or DOWN keys to scroll to On/Off; press
ENTER key.

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

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

The wall-mount unit may also be turned off by certain
alarms. Below is a list of conditions that will disable
unit operation to prevent damage to unit or property:

• System Off (set from LC6000)

• Emergency Off (set from LC6000)

• Unit Disable Input

• Invalid Model Number Size

• Return Air Sensor Failure Alarm in Orphan Mode

• Damper Failed to Close Alarm

• No Airflow Alarm (will cycle unit to attempt blower
restart)

the screen at the end of the alarm list (shown in Figure

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

FIGURE 16

Clearing All Alarms

Clearing Alarm Logs and Counters

To clear the alarm log and alarm counters:

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

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

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

4. Press UP or DOWN keys to scroll to Initialization.
(Alarm Management 1/2 screen will be displayed.)

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

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

7. Press ENTER key to scroll to Clear Counters.

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

• Power Loss Input Active on Non-Inverter Model
Number

Alarm Adjustment

Acknowledging Alarms

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

Clearing Alarms

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

Manual 2100-695
Page 12 of 54

FIGURE 17

Clearing Alarm Logs and Counters

Exporting Alarm Logs

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

Exporting 7 Day Logs

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

Orphan Mode

FUSION-TEC WR Series wall-mount units have the
capability to run without the LC6000 controller
attached—this feature is called orphan mode. This
keeps the shelter between 60°F and 77°F (factory
default settings) by the use of the factory-installed
return air sensor in each wall-mount unit. In orphan
mode, no auxiliary temperature measurement devices
are required for operation. The wall-mount unit
automatically uses a continuous blower setting to
circulate room air into the return air inlet and uses
the return air temperature sensor to control room
temperature.

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

During installation, the ability to run in orphan mode
allows deactivation of one of the existing, older wall­mount units, while keeping the shelter cool with the
other unit still operating. Once the first of the Bard
wall-mount units is installed and powered on, it will
operate in orphan mode—keeping the climate inside
the shelter stable and the installers comfortable while
the remainder of the older equipment is removed and
the remaining Bard wall-mount units and LC6000
controller are installed.

Additionally, should any or all of the FUSION-TEC WR
Series wall-mount units lose communication with the
LC6000 controller (such as during maintenance), they
will continue to serve the shelter’s needs until a repair
can be made.

Zone

When paired with a supervisory controller that uses
zones to control groups of wall units, this unit uses the
zone setting to relay to the supervisory controller what
zone it is set to operate in.

To change the zone:

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

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

TECHNICIAN password 1313.

3. Press UP or DOWN keys to scroll to Sys Config;

press ENTER key.

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

screen.

5. Press ENTER key to scroll to Zone (see Figure 18).

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

value.

7. Press ENTER key to save value.

FIGURE 18

Changing Zone

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 orphan 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 LC controller if the return air
temperature sensor is disconnected. The temperature is
measured with a 10k ohm NTC thermistor.

This sensor can be verified and adjusted by:

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

2. Press UP or DOWN keys and ENTER key to enter
TECHNICIAN password 1313.

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

4. Press UP or DOWN keys to scroll to Return Air
Sensor C4.

5. Verify the measurement displayed on screen is
accurate (see Figure 19).

FIGURE 19

Adjusting Return Air Sensor

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

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

Manual 2100-695
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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.

Return Air Temperature Alarm

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

This alarm is fixed and cannot be adjusted.

Temperature/Humidity Control Operation

When the unit is connected to the LC controller, it
will receive all of its heating, cooling and ventilation
commands from the controller. When the unit is in
orphan mode, it will heat, cool and ventilate based on
the return air temperature measurement. The return air
temperature will be compared to the cooling setpoint.
Based on differentials above and below the setpoint,
the available cooling and heating stages will be utilized.

To change or view the unit setpoint:

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

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

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

Cooling Sequence – Economizer Available

NOTE: This description is based on the example shown

in Figure 20 and Figure 23 (page 16).

If the return air temperature is higher than 79°F
(Setpoint of 77°F + Stage 1 On Differential of 2°F) and
outdoor conditions are acceptable for economizing, the
unit will enable economizer operation (free cooling).
If the return air temperature is higher than 80°F
(Setpoint of 77°F + Stage 2 On Differential of 3°F),
the unit will enable mechanical cooling stage 1. If the
return air temperature is higher than 81°F (Setpoint
of 77°F + Stage 3 On Differential of 4°F), the unit
will enable mechanical cooling stage 2. Each stage
will then be disabled when the return air temperature
reaches the setpoint plus the stage off differential.

Economizer Operation in Orphan Mode

In orphan mode,there is a chance that the economizer
will not be given ample time to operate before the
heat load requires more cooling. In this case, there is
a delay that can be enabled in order to allow for the
most amount of free cooling to be utilized before the
compressor is staged on.

Free Cooling

Available

Free Cooling

Mechanical

Cooling Stage 1

Mechanical

Cooling Stage 2

Free Cooling

Not Available

Mechanical

Cooling Stage 1

Mechanical

Cooling Stage 2

Not Used

Heat Stage 1

FIGURE 20

Staging

Setpoint

72°F 73°F 74°F 75°F 76°F 77°F 78°F 79°F 80°F 81°F 82°F 83°F

Off

55°F 56°F 57°F 58°F 59°F 60°F 61°F 62°F 63°F 64°F 65°F 66°F

Off

Deadband

Setpoint

Deadband

On

On

NOTE: Deadband refers to a region where one end limit will turn the heating or cooling function on and the opposite end

limit will turn the heating or cooling function off.

Manual 2100-695
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To enable this delay:

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

2. Press UP or DOWN keys and ENTER key to enter
TECHNICIAN password 1313.

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

4. Press UP or DOWN keys to scroll to FC Comp.
Delay B7.

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

21).

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

7. Press ENTER key to save value and move cursor to
Delay.

8. Press UP or DOWN keys to change the time value.

9. Press ENTER key to save value and move cursor to
top of the screen.

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

FIGURE 21

Enabling Free Cooling Delay

when the return air temperature reaches the setpoint
plus the stage off differential.

Staging

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

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

To view unit stages:

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

( ). Press ENTER key.

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

FIGURE 22

Viewing Unit Stages

Cooling Sequence – Economizer Not Available

NOTE: This description is based on the example
shown in Figure 20 and Figure 23.

If the return air temperature is higher than 79°F
(Setpoint of 77°F + Stage 1 On Differential of 2°F),
the unit will enable mechanical cooling stage 1. If the
return air temperature is higher than 80°F (Setpoint
of 77°F + Stage 2 On Differential of 3°F), the unit
will enable mechanical cooling stage 2. Each stage
will then be disabled when the return air temperature
reaches the setpoint plus the stage off differential.

Heating Sequence

NOTE: This description is based on the example
shown in Figure 20 and Figure 23.

If the return air temperature is below 58°F (Setpoint
of 60°F + Stage 1 On Differential of -2°F), the unit
will enable electric heat stage 1. If the return air
temperature is below 57°F (Setpoint of 60°F + Stage
2 On Differential), the unit will enable electric heat
stage 2 (if available). Each stage will then be disabled

Adjusting Cooling Staging

This unit uses staging differentials to control cooling
operation. The on differential for a stage references
the number of degrees above the setpoint at which
the stage turns on. The off differential for a stage
references the number of degrees below the setpoint at
which the stage turns off.

To adjust cooling stage differentials:

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

2. Press UP or DOWN keys and ENTER key to enter
TECHNICIAN password 1313.

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

4. Press UP or DOWN keys to scroll to Cooling Setup
B4.

5. Press ENTER key to scroll to Stage 1 On
Differential (see Figure 23 on page 16).

Press UP or DOWN keys to adjust number of

6.
degrees above setpoint to turn cooling operation on.

Manual 2100-695
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7. Press ENTER key to save value and move cursor to
Stage 1 Off Differential.

8. Press UP or DOWN keys to adjust number of
degrees below setpoint to turn cooling operation
off.

9. Press ENTER key to save value and move cursor to
next stage differential.

10. Repeat steps 6 through 9 for Stage 2 and Stage 3
differentials.

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

FIGURE 23

Adjusting Cooling Stage Differentials

Adjusting Heating Staging

This unit uses staging differentials to control heating
operation. The on differential for a stage references
the number of degrees below the setpoint at which
the stage turns on. The off differential for a stage
references the number of degrees above the setpoint at
which the stage turns off.

To adjust heating stage differentials:

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

2. Press UP or DOWN keys and ENTER key to enter
TECHNICIAN password 1313.

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

4. Press UP or DOWN keys to scroll to Heating Setup
B5.

5. Press ENTER key to scroll to Stage 1 On
Differential (see Figure 24).

6. Press UP or DOWN keys to adjust number of
degrees below setpoint to turn heating operation
on.

7. Press ENTER key to save value and move cursor to
Stage 1 Off Differential.

8. Press UP or DOWN keys to adjust number of
degrees above setpoint to turn heating operation
off.

9. Press ENTER key to save value and move cursor to
next stage differential.

10. Repeat steps 6 through 9 for Stage 2 and Stage 3
differentials.

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

FIGURE 24

Adjusting Heating Stage Differentials

Dehumidification

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

NOTE: This feature is dependent upon the LC6000

indoor humidity sensors and a command
from the LC to enter dehumidification mode.
See the latest revision of LC6000 Service
Instructions 2100-669 for adjustment of the
dehumidification setpoint and differentials.

Electronic Expansion Valve (EEV)

EEV Components

Electronic Expansion Valve

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

EEV Instructions for Vacuum, Reclaim, Charge Unit

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

Manual 2100-695
Page 16 of 54

To manually override the valve:

NOTE: The unit must be off to perform this override.

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

2. Press UP or DOWN keys and ENTER key to enter
TECHNICIAN password 1313.

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

4. Press UP or DOWN keys to scroll to EEV Service
C15.

Press ENTER key to scroll to Enable (see Figure 25).

5.

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.

FIGURE 25

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 26) 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.

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

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

FIGURE 26

Electronic Expansion Valve (EEV) and Service Tool

EEV Stator

Coil

EEV

EEV Service

Tool

System Pressures

To view system pressure and temperatures during this
process:

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

2. Press UP or DOWN keys to scroll to EEV 1 Circuit
and EVD 1 Compressor screens (see Figure 7 on
page 9).

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

Suction Pressure Transducer

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

This sensor can be verified and adjusted by:

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

2. Press UP or DOWN keys and ENTER key to enter
TECHNICIAN password 1313.

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

4. Press UP or DOWN keys to scroll to Liquid Pr
Sensor C9.

5. Verify the measurement displayed on screen is
accurate (see Figure 27 on page 18).

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

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

Manual 2100-695
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