Bard FUSION-TEC HR58APA Installation Support Materials
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- Measuring, testing & control
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- Installation Support Materials
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Page 1 of 53
Bard Manufacturing Company, Inc.
Bryan, Ohio 43506
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 of 53
CONTENTS
SECTION 1: Installation Instructions ......................................................................................................... 7
List of Necessary Materials/Tools ...................................................................................................................... 8
Site Preparation ............................................................................................................................................. 9
Model Indentification ................................................................................................................................ 9
New Shelter Installation vs. Retrofit Installation .......................................................................................... 9
Minimum Clearance .................................................................................................................................. 9
Clearance to Combustibles ........................................................................................................................ 9
Wall-Mount Unit Mounting ............................................................................................................................. 11
Wall-Mount Unit Wiring ................................................................................................................................. 16
Main Power Wiring .................................................................................................................................. 16
Unit Voltage Wiring ................................................................................................................................. 16
Communication Wiring ............................................................................................................................ 18
Preliminary Start Up ..................................................................................................................................... 20
Running in Stand Alone (Orphan) Mode .................................................................................................... 20
Completing Wall-Mount Set Up ...................................................................................................................... 21
Setting Up Wall-Mount Unit for Operation ................................................................................................. 21
Setpoints ......................................................................................................................................... 21
Executing a Run Test ........................................................................................................................ 21
Addressing Wall-Mount Units............................................................................................................. 22
Supply Air Grill Installation ..................................................................................................................... 22
Completing the Installation...................................................................................................................... 23
SECTION 2: Service Instructions ............................................................................................................... 26
Using the TEC-EYE
TM
.................................................................................................................................... 26
TEC-EYE
TM
Hand-Held Diagnostic Tool ...................................................................................................... 26
TEC-EYE
TM
Menu Structure ............................................................................................................... 27
TEC-EYE
TM
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
Cooling ..................................................................................................................................... 29
Heating ..................................................................................................................................... 29
Staging ..................................................................................................................................... 29
Dehumidification ....................................................................................................................... 30
Temperature/Humidity Control Alarms ................................................................................................ 30
Return Air Temperature Alarm ..................................................................................................... 30
Electronic Expansion Valve (EEV) ............................................................................................................. 31
EEV Components .............................................................................................................................. 31
Electronic Expansion Valve .......................................................................................................... 31
Low Pressure Transducer............................................................................................................. 31
EEV Operation ................................................................................................................................. 31
EEV Superheat Control ............................................................................................................... 31
EEV Instructions for Vacuum, Reclaim, Charge Unit ...................................................................... 31
System Pressures ....................................................................................................................... 32
EEV Alarms ..................................................................................................................................... 33
Refrigerant Low Pressure Alarm ................................................................................................... 33
Suction Temperature Alarm ......................................................................................................... 33
Suction Pressure Alarm .............................................................................................................. 33
Low Superheat Alarm ................................................................................................................. 33
Page 3 of 53
Indoor Airflow ......................................................................................................................................... 33
Indoor Airflow Components ................................................................................................................ 33
Blower ...................................................................................................................................... 33
Filters ....................................................................................................................................... 34
Differential Airflow Switch ........................................................................................................... 34
Freezestat ................................................................................................................................. 34
Dirty Filter Switch ...................................................................................................................... 35
Filter Indicator Light .................................................................................................................. 35
Indoor Airflow Operation ................................................................................................................... 35
Blower Speed Control ................................................................................................................. 35
Indoor Airflow Alarms........................................................................................................................ 35
Blower Status Alarm ................................................................................................................... 35
Freezestat Alarm ........................................................................................................................ 36
Dirty Filter Alarm ....................................................................................................................... 36
Supply Air Temperature Alarm ..................................................................................................... 36
Condenser Fan ....................................................................................................................................... 36
Condenser Fan Components .............................................................................................................. 36
Condenser Fan ........................................................................................................................... 36
High Pressure Transducer ........................................................................................................... 37
Discharge Temperature Sensor .................................................................................................... 37
Condenser Fan Operation .................................................................................................................. 38
Condenser Fan Speed Control ...................................................................................................... 38
High Pressure Control ................................................................................................................. 38
Low Pressure Control .................................................................................................................. 38
Condenser Fan Alarms ...................................................................................................................... 39
Dirty Condenser Coil Alarm ......................................................................................................... 39
Compressor ............................................................................................................................................ 39
Compressor Components ................................................................................................................... 39
Compressor ............................................................................................................................... 39
Compressor Control Module (CCM) ............................................................................................... 39
High Pressure Safety Switch ....................................................................................................... 40
Phase Monitor ........................................................................................................................... 40
Compressor Operation ....................................................................................................................... 40
Compressor Alarms ........................................................................................................................... 40
Refrigerant High Pressure Alarm .................................................................................................. 40
Economizer ............................................................................................................................................ 41
Economizer Components ................................................................................................................... 41
Actuator .................................................................................................................................... 41
Damper Blade ............................................................................................................................ 41
Dust Sensor ............................................................................................................................... 41
Damper Switch .......................................................................................................................... 41
Outdoor Temperature and Humidity Combination Sensor ................................................................ 42
Supply Temperature Sensor ......................................................................................................... 42
Economizer Operation ....................................................................................................................... 43
Economizer Alarms ........................................................................................................................... 44
Damper Failed to Close Alarm ..................................................................................................... 44
Damper Failed to Open Alarm ..................................................................................................... 45
Outdoor Temperature Sensor Failure Alarm ................................................................................... 45
Outdoor Humidity Sensor Failure Alarm ........................................................................................ 45
Supply Temperature Sensor Failure Alarm .................................................................................... 45
Dust Sensor Failure Alarm .......................................................................................................... 45
Dust Limit Alarm ....................................................................................................................... 45
High Supply Air Temperature Alarm ............................................................................................. 46
Low Supply Air Temperature Alarm .............................................................................................. 46
Emergency Ventilation Mode .................................................................................................................... 46
Page 4 of 53
FIGURES AND TABLES
Figure 1.1 FUSION-TEC Model Nomenclature ...........8
Figure 1.2 Dimensions ..........................................10
Figure 1.3 Prefilling Traps on Indoor Drain Pan
Hoses
....................................................
12
Figure 1.4 Mounting Instructions ...........................13
Figure 1.5 Electric Heat Clearance ......................... 14
Figure 1.6 Wall Mounting Instructions ....................14
Figure 1.7 Wall Mounting Instructions ....................15
Figure 1.8 Common Wall Mounting Installations ......15
Figure 1.9 Wire Routing ........................................17
Figure 1.10 WIRING: VAC Supply Wiring
Landing Points .....................................17
Figure 1.11 Adjusting the 230/208 VAC
Transformer ..........................................17
Figure 1.12` WIRING: Connecting Communication
Wires to Unit ........................................18
Figure 1.13 WIRING: HR58AAP* Wiring Diagram ...... 19
Figure 1.14 Cooling and Heating Setpoints ...............21
Figure 1.15 Executing Run Test ...............................21
Figure 1.16 Addressing Wall-Mount Units .................22
Figure 1.17 Changing Economizer Control Type .........22
Figure 1.18 Fold-Out Diverter ..................................23
Figure 1.19 Downward Curved Diverter Blades ..........23
Figure 1.20 View of Installed Grille ..........................23
Figure 2.1 TEC-EYE
TM
Display and Interface ............26
Figure 2.2 TEC-EYE
TM
Connection to Unit Control ....26
Figure 2.3 Quick Menu Icons .................................27
Figure 2.4 Clearing All Alarms ...............................28
Figure 2.5 Adjusting Return Air Sensor ................... 28
Figure 2.6 Setpoints .............................................29
Figure 2.7 Cooling w/Economizer ...........................29
Figure 2.8 Cooling w/No Economizer ......................30
Figure 2.9 Heating ...............................................30
Figure 2.10 Viewing Unit Stages ..............................30
Figure 2.11 Adjusting Low Pressure Sensor Values ....31
Figure 2.12 Adjusting Suction Temperature Sensor
Values .................................................31
Figure 2.13 Overriding EEV Output ..........................32
Figure 2.14 Electronic Expansion Valve (EEV) and
Service Tool .........................................32
Figure 2.15 Adjusting Low Pressure Alarm Settings ...33
Figure 2.16 Putting Blower Output into Override
Mode ...................................................32
Figure 2.17 Verifying Differential Airflow Status ........34
Figure 2.18 Verifying Freeze Switch Status ...............35
Figure 2.19 Adjusting Air Flow Alarm Delay ..............35
Figure 2.20 Adjusting Freezestat Alarm Delay ...........36
Figure 2.21 Verifying Condenser Fan Output .............36
Figure 2.22 Fan Blade Setting ................................. 37
Figure 2.23 Adjusting High Pressure Input ...............37
Figure 2.24 Adjusting Discharge Temperatue Input .... 38
Figure 2.25 Pressure Control ...................................38
Figure 2.26 Adjusting Dirty Condenser Alarm
Setting ................................................39
Figure 2.27 Adjusting Compressor Delays .................40
Figure 2.28 Damper Override ..................................41
Figure 2.29 Dust Sensor .........................................41
Figure 2.30 Damper Switch ..................................... 42
Figure 2.31 Outdoor Air Sensor ...............................42
Figure 2.32 Outdoor Humidity Sensor ......................42
Figure 2.33 Supply Air Sensor .................................43
Figure 2.34 Economizer Setup ................................43
Figure 2.35 Economizer Setup – Enthalpy Control .....44
Figure 2.36 Economizer Setup – TempHum Control ...44
Figure 2.37 Adjusting Damper Failed to Close Delay ..45
Figure 2.38 Adjusting Dust Sensor Alarm Setpoint ....45
Figure 2.39 Adjusting High Supply Air Temperature
Differential ..........................................46
Table 1.1 Clearance Required for Service Access
and Adequate Condenser Airflow ..............9
Table 1.2 Minimum Clearances Required to
Combustible Materials ............................9
Table 1.3 Electrical Specification .........................16
Table 2.1 Blower Speeds .....................................34
Table 2.2 Filter Switch Pressure Settings ..............35
Table 2.3 Condenser Fan Speeds ..........................38
Table 2.4 Economizer Default Setting ...................44
Table 2.5 Cooling Pressures .................................49
Table 2.6 Rated Airflow .......................................51
Table 2.7 Indoor Blower Performance .................... 51
Table 2.8 Maximum ESP of Operation:
Electric Heat Only ................................51
Model/Serial Number Configuration .......................................................................................................... 46
Electric Heat Option ............................................................................................................................... 46
Electric Heat Components ................................................................................................................. 46
Electric Heating Element ............................................................................................................ 46
Thermal Overload ....................................................................................................................... 46
Electric Heat Operation ..................................................................................................................... 47
Bard Guard Anti-Theft System Option ....................................................................................................... 47
Smoke Detector Option ........................................................................................................................... 47
Refrigerant Information ................................................................................................................................. 48
General ................................................................................................................................................. 48
Topping Off System Charge ...................................................................................................................... 48
Safety Practices ..................................................................................................................................... 48
Important Installer Note .......................................................................................................................... 48
R410-A Refrigerant Charge ..................................................................................................................... 48
Pressure Service Ports ............................................................................................................................ 49
Maintenance and Troubleshooting .................................................................................................................. 50
Standard Maintenance Procedures ........................................................................................................... 50
Troubleshooting FUSION-TEC Wall-Mount Unit Alarms ............................................................................... 52
Page 5 of 53
GENERAL INFORMATION
Free Cooling Unit System
This Bard Free Cooling Unit System is composed of
FUSION-TEC wall-mounted air conditioners matched
with an LV1000 lead/lag controller. The wall mounts
are specifically engineered for telecom/motor control
center rooms.
NOTE: The LV1000 lead/lag controller and FUSION-
TEC wall-mount units are designed specifically
to work together. The controller cannot run
other Bard models or other brands of systems,
nor can other controllers run the FUSION-TEC
wall-mount units. They are a complete system,
and must be used together.
Wall-Mount Air Conditioner Units
The FUSION-TEC units operate on VAC power.
The
units will supply 100% of rated cooling airflow in free
cooling mode with ability to exhaust the same amount
through the unit itself without any additional relief
openings in the shelter.
Each of these units are fully charged with refrigerant
and have optional auxiliary heat.
General
The equipment covered in this manual is to be installed
by trained, experienced service and installation
technicians.
The refrigerant system is completely assembled and
charged. All internal wiring is complete.
The unit is designed for use without duct work. Flanges
are provided for transition from unit to wall grilles.
These instructions explain the recommended method
to install the air cooled self-contained unit and the
electrical wiring connections to the unit.
These instructions and any instructions packaged with
any separate equipment required to make up the entire
air conditioning system should be carefully read before
beginning the installation. Note particularly any tags
and/or labels attached to the equipment.
While these instructions are intended as a general
recommended guide, they do not supersede any national
and/or local codes in any way. Authorities having
jurisdiction should be consulted before the installation is
made. See Additional Publications for information
on codes and standards.
Sizing of systems for proposed installation should be
based on heat loss and heat gain calculations made
according to methods of Air Conditioning Contractors of
America (ACCA). The supply flange should be installed
in accordance with the Standards of the National
Fire Protection Association for the Installation of Air
Conditioning and Ventilating Systems of Other Than
Residence Type, NFPA No. 90A, and Residence Type
Warm Air Heating and Air Conditioning Systems, NFPA
No. 90B. Where local regulations are at a variance with
instructions, installer should adhere to local codes.
Shipping Damage
Upon receipt of equipment, the cartons should be
checked for external signs of shipping damage. If
damage is found, the receiving party must contact
the last carrier immediately, preferably in writing,
requesting inspection by the carrier’s agent.
These units must remain in upright position at all
times.
Additional Publications
These publications can help when installing the
furnace. They can usually be found at the local library
or purchased directly from the publisher. Be sure to
consult the current edition of each standard.
National Electrical Code ......................ANSI/NFPA 70
Standard for the Installation of Air Conditioning
and Ventilating Systems ...................ANSI/NFPA 90A
Standard for Warm Air Heating
and Air Conditioning Systems ............ANSI/NFPA 90B
Load Calculation for Residential Winter
and Summer Air Conditioning ............. ACCA Manual J
For more information, contact these publishers:
Air Conditioning Contractors of America (ACCA)
1712 New Hampshire Ave. N.W.
Washington, DC 20009
Telephone: (202) 483-9370 Fax: (202) 234-4721
American National Standards Institute (ANSI)
11 West Street, 13th Floor
New York, NY 10036
Telephone: (212) 642-4900 Fax: (212) 302-1286
American Society of Heating, Refrigeration and Air
Conditioning Engineers, Inc. (ASHRAE)
1791 Tullie Circle, N.E.
Atlanta, GA 30329-2305
Telephone: (404) 636-8400 Fax: (404) 321-5478
National Fire Protection Association (NFPA)
Batterymarch Park
P. O. Box 9101
Quincy, MA 02269-9901
Telephone: (800) 344-3555 Fax: (617) 984-7057
Page 6 of 53
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.
!
WARNING
Cut hazard.
Wear gloves to avoid contact with sharp
edges.
Failure to do so could result in personal injury.
!
CAUTION
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.
Page 7 of 53
SECTION 1:
INSTALLATION
INSTRUCTIONS
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
Page 9 of 53
SITE PREPARATION
Model Identification
Identify the specific model using the model
nomenclature information found in Figure 1.1 and
the model/serial tag found on the unit. See Figure 1.2
on page 10 for dimensions and critical installation
requirements.
New Shelter Installation vs. Retrofit
Installation
These installation instructions cover both new shelter
installations and retrofit installations. Each installation
is unique and may require special accommodations and
modifications. Although Bard Manufacturing follows a
long-established tradition of manufacturing equipment
using industry standard dimensions for building
penetration, it is occasionally necessary to move or
enlarge supply and return openings when replacing
non-standardized equipment in a retrofit application.
IMPORTANT: All retrofit installations require any
existing supply and return grilles be removed and
discarded. This is a counterflow unit and requires
specified grilles to ensure proper system performance.
Minimum Clearance
Counter flow wall-mount air conditioner models have
a removable lower front service panel that allows
access to the control panel, blower, compressor, circuit
breakers and heat strip. There is a hinged access panel
on both sides for filter change and evaporator coil
service.
The upper side panel is removable to allow access
to condenser fan, condenser coil and filter drier. The
design allows for installations to place units within
close proximity without complicating maintenance and
repair.
The unit itself is suitable for 0" clearance, but the
supply air flange requires a minimum of 1/4" clearance
to combustible material. However, it is generally
recommended that a 1" clearance is used for ease of
installation and maintaining the required clearance to
combustible material. See Figure 1.4 on page 13 for
details on opening sizes.
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
To maintain full serviceability, side-by-side installations
require 15" of clearance between units.
The condenser discharge air exits through the top
of the unit. Although this reduces the potential for
recirculation, it is still critical to system performance
that any obstruction, shrubbery or structure adhere to
minimum clearances listed (see Table 1.1).
For overhangs not exceeding 12" from exterior wall,
minimum allowable clearance from top of unit
to bottom of overhang should be no less than 5".
For overhangs greater than 12" from exterior wall,
minimum allowable clearance from top of unit to
bottom of overhang should be no less than 10" .
Clearance to Combustibles
TABLE 1.1
Clearance Required for Service Access and Adequate Condenser Airflow
Model Side(s)
Discharge (Top)
Overhang 12" or less
Discharge (Top)
Overhang
Exceeding 12"
Intake (Base) Front of Unit
Shelter
Equipment from
Supply Grille
HR58 15" 5" 10"
15" from
Snowline
36" 24"
TABLE 1.2
Minimum Clearances Required to Combustible Materials
Model Supply Air Flange Cabinet
HR58 1/4" 0"
Page 10 of 53
FIGURE 1.2
Dimensions of Basic Unit for Architectural and Installation Requirements (Nominal)
Model
Width
(W)
Depth
(D)
Height
(H)
Return Supply
A B C B E F G I J K L M N O P Q R
HR58 42.00 30.00 76.00 9.88 29.88 14.25 15.63 44.00 39.00 35.00 30.00 29.13 13.00 31.13 34.13 3.50 43.00 6.69 16.00 3.88
All dimensions are in inches. Dimensional drawings are not to scale.
Side ViewFront View
Electric
Heat
Back View
G
F
W
2° Pitch
Rain Hood
Access Panel
Access Panel
Condenser
Disconnect
C. Breaker
Built In
Service Port
Cover
L
7.125
D
M
C
I
1.500
K
J
N
A
H
Mounting
Brackets
Side Wall
(Built In)
Top Rain
Flashing
Shipping
Location
Q
E
B
B
Q
Q
P
.500
R
Q
O
MIS-3894
HR58
UNIT
Page 11 of 53
NOTE: Top rain flashing is attached to back of unit
for shipping purposes. Be sure to remove this
flashing before installing unit.
2. If desired, hook top rain flashing under back bend
of top.
3. Position unit in opening and secure with fasteners
sufficient for the application such as 5/16" lag/
anchor bolts; use 7/8" diameter flat washers on
the lag bolts. It is recommended that a bead of
commercial grade outdoor silicone sealant caulk be
placed behind the side mounting flanges.
NOTE: Opening and removing the filter access door
from each side may make fastening unit to wall
easier.
4. Secure optional rain flashing to wall and caulk
around entire unit (see Figure 1.4).
5. For additional mounting rigidity, the return air
and supply air frames or collars can be drilled
and screwed or welded to the structural wall itself
(depending upon wall construction). Be sure to
observe required clearance if combustible wall.
6. Four plastic drain hoses extend from the condenser
and evaporator drain pans. The drain hoses are
secured to fittings mounted to the unit base.
NOTE: At the time of installation, Bard highly
recommends prefilling of the traps on both of
the indoor drain pan hoses to ensure proper unit
drainage at start. The water traps can easily
be seen with the front service panel removed.
To fill traps, pour water into both sides of
evaporator drain pan until the drain hoses are
visibly full (see Figure 1.3 on page 12.)
A unique feature of the FUSION-TEC is ability to hang
the font service panel on the unit in a position that
allows full access to the control panel (see Figure 1.4
on page 12). To do this, remove the panel and hook top
lip of panel into bottom channel of control panel. For
added front panel stability, use several of the screws
that were removed to temporarily connect the panel to
the unit.
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 wood frame walls, the wall construction must
be strong and rigid enough to carry the weight of the
unit without transmitting any unit vibration. All walls
must be thoroughly inspected to ensure that they are
capable of carrying the weight of the installed unit.
In retrofit (unit replacement) installations, the openings
cut for the original equipment may not line up exactly
with needs of this installation. Modifications may need
to be made, such as increasing or decreasing the size
of the wall cutouts. The existing bolt placement may
not line up in which case the original bolts would need
to be removed or cut away.
These units are secured by wall mounting flanges which
secure the unit to the outside wall surface at both
sides. An optional bottom mounting bracket (purchased
separately) is available, but not required.
The unit itself is suitable for 0" clearance, but the
supply air flange requires a minimum of 1/4" clearance
to combustible material. However, it is generally
recommended that a 1" clearance is used for ease of
installation and maintaining the required clearance
to combustible material. See Figure 1.4 for details on
opening sizes.
IMPORTANT: When removing the shipping pallet from
beneath the wall unit, do not loosen or remove any of
the screws from either side of the unit.
1. Locate and mark lag bolt locations on both sides
and location for optional bottom mounting bracket,
if desired (see Figure 1.4).
WALL-MOUNT UNIT MOUNTING
Heavy item hazard.
Use more than one person to handle unit.
Failure to do so could result in unit damage or
serious injury.
!
WARNING
Page 12 of 53
FIGURE 1.3
Prefilling Traps on Indoor Drain Pan Hoses
Pour 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 of 53
FIGURE 1.4
Mounting Instructions
A
30"
17"
17"
17"
17"
B
16"
E
D
Supply Air Opening
Return Air Opening
WALL
Foam Air Seal
Entire 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 of 53
FIGURE 1.5
Electric Heat Clearance
FIGURE 1.6
Wall Mounting Instructions
See FIGURE 2 – Mounting Instructions
1/4" Min.
1/4" Min.
Supply Air Duct
Flange of Wall
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 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 of 53
FIGURE 1.7
Wall Mounting Instructions
FIGURE 1.8
Common Wall Mounting Installation
A
C
K
I
B
1.000
E + 1.000
FRAMING MATERIAL
2 x 4'S, 2 x 6'S &/OR
STRUCTURAL STEEL
L
2 x 6
C
SEE UNIT DIMENSIONS, FIGURE 2,
FOR ACTUAL DIMENSIONS.
SUPPLY DUCT
IF REQUIRED
ALL AROUND DUCT
1.000" CLEARANCE
OPENING
RETURN 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 CEILING SURFACE
WALL
OPENING W/ GRILLE
W/ GRILLE
SUPPLY AIR
FREE AIR FLOW
NO DUCT
RETURN AIR DUCT
RAIN
FLASHING
Page 16 of 53
WALL-MOUNT UNIT WIRING
Main Power Wiring
Refer to the unit rating plate or Table 1.3 for wire
sizing information and maximum fuse or circuit breaker
size. Each outdoor unit is marked with a “Minimum
Circuit Ampacity”. The field wiring used must be sized
to carry
that amount of current. Depending on the
installed KW of electric heat, there may be two field
power circuits required. If this is the case, the unit
rating plate will so indicate. All models are suitable
only for connection with copper wire. Each unit and/or
wiring diagram will be marked “Use Copper Conductors
Only”. These instructions must be adhered to. Refer
to the National Electrical Code (NEC) for complete
current carrying capacity data on the various insulation
grades of wiring material. All wiring must conform to
NEC and all local codes.
Electrical shock hazard.
Have a properly trained individual perform
these tasks.
Failure to do so could result in electric shock
or death.
!
WARNING
TABLE 1.3
Maximum size of the time delay fuse or circuit breaker for protection of field wiring conductors.
Based on 75°C copper wire. All wiring must conform to the National Electrical Code and all local codes.
These “Minimum Circuit Ampacity” values are to be used for sizing the field power conductors. Refer to the National
Electrical code (latest version), Article 310 for power conductor sizing.
CAUTION: When more than one field power circuit is run through one conduit, the conductors must be derated. Pay
special attention to Note 8 of Table 310 regarding Ampacity Adjustment Factors when more than three current
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 Fuse or
Circuit Breaker
Field Power
Wire Size
Ground Wire
HR58 A0Z
A05
230/208-1
1
1
43
43
60
60
8
8
10
10
HR58 B0Z
B06
230/208-3
1
1
30
30
45
45
8
8
10
10
The unit rating plate and Table 1.3 list fuse and wire
sizes (75°C copper) for all models including the most
commonly used heater sizes. Also shown are the
number of field power circuits required for the various
models with heaters.
The unit rating plate lists a maximum circuit breaker or
fuse that is to be used with the equipment. The correct
size must be used for proper circuit protection and also
to assure that there will be no nuisance tripping due to
the momentary high starting current of the compressor
motor.
The main unit circuit breaker disconnect access is
located on the front panel of the unit. Located at the
upper right corner of this panel is the rubber circuit
breaker boot. This allows unit power to be disconnected
without panel removal.
Route all field wires in channel under the control panel
as shown in Figure 1.9.
See Figure 1.10 to reference VAC landing points.
Unit Voltage Wiring
230/208V 1 phase and 3 phase equipment use dual
primary voltage transformers. All equipment leaves the
factory wired on 240V tap. It is very important that
the correct voltage tap is used. For 208V operation,
reconnect from 240V to 208V tap (see Figure 1.11).
The acceptable operating voltage range for the 240 and
Page 17 of 53
FIGURE 1.9
Wire Routing
FIGURE 1.10
VAC Supply Wiring Landing Points
FIGURE 1.11
Adjusting the 230/208 VAC Transformer
230/208V 1 phase and 3 phase equipment use dual primary voltage transformers. All equipment leaves the factory wired on
240V tap. It is very important that the correct voltage tap is used. For 208V operation, reconnect from 240V to 208V tap.
The acceptable operating voltage range for the 240 and 208V taps are: 240V Tap (253 – 216) and 208 Tap (220 – 197).
...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 Voltage Range:
197VAC – 253VAC
230V/208V Three Phase Voltage Range:
197VAC – 253VAC
(not shown)
.
230VAC
1. Verify incoming AC voltage: Multimeter set to VAC
+
NEW IMAGE
NEEDED
Page 18 of 53
208V taps are: 240V Tap (253 – 216) and 208 Tap
(220 – 197).
NOTE: The voltage should be measured at the field
power connection point in the unit and while
the unit is operating at full load (maximum
amperage operating condition.
Communication Wiring
For low voltage wiring, 2-wire 18 gauge shielded with
drain is recommended.
From the controller, extend the shielded cable through
a separate conduit and route to the terminal block
mounted on the wall-mount unit next to the control
board (see Figure 1.12).
Note that the terminal block label is clearly marked “+”
and “-”. These connections are polarity-sensitive. 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. See LV1000 controller manual 2100-673 for
complete information on connecting the wall units to
the LV controller.
FIGURE 1.11
Connecting Communication Wires to Unit
From LV1000
Controller
1 2 4 5 7 9 108 12 14 16 173 6
11
13 15
Unit Terminal Block
– +
Page 19 of 53
FIGURE 1.13
HR58AAP* Wiring Diagram
3
21
DI1
DI2
DI3
DI4
DI5
DI6
DI7
GND
B1
B2
B3
B4
B5
B6
B7
GND
+VDC
B8
B9
GND
Y1
Y2
Y3
C1
NO1
NO2
NO3
C2
NO6
NO5
NO4
NO7
C7
NC7
C8
NO8
NO9
GO
G
AC
GND
ACG
V+
Dust
Sensor
NO C
NC
Com
SAT
RAT
L2
L1
FAN
MOTOR
BLOWER
MOTOR
COMPRESSOR
CNC
AUX
COM PRESSOR
CON TACTOR
L2
L1
T1
T2
CAP
CC
C
R
HPC
LPCLPC
ALR
Y
Blue
2
GND
2-10
3
VDC
1
24VAC
Damper Motor
HPC
Alaram
Relay Coil
Contactor
Comp
Coil
Contactor
Heat
Coil
DP
SP
ST
OATH
FS
UNLOADER
SOLINOID
+5V
Pink
Pink
Blue Blue
Blue
Blue
Blue
Blue/Wht
Blue/White
Orange
Orange
Orange
Yellow
Yellow/White
Yellow/Red
Yellow Yellow
Yellow
Yellow
Green
Brown/White
72
80
80
79
70
Red/White
71
50
Red/White
53
Red/White
18
Red/Yellow
73
73
Red/Yellow
93
30
52
Red/White
18
28
27
26
25
51
68
69
63
64
Red
31
Red
33
Block
Terminal
46
Red
46
Red
61
62
Red
38 36
34
32
Red
15
40
22
22
22
19
21
17
24
56
8
23
Red
23
Red
17 17
7
94
Red
72
29
48
41
41
Red
41 35
10
9
11
8
Red/White
18
Red/White
20
17
28
17
62
67
66
65
43
Red
47
47
57
103
103
Red
103
57
45
45
Red
45
48
48
49
49
44
44
58
43
Red/White
18
18
Red/White
8
13
12
42
Red
18
47
48
AC
CB
Blue
27 27
2626
25
24
12
88
9
7
6
4
5
4
5
3
2
1 1
2
3
6
7
9
11
1010
11
12
13
16
15
14
13
15
14
16
17
1818
17
19 19
2020
2121
22 22
2323
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
Black
Black
Black
Black
Black/White
Black/White
Black/White
Black/White
CCH
Black
Black
TRANSFORMER
Black/White
Black/White
Black/White
Red/White
Black
Black
Black
Black
Black
Gray/Red
Gray/Black
Black/Green
Gray/White
Black
Black
Gray/Green
EEV
4097-701 B
LT
HIGH PRESSURE CONTROL
Black
Black/Green
Field OptionalFactory
High Voltage
Low Voltage
D-10VDC
Black
Alarm R elay
Blade Switch
smoke sensor
BOARD
SENSOR
DUST
when connecting
Remove jumpers
T
SPEAKER
F
LOOP
SECURITY
E
H
T
DFS
TERMINAL BLOCK
BOTTOM
TOP
LT
CRANKCASE HEATER
EEV
LT
AFS
DFS
OATH
CCH
HPC
TB
DFL
FS
BS
ST
RAT
SAT
DP
SP
ELECTRONIC EXPANSION VALVE
LIQUID TEMPERATURE
AIR FLOW SWITCH
DIRTY FILTER SWITCH
OUTDOOR TEMP. AND HUMID. SENSOR
SUCTION PRESSURE SENSOR
DISCHARGE PRESSURE SENSOR
SUPPLY AIR TEMPERATURE
RETURN AIR TEMPERATURE
SUCTION TEMPERATURE
BLADE SWITCH
FREEZE STAT
DIRTY FILTER LIGHT
AFS
GND
Page 20 of 53
PRELIMINARY START UP
Running in Stand Alone (Orphan) Mode
With the AC breakers turned on, each FUSION-TEC
wall-mount unit has the capability to run without the
LV1000 controller attached—this feature is called
stand alone or orphan mode. This keeps the shelter
between 60°F and 79°F (factory default settings) by
the use of the factory-installed return air sensor in
each wall-mount unit. In stand-alone mode, the wall
unit uses a continuous blower setting to circulate room
air into the return air inlet and uses the return air
temperature sensor to control room temperature.
The wall-mount unit can be turned on and off with
the TEC-EYE
TM
hand-held diagnostic tool. When ON is
chosen, the system will heat or cool.
NOTE: The blower will continue to run when OFF is
chosen. Refer to page 28 to change ON/OFF
Control.
The unit will not go into stand alone mode until after
an initial call for cooling. (?)
To change default setpoints, refer to Setpoints on page
21.
During installation, the ability to run in stand alone
mode allows deactivation of one of the existing, older
wall-mount units, while keeping the shelter cool
with the other unit still operating. Once the first of
the Bard FUSION-TEC wall-mount units is installed,
orphan mode can be enabled early in the installation—
keeping the climate inside the shelter stable and
the installers comfortable while the remainder of the
older equipment is removed and the remaining Bard
FUSION-TEC wall-mount units and LV1000 controller
are installed.
To ensure units will go into stand alone mode,
disconnect the plug marked R-T-/R+T+/GND on the
control board located in the wall-mount unit. Be sure
to reconnect the plug before operating the wall-mount
unit as part of the Bard Free Cooling Unit System.
Additionally, should any or all of the FUSION-TEC
wall-mount units lose communication with the LV1000
controller (such as during maintenance), they will
continue to serve the shelter’s needs until a repair can
be made.
See the LV1000 controller manual for complete
information on connecting the communication wiring
from the controller to the wall-mount units and
operating the Bard Free Cooling Unit System.
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Bard FUSION-TEC HR58APA Installation Support Materials
- Category
- Measuring, testing & control
- Type
- Installation Support Materials
- This manual is also suitable for
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