Bard FUSION-TEC WR Series Literature Assembly Download Page 54

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USER’S GUIDE

For all Packaged Systems (Air Conditioners and Heat Pumps)

DATE: 02-21-12

PA - Series Air Conditioners
PH - Series Air Source Heat Pumps

QA - Series Air Conditioners
QH - Series Air Source Heat Pumps
QW - Series Water Source Heat Pumps

WA & WL - Series Air Conditioners
WH & SH - Series Air Source Heat Pumps

MANUAL 2100-034 REV. F
SUPERSEDES REV. E
FILE VOL. I, TAB 6

- Series Air Source Heat Pumps

Summary of Contents for FUSION-TEC WR Series

Page 1: ...following 2100 704 C Fusion Tec A C Install Inst WR 2100 709 Fusion Tec Quick Start Guide WR 2100 034 F User s Guide 2100 479 Leak Test Evacuation Charging 2110 1547 E Replacement Parts Manual 7960 7...

Page 2: ......

Page 3: ...s Wall Mount Air Conditioner Bard Manufacturing Company Inc Bryan Ohio 43506 www bardhvac com Manual 2100 704C Supersedes 2100 704B Date 1 2 20 INSTALLATION INSTRUCTIONS LC6000 200 Supervisory Control...

Page 4: ...s 11 Figure 4 Hanging Front Access Panel to Allow Access to Control Panel 11 Figure 5 Fold Out Diverter 12 Figure 6 Downward Curved Diverter Blades 12 Figure 7 View of Installed Grille 12 Figure 8 WR3...

Page 5: ...Adjusting Sensor Offset Value 45 Figure 58 Current Sensor Orientation 47 Figure 59 Earlier Sensor Orientation 47 TABLES Table 1 Clearance Required for Service Access and Adequate Condenser Airflow 8 T...

Page 6: ...ary heat Controller LC6000 controller and accessories are shown below 1 One remote temperature humidity sensor is included with the LC6000 controller If the site in which the LC6000 controller will be...

Page 7: ...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 con...

Page 8: ...t 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 3 on...

Page 9: ...X X UNIT SERIES REVISION B Revision Level MAXIMUM SENSIBLE CAPACITY 35 3 Ton 2 Stage Step Capacity Small Chassis 36 3 Ton 2 Stage Step Capacity 58 5 Ton 2 Stage Step Capacity VOLTS PHASE A 230 208 60...

Page 10: ...to system performance that any obstruction shrubbery or structure adhere to minimum clearances listed see Table 1 For overhangs not exceeding 12 from exterior wall minimum allowable clearance from to...

Page 11: ...6 00 9 88 29 88 15 88 29 88 44 00 40 00 34 13 30 00 29 13 13 00 31 13 34 13 3 50 43 00 2 69 17 00 3 88 All dimensions are in inches Dimensional drawings are not to scale 2 Pitch Rain Hood Access Panel...

Page 12: ...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 2 to locate pre pun...

Page 13: ...ater into evaporator drain pan directly above left and right drain fittings until coiled drain tubes in blower section are visibly full Evaporator Drain Pan Left Side Drain Hose Evaporator Drain Pan R...

Page 14: ...g 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 feat...

Page 15: ...O MAINTAIN 1 MIN CLEARANCE FROM COMBUSTIBLE MATERIALS 29 7 8 9 7 8 4 6 16 7 8 Supply Air Opening Return Air Opening WALL Foam Seal Foam Seal Foam Seal Foam Seal Right Side View Supply Air THE SIDE MOU...

Page 16: ...RED DIMENSIONS TO MAINTAIN 1 MIN CLEARANCE FROM COMBUSTIBLE MATERIALS 32 12 5 1 2 2 29 Top Of Unit Foam Air Seal To Support Rain Flashing Entire Length Of Top Of Calking Along Wall Structure Seal With...

Page 17: ...l Wall 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 INST...

Page 18: ...D SPACING FOR REST OF WALL A SECOND MEMBER MAY BE REQUIRED FOR SOME WALLS RETURN DUCT SUPPLY DUCT OPENING MIS 4033 9 88 14 25 13 00 29 88 1 000 45 00 FRAMING MATERIAL 2 x 4 S 2 x 6 S OR STRUCTURAL STE...

Page 19: ...nting Installation MIS 3899 RAFTERS OUTSIDE FINISHED CEILING SURFACE WALL OPENING W GRILLE W GRILLE SUPPLY AIR FREE AIR FLOW NO DUCT RETURN AIR DUCT RAIN FLASHING RETURN AIR WALL SLEEVE FIELD SUPPLIED...

Page 20: ...n and also to ensure that there will be no nuisance tripping due to the momentary high starting current of the compressor motor TABLE 3 Electrical Specifications Model Rated Volts Phase No Field Power...

Page 21: ...VAC landing points LOW VOLTAGE COMMUNICATION WIRE ENTRANCE HIGH VOLTAGE POWER WIRE ENTRANCE MIS 3927 FIGURE 16 Side Communication and Power Wire Entrances Recommended FIGURE 15 VAC Supply Wiring Landi...

Page 22: ...ptional Unit Control 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 correc...

Page 23: ...table 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 m...

Page 24: ...ENTER key to scroll to the selected choice see Figure 19 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 ke...

Page 25: ...pical LC6000 200 Component Location Transformer RJ11 Cable to Display Four Fused Power Supply Terminals Terminal Block Emergency Off Alarm Jumper Emergency Vent Alarm Jumper Generator Run Alarm Jumper...

Page 26: ...cal shock hazard Disconnect VAC power supplies before servicing Failure to do so could result in electric shock or death WARNING IMPORTANT When working with circuit board components Bard recommends th...

Page 27: ...19 and 22 TB Wire Mark Sensor Description 18 B6 NTC OUT Indoor Remote Sensor Zone 1 19 GND NTC OUT Ground 12 B2 OUT H Remote Indoor Humidity Sensor 0 1 VDC Zone 1 13 GND M GO Ground 22 VDC G Power fo...

Page 28: ...k and sensor as listed below Zone 1 Optional Remote Temperature Sensor Terminals 20 21 The two wire connections for the optional remote temperature sensor are not polarity sensitive TB Wire Mark Descr...

Page 29: ...the manufacturer s mounting instructions Use 18 gauge 5 conductor shielded cable to connect to controller FIGURE 24 Remote Outdoor Temperature Humidity Sensor Installation 1 Connect wires from the 18...

Page 30: ...nd 7 emergency off 8 and 9 emergency ventilation and 10 and 11 generator run Remove the factory installed jumpers before making the connections FIGURE 25 LC6000 200 Series Connection for Emergency Off...

Page 31: ...on purposes only Do not run communication wiring in same conduit as supply wiring Route communication wiring and power supply wiring in their own separate conduits FIGURE 27 Communication Wiring Alter...

Page 32: ...Unit 1 Unit 2 Unit 3 Unit 4 up to 14 units Place filter here Place filter here NOTE Line filters can be on either the unit or controller whichever device is on the end of the chain No matter how many...

Page 33: ...d the drain wire to ground terminal 60 The steps outlined on the following pages show how to connect the communication wiring using the daisy chain method shown in Figure 26 on page 29 If using the al...

Page 34: ...symbols on controller terminal block 2 Connect the wires matching the terminal designations of the controller terminals Leave the drain wire loose 3 Connect another cable in a similar fashion daisy ch...

Page 35: ...gnations of the controller terminals Cap the loose drain with a wire nut or electrical tape 3 Continue daisy chaining units by connecting to to and wire nutting drain together until last unit which is...

Page 36: ...st be field supplied Install as shown in Figure 33 Failing to ground the controller box properly could result in damage to the equipment FIGURE 33 Controller Grounding Posts 5 7 9 17 19 21 11 13 15 6...

Page 37: ...Humidifier 2 35 C1 Common 36 NO3 Humidifier 3 37 C1 Common 38 NO4 Emergency Off Alarm TB Wire Mark Description 39 C2 Common 40 NO5 Emergency Vent Alarm 41 C2 Common 42 NO6 Generator Run Alarm 43 C2 Co...

Page 38: ...B 52 TB 54 NO7 BLUE BLK NO8 BLUE BLK NO9 BLUE BLK NO10 BLUE BLK NO11 BLUE BLK NO12 BLUE BLK 1 RX TX C7 BLACK C8 BLACK 2 RX TX 1 RX TX 2 RX TX GREEN TB 28 B8 RED SMK JUMPER HYD JUMPER GEN JUMPER ORANGE...

Page 39: ...5 minutes of no activity The screen can be accessed any time by pressing the ESCAPE key repeatedly SYSTEM SET UP FIGURE 35 TEC EYE Connection to Unit Control Modular Connector for TEC EYE Hand Held D...

Page 40: ...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 key to scroll to Run Test A10 sc...

Page 41: ...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 3 Clear Unit Alarm Logs on Each Unit Unit...

Page 42: ...Follow steps 6 8 to change timezone 10 Press ESCAPE key several times to return to Main Menu screen NOTE The LC6000 will sync the time and date configured to each of the wall mount units once communic...

Page 43: ...y 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 IO Config press ENTER key 4 Press UP or DOWN key...

Page 44: ...Disable Zone 1 Remote Temperature Sensor FIGURE 50 Enable Disable Zone 2 Remote Temperature Sensor FIGURE 51 Enable Disable Zone 3 Remote Temperature Sensor To enable disable Zone 3 Remote Temperature...

Page 45: ...veral times to return to Main Menu screen 7 Verify Units Are Online Once a unit is uniquely addressed communication can be verified at the LC controller With the correct number of units set at the LC...

Page 46: ...have alarms logged due to bench testing Controller alarm logs must be cleared at time of installation To clear the LC controller alarm logs 1 Press MENU key to go to the Main Menu screen 2 Use UP or D...

Page 47: ...art User 2000 Parameter Config Engineer 9254 Alarm Export User 2000 Logout Used to log out of the current password level Entering back into the menu requires password ADDITIONAL INFORMATION Setpoints...

Page 48: ...ory controller Off by Keyboard Unit has been turned off by the local user Override Active There is an active override on the system Emergency Vent Unit is in Emergency Ventilation LC6000 has an active...

Page 49: ...cts the position of the DP1 DP2 jumpers Depending on how the sensor is installed be sure to confirm that the jumpers are in the proper position for the 0 1 V setting as shown in the figures below This...

Page 50: ......

Page 51: ...UP DOWN ENTER keys to enter password 1313 3 Press UP DOWN keys to scroll to Settings press ENTER key 4 Press UP DOWN keys to scroll to Initialization press ENTER key 5 Press ENTER key to scroll to Cl...

Page 52: ...SCAPE key to view the Status screen May need to be pressed more than once 2 Press UP DOWN key until the Quick Menu in the lower right corner of the screen displays the Information icon press ENTER key...

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Page 54: ...eries Air Conditioners PH Series Air Source Heat Pumps QA Series Air Conditioners QH Series Air Source Heat Pumps QW Series Water Source Heat Pumps WA WL Series Air Conditioners WH SH Series Air Sourc...

Page 55: ...s Page 4 5 Heat Pump Air to Air Page 5 6 Heat Pump Water to Air Page 6 Ventilation Page 7 Dehumidification Circuits Page 7 Automatic Control Systems Thermostats Page 7 Humidistats Humidity Controllers...

Page 56: ...pending upon application and use of the equipment and it is critical to monitor filter condition and establish an acceptable maintenance schedule Failure to do so will increase operating and repair co...

Page 57: ...ctually entering into the equipment enclosure which should only be done by qualified service technicians See section on Air to Air Heat Pumps for additional information concerning blockage due to heav...

Page 58: ...e equipped with some amount of electric heat to supplement the heating capacity of the compressor system on an as needed basis This operation is entirely automatic and is controlled by the indoor ther...

Page 59: ...ats and cools using a compressor for both modes of operation The primary difference is that the system uses water or antifreeze protected water solution instead of an air cooled outdoor heat transfer...

Page 60: ...ntenance requirements you should be aware of as the user AUTOMATIC CONTROL SYSTEMS THERMOSTATS There are many types of thermostats available to properly control your system and these can vary in featu...

Page 61: ...ace and that all supply registers and return air grilles are not blocked 5 Make sure that the outdoor coil is not blocked with any foreign matter or otherwise restricted with any growth or other items...

Page 62: ...lengthy period it is best to adjust the thermostat to a reasonable higher or lower depending upon the season setting rather than turning it completely off Upon return the inside conditions will not be...

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Page 64: ...1 of 11 Manual No 2100 479 Supersedes NEW File Volume I Tab 1 Date 03 08 07 SERVICING PROCEDURE R 410A LEAK TEST EVACUATION CHARGING Bard Manufacturing Company Inc Bryan Ohio 43506 Since 1914 Moving a...

Page 65: ...tioning Heat Pump Cooling 9 Low Suction Low Head Pressure 9 High Suction Low Head Pressure 9 Low Suction High Head Pressure 9 High Suction High Head Pressure 9 Heat Pump Heating 9 Low Suction Low Head...

Page 66: ...tion of the system The valving on the manifold is so arranged that when the valves are closed front seated the center port on the manifold is closed to the gauges and gauge ports With the valves in th...

Page 67: ...Relieve all pressure from the system down to 0 psig 5 Change the dryer When leaks if any have been repaired system is ready to be evacuated and charged Relieve all pressure from the system down to 0 p...

Page 68: ...serial plate for the full operating charge PRELIMINARY CHARGING STEPS If the system has been open to the atmosphere the dryer should be replaced and then evacuated Then proceed as follows 1 Attach a d...

Page 69: ...Manual 2100 479 Page 6 of 11 FIGURE 1 TYPICAL AIR CONDITIONING SYSTEM COOLING CYCLE MIS 369...

Page 70: ...Manual 2100 479 Page 7 of 11 FIGURE 2 TYPICAL HEAT PUMP SYSTEM COOLING CYCLE MIS 368...

Page 71: ...ed refrigerant flow it may be necessary to place refrigerant drum in a pan of warm water not greater than 130 F Remember to either consider the total weight of the pan of water or remove the drum for...

Page 72: ...ing device etc 6 Low charge 7 Low ambient entering air temperature Low entering water temperature to water coil HIGH SUCTION LOW HEAD PRESSURE 1 Defective or broken valves 2 IPRV valve open 3 Defectiv...

Page 73: ...r o s s e r p m o c m e t s y s e b u t p a c e r u t a r e p m e t e c a p S h g i h o o t Power Failure Blown Fuses or Tripped Circuit Breakers Faulty Wiring Loose Terminals Low Voltage Single 1PH...

Page 74: ...l n o p u d l i u b e c I l i o c D O f o g n i d o o l f t n a r e g i r f e r d i u q i L r o s s e r p m o c o t k c a b D I n o t a e h y r a i l i x u A f f o r e w o l b s t s o c g n i t a r e...

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Page 76: ...y Components WR58BP Exploded View 16 Usage List 16 FUSION TEC Wall Mount Air Conditioner Description Page Heater Packages WR35BP Exploded View 17 Usage List 17 Heater Packages WR36BP WR58BP Exploded V...

Page 77: ...r area note any use of caulk as a sealant Be sure to replace caulk seals using 100 silicone outdoor rated caulk 35 29 25 16 7 11 14 17 26 23 15 21 44 11 2 28 32 38 20 8 31 30 10 12 41 4 27 3 1 6 42 43...

Page 78: ...amper Blade Assembly X X 26 S509 397 Back Assembly X X 27 113 677 Motor Control Bracket X X 28 127 555 Compressor Isolation Plate X X 29 8550 011 2 1 2 Single Hole Strap X X 30 521 565 Evaporator Part...

Page 79: ...Back Assembly X X X X 27 113 677 Motor Control Bracket X X X X 28 127 555 Compressor Isolation Plate X X X X 29 8550 011 2 1 2 Single Hole Strap X X X X 30 521 555 Evaporator Partition X X X X 31 113...

Page 80: ...Manual 2110 1547E Page 5 of 20 This page intentionally left blank...

Page 81: ...Manual 2110 1547E Page 6 of 20 FUNCTIONAL COMPONENTS SEXP 886 A 17 18 4 5 24 3 6 15 9 8 1 13 11 12 2 10 26 25 20 14 22 7 21 19 23 27 18 This drawing is referenced in tables on pages 7 and 8...

Page 82: ...lter MERV 8 18 x22 x2 Air Filter MERV 8 20 x30 x2 2 2 2 2 2 2 2 2 11 8406 157 Liquid Line Pressure Transducer X X X X 12 8406 158 Suction Pressure Transducer X X X X 13 8406 142 High Pressure Switch X...

Page 83: ...ressure Switch X X 14 8611 199 Filter Service LED X X 15 5201 022 Filter Drier X X 17 5651S245 Electronic Expansion Valve less cable and stator see NS below X X 18 18 8408 044 8408 054 Return Air Sens...

Page 84: ...Manual 2110 1547E Page 9 of 20 This page intentionally left blank...

Page 85: ...BOTTOM 15 SEXP 887 B 12 24 TOP 1 5 4 3 2 1 2 3 4 5 6 7 8 9 10 11 12 14 13 15 16 17 18 19 20 21 22 10 17 25 TERMINAL BLOCK ASSEMBLY 24 23 25 22 21 20 19 18 17 16 15 13 14 12 11 10 9 8 7 6 26 27 26 16...

Page 86: ...or 3 3 3 15 8611 148 4 Pin Circuit Board Connector 3 3 3 16 8611 183 2 Pin Circuit Board Connector 2 2 2 17 8611 192 3 Pin Circuit Board Connector 1 1 1 18 8611 185 8 Pin Circuit Board Connector 1 1 1...

Page 87: ...21 6 5 2 7 4 8 3 13 SEXP 891 16 TERMINAL BLOCK ASSEMBLY 11 1 17 16 1 24 23 25 22 21 20 19 18 17 16 15 13 14 12 11 10 9 8 7 6 5 4 3 2 1 2 3 4 5 6 7 8 9 10 11 12 14 13 15 16 17 18 19 20 21 22 25 BOTTOM...

Page 88: ...X X X 14 8611 147 3 Pin Circuit Board Connector 3 3 3 15 8611 148 4 Pin Circuit Board Connector 3 3 3 16 8611 183 2 Pin Circuit Board Connector 2 2 2 17 8611 192 3 Pin Circuit Board Connector 1 1 1 1...

Page 89: ...5152 014 Blower Wheel X 2 2 S8106 051 0154 C8106 051 0154 1 3 HP Programmed Motor 1 3 HP Control Only Replacement X X 3 151 126 Housing X 4 105 1435 Left Mounting Angle X 5 105 1443 Right Mounting An...

Page 90: ...r Description 1 5152 049 Blower Wheel X 2 S8105 059 0146 1 3 HP Programmed Motor X 3 151 122 Housing X NS C8105 059 0146 1 3 HP Control Only Replacement X NS 3000 1578 0 10VDC Adapter Wire X 5154 002...

Page 91: ...f 20 Drawing No Part Number Description 1 5154 007 0142 Complete Blower Wheel X 2 C5154 007 0142 3 4 HP Control Only Replacement X NS 3000 1578 0 10VDC Adapter Wire X 5154 007 0142 BLOWER ASSEMBLY COM...

Page 92: ...X X 3 3 3 8604 150 8604 148 8604 149 Heat Strip 1 5KW 240V 2 Term Heat Strip 5 0KW 240V 2 Term Heat Strip 6 0KW 240V 3 PH X X X 4 8402 190 Limit Control 130P 150BU 1 1 1 5 1012 065 Screw Type AB PZPN...

Page 93: ...ket Front X X X X X X 4 4 4 8604 150 8604 148 8604 149 Heat Strip 1 5KW 240V 2 Term Heat Strip 5 0KW 240V 2 Term Heat Strip 6 0KW 240V 3PH X X X X X X 5 8402 190 Limit Control 130P 150BU 1 1 1 1 3 3 6...

Page 94: ...cket X 4 141 326 Gusset X 5 8602 093 90 in lb Actuator X 6 6 8602 101 8602 102 Actuator Drive Rod Assembly Actuator Drive Rod Assembly X X X 7 8602 008 Ball Joint X 8 8 8602 042 8602 091 1 4 x 6 Rod 1...

Page 95: ...Frame Assembly Frame Assembly X X X 2 9050 005 Base Bracket X X X 3 3 9050 006 9050 007 Top Bracket Top Bracket X X X 4 8406 135 Low Pressure Switch X X X 5 8406 156 Panel Switch 4 4 4 6 910 2038 Spe...

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Page 97: ...ories including supply and return louvers Are they free of damage Model and Serial Numbers of HVAC units Unit Model Number Serial Number 1 2 3 4 Model and Serial Number of Controller Model Number Seri...

Page 98: ...economizer compressor condenser fan electric heat is operational High Pressure psi measurement from TEC EYE service tool Low Pressure psi measurement from TEC EYE service tool Measure Voltage at unit...

Page 99: ...Record indoor humidity displayed on the controller Power Supply Voltage at unit controller measured with Multimeter Controller Software Version Final Jobsite review Verify the following Yes No Are all...

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Page 101: ...ting environment is exposed to airborne saline particles typically 5 miles from coast line must have corrosion protection or warrenty claims will be declined on corrosion based cabinet and part failur...

Page 102: ...rts Must be registered at www wallmountwarranty com within 90 days of installation for the 10 year parts coverage to be in effect Factory coated coils have a 5 year warranty in corrosive environments...

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