Bard D36A2P/BLD.10304, Installation And Service Instructions Manual

Page 1: ...D42L2P BLD 10307 D48A2P BLD 10308 D48L2P BLD 10309 D60A2P BLD 10310 D60L2P BLD 10303 CONTROLLER MODELS LC1000 100 BLD 10293 LC1500 100 BLD 10291 NOTE BARD LINKTM LC1000 1000 or LC1500 100 Controllers must be used with D Series Wall Mount Units INSTALLATION AND SERVICE INSTRUCTIONS REPLACEMENT PARTS MANUAL Bard Manufacturing Company Inc Bryan Ohio 43506 www bardhvac com Manual 2100 620A Supersedes ...

Page 2: ...ring 15 Preliminary Start Up 19 Bard LinkTM Controller Installation 20 System Start Up 36 SECTION 2 Service Instructions 39 General Refrigerant Information 40 Sequence of Operation 42 Advanced Programming 49 Using the TEC EYE 54 Componentry Specifications 57 Maintenance and Troubleshooting 64 SECTION 3 Parts Manual 73 D Series Wall Mount Unit 74 Bard LinkTM PLC Lead Lag Controller 88 SECTION 4 App...

Page 3: ... of VAC power supply shore and or back up generator the unit will continue to operate as free cooling or ventilation system using the shelter s VDC power The indoor blower and free cooling unit operate from 48VDC and no inverter is required 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 ...

Page 4: ...plete The unit is designed for use with or without duct work Flanges are provided for attaching the supply and return ducts 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 syste...

Page 5: ...o 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 Electrical shock hazard Have a proper...

Page 6: ...Manual 2100 620A Page 6 of 107 ...

Page 7: ...Manual 2100 620A Page 7 of 107 SECTION 1 INSTALLATION INSTRUCTIONS ...

Page 8: ...applicable D 36 A 2 P A 05 4 P X X X J MODEL SERIES CONTROL MODULES J High Pressure Switch Low Pressure Switch Compressor Control Module Low Ambient Control Alarm Contacts Start Assist C J Module Compressor Crankcase Heater 48VDC Free Cooling Unit FILTER OPTIONS P 2 Inch Pleated MERV 8 M 2 Inch Pleated MERV 11 COLOR OPTIONS X Beige 1 White 4 Buckeye Gray SPECIAL FEATURES COIL OPTIONS X Standard 3 ...

Page 9: ...ulation of condenser discharge air can be from either a single unit or multiple units Any object such as shrubbery a building or a large object can cause obstructions to the condenser discharge air Recirculation or reduced airflow caused by obstructions will result in reduced capacity possible unit pressure safety lockouts and reduced unit service life For units with blow through condensers such a...

Page 10: ...RIC HEAT DISCONNECT ENTRANCE ELECTRICAL HIGH VOLTAGE ENTRANCE VENT HOOD ELECTRICAL LOW VOLTAGE LOCKABLE BUILT IN RAIN HOOD 4 PITCH C BREAKER HEATER ACCESS PANEL SIDE VIEW H D K J C I A 2 13 7 VENT HOOD DOOR Air Outlet Condenser VENTILIATION AIR BACK VIEW F G W Entrances Optional Electrical RETURN AIR OPENING BRACKET INSTALLATION BOTTOM Side Wall Mounting Brackets Built In BACK VIEW S E O T S S S S...

Page 11: ...ype system to assure proper drainage MOUNTING THE UNITS NOTE It may be best to spot some electrical knockouts such as those located on the back 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 3 on page 12 On wood fram...

Page 12: ...IBLE MATERIALS A B C D E 30 1 2 10 1 2 6 1 4 1 1 4 29 3 4 32 12 5 1 2 2 RETURN AIR OPENING 29 1 Right Side View NOTES SUPPLY AIR RAIN FLASHING IT IS RECOMMENDED THAT A BEAD OF SILICONE CAULKING BE PLACED BEHIND TOP FLASHING AT TIME OF INSTALLATION THE SIDE MOUNTING FLANGES AND UNDER TOP FOUR SIDES OF SUPPLY WALL AIR DUCT IS REQUIRED WALL STRUCTURE FROM COMBUSTABLE 1 4 CLEARANCE ON ALL MATERIALS PA...

Page 13: ...RAME WALL INSTALLATION OPENING WALL BEFORE MOUNT ON UNIT OPENING BEFORE INSTALLATION BOTTOM MOUNTING CONCRETE BLOCK WALL INSTALLATION BRACKET MOUNT ON OPENING WOOD OR STEEL SIDING OPENING INSTALLING UNIT RETURN AIR WALL STRUCTURE RETURN AIR SUPPLY AIR FACTORY SUPPLIED RAIN FLASHING SUPPLY AIR MIS 548 A SIDE VIEW See FIGURE 2 Mounting Instructions ...

Page 14: ...ED TO MATCH STUD SPACING FOR REST OF WALL A SECOND MEMBER MAY BE REQUIRED FOR SOME WALLS MIS 549 B ALL AROUND DUCT FIGURE 1 7 Common Wall Mounting Installations SUPPLY DUCT MAYBE LOCATED IN AN ATTIC OR BELOW CEILING RAFTERS AS SHOWN SUPPLY DUCT MAY BE LOCATED IN AN ATTIC OPENING W GRILLE SUPPLY DUCT MAYBE LOCATED IN AN ATTIC OR BELOW CEILING RAFTERS AS SHOWN RAIN SUPPLY AIR DUCT RAFTERS RAFTERS RE...

Page 15: ...Phase AC POWER CIRCUIT DC POSITIVE GROUND POWER CIRCUIT Minimum Circuit Ampacity Maximum External Fuse or Ckt Breaker Field Power Ground Wire Size Minimum Circuit Ampacity Maximum External Fuse or Ckt Breaker Field Power Ground Wire Size D36A2PA05 D36L2PA05 D36A2PA10 D36L2PA10 208 230 60 1 26 52 45 60 8 6 17 5 17 5 20 20 12 12 D36A2PB06 D36L2PB06 D36A2PB09 D36L2PB09 208 230 60 3 18 27 1 25 30 10 1...

Page 16: ...from 240V to 208V tap see Figure 1 10 The acceptable operating voltage range for the 240 and 208V taps are 240V Tap 253 216 and 208 Tap 220 197 FIGURE 1 8 Circuit Routing Label 2 500 5 000 DISTRIBUTION APPROVED NO DATE DWG NO PART NAME MAT L Bard Mfg Co Bryan Ohio SCALE DRAWN BY CHECKED PART 1 2 3 4 5 REV DATE DESCRIPTION ECN NO DRN CHK APR WIRING ROUTING LABEL 7961 807 1 4 7 21 2014 BD SD CY NOTI...

Page 17: ...AC or above 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 FIGURE 1 11 VDC Supply Wiring Landing Points Field Wiring Factory Wiring NOTE Right hand access model wi...

Page 18: ... and system will operate normally If the Polarity Voltage Monitor is showing a problem with polarity and or voltage see pages 67 and 68 of the Service section of this manual for instructions on checking VDC polarity and verifying incoming VDC voltage The Bard Polarity Voltage Monitor continually monitors for correct polarity and voltage If field wiring is connected improperly or the voltage is out...

Page 19: ...tivation of one of the two existing older wall mount units while keeping the shelter cool with the other unit still operating Once the first of the two Bard 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 second Bard wall moun...

Page 20: ...Relay Smoke Alarm Relay RJ11 Cable to Display 48VDC Power Supply 24VDC Power to PLC Ethernet Cable 48VDC Power Input 24VDC Hydrogen Power 24VDC Smoke Power Generator Alarm Jumper Remote Temp Sensor Alarm Block Wiring Hydrogen Alarm Relay Generator Alarm Relay Web Card RS485 Communication Cable High Temp Alarm Relay Low Temp Alarm Relay HVAC1 Fail Alarm Relay ...

Page 21: ...rature sensor a pair of communication EMI filters and a smoke detector The optional 8301 061 hydrogen detector if ordered from Bard is also included with the LC1500 100 controller The LC1500 100 has an umbilical cord and 66 punch down block attached The LC1500 controller is to be used in all retrofit applications and all existing smoke detectors and hydrogen detectors if applicable are to be remov...

Page 22: ... the controller This sensor must be installed for proper operation Use the included 35 shielded cable to mount the temperature sensor in a location least likely to be affected by open doors rack mounted fans radiant heat sources etc Locating the sensor between both return grilles is often the best location but every installation is unique Location height should be approximately 48 above the floor ...

Page 23: ...or 0 This is the default setting For information on checking the remote indoor temperature sensor configuration see Configuring Additional Remote Indoor Temperature Sensors on page 51 For unique situations involving temperature flux within the shelter up to two 2 additional sensors may be purchased and installed to provide temperature averaging or highest temperature protection see Figure 1 15 Ple...

Page 24: ...ity to provide power to a 24VDC smoke detector and a 24VDC hydrogen detector through fused power supply terminals For proper power and alarm wiring review the provided wiring diagrams see Figures 1 16 and 1 17 Please note that the provided smoke detector and hydrogen detector if applicable has external testing buttons to artificially and temporarily create an alarm sequence Additionally should the...

Page 25: ...turn Signal 24VDC 24VDC 24VDC 24VDC FIGURE 1 18 LC1000 100 and LC1500 100 Series Generator Run NC COM 1 If there is a generator on site remove the factory installed jumper on Terminals 9 and 10 Using minimum 18 gauge non shielded wire supply the common terminal on the existing generator relay with 24VDC from terminal 9 on the PLC controller 2 From the normally closed contact of the relay return th...

Page 26: ...00 External Alarm Wiring On the terminal strip of the LC1000 controller there are eight 8 separate series of normally closed dry contacts for the following alarm scenarios Smoke Hydrogen Generator Lag Unit Run High Temp Low Temp HVAC 1 Fail HVAC 2 Fail 4 Connecting External Alarm Points Both the LC1000 and LC1500 PLC controls have the capability to provide NC contacts for the following eight 8 ala...

Page 27: ...00 100 but has a prewired 66 punch down block to make external connections easier Smoke Hydrogen 48 umbilical cord allows for mounting the 66 punch down block to either side top or bottom of PLC controller cox Bridge clips have been inserted for convenience Field wiring for alarms Generator Lag Unit Run High Temp Low Temp HVAC 1 Fail HVAC 2 Fail There is no longer any need for the electro mechanic...

Page 28: ...nits to the controller in the manner shown in Figure 1 21 The communication wire should be 2 wire 18 gauge shielded cable with drain Any color can be used Be sure to match and symbols on controller terminal blocks to prewired unit control terminal block see Figures 1 23 and 1 24 on pages 30 and 31 Attach communication wire filters as shown below in Figure 1 22 Use separate conduits for communicati...

Page 29: ...g the controller and attach the provided EMI filter at the intersection of the loop FIGURE 1 22 Communication Wiring Termination at the Controller 2 Connect one wire to terminal 33 negative the other wire to terminal 34 positive and the drain wire to ground terminal 35 G G To Wall Mount Unit 1 Control Board RS485 ...

Page 30: ...ard is prewired to terminal block Make sure to match and symbols on controller terminal blocks 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 chain to route in conduit to the second wall mount unit Connect both drain wires with wire nut Wall Mount Unit 1 Control Board Wall Mount Unit 1...

Page 31: ...ilter as shown FIGURE 1 24 Communication Wiring Termination at the Second Wall Mount Unit RS485 R T R T 2 Connect the wires matching the terminal designations of the controller terminals Cap the loose drain with a wire nut or electrical tape RS485 R T R T From Wall Mount Unit 1 RS485 From Wall Mount Unit 1 RS485 Wall Mount Unit 2 Control Board Wall Mount Unit 2 Control Board ...

Page 32: ...tions and wait to initialize controller until startup procedures 6 Supply Wiring The LC1000 100 LC1500 100 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 guage maximum 14 guage see Figure 1 25 A reliable earth ground must be connected in addition to any grounding from conduit Grounding posts ar...

Page 33: ...S24 Smoke ALR Relay Contact 18 S21 Smoke ALR Relay Contact Common 19 H24 Hydrogen ALR Relay Contact 20 H21 Hydrogen ALR Relay Contact Common 21 G24 Generator ALR Relay Contact 22 G21 Generator ALR Relay Contact Common 23 NO1 Lag Unit Run Relay Contact 24 C1 Lag Unit Run Relay Contact Common 25 HT12 High Temp ALR Relay Contact 26 HT11 High Temp ALR Relay Contact Common 27 LT12 Low Temp ALR Relay Co...

Page 34: ...ND 5 VREF B1 B2 B3 B4 B5 B6 B7 GND D11 D12 D13 D14 D15 D16 D17 DIC1 GND Y1 Y2 Y3 VDC A2 BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK 14 21 24 11 21 11 24 14 22 12 RX TX RX TX GND VOUT RX TX RX TX GND C1 N01 N02 N03 C2 N04 N05 N06 N07 C3 NC7 A1 RED BLACK BLACK RED BLACK RED BLACK RED BLACK RED 22 24 21 11 14 12 12 14 11 22 24 21 12 RELAY MIS 3632 NO NC NO COM COM NC TO HF 12 TO LT 12 TO HT...

Page 35: ... 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 BROWN RED RED BROWN BLUE WHITE WHITE GREEN GREEN WHITE WHITE BLUE GRAY WHITE RED ORANGE ORANGE RED A JUMPER CONNECTED TO TERMINAL PAIR TO PROVIDE A DEMARCATION POINT DETAIL A MIS 3631 WHITE GRAY TO TERMINAL BLOCKS GRAY BLACK BLACK GRAY GREEN BLACK BLACK GREEN BLUE BLACK BLACK BLUE 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 ...

Page 36: ...tion other than display backlight becoming active The Status screen is the default screen when the controller has power 4 Access the Main Menu by pressing the Menu key 5 Press the UP or DOWN keys to scroll to the Clock Scheduler menu Press the ENTER key see Figure 1 30 6 Move the cursor to the Date line by pressing the ENTER key Press the UP or DOWN keys to change the date The Day line will automa...

Page 37: ...62 F All heating stops blowers stop Warm Weather Operation No Free Cooling Available Stage 1 Cooling 78 F Lead unit compressor Setpoint Cooling Stage 1 Differential Stage 2 Cooling 83 F Lag unit compressor Cooling Stage 2 Stage 3 and Stage 4 Differentials Hi Temp Alarm 1 85 F Hi Temp Alarm 2 90 F Emergency ventilation initiates both dampers open both blowers run 75 F All cooling stops blowers stop...

Page 38: ...p of the PLC control box Although the tool is not necessary for installation purposes the TEC EYE will be very valuable to technicians performing maintenance or repair procedures Do not let the TEC EYE leave the shelter SINGLE HVAC UNIT SHELTERS ONLY In certain applications only one wall mount unit will be installed on a particular shelter This may be desirable due to space considerations load spe...

Page 39: ...Manual 2100 620A Page 39 of 107 SECTION 2 SERVICE INSTRUCTIONS ...

Page 40: ...as a guideline REMEMBER When adding R 410A refrigerant 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 ...

Page 41: ... 75 DB 62 WB Low Side High Side 133 325 136 341 137 360 139 379 141 401 142 424 144 449 145 477 147 505 148 535 8552 089 8552 005 1 Ø 240V 70 10 370 3 Ø 240V 10 370 80 DB 67 WB Low Side High Side 142 333 145 350 147 369 149 389 151 411 152 435 154 461 155 489 157 518 158 549 85 DB 72 WB Low Side High Side 147 345 150 362 152 382 154 403 156 425 157 450 159 477 160 506 162 536 164 568 D60A 75 DB 62...

Page 42: ...m the Y2 terminal Additionally while other modes get only a single speed from the indoor blower free cooling mode will get two 2 one for outdoor air temperature above 40 F faster and another for those below 40 F slower See Table 2 2 Cooling Call When a call for cooling generates from the controller the system will first determine which mode of cooling to employ based on the outdoor temperature the...

Page 43: ...tes High Pressure Situation The high pressure switch routes through the compressor control module CCM which allows one switch opening followed by a delay soft lockout of at least 2 minutes before trying again If the switch is still open or opens again on the same call the CCM locks out the compressor and outdoor fan Additionally the CCM will send 24V to the high pressure alarm relay which will the...

Page 44: ... and outdoor fan until manually reset High Temperature 2 Alarm Should the shelter controller see 90 F both free cooling dampers will open regardless of outdoor temperature to cool the building Smoke Alarm Should the smoke detector send an alarm signal to the controller all blower compressor and ventilations functions cease Hydrogen Alarm if installed Should the hydrogen detector send an alarm sign...

Page 45: ...tectors with all alarm signals sent through the NO contacts of the relays which are closed as long as the relays are energized The remaining three factory wired isolation relays low temp high temp and HVAC 1 fail relays are only energized during an alarm situation and all alarm signals are sent through the NC contacts of the relays These contacts open on alarm Smoke If smoke is detected in the she...

Page 46: ...end 24VAC to the low temp relay to energize the relay opening contacts on terminals 27 and 28 Additionally the board will send remote alarms High Temp If 90 F is sensed in the shelter the LC board will send 24VAC to the high temp relay to energize the relay opening contacts on terminals 25 and 26 Additionally the LC will send remote alarms and enable blowers and free cooling dampers in an attempt ...

Page 47: ...Cooling 78 F Lead unit compressor Setpoint Cooling Stage 1 Differential Stage 2 Cooling 83 F Lag unit compressor Cooling Stage 2 Stage 3 and Stage 4 Differentials Hi Temp Alarm 1 85 F Hi Temp Alarm 2 90 F Emergency ventilation initiates both dampers open both blowers run 75 F All cooling stops blowers stop Setpoint 2 F Unit 1 Damper Fail to Close Unit 1 Filter Maintenance Alarm Should Unit 1 encou...

Page 48: ...mperature at local remote main sensor Temperature Setpoint 77 F Heating Setpoint 60 F Temperature High Limit Level 1 85 F Temperature High Limit Level 2 High Temp Alarm 90 F Temperature Low Limit 45 F Cooling Stage 1 Differential 1 F Cooling Stage 2 Differential 1 F Cooling Stage 3 Differential 2 F Cooling Stage 4 Differential 2 F TABLE 2 3 Controller Default Settings Description Default Setpoint ...

Page 49: ...up However the default setpoints and their ranges are easily viewed and adjusted from the controller display The program and operating parameters are permanently 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 WEB CARD COMMUNICATION BOARD A web car...

Page 50: ...n overide mode 4 Pressing the ENTER key during the 1 hour period will deactivate COMFORT MODE Status Screen 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 button repeatedly The main screen of the STATUS screen displays the current date time space temperature and temperature setpoi...

Page 51: ...ry Settings screen press ENTER key 3 Press the ENTER key to move the cursor to the Serial Number selection Press and hold UP or DOWN arrow keys to get to the desired value and then press ENTER key Repeat for the rest of the digits characters Press and hold UP or DOWN arrow keys to get to the desired value and then press ENTER key to key in next digits characters 4 Model number is entered by the fa...

Page 52: ...arrow keys to change the value from On to Off alarm activates 6 Reverse procedure to terminate test 7 Repeat steps using programming lines for low temp HVAC fail and lag unit alarms Changing NC Contacts to NO Contacts For lag unit on high temp alarm low temp alarm HVAC 1 fail alarm and HVAC 2 fail alarm 1 Go to Factory menu press ENTER key 2 Go to I O Configuration press ENTER key 3 Go to Relay Ou...

Page 53: ...ries Controller or the TEC EYE not covered within this manual may cause the systems to operate improperly cause internal damage to the HVAC units cause the shelter to overheat or other very serious consequences Although complete controller programming architecture for both the LC Controller and TEC EYE has been provided going outside the boundaries of what has been covered in this manual is not re...

Page 54: ...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 EYE connects to the wall mount unit control board via an RJ11 modular phone connector as shown in Figure 2 9 ALARM KEY Allows viewing of active alarms Silences audible alarms Resets active alarms MENU KEY All...

Page 55: ...be flashing in upper left corner of screen Press DOWN arrow key to scroll through screens to Run Test 5 Press ENTER key to scroll to Enable Press Up or DOWN arrow keys to change No to Yes Unit will begin the run test FIGURE 2 10 TEC EYE Status Display TEC EYE Menu Structure On Off Unit Setpoint Clock Scheduler Input Output Analog Inputs Digital Inputs Relay Outputs Analog Outputs Alarm History Tec...

Page 56: ...roll to Mode line Press DOWN key to change Auto to Hand 6 Press ENTER key to scroll to Manual Value line Press UP or DOWN arrow keys to change the manual value to a desired value maximum is 10VDC to perform damper test 7 Verify damper operation Compressor 1 Go to Technician menu press ENTER key 2 Go to Manual Management press ENTER key 3 Go to Relay Output press ENTER key 4 Go to Relay Output Cool...

Page 57: ... initial start up or anytime power is interrupted for a minum 2 minutes plus 10 of the red dial setting There is no delay during routine operation of the unit The compressor control module CCM also monitors the high pressure switch and will allow one automatic retry after soft lockout delay before disabling the compressor in a hard lockout requires manual reset If hard lockout does occur the ALR t...

Page 58: ...574 69 0 12183 107 0 4982 6 0 103574 32 0 32634 70 0 11883 108 0 4873 5 0 100260 33 0 31723 71 0 11591 109 0 4767 4 0 97064 34 0 30840 72 0 11307 110 0 4663 3 0 93981 35 0 29986 73 0 11031 111 0 4562 2 0 91008 36 0 29157 74 0 10762 112 0 4464 1 0 88139 37 0 28355 75 0 10501 113 0 4367 0 0 85371 38 0 27577 76 0 10247 114 0 4274 1 0 82699 39 0 26823 77 0 10000 115 0 4182 2 0 80121 40 0 26092 78 0 97...

Page 59: ...wall mount unit to isolate the start signal from Power loss relay circuit see Figure 2 13 on page 60 High pressure relay circuit see Figure 2 14 on page 60 Blower motor start signal relay circuit see Figure 2 15 on page 60 ISOLATION RELAYS LC CONTROLLER Blue DIN Rail mount isolation relays used in the controller to isolate the PLC board from varying voltages within the same shelter Model Dimension...

Page 60: ...Manual 2100 620A Page 60 of 107 FIGURE 2 13 Power Loss Relay Circuit FIGURE 2 14 High Pressure Relay Circuit FIGURE 2 15 Blower Motor Start Relay Circuit Blower Motor Start Relay ...

Page 61: ...K DC CIRCUIT DC POLARITY CABLE DUCT RS485 LABEL DIN RAIL END CLAMP TERMINAL BLOCK SHEATHED CABLE WIRE SHIELD DEVICE MOTOR STARTING BRACKET CAPACITOR CAPACITOR PANEL CONTROL BLOCK TERMINAL CONTROLLER PLC MODULE ISOLATION COMMON 40 AMP END CLAMP L1 L1 CONTACTOR CONTROL MOD COMPRESSOR CONTROL MOD COMMON START RELAY BLOWER MOTOR RELAY POWER LOSS HARNESS WIRE 2 POLE ASSEMBLY DC CONVERTER LABELS FILTER ...

Page 62: ...ltage Factory Optional 1 Field COMP CCH Compressor Contactor 33 COMPRESSOR CONTROL MODULE 28 23 23 35 14 11 9 3 2 22 37 88 87 90 39 30 40 41 40 43 42 42 42 44 45 47 75 48 46 46 46 51 47 52 42 40 42 45 50 42 40 58 57 59 42 63 61 62 60 64 66 67 67 68 68 70 Red Red Black Red Red Red White 71 Red White Red White 70 24 VDC Red 53 Red Black 65 66 83 125 126 48 76 49 99 50 47 52 53 38 54 55 56 69 Red Red...

Page 63: ...n For Alarms Freeze Stat TERMINAL BLOCK 0 10vdc 24Vdc OVdc Damper Motor Temp OAT RAT OAH Common Supply Air OAH Power Loss Dirty Filter Power For Alarm High Pressure Alarm Damper Alarm Freeze Stat Low Pressure AO Common for 0 10vdc Indoor Blower Motors DC Free Cooling Voltage High Temp Comp Stage 1 24 Vac Heater Damper Motor On Indoor Blower 0 10vdc Comp Stage 2 Dry No DC Free Cooling Wiring Nomenc...

Page 64: ...ll mount unit 1 Disable system from LC controller see Advanced Programming section 2 Turn off both AC and DC 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 fan shroud motor motor bracket as an assem...

Page 65: ... Blower Motor To troubleshoot the 48VDC blower motor check for proper voltage and commands to the motor controller from the wall mount unit Under a command for blower FIGURE 2 19 Troubleshooting Motor Power Supply disconnect the 9 pin Molex plug connecting the motor control to the wall mount unit control wiring harness this Molex is located in the chassis wall of the control panel and test for the...

Page 66: ... place the black lead on Pin 5 and the red lead on Pin 4 of the female portion of the Molex style plug connecting the motor controller to the back of the wall mount control cabinet Meter should audibly alert a closed contact condition Note the plug pin flats for proper orientation of the plug Female Plug VDC Speed Voltage With the meter set to VDC place the black lead on Pin 5 and the red lead on ...

Page 67: ... Step 1 Multimeter set to VDC Display reveals 0 voltage potential Bard System Supply Breakers VDC breaker in OFF position Shelter VDC Power Supply 48VDC Positive Ground 0 VDC Bard System Supply Breakers VDC breaker in OFF position Step 2 Multimeter set to VDC Positive to ground reveals 0 voltage potential Shelter VDC Power Supply 48VDC Positive Ground 0 VDC Step 3 Multimeter set to VDC Negative to...

Page 68: ...ing Incoming Voltage VDC 48VDC Shelter System Voltage Range 40VDC 56VDC Typical Running Range 48VDC 53VDC Multimeter set to VDC Shelter supply breaker in ON position Bard system breaker in OFF position 52VDC Displayed voltage must be within this range ...

Page 69: ...larm setpoint value The default is 95 F The cooling capacity loss or heat load loss is too great Check for leakages in the refrigerant circuit Check if heat load exceeds the design range Remove the leakage Increase the cooling capacity Compressor Condensor Fan Off Compressor circuit failure Check if components connected to the compressor are ok Check if compressor is ok Check if the electric conne...

Page 70: ...Check temperature vs resistance of temperature sensor see Table 2 5 on page 58 Replace the indoor temperature sensor Spare Remote Indoor Temperature 1 Sensor Failed Alarm B02 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 Configuration shoul...

Page 71: ...fan status while the high pressure is outside the normal setting Replace the condenser fan Replace the condenser low ambient fan speed controller The switch is defective Check if the high pressure switch is OK If defective replace Check if the connection to the corresponding input terminal is ok or if the controller board is defective Check if the connection is OK Check is the controller board is ...

Page 72: ...the sensor is faulty a sensor wire is loose or an out of range value is read Check the outdoor temperature sensor wiring Check temperature vs resistance of temperature sensor see Table 2 5 on page 58 Replace the outdoor temperature sensor Outdoor Humidity Sensor Failed Alarm B05 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 acti...

Page 73: ...Manual 2100 620A Page 73 of 107 SECTION 3 PARTS MANUAL ...

Page 74: ...Manual 2100 620A Page 74 of 107 SEXP 713 24 16 26 27 28 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 18 19 20 21 22 23 25 29 CABINET COMPONENTS Right Hand ...

Page 75: ...e 2 2 2 2 16 113 150 Rain Flashing X X X X 17 17 508 098 509 251 Back Back X X X X 18 18 125 069 125 070 Fan Shroud Fan Shroud X X X X 19 523 144 Drain Pan Assembly X X X X 20 553 570 Hood Mounting Door X X X X 21 553 564 Filter Door X X X X 22 521X258 Condenser Partition X X X X 23 131X164 Filter Tray X X X X 24 131 165 Filter Tray Angle X X X X 25 137 209 Fill Plate X X X X 26 121X501 Blower Par...

Page 76: ...Manual 2100 620A Page 76 of 107 SEXP 714 25 26 27 28 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 29 CABINET COMPONENTS Left Hand ...

Page 77: ...le 2 2 2 2 16 113 150 Rain Flashing X X X X 17 17 508 098 509 251 Back Back X X X X 18 18 125 069 125 070 Fan Shroud Fan Shroud X X X X 19 523 145 Drain Pan Assembly X X X X 20 553 570 Hood Mounting Door X X X X 21 553 564 Filter Door X X X X 22 521Y258 Condenser Partition X X X X 23 131Y164 Filter Tray X X X X 24 131 165 Filter Tray Angle X X X X 25 137 209 Fill Plate X X X X 26 121Y501 Blower Pa...

Page 78: ...Manual 2100 620A Page 78 of 107 FUNCTIONAL COMPONENTS SEXP 715 19 20 22 23 21 1 2 3 4 5 6 7 8 9 10 11 13 12 16 15 14 17 18 24 ...

Page 79: ...X X X X 12 1804 0462 High Pressure Switch Flare X X X X X X X X 13 1804 0386 Low Pressure Switch Flare X X X X X X X X 14 1171 022 1 4 Turn Fastener X X X X X X X X 15 1171 024 1 4 Retainer Clip X X X X X X X X 16 1171 023 1 4 Receptacle X X X X X X X X 17 1171 028 No 9 Clip on Receptacle 2 2 2 2 2 2 2 2 18 1171 027 No 9 Retainer Clip 2 2 2 2 2 2 2 2 19 1171 057 No 9 Captive Screw Fastener 2 2 2 2...

Page 80: ...Manual 2100 620A Page 80 of 107 CONTROL PANEL Right Hand L1 L1 28 6 16 27 18 19 20 25 7 23 22 24 19 1 2 3 4 17 5 7 21 8 9 10 11 12 13 14 15 29 26 FILTER SWITCH ASSEMBLY SEXP 750 ...

Page 81: ...actor 2 Pole 20 Amp 1 1 1 1 14 8407 048 Transformer 208 240 24 75VA X X X X 15 8611 139 2600 1 1 2 x 1 1 2 Cable Duct 26 X X X X 16 8301 050 48VDC to 24VDC Converter 5 Amps X X X X 17 8201 130 Compressor and Power Loss SPDT Relays 2 2 2 2 18 3000 1471 Wire Assembly X X X X 19 8607 037 Terminal Block 4 Position 2 2 2 2 20 8201 088 Compressor Control Module X X X X 21 8611 145 35mm DIN Rail 8 1 2 X ...

Page 82: ...Manual 2100 620A Page 82 of 107 CONTROL PANEL Left Hand 27 L1 L1 14 15 16 18 26 19 7 23 22 19 1 2 3 4 5 17 24 7 21 8 9 10 11 12 29 13 28 6 ASSEMBLY FILTER SWITCH 25 SEXP 751 ...

Page 83: ...X X X X 13 8401 006 Contactor 2 Pole 20 Amp 1 1 1 1 14 8407 048 Transformer 208 240 24 75VA X X X X 15 8611 139 2600 1 1 2 x 1 1 2 Cable Duct 26 X X X X 16 8301 050 48VDC to 24VDC Converter 5 Amps X X X X 17 8201 130 Compressor and Power Loss SPDT Relays 2 2 2 2 18 3000 1471 Wire Assembly X X X X 19 8607 037 Terminal Block 4 Position 2 2 2 2 20 8201 088 Compressor Control Module X X X X 21 8611 14...

Page 84: ... X 4 144 167 Diffuser 2 5 105 880 Blower Angle 4 6 129 024 Cradle Support 1 7 129 022 Cradle Motor Mount X 8 S8107 021 3 4 HP Motor Motor Controller X 9 8200 018 Motor Mount Latch 2 10 103 514 Hold In Offset X 11 105 1332 Rear Blower Angle X 12 113 518 Motor Controller Mount X S900 338 SEXP 718 A 10 11 5 1 2 3 4 7 6 9 8 12 BLOWER ASSEMBLY ...

Page 85: ...n 10 141 426 Blade Support 11 8602 077 1 4 x 9 Rod 12 1921 067 2909 29 9 16 Damper Blade Seal 13 1921 067 1300 13 Damper Blade Seal 14 1921 067 1011 10 11 16 Damper Blade Seal 15 1921 067 2906 29 3 8 Damper Blade Seal 16 8408 044 Defrost Support 10K Ohm Curve J w 5 16 Clip 17 1012 052 Hex Head Bolt 5 16 18x1 3 4 0 0005 Zinc w Yellow Chromate 18 1012 210 5 16 Nut 0 0005 Zinc w Yellow Chromate 19 11...

Page 86: ...er 40 1 4 x 17 7 8 x 7 8 5 S101 870 Right Side 6 105 1342 Side Filter Angle 7 553 600 Hood Mounting Door 8 105 1343 Filter Door Angle 9 S107 344 Hood Top 10 553 596 Filter Door 11 S101 860 Left Side Exterior cabinet parts are manufactured with various paint color options To ensure the proper paint color is received reference the following codes Beige X White 1 Buckeye Gray 4 Desert Brown 5 Dark Br...

Page 87: ...5 Direct Coupled Actuator 4 8602 037 Damper Motor M7415B1004 5 8602 078 Belimo Actuator Crank Arm 1 2 6 1012 174 1 4 20x3 1 4 Hex Cap Screws 7 1012 201 1 4 20 Steel Keps Hex Nut Zinc 8 141 427 Actuator Support Bar 9 113 525 Blade Switch Bracket 10 8406 138 Lever Switch SPDT Sealed Pilot Duty 11 1012 178 4 40 x 5 8 Phillips Pan Head Machine Screw Zinc Plated 12 1012 231 4 40 Steel Keps Hex Nut Zinc...

Page 88: ...Manual 2100 620A Page 88 of 107 BARD LINKTM PLC LEAD LAG CONTROLLER SEXP 755 6 4 8 7 2 9 1 5 3 ...

Page 89: ...flush pGDEvolution 132x64 black buttons with cable X X 5 8201 154 24VDC Isolation Relay DPDT 6 6 6 8614 055 2 5 Amp Fuse 2 2 7 8607 039 Fused Terminal Block 2 2 8 8607 038 Terminal Block 32 32 9 8611 144 End Clamp for din rail 2 2 NS 8301 055 EMI Ferrite Filter 2 2 NS 8301 058 Remote Temp Sensor X X NS 8611 181 Umbilical Cord for Punch Down Alarm Block X NS 8607 040 66 Punch Down Alarm Block X NS ...

Page 90: ...Manual 2100 620A Page 90 of 107 ...

Page 91: ...Manual 2100 620A Page 91 of 107 SECTION 4 APPENDICES ...

Page 92: ... hour of operation Inside Temp Avg F Outside Temp Avg F Outside Hum Avg H OA Dewpoint Avg F Last Hour Tracking Statistics from last 60 min of operation Free Cool U1 U2 Run Minutes Running minutes of damper activation Free Cool U1 U2 Start Damper initiations Compressor 1 U1 U2 Run Minutes Compressor run time single stage units or 1st stage compressor of 2 stage units Compressor 1 U1 U2 Start Compre...

Page 93: ...eeCool 55 F FreeCool Enable 50 F Differential 10 F DC OA Return Diff 10 F Supply Temp Low Limit 45 F Differential 5 F Alarm Delay 10 seconds Run Test Time 60 seconds Low Alarm 45 F High Alarm 85 F High Alarm 2 90 F Blower Settings Continuous None Lead Only or Both also available Blower Speeds Heat 7 0V Control voltage supplied from wall mount unit control boards to blower in heat Econ 7 0V Control...

Page 94: ...tes Setpoint of 72 is maintained for 60 minutes for technician comfort Comfort Setpoint 72 F Setpoint of 72 is maintained for 60 minutes for technician comfort Number of Units 2 Amount of systems connected to controller choice of 1 or 2 See page 38 Clock Scheduler Date Current date Hour Current time Day Current day of week Unit Rotation 1 or 2 Which unit is currently in lead status Switch Lead No ...

Page 95: ... programmed wall mount unit board Version Current version Bios Current bios Root Current root Flshram N A Internal memory specifications Power Cycle N A Count of power initiations BMS Configuration BMS Port 1 Protocol Carel BMS Port 1 Address 1 BMS Baud Rate 19200 Service Settings Probe Adjustment Input B01 Offset 0 Calibrating indoor sensor if necessary Input B01 Value Current Temp Current temper...

Page 96: ...tor run input D3 Status Open Current status of generator run input open means no input Relay Outputs Smoke Manual Relay 1 Off On to allow artificial manipulation of smoke alarm relay action Manual Position On Off Change to Off to artificially force smoke alarm relay Relay 1 Status On Current status of smoke alarm relay on means no relay action High Temp Relay 4 Off On to allow artificial manipulat...

Page 97: ... Factory Configuration Temperature Units F C units available as well Pressure Units PSI N A Force Clock Enable Yes Clock Mode 24 hour 12 hour available Disable Buzzer Yes Audible buzzer available Startup Delay 1 second Enable Unit On Off By digit input off N A By supervisor off N A By pLAN network off N A By schedule off N A Unit Control Custom 1 off N A Custom 2 off N A Custom 3 off N A Custom 4 ...

Page 98: ...cheduler Number of Schedules 0 N A Optimized Start No N A Set 1 Adjust No N A Set 2 Adjust No N A Holidays Number 0 N A Initialization Default Installation No Change to Yes to reset to factory default values NOTE Be sure to enter the serial number and model number for unit to operate with correct blower trigger voltage ...

Page 99: ...cal address of controller Power by Display On Off Status On OFF by Keyboard system has been turned off at controller Setpoint All setpoint changes are limited to 60 minutes Cooling Setpoint 77 F Heating Setpoint 60 F Cooling Stg Diff 5 F Heating Stg Diff 2 F FreeCool 55 F FreeCool Enable 50 F Differential 10 F DC OA Return Diff 10 F Supply Temp Low Limit 45 F Damper Time 150 seconds Time alloted b...

Page 100: ...rol separates two 2 different low pressure situations Differential 5 F This differential applies to the outside setpoint Above Setpoint Delay 120 seconds Any low pressure situation above the outside setpoint will be delayed 120 seconds before an alarm is initialized Below Setpoint Delay 180 seconds Any low pressure situation below the outside setpoint will be delayed 180 seconds before an alarm is...

Page 101: ...t B007 Current Freezestat temp Digital Inputs Power Loss DI 1 Status Closed Filter Switch DI 2 Status Closed High Pressure Switch DI 3 Status Closed Low Pressure Switch DI4 Status Closed Blower DI 5 Status Closed Damper Switch DI 6 Status Closed Relay Outputs Cooling Stage 1 Relay 2 Status Off Cooling Stage 2 Relay 3 Status Off Heating Relay 4 Status Off Blower Relay 7 Status Off Alarm History Tec...

Page 102: ...rating sensor if necessary Value Current Temp Current temp plus offset OAT Input B02 Offset 0 Calibrating sensor if necessary Value Current Temp Current temp plus offset RAT Input B03 Offset 0 Calibrating sensor if necessary Value Current Temp Current temp plus offset Oudoor Air Humidity Input B05 Offset 0 Calibrating sensor if necessary Value Current RH Current RH plus offset Freezestat Input B07...

Page 103: ...grees of change in sensor for manual control Value Temp Value Current temperature plus the value in manual position OAH Manual Control B005 Off On to manually change temperature seen by controller Manual Position 0 Degrees of change in sensor for manual control Value RH Value Current RH plus the value in manual position Freezestat Manual Control B007 Off On to manually change temperature seen by c...

Page 104: ...Switch Status DI 6 Off On to allow artificial manipulation of damper switch status input Manual Position Open Closed Change to Closed to artificially create damper switch status input D3 Status Closed Current status of damper switch status input open means no input Relay Outputs Cooling Stg 1 Manual Relay 2 Off On to allow artificial manipulation of cooling stage 1 relay action Manual Position On ...

Page 105: ...r Yes Audible buzzer available Startup Delay 1 second Enable Unit On Off by digit input ON Allows unit control by supervisor off N A by pLAN network off N A by schedule off N A Analog Input Fitering Enable No N A Input 1 19 seconds N A Input 2 19 seconds N A Input 3 19 seconds N A Input 4 19 seconds N A Input 5 19 seconds N A I O Configuration Analog Inputs Supply Air Temp Enable B001 on Normal Oh...

Page 106: ... 0 Value F Input B003 F Power Delay 5 seconds Run Delay 5 seconds Units Temperature Outdoor Air Hum Enable B005 on Normal 4 20mA Min 0 Max 100 Offset 0 Value RH Input B003 RH Power Delay 5 seconds Run Delay 5 seconds Units blank Freezestat Enable B003 on Normal Ohms x5 Min 0 Max 100 Offset 0 Value F Input B003 F Power Delay 5 seconds Run Delay 5 seconds Units Pressure Analog Outputs Blower Motor E...

Page 107: ...per test Voltage 2 5VDC 25 opening Blower Status Switch Minimum Off 45 seconds Allows motor to come to full stop before re engaging Unit Controller Serial Number Wall mount unit serial sumber Model Number Wall mount unit model number Factory Save Save No Restore No Auto Restore User Save Save No Restore No Auto Save Yes Factory Delete Clear ALL DATA No Passwords User OOOO Tech OOOO Factory OOOO ...