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Bard FUSION-TEC HR58APA, Installation Support Materials

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Bard FUSION-TEC HR58APA Installation Support Materials Download Page 8

 

Page 

8 of 53

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

•  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

FIGURE 1.1

FUSION-TEC Wall-Mount Unit Model Nomenclature

CONTROL LOGIC AND CLIMATE OPTIONS

P – Programmable Logic Board

 

HR  58 

A 

P   A 

0Z    E   P   X   X   X

  

X

UNIT SERIES

REVISION 

A – Revision Level 

MAXIMUM SENSIBLE CAPACITY 

58

 

–

 

5 Ton 2 Stage Step Capacity

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

VENT PACKAGE

E – Factory-Installed Economizer (All Units)

FILTER

P – MERV8 Disposable Pleated Filter

COLOR AND CABINET FINISH

X

 

–

 

Beige Baked Enamel Finish

1

 

–

 

White Baked Enamel Finish

4

 

–

 

Buckeye Gray Baked Enamel Finish

5

 

–

 

Desert Brown Baked Enamel Finish

8

 

–

 

Dark Bronze Baked Enamel Finish

PLACEHOLDER

X – Future Use

COIL AND UNIT COATING OPTIONS

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

ACCESSORIES AND CONTROLS OPTIONS

X

 

–

 

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

S

 

–

 

All standard accessories plus additional security features and security cage

Summary of Contents for FUSION-TEC HR58APA

Page 1: ...06 www bardhvac com Date 4 18 17 NOTE LV1000 Controller is required for operation when multiple HR58AP units are used FUSION TEC WALL MOUNT PACKAGE AIR CONDITIONER Models Part of the Bard Free Cooling Unit System HR58APA HR58APB INSTALLATION SUPPORT MATERIALS ...

Page 2: ... Using the TEC EYETM 26 TEC EYETM Hand Held Diagnostic Tool 26 TEC EYETM Menu Structure 27 TEC EYETM Acronyms 27 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 Cooli...

Page 3: ... 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 ...

Page 4: ...djusting 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 D...

Page 5: ...ade 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...

Page 6: ... 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 in...

Page 7: ...Page 7 of 53 SECTION 1 INSTALLATION INSTRUCTIONS ...

Page 8: ...Model Nomenclature CONTROL LOGIC AND CLIMATE OPTIONS P Programmable Logic Board HR 58 A P A 0Z E P X X X X UNIT SERIES REVISION A Revision Level MAXIMUM SENSIBLE CAPACITY 58 5 Ton 2 Stage Step Capacity 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 ...

Page 9: ... to place units within close proximity without complicating maintenance and repair 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 detail...

Page 10: ... 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 Side View Front 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 ...

Page 11: ... to temporarily connect the panel to the unit Mounting the Units 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...

Page 12: ...water into evaporator drain pan directly above left and right drain fittings until coiled drain tubes are visibly full Evaporator Drain Pan Left Side Drain Hose Evaporator Drain Pan Right Right Drain Hose FIGURE 1 4 Hanging Front Access Panel to Allow Access to Control Panel ...

Page 13: ...re Length Of Top Wall Structure Top Of Unit Of Calking Along Seal With Bead Rain Flashing Supplied Wall Opening and Hole Location View Opening THE SIDE MOUNTING FLANGES AND UNDER Air MIS 3898 Right Side View TOP FLASHING AT TIME OF INSTALLATION Return Supply Air NOTES IT IS RECOMMENDED THAT A BEAD OF SILICONE CAULKING BE PLACED BEHIND ...

Page 14: ... Frame Inside Sheeting Typical Building Outside Sheeting MIS 3897 SUPPLY GRILLE MOUNT ON UNIT RETURN AIR OPENING RETURN AIR OPENING SUPPLY AIR OPENING SUPPLY AIR OPENING CONCRETE BLOCK WALL INSTALLATION WOOD FRAME WALL INSTALLATION OPENING RETURN AIR SIDE VIEW OPENING BEFORE INSTALLATION WALL STRUCTURE WOOD OR STEEL SIDING FACTORY SUPPLIED RAIN FLASHING SUPPLY AIR MIS 3896 ...

Page 15: ...N DUCT INTERIOR FINISHED WALL OVER FRAME EXTERIOR FINISH WALL OVER FRAME ATTACH TO BOTTOM PLATE OF WALL 1 000 CLEARANCE ALL AROUND DUCT ATTACH TO TOP PLATE OF WALL OPENING MIS 3895 THIS STRUCTURAL MEMBER LOCATED TO MATCH STUD SPACING FOR REST OF WALL A SECOND MEMBER MAY BE REQUIRED FOR SOME WALLS IF REQUIRED SEE UNIT DIMENSIONS FIGURE 1 2 FOR ACTUAL DIMENSIONS MIS 3899 RAFTERS OUTSIDE FINISHED CEI...

Page 16: ...rent carrying conductors are in a raceway IMPORTANT While this electrical data is presented as a guide it is important to electrically connect properly sized fuses and conductor wires in accordance with the National Electrical Code and all local codes Electrical Specifications HR58AP Series Model Rated Volts Phase No Field Power Circuits Single Circuit Minimum Circuit Ampacity Maximum External Fus...

Page 17: ...to 208V tap The acceptable operating voltage range for the 240 and 208V taps are 240V Tap 253 216 and 208 Tap 220 197 do not adjust transformer 2 If incoming AC voltage is 220VAC or above shut off AC breaker to unit and move factory 240V wire to 208V terminal 3 If incoming AC voltage is below 220VAC Shelter supply breaker in ON position Bard system breaker in OFF position 230V 208V Single Phase Vo...

Page 18: ...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 Two wire 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 ...

Page 19: ...d White 18 18 Red White 8 13 12 42 Red 18 47 48 AC CB Blue 27 27 26 26 25 24 12 8 8 9 7 6 4 5 4 5 3 2 1 1 2 3 6 7 9 11 10 10 11 12 13 16 15 14 13 15 14 16 17 18 18 17 19 19 20 20 21 21 22 22 23 23 24 25 Power loss OPT Gray Black Gray White FIELD BUS 2 Black White DFL White Black Blk Wht Black Green Black Green Black Green Black Green Orange Black Orange Black Black Green Black Black Black Black Bl...

Page 20: ...allation 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 o...

Page 21: ...meter 6 Press ESCAPE key until Main Menu screen is displayed 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 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 openin...

Page 22: ...ng Economizer Control Type 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 ob...

Page 23: ...tern 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 FIGURE 1 22 Downward Curved Diverter Blades Diverter blades as shipped left and after raising right FIGURE 1 23 View of Installed Grille as seen ...

Page 24: ...Page 24 of 53 ...

Page 25: ...Page 25 of 53 SECTION 2 SERVICE INSTRUCTIONS ...

Page 26: ...manently 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 The TEC EYETM connects to the wall mount unit control board via an RJ11 modular phone connector as shown in Figure 2 2 ALARM KEY Allows viewing of active alarms Silences audible alarms Resets...

Page 27: ... 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 M...

Page 28: ...rected 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 tempe...

Page 29: ...e 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 econ...

Page 30: ... enter dehumidification mode See the LV manual for adjustment of the dehumidification setpoint and differentials 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 FIG...

Page 31: ... Menu screen FIGURE 2 12 Adjusting Suction Temperature 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 ...

Page 32: ... 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 EE...

Page 33: ...er 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 EEV Alarms Refrigerant Low Pressure Alarm When the low pressure transducer indicate...

Page 34: ...0 v 1705 Standard Full Load Cooling 55 0 5 5 v 1830 Standard Part Load Cooling 35 0 3 5 v 1335 Economizer Speed 45 0 4 5 v 1600 Heating 35 0 3 5 v 1335 Dehumidification Mode 35 0 3 5 v 1335 TABLE 2 1 Blower Speeds FIGURE 2 16 Putting Blower Output into Override Mode Freezestat These units are equipped with a switch that monitors the temperature of the refrigerant line leaving the evaporator coil T...

Page 35: ...r 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 th...

Page 36: ...ed 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 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 fix...

Page 37: ...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 23 Adjusting High Pressure Input 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 eff...

Page 38: ...eaches 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 compres...

Page 39: ...re 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 i...

Page 40: ...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...

Page 41: ...ose 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 ...

Page 42: ...s 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 The outdoor humidity can be verified by 1 Press MENU key to go to ...

Page 43: ...TER key to save the value and scroll to the next parameter FIGURE 2 33 Supply Air Sensor 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 th...

Page 44: ...or 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...

Page 45: ...ceptable 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 indicatin...

Page 46: ...ill 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 progra...

Page 47: ...y 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 t...

Page 48: ...frigerant it must come out of the charging cylinder tank as a liquid to avoid any fractionation and to insure optimal system performance Refer to instructions for the cylinder that is being utilized for proper method of liquid extraction Safety Practices 1 Never mix R 410A with other refrigerants 2 Use gloves and safety glasses Polyol ester oils can be irritating to the skin and liquid refrigerant...

Page 49: ...m evacuated and recharged to serial plate charge weight NOTE Pressure table based on high speed condenser fan operation If condensing pressures appear elevated check condenser fan wiring See Condenser Fan Operation Full Load Cooling Air Temperature Entering Outdoor Coil F Model Return Air Temp DB WB Pressure 75 80 85 90 95 100 105 110 115 120 125 HR58 75 62 Low Side High Side 129 318 130 340 131 3...

Page 50: ...r additional wall mount units 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 Condenser coil Remove the upper side panels from the condenser section ...

Page 51: ...r Blower Performance Speed High Low ESP Inch H20 Dry Coil Wet Coil Dry Coil Wet Coil 0 1 1885 1800 1470 1400 TABLE 2 8 Maximum ESP of Operation Electric Heat Only Unit is rated for free blow non ducted operation with SGR 5W Supply Grille and RGR 5W Return Grille Model Static Pressure A0Z A05 00 00 B0Z B06 00 00 ...

Page 52: ...d controller The switch is defective Check if the high pressure switch is OK If defective replace Connection to the corresponding input terminal is disconnected or the controller board is defective Check if the connection is OK Check if the controller board is OK Repair connection If the controller board is defective replace Dirty Air Filter Alarm The alarm is a warning to check the filter Alarm c...

Page 53: ...umidity sensor wiring Replace the humidity sensor Return Air Temperature Sensor Failed 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 Check the return air temperature sensor wiring Check temperature vs resistance of temperature sensor ...

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