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INSTALLATION INSTRUCTIONS
FUSION-TEC™/LV1000
Free Cooling Unit System
Wall-Mount Air Conditioner
LV1000-100 Lead/Lag Controller
NOTE: LV1000 Controller is required for operation when
multiple HR58AP* units are used.
FUSION-TEC™
Models:
HR58APA
HR58APB
Bard Manufacturing Company, Inc.
Bryan, Ohio 43506
www.bardhvac.com
Manual :
2100-674
Supersedes:
NEW
Date:
6-2-17
Page
1 of 42
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Table of Contents
Summary of Contents for FUSION-TEC HR58APA
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Page 1: Installation Instructions
INSTALLATION INSTRUCTIONS FUSION-TEC™/LV1000 Free Cooling Unit System FUSION-TEC™ Wall-Mount Air Conditioner Models: HR58APA HR58APB LV1000-100 Lead/Lag Controller NOTE: LV1000 Controller is required for operation when multiple HR58AP* units are used. Bard Manufacturing Company, Inc. Manual : 2100-674 Bryan, Ohio 43506 Supersedes: www.bardhvac.com... -
Page 2: Table Of Contents
Mounting the LV Controller ......21 Additional Information ........41 Installing Remote Indoor Temperature/Humidity Sensor(s) ....22 FIGURES AND TABLES Figure 1 FUSION-TEC Model Nomenclature ...7 Figure 27 LV1000-100 Controller Supply Wiring ..30 Figure 2 Dimensions ..........9 Figure 28 Controller Grounding Posts ....30... -
Page 3: General Information
Wall-Mount Air Conditioner Units These instructions and any instructions packaged with The FUSION-TEC units operate on VAC power. The any separate equipment required to make up the entire units will supply 100% of rated cooling airflow in free... -
Page 4: Figure 25 Communication Wiring: Termination Table
ANSI Z535.5 Definitions: Sizing of systems for proposed installation should be based on heat loss and heat gain calculations made DANGER: Indicate[s] a hazardous situation which, if according to methods of Air Conditioning Contractors of not avoided, will result in death or serious injury. The America (ACCA). - Page 5 WARNING WARNING Heavy item hazard. Electrical shock hazard. Use more than one person to handle unit. Have a properly trained individual perform these tasks. Failure to do so could result in unit damage or serious injury. Failure to do so could result in electric shock or death.
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Page 6: List Of Necessary Materials/Tools
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/ anti- static wrist straps •... -
Page 7: Site Preparation
These installation instructions cover both new shelter specified grilles to ensure proper system performance. installations and retrofit installations. Each installation FIGURE 1 FUSION-TEC Wall-Mount Unit Model Nomenclature UNIT SERIES MAXIMUM SENSIBLE CAPACITY 58 – 5 Ton 2 Stage Step Capacity REVISION A –... -
Page 8: Minimum Clearance
Minimum Clearance Clearance to Combustibles Counter flow wall-mount air conditioner models have The unit itself is suitable for 0" clearance, but the a removable lower front service panel that allows supply air flange requires a minimum of 1/4" clearance access to the control panel, blower, compressor, circuit to combustible material. -
Page 9: Figure 2 Dimensions
Manual 2100-674 Page 9 of 42... -
Page 10: Wall-Mount Unit Mounting
(see Figure 3). not line up in which case the original bolts would need A unique feature of the FUSION-TEC is the ability to to be removed or cut away. hang the front service panel on the unit in a position... -
Page 11: Hoses
FIGURE 3 Prefilling Traps on Indoor Drain Pan Hoses Evaporator Drain Pan Left Side Drain Hose Evaporator Drain Pan Right Right Drain Hose Pour water into evaporator drain pan directly above left and right drain fittings until coiled drain tubes in blower section are visibly full. FIGURE 4 Hanging Front Access Panel to Allow Access to Control Panel... -
Page 12: Figure 5 Fold-Out Diverter
Supply Air Grill Installation equipment would be directly mounted in front of the unit. The rear deflectors must be folded out and Bard model SGR-5W grille is custom designed for secured by the installer with the supplied screws utilization with Bard wall-mount unit HR58AP for (see Figure 5). -
Page 13: Figure 8 Mounting Instructions
Manual 2100-674 Page 13 of 42... -
Page 14: Figure 9 Electric Heat Clearance
FIGURE 9 Electric Heat Clearance Typical Building Outside Sheeting Wall Frame Inside Sheeting 1/4" Min. Supply Air Duct Flange of Wall 1/4" Min. SUPPLY GRILLE MIS-3897 FIGURE 10 Wall Mounting Instructions WALL STRUCTURE See FIGURE 2 – Mounting Instructions FACTORY SUPPLIED RAIN FLASHING. -
Page 15: Figure 11 Wall Mounting Instructions
FIGURE 11 Wall Mounting Instructions 45.00 ATTACH TO TOP PLATE OF WALL 29.88 1.000 1.000" CLEARANCE ALL AROUND DUCT IF REQUIRED RETURN DUCT 9.88 INTERIOR FINISHED WALL OPENING OVER FRAME 30.00 1.000" CLEARANCE ALL AROUND DUCT IF REQUIRED SUPPLY DUCT 14.25 OPENING EXTERIOR FINISH WALL... -
Page 16: Wall-Mount Unit Wiring
WALL-MOUNT UNIT WIRING capacity data on the various insulation grades of wiring WARNING material. All wiring must conform to NEC and all local codes. The unit rating plate and Table 3 list fuse and wire Electrical shock hazard. sizes (75°C copper) for all models including the most commonly used heater sizes. -
Page 17: Unit Voltage Wiring
FIGURE 13 When running wires to unit from shelter, be careful to not place wiring and conduit where it will interfere with Wire Routing opening filter access doors. Unit Control Voltage Wiring 230/208V 1 phase and 3 phase equipment use dual primary voltage transformers. -
Page 18: Transformer
FIGURE 15 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 –... -
Page 19: Preliminary Start Up
FIGURE 16 Running in Stand Alone (Orphan) Mode Cool and Heat Setpoints 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... -
Page 20: Lv1000 Controller Installation
LV1000 CONTROLLER INSTALLATION FIGURE 17 Typical LV1000 Component Location RJ11 Cable to Display -48VDC to 24V Power Supply Control Board Power Loss Relay Power Supply Connections Terminal Block Connection Manual 2100-674 Page 20 of 42... -
Page 21: Lv1000 Controller
Mounting the LV1000 Controller WARNING The dimensions of the LV controller are 16" by 12" by 6". Because the LV1000 controller utilizes a remote Electrical shock hazard. temperature sensor as opposed to one located in the Disconnect VAC and VDC power supplies controller box, the controller itself can be installed in before servicing. -
Page 22: Installing Remote Indoor Temperature/Humidity Sensor(S)
Installing Remote Indoor Temperature/Humidity Sensor(s) One remote indoor temperature/humidity sensor and 35' of 18 gauge 5-conductor shielded cable is included with the controller. This sensor must be installed for proper operation. Mount the temperature/humidity sensor in a location least likely to be affected by open doors, rack-mounted fans, radiant heat sources, etc. Location height should be approximately 60"... -
Page 23: Figure 20 Additional Remote Sensor Installation
Up to two additional temperature and humidity sensors can be purchased and installed. Alternately, temperature- only sensors can be purchased and installed instead of the combination sensors. Use shielded cable to connect additional sensors to controller. FIGURE 20 Additional Remote Temperature and Temperature/Humidity Sensor Installation Up to two additional temperature/humidity sensors may be added. -
Page 24: Additional Lv1000 Connections
Additional LV1000 Connections There are factory-installed jumpers across terminals #8 and #9 (smoke detector), #10 and #11 (hydrogen detector) and #12 and #13 (generator run). Remove the factory-installed jumpers before connecting to the detectors and/or generator (if applicable). INPUTS LV1000 Connections Sensor Connections Description Wire Mark... -
Page 25: Figure 21 Communication Wiring (Daisy Chain)
Communication Wiring Connect the communication wiring from the wall-mount units to the controller in the manner shown in Figures 21, 22 or 23 (page 26). The daisy chain does not need to follow the addressing order. The communication wire should be 2-wire, 18 gauge shielded cable with drain. -
Page 26: Figure 23 Placement Of Communication Filters
FIGURE 23 Placement of Communication Wire Filters (Daisy Chain and Alternate Methods) Daisy Chain Wiring (up to four units) Place filter here Place filter here LV1000 Unit 1 Unit 2 Unit 3 Unit 4 Alternate Wiring (up to four units) Place filter here Place filter here LV1000*... -
Page 27: Figure 24
The steps outlined on the following pages show how to connect the communication wiring using the daisy chain method shown in Figure 21 If using the alternate method (as shown in Figure 22), the connections to the controller and each wall-mount unit will be the same but the filters need to be placed in the positions shown in Figure 23. FIGURE 24 Communication Wiring: Termination at the Controller Using the field-provided shielded cable, make a small service loop after entering the controller and attach the provided... -
Page 28: At The First Wall-Mount Unit
FIGURE 25 Communication Wiring: Termination at the First Wall-Mount Unit Unit 1 Terminal Block 9 10 16 17 – From LV1000 Controller From the controller, extend the shielded cable through a separate conduit and route to the provided terminal block next to the wall-mount control board. -
Page 29: Figure 3 Prefilling Traps On Indoor Drain Pan Figure
FIGURE 26 Communication Wiring: Termination at Additional Wall-Mount Units Unit 2 Terminal Block 9 10 16 17 – From Wall-Mount Unit 1 Route the cable from the first wall-mount unit to the terminal block of the second wall-mount unit. If this is the last unit to be connected, make a small service loop Wall-Mount Unit 2 and attach EMI filter as shown. -
Page 30: Lv1000 Supply Wiring
LV1000 Supply Wiring The LV1000 controller is powered by -48VDC from the shelter. A field-supplied 5 amp DC circuit breaker is required. Field-supplied supply wiring should be minimum 16 gauge, maximum 14 gauge (see Figure 27). A reliable earth ground must be connected in addition to any grounding from conduit. Grounding posts are included with the controller for this purpose;... -
Page 31: Lv1000-100 Terminal Block Index
TABLE 4 LV1000 Terminal Block Index Wire Wire Description Description Mark Mark 48VDC +Input Temperature Sensor 1 48– 48VDC – Input Ground Ground Temperature Sensor 2 24VDC + Ground 24VDC – Temperature Sensor 3 24VDC + Ground 24– 24VDC – VDC+ Sensor Power Distribution Smoke Detector Input... -
Page 32: Wiring: Lv1000 Wiring Diagram
FIGURE 29 LV1000 Wiring Diagram Manual 2100-674 Page 32 of 42... -
Page 33: Wiring: Hr58Aap* Wall Unit Wiring Diagram
FIGURE 30 HR58AAP* Wall-Mount Unit Wiring Diagram Blk/Wht BOTTOM Manual 2100-674 Page 33 of 42... -
Page 34: System Set Up
Use UP or DOWN keys and ENTER key to enter password TEC-EYE Hand-Held Diagnostic Tool The microprocessor control used in the FUSION-TEC wall-mount air conditioners allows for complete control and monitoring through the use of the provided TEC- EYE hand-held monitor. -
Page 35: Setting Up Wall-Mount Units For Operation
FIGURE 33 TEC-EYE Status Screen Changing Unit Setup Values The Status screen is the default start-up screen and also the return screen after 5 minutes of no activity. The screen can be accessed any time by pressing the ESCAPE key repeatedly. The wall-mount unit address is displayed in the upper right corner on the Status screen (see Figure 31). -
Page 36: Execute A Run Test On Each Unit
FIGURE 34 Run Test Approximate Timings (in Minutes) Changing Economizer Control Type 0:00 • Blower starts. • Damper begins to open to damper test volts parameter. To verify damper operation, open unit side door. Inspect upper and lower blades. 2:30 • Damper closes. Compressor Stage 1 turns on. Condenser fan may also turn on depending on ambient conditions. -
Page 37: Setting Up Lv1000 For Operation
FIGURE 37 LV1000 Controller Display and Interface (Status Screen Shown) UP KEY ALARM KEY ENTER KEY MENU KEY DOWN KEY ESCAPE KEY LV1000 interface key functions are the same as those shown for the TEC-EYE in Figure 32 on page 34. Setting Up LV1000 for Operation 12) Press UP or DOWN keys to change the value. -
Page 38: Configure Sensors
5. Configure Sensors 6) Press UP or DOWN key to change value to ON to enable sensor (or change value to OFF to The system will need to be configured for the disable sensor). number of temperature and humidity sensors installed. -
Page 39: Enter Total Number Of Units
4) Press UP or DOWN keys to scroll to Indoor To enable/disable Indoor Temperature 3: Temperature 1 (C6). 1) Press MENU key to go to the Main Menu 5) Press ENTER key to scroll to Enable (see screen. Figure 43). 2) Press UP or DOWN keys and ENTER key to 6) Press UP or DOWN key to change value to ON enter TECHNICIAN password 1313. -
Page 40: Verify Units Are Online
In addition to being able to remotely view the units, considered “complete". an alarm will be generated on the LV controller for units not communicating. Additional programming information can be found in FUSION-TEC Service Instructions 2100-670 FIGURE 47 and LV1000 Service Instructions 2100-673. Verifying Units Manual 2100-674... -
Page 41: Figure 14 Wiring: Vac Supply Wiring Figure
ADDITIONAL INFORMATION Menu Screens and Password Levels FIGURE 49 Adjusting Sensor Offset Value System Config: A1-A10 User Adv Sys Config: B1-B4 Technician I-O Config: C1-C18 Technician On/Off: User Alarm Logs: User Settings: Date/Time: Technician Language: User Network Config: Technician Serial Ports: Technician Reset to Factory Defaults Initialization To reset the LV controller to factory default settings:... -
Page 42: Unit Status Messages
TABLE 6 TABLE 7 Unit Status Messages LV1000 Status Messages Message Description Message Description Unit is on and in orphan mode with System is on and waiting for heat, Orphan Stby Ready no calls for heating or cooling cooling, etc. Freecooling System is actively economizing Unit is operating under power loss...
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